SECTION 303-01C: Engine — SVT
2004 Focus Workshop Manual
Procedure revision date: 08/28/2003
Peg, Crankshaft TDC
Anti seize grease
1. General Instructions.
· The positions of the engine mounting and the engine roll restrictor are described looking from the transmission toward the engine.
· If necessary, use special tool 412-108 to remove coolant and ventilation hoses.
· Due to special model variants, some steps do not apply to all vehicles. These are clearly marked in the text.
· If necessary, cut the cable ties and install new cable ties on installation.
2. Remove the battery cover.
3. CAUTION: Disconnect the battery ground cable.
Raise and support the vehicle. For additional information, refer to Section 100-02 .
4. Detach the drive belt cover.
5. Loosen the coolant pump pulley retaining bolts.
6. Remove the accessory drive belt.
1. Rotate the accessory drive belt tensioner clockwise.
2. Remove the accessory drive belt.
7. Remove the crankshaft pulley.
8. Remove the accessory drive belt idler pulley.
9. Remove the coolant pump pulley.
10. CAUTION: The removal of the lower part of the engine front cover is necessary to avoid damage to the timing belt.
Detach the timing belt lower cover.
11. Lower the vehicle.
12. Detach the coolant expansion tank and position it to one side.
13. Detach the power steering fluid reservoir and position it to one side.
14. CAUTION: Insert a suitable wooden block between the oil pan and the trolley jack.
Position the trolley jack with the wooden block under the oil pan and raise the engine so that the engine front mount is free from load.
15. NOTE: Mark the position of the engine front mount.
Remove the engine front mount.
16. Detach the timing belt upper cover.
· Leave the timing belt cover in its installed position.
17. Remove the engine front mount bracket.
· Remove the timing belt upper cover.
18. Remove the electronic ignition (EI) coil cover.
19. Remove the engine upper cover.
20. Disconnect the variable cam timing (VCT) valve electrical connector.
21. CAUTION: Do not pull the cable when removing the spark plug connectors. If necessary, remove the ignition cables from the ignition coil to avoid kinking the cables. Turn the spark plug connectors slightly before removing to loosen the seal.
CAUTION: Pull off the spark plug connectors in line with the spark plugs.
NOTE: Loosening sequence: from the outside to the inside, working diagonally.
Remove the valve cover.
1. Disconnect the spark plug connectors.
2. Detach the positive crankcase ventilation (PCV) hose.
3. Remove ten bolts.
22. Remove the spark plugs.
23. Turn the engine to TDC on cylinder number 1.
24. Detension the timing belt (timing belt shown removed for clarity).
1. Loosen the bolt four turns.
2. Position the tensioner so that the locating tab is at approximately the 4 o'clock position.
3. Line up the hexagonal key slot in the tensioner adjusting washer with the pointer that is located behind the pulley.
25. Remove the timing belt.
26. NOTE: Use an open ended wrench to prevent the camshaft from rotating.
Remove the intake camshaft pulley blanking plug.
27. NOTE: Use an open ended wrench to prevent the camshaft from rotating.
Loosen the camshaft pulley retaining bolts.
1. NOTE: Do not tighten the bolts. The camshaft timing pulleys must be able to turn freely on the camshafts.
Turn the camshafts to the ignition position on cylinder No. 1 and insert the special tool into the camshafts.
2. Rotate the crankshaft to TDC on cylinder No. 1.
3. Remove the blanking plug, install the special tool.
4. CAUTION: Do not kink the timing belt (do not bend the timing belt less than a diameter of 35 mm).
CAUTION: Do not rotate the crankshaft, check that it is still resting against the timing pin.
NOTE: The lug of the belt tensioner must not be hooked into the sheet metal cover during timing belt installation.
Install a new timing belt.
· Starting from the crankshaft timing belt pulley and working counterclockwise install the timing belt, keeping it under tension.
5. CAUTION: Incorrect timing belt tension will result in incorrect valve timing.
Pretension the timing belt.
1. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover.
2. Position the hexagonal key slot in the tensioner adjusting washer to the 4 o'clock position.
3. Tighten the attaching bolt enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 6 mm hexagonal key.
6. CAUTION: Tension the timing belt, working counterclockwise.
Using the hexagonal key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment).
7. Tighten the bolt, while holding the adjusting washer in position.
8. NOTE: Use an open ended wrench to prevent the camshaft from rotating.
Tighten the camshaft pulley retaining bolts.
9. NOTE: Use an open ended wrench to prevent the camshaft from rotating.
Install the intake camshaft pulley blanking plug.
10. Remove the special tool.
11. Remove the special tool 303-465 from the camshafts.
12. NOTE: Turn the crankshaft two revolutions in the normal direction of rotation.
Check the valve timing by inserting the special tool. Correct it if necessary.
· Install the special tool and make sure that the it is contact with the crankshaft.
· Install the special tool into the camshafts; if necessary loosen the timing pulleys and correct the camshaft alignment.
· Remove the special tools.
13. Install the special tool.
14. Install the spark plugs.
15. CAUTION: Use a blunt object (a plastic cable tie) to apply the silicone grease, to avoid damaging the spark plug connectors.
CAUTION: Push on the spark plug connectors, keeping them in line with the spark plugs.
NOTE: Coat the inside of the spark plug connectors with silicone grease to a depth of 5-10 mm.
Install the valve cover.
1. Tighten the bolts in two stages.
§ Stage 1: 2 Nm.
§ Stage 2: 7 Nm.
2. Attach the PCV hose to the valve cover.
§ Connect the VCT actuator electrical connector.
3. Coat the spark plug thread with anti-seize grease, screw in the spark plugs and push in the spark plug connector until it engages.
16. Connect the VCT valve electrical connector.
17. Install the engine upper cover.
18. Install the spark plug cover.
19. NOTE: Position the upper timing belt cover and the center timing belt.
Install the engine front mount bracket.
20. NOTE: Check the seating of the timing belt upper cover gasket and correct as necessary.
Attach the timing belt upper cover.
21. Install the engine front mount.
22. Attach the power steering pump fluid reservoir.
23. Attach the coolant expansion tank.
24. Remove the hydraulic jack and wooden block.
25. Raise and support the vehicle. For additional information, refer to Section 100-02 .
26. Attach the lower timing belt cover.
27. NOTE: Do not tighten the bolts at this stage.
Install the coolant pump pulley retaining bolts.
28. Install the crankshaft pulley.
29. Install the crankshaft pulley.
30. NOTE: Direction of travel on a used drive belt.
Install the drive belt.
1. Attach the multi-groove belt idler pulley.
§ Attach the coolant pump pulley. Do not tighten the bolts at this stage.
2. Install the drive belt by turning clockwise and tension it.
3. Tighten the bolts on the coolant pump pulley.
31. Tighten the bolts on the coolant pump pulley.
32. Atatch the drive belt cover.
33. Lower the vehicle.
34. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
Standard finishing operations:
· Connect the battery negative cable.
· Install the battery cover.
· Check fluid levels and correct if necessary.
· Check the routing of vacuum hoses and cables and secure them with cable ties.