Timing Belt. Removal and Installation

Special Service Tools / General Equipment

	303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve TKIT-2010B-FLM TKIT-2010B-RYAD
	303-1550 Alignment Tool, Crankshaft Damper TKIT-2012A-FL TKIT-2012A-RYAD
	303-393-02 Adapter, 303-393 TKIT-2012A-FL TKIT-2012A-RHD
	303-393A Flywheel Locking Tool TKIT-2012A-FL TKIT-2012A-RHD
	303-748 Crankshaft Locking Tool TKIT-2010B-FLM TKIT-2010B-RHD
Floor Jack
Hose Clamp Removal/Installation Tool
Wood block

Removal

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools. The crankshaft pulley and crankshaft sprocket are not engaged with the crankshaft. Before any repair that requires loosening or removing the crankshaft pulley bolt, the crankshaft and camshafts must be locked with the special service tools, otherwise serious engine damage may occur.

1. 1
   Position the vehicle in NEUTRAL on the lift.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
2. 2
   Remove the engine appearance cover.

   

3. 3
   Disconnect the PCM electrical connector.

   

4. 4
   Remove the engine cover.
   Release the clip and disconnect the electrical connector.

   

5. 5
   Remove the following components:

   1. Remove the degas bottle.
      Refer to: Degas Bottle (303-03A Engine Cooling - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation).
   2. Remove the upper air cleaner outlet tube.
      Refer to: Air Cleaner Outlet Tube (303-12A Intake Air Distribution and Filtering – 1.5 L EcoBoost (118 kW/160 L PS) – I4, Removal and Installation).
6. 6
   Disconnect the electrical harness connector, the retainer, and disconnect and remove the crankcase ventilation hose.
   Use common equipment: hose clamp removal/installation tool.

   

7. 7
   Disconnect the EVAP canister purge valve tubes from the TC intake pipe.

   

8. 8
   • Release the harness retainers and disconnect the TC bypass hose.
     Use common equipment: hose clamp removal/installation tool.

   • Loosen the TC intake hose clamp.

   

9. 9
   Remove the bolts and the TC intake pipe assembly.

   

10. 10
    Loosen the coolant pump pulley bolts.

    

11. 11
    Remove the following components:

    1. Remove the RH front wheel and tire.
       Refer to: Wheels and Tires (204-04A Wheels and Tires, Removal and Installation).
    2. Remove the right front fender splash shield.
       Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
12. 12
    Remove the retainers and the lower engine splash shield.

    

13. 13
    Remove and discard the right half shaft bearing lock strip and nut.

    

14. 14
    Remove the right half shaft bracket bolts.

    

15. 15
    Remove the engine plug bolt.

    

16. 16
    Remove the following components:

    1. Remove the starter.
       Refer to: Starter (303-06A Starting System - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation).
    2. Remove the generator.
       Refer to: Generator - 1.5 L EcoBoost (118 kW/160 L PS) - I4 (414-02 Generator and Regulator, Removal and Installation).
17. 17
    Install the following components:

    • Use common shop equipment: Jack Stand
      Use common shop equipment: Wood block

    

18. 18
    Remove the nuts, bolts and engine mount.

    

19. 19
    If equipped with an accessory drive belt tensioner, remove the bolts, the accessory drive belt tensioner and the accessory drive belt.

    

20. 20
    • Release the vacuum hose retainer.

    • Remove the bolt, nut and support bracket.

    

21. 21
    Remove the stud and the cover from the front cover.

    

22. 22
    • Remove the coolant pump bolts and pulley.

    • Disconnect the wiring harness clips.

    

23. 23
    Remove the engine mount stud.

    

24. 24
    • Remove the harness bolt.

    • Disconnect the wiring harness clips and set the wiring harness aside.

    

25. 25
    Remove the engine front cover bolts.

    

26. 26
    Remove the engine front cover.

    

27. 27
    Remove the bolts and the engine mount bracket.

    

28. 28
    Rotate the crankshaft clockwise and set the VCT mark to the 11 o'clock position.

    

29. 29
    Install the special service tool: 303-748 Crankshaft Locking Tool.

    

30. 30
    Slowly rotate the crankshaft clockwise until the crankshaft balance weight contacts the crankshaft locking pin. The engine is now at TDC.

    

31. 31
    Install the special service tools: 303-393-02 Adapter for 303-393, and 303-393A Locking Tool, Flywheel.

    

32. 32
    Remove and discard the crankshaft pulley bolt. Remove the crankshaft pulley.

    

33. 33
    Install the special service tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve.

    

34. 34
    • Rotate the timing belt tensioner clockwise.

    • Install the retaining pin.

    • Remove the timing belt.

    

35. 35
    Remove and inspect the timing belt sprocket.

    

36. 36
    • Disconnect the CKP sensor electrical connector.

    • Remove the bolt and the CKP sensor.

    

Installation

1. 1
   Install the crankshaft sprocket.

   

2. 2
   Install the timing belt in the following sequence.

   

3. 3
   Remove the retaining pin.

   

4. 4
   Install the crankshaft pulley.

   

5. 5
   1. Install the special service tool: 303-1550 Alignment Tool, Crankshaft Damper.

   2. Rotate the crankshaft pulley to align the special tool:
      Use the special service tool: 303-1550 Alignment Tool, Crankshaft Damper.

