Timing Belt

Removal

NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

1. Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. Refer to: Degas Bottle (303-03B Engine Cooling - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
   

1. Remove the RH front wheel and tire.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. NOTE: It may be necessary to rotate the halfshaft to remove the front lower bolt.

1. Remove the following items:
   1. Refer to: Starter Motor (303-06B Starting System - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
      
   2. Refer to: Generator - 1.6L EcoBoost (132kW/180PS) - Sigma (414-02 Generator and Regulator, Removal and Installation).
      

1. Install the following items:
   • General Equipment : Trolley Jack
     General Equipment : Wooden Block

1. NOTE: Note the different lengths of the bolts for installation.

1. NOTE: Only rotate the crankshaft in a clockwise direction.

   11 o'clock position.
   

1. NOTE: The Crankshaft TDC Timing Pin will contact the crankshaft and prevent it from turning past TDC . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.

   Install Special Service Tool : 303-748 Locking Tool, Crankshaft

1. NOTE: Only rotate the crankshaft clockwise direction.

   Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the crankshaft locking tool. The engine is now at TDC .
   

1. Install Special Service Tool : 303-393-02 Adapter for 303-393 , 303-393A Locking Tool, Flywheel

1. NOTE: It may necessary to rotate the camshafts slightly to install the special tool.

   Install Special Service Tool : 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit

1. WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury.

   Install a holding pin.
   

Installation

1. NOTE: Before installation, clean and inspect the sprocket for any damage. If damage is evident, replace the sprocket. If no damage, the sprocket is to be reused.

1. WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury.

   Remove the holding pin.
   

1. 1. Install Special Service Tool : 303-1550 Alignment Tool, Crankshaft Vibration Damper
   2. Rotate crankshaft pulley to align the Special Tool:
      Special Tool(s) : 303-1550 Alignment Tool, Crankshaft Vibration Damper
   3. Finger tight at this stage.
      
   4. Using a new bolt, finger tight at this stage.
      

1. Remove Special Service Tool : 303-1550 Alignment Tool, Crankshaft Vibration Damper

1. Torque :
     Stage 1:  100 Nm
     Stage 2:  90°
     Stage 3:  Wait 2s
     Stage 4:  Tighten an additional 15°

1. Remove Special Service Tool : 303-748 Locking Tool, Crankshaft

1. Remove Special Service Tool : 303-393-02 Adapter for 303-393 , 303-393A Locking Tool, Flywheel

1. Remove Special Service Tool : 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit

1. NOTE: Only rotate the crankshaft in a clockwise direction.

   Rotate about 1 3/4 turns.
   

1. Install Special Service Tool : 303-748 Locking Tool, Crankshaft

1. NOTE: Only rotate the crankshaft in a clockwise direction.

   Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the crankshaft locking tool. The engine is now at TDC .
   

1. NOTE: It may necessary to rotate the camshafts slightly to install the special tool.

   NOTE: The special tool can only be installed if the valve timing is correct.

   If the special tool cannot be installed, repeat the adjustment according to the preceding steps.
   Install Special Service Tool : 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit

1. Remove Special Service Tool : 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit

1. NOTE: There are different length of bolts noted in removal.

   Torque : 55 Nm

1. 1. Torque : 10 Nm
   2. Finger tight.
      
   3. Finger tight.
      
   4. Torque : 8 Nm

1. Torque : 10 Nm

1. Torque : 48 Nm

1. Torque : 10 Nm

1. 1. Torque : 80 Nm
   2. Torque : 48 Nm

1. Remove the following items:
   1. General Equipment : Trolley Jack
      General Equipment : Wooden Block

1. Remove Special Service Tool : 303-748 Locking Tool, Crankshaft

1. Torque : 20 Nm

1. Torque : 10 Nm

1. Torque : 48 Nm

1. 1. Torque : 5 Nm
   2. Torque : 25 Nm
   3. Torque : 25 Nm

1. Install the following items:
   1. Refer to: Generator - 1.6L EcoBoost (132kW/180PS) - Sigma (414-02 Generator and Regulator, Removal and Installation).
      
   2. Refer to: Starter Motor (303-06B Starting System - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
      

1. Install the RH front wheel and tire.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Torque : 24 Nm

1. Torque : 5 Nm

1. Torque : 5 Nm

1. Refer to: Degas Bottle (303-03B Engine Cooling - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
   

1. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.
   

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