TIMING BELT REMOVAL/INSTALLATION [YF (2.0L Zetec)]

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Valve Cover

Removal and Installation

1. Remove the air cleaner outlet pipe. (See AIR CLEANER REMOVAL/INSTALLATION [YF (2.0L Zetec)].)

2. Remove the ignition wires from the spark plugs.

3. Disconnect the throttle cables.

• Disconnect the speed control actuator cable (if equipped).

• Disconnect the accelerator cable.

4. Remove the valve cover.

(1) Remove the studbolts

(2) Remove the bolts.

Caution

• The valve cover sealing surfaces are soft materials. Do not use abrasive grinding discs to remove gasket material; only use manual scrapers. Do not scratch or gouge sealing surfaces or oil leaks may occur.

5. Clean and inspect the sealing surfaces of the valve cover and the cylinder head. Both surfaces must be clean and flat.

6. To install, reverse the removal procedure.

• Install a new valve cover gasket if damaged.

Timing Belt Cover - Upper and Lower

Removal and Installation

1. Disconnect the battery ground cable.

2. Remove the crankshaft pulley. (See FRONT OIL SEAL REPLACEMENT [YF (2.0L Zetec)].)

3. Remove the bolts and the lower timing belt cover.

4. Lower the vehicle.

5. Install the SST.

6. Remove the ground strap.

7. Remove the engine mount upper bracket.

8. Remove the studs.

9. Remove the bolts and the upper timing belt cover.

10. To install, reverse the removal procedure.

Timing Belt

Removal

1. Remove the valve cover.

2. Remove the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [YF (2.0L Zetec)].)

3. Remove the catalytic converter. (See CATALYTIC CONVERTER REMOVAL/INSTALLATION [YF (2.0L Zetec)]

4. Remove the bolt, nut, and position the coolant tube aside.

5. Rotate the crankshaft to just before top dead center (TDC) (No. 1 cylinder).

6. Remove the stud.

7. Install the SST.

Note

• Make sure the correct (second) notch in the pulley is indexed to the lower cylinder block.

8. Rotate the crankshaft clockwise against the peg to bring it to TDC (No. 1 cylinder).

9. Loosen the water pump pulley bolts.

10. Remove the timing belt covers.

11. Remove the water pump pulley.

12. Remove the drive belt idler pulley.

Note

• Installation of the alignment tool into the exhaust camshaft may require the camshafts to be rotated clockwise slightly.

13. Install the SST and align the camshafts.

14. Raise and support the vehicle.

15. Remove the bolts and the engine mount lower bracket.

16. Loosen the timing belt tensioner pulley and allow to slide down to the bottom of its travel.

Caution

• If the camshaft timing belt is to be reused, mark the direction of the camshaft timing belt to rotation of camshaft prior to removal or premature wear or failure may occur.

17. Slide the timing belt off of the camshaft and crankshaft sprockets.

18. Inspect the timing belt for wear. Install a new belt if necessary.

Installation

Note

• Make sure the correct (second) notch in the pulley is indexed to the lower cylinder block.

1. Slide the crankshaft pulley onto the crankshaft and confirm the crankshaft position is at TDC (No. 1 cylinder) by rotating it clockwise against the alignment peg.

• Remove the crankshaft pulley.

2. Lower the vehicle.

3. Confirm that the timing belt tensioner is installed correctly with the tab positioned in the slot in the inner timing cover.

4. Install the timing belt onto the timing belt sprockets.

5. Adjust the timing belt tensioner.

(1) Using a 6 mm Allen wrench, rotate the adjuster counterclockwise and align the marks as shown.

(2) Tighten the tensioner pulley bolt.

6. Raise the vehicle.

7. Install the front engine mount lower bracket.

8. Install the drive belt idler pulley.

9. Install the water pump pulley.

• Hand tighten the bolts.

10. Install the timing belt covers.

11. Tighten the water pump pulley bolts.

12. Remove the SST.

13. Install the stud.

14. Install the coolant tube.

15. Install the catalytic converter. (See CATALYTIC CONVERTER REMOVAL/INSTALLATION [YF (2.0L Zetec)]

16. Remove the SST.

17. Install the valve cover.

18. Install the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [YF (2.0L Zetec)].)

Timing Drive Components - Timing Sprockets

Removal

1. Remove the timing belt.

2. Raise and support the vehicle.

Caution

• The camshaft alignment tool is not recommended to hold the camshafts in place when removing or tightening the bolts. Damage to camshaft may result.

Note

• Use an open-end wrench to keep each camshaft from rotating.

3. Remove the bolts and the camshaft timing sprockets.

Installation

1. Install the camshaft sprockets onto the camshafts and loosely install the bolts.

2. Raise and support the vehicle.

Note

• Make sure the correct (second) notch in the pulley is indexed to the lower cylinder block.

3. Slide the crankshaft pulley onto the crankshaft and confirm the crankshaft position is at TDC (No. 1 cylinder) by rotating it clockwise against the alignment peg.