   3. At this stage, finger-tighten.

   4. Using a new bolt, hand-tighten it at this stage.

   

6. 6
   Tighten the crankshaft pulley bolt in 4 stages.
   Torque:
   Stage 1: 74 lb-ft (100 N·m)
   Stage 2: 90°
   Stage 3: Wait 2 s
   Stage 4: 15°

   

7. 7
   Remove the special service tool: 303-1550 Alignment Tool, Crankshaft Damper.

   

8. 8
   Remove the special service tool: 303-748 Crankshaft Locking Tool.

   

9. 9
   Remove the special service tools: 303-393-02 Adapter for 303-393, and 303-393A Locking Tool, Flywheel.

   

10. 10
    Remove the special service tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve.

    

11. 11
    Rotate approximately 1 3/4 turns.

    

12. 12
    Install the special service tool: 303-748 Crankshaft Locking Tool.

    

13. 13
    Slowly rotate the crankshaft clockwise until the crankshaft balance weight contacts the crankshaft locking pin. The engine is now at TDC.

    

14. 14
    If the special tool cannot be installed, repeat the adjustment according to the previous steps.
    Install the special service tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve.

    

15. 15
    Remove the special service tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve.

    

16. 16
    Install the engine mount bracket and bolts.
    Torque: 41 lb-ft (55 N·m)

    

17. 17
    Install the engine front cover.

    

18. 18
    Install the front engine cover bolts.
    Torque: 89 lb-in (10 N·m)

    

19. 19
    • Attach the wiring harness retainers.

    • Install the harness bolt.
      Torque: 89 lb-in (10 N·m)

    

20. 20
    Install the engine mount stud, hand-tightening it.

    

21. 21
    • Attach the wiring harness retainers.

    • Install the coolant pump pulley and hand-tighten the bolts.

    

22. 22
    Install the cover to the front engine cover and install the stud.
    Torque: 89 lb-in (10 N·m)

    

23. 23
    • Install the support bracket, nut and bolt.
      Torque:
      1: 17 lb-ft (23 N·m)
      2: 62 lb-in (7 N·m)

    • Attach the vacuum hose retainer.

    

24. 24
    If equipped with a drive belt tensioner, install the accessory drive belt, accessory drive belt tensioner pulley and bolts.
    Torque: 35 lb-ft (48 N·m)

    

25. 25
    Tighten the engine mount studs.
    Torque: 89 lb-in (10 N·m)

    

26. 26
    Install the engine mount, nuts and bolts.
    Torque:
    1: 85 lb-ft (115 N·m)
    2: 66 lb-ft (90 N·m)

    

27. 27
    Remove the following components:

    • Use common shop equipment: Jack Stand
      Use common shop equipment: Wood block

    

28. 28
    Install the following components:

    1. Install the alternator.
       Refer to: Alternator — 1.5 L EcoBoost (118 kW/160 L hp) — I4 (414-02 Generator and Regulator, Removal and Installation).
    2. Install the starter motor.
       Refer to: Starter Motor (303-06A Starting System - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation).
29. 29
    Remove the special service tool: 303-748 Crankshaft Locking Tool.

    

30. 30
    Install the engine plug bolt.
    Torque: 177 lb-in (20 N·m)

    

31. 31
    • Install the CKP sensor and bolt.
      Torque: 89 lb-in (10 N·m)

    • Connect the CKP sensor electrical connector.

    

32. 32
    Install the right-hand halfshaft support bracket and install the bolts.
    Torque: 35 lb-ft (48 N·m)

    

33. 33
    1. Install the right-hand halfshaft retaining strap and nuts.
       Torque: 44 lb-in (5 N·m)

    2. Tighten the right-hand halfshaft retaining nut.
       Torque: 18 lb-ft (25 N·m)

    3. Tighten the right-hand halfshaft retaining nut.
       Torque: 18 lb-ft (25 N·m)

    

34. 34
    Install the engine shield and clips.

    

35. 35
    Install the following components:

    1. Install the right-hand front fender splash shield.
       Refer to: Splash Shield - Fender (501-02 Front End Body Panels, Removal and Installation).
    2. Install the right front wheel and tire.
       Refer to: Wheels and Tires (204-04A Wheels and Tires, Removal and Installation).
36. 36
    Tighten the coolant pump pulley bolts.
    Torque: 18 lb-ft (24 N·m)

    

37. 37
    Install the TC inlet pipe assembly and bolts.
    Torque: 71 lb-in (8 N·m)

    

38. 38
    • Tighten the TC inlet pipe clamp.
      Torque: 44 lb-in (5 N·m)

    • Connect the TC bypass hose and attach the harness retainers.
      Use common service equipment: hose clamp removal and installation tool.

    

39. 39
    Connect the EVAP canister purge valve tubes to the TC inlet pipe.

    

40. 40
    Install and connect the PCV hose, and the electrical connector and harness retainer.
    Use common service equipment: hose clamp removal and installation tool.

    

41. 41
    Install the following components:

    1. Install the upper air cleaner outlet pipe.
       Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation).
    2. Install the degas bottle.
       Refer to: Degas Bottle (303-03A Engine Cooling — 1.5 L EcoBoost (118 kW/160 L PS) — I4, Removal and Installation).
42. 42
    Connect the electrical connector and attach the wiring harness clip.

    

43. 43
    Connect the PCM electrical connector.

    

44. 44
    Install the engine outer cover.

    

45. 45
    Use the Powertrain Control Module (PCM) misfire monitor profile correction procedure with the diagnostic scan tool.