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5.3.
FORD 2.0TDCi (Belt)
Introduced 2003 in the Focus C-Max following an engine development joint venture with PSA (Citroen/Peugeot), these second generation
common rail diesels have a camshaft timing belt (unlike the Ford 2.0 / 2.2 / 2.4 diesels in Mondeo / Transit which are Chain Drive).
It is necessary to dismantle major components for this belt replacement application including removal of the auxiliary belt, starter motor and
coolant expansion tank.
5.3.1
VS4735/P17 Camshaft Locking Pin
Turn the crankshaft until the timing hole in the camshaft sprocket aligns with the datum hole – 4-o-clock position. (Fig.10). Insert VS4735/
P17 Camshaft Locking Pin.
5.3.2
VS4830/F6 Flywheel Locking Pin
Insert VS4830/F6 Locking Pin in to the flywheel to 'set' the crankshaft position prior to 'locking' in place with the Flywheel Locking Tool.
(Fig.11).
5.3.3
VS1012/02 Flywheel Locking Tool and VS4834/01 Adaptor
The Flywheel Locking Tool configuration for the 2.0TDCi engine is obtained by using the Main Plate from VS1012/02 Locking Tool and
attaching to it the VS4834/01 Adaptor. (Fig.12).
the Flywheel Locking Tool Assembly is firmly bolted in position where the starter motor is normally fitted and locates on to the flywheel
through the starter motor aperture. Adjust the Adaptor to 'lock' in to the teeth of the flywheel before firmly bolting it in place, to retain the
crankshaft in a fixed position.
5.3.4
Release and remove the crankshaft pulley bolt (DO NOT discard bolt at this stage).
5.3.5
Remove the crankshaft pulley. WARNING: DO NOT touch the outer sensor ring.
Remover the tensioner pulley and the old timing belt – DO NOT re-fit a used belt.
5.3.6
5.4
Installing new timing belt
Install the new belt with the directional arrows in the direction of crankshaft rotation. Fit new tensioner pulley with its retaining bolt screwed
in finger-tight only.
5.4.1
Use an Allen key to turn the tensioner anti-clockwise to apply tension to the belt. Check that the tensioner pointer is positioned on the
left side of the tensioner window, and tighten the pulley retaining bolt. (Fig.13).
5.4.2
Prepare to re-fit the crankshaft pulley. WARNING: DO NOT touch the outer sensor ring.
5.4.3
Use the old pulley centre bolt to install the crankshaft pulley, tighten the bolt to 50Nm.
5.4.4
Remove the VS4830/F6 Flywheel Locking Pin and VS4735/P17 Camshaft Locking Pin. Remove the Flywheel Locking Tool.
5.4.5
Turn the crankshaft 4 times, by hand, in the normal direction of rotation. Align the timing and datum holes for the camshaft sprocket and
insert VS4735/P17 Pin. Insert the VS4830/F6 Flywheel Locking Pin and the Flywheel Locking Tool.
5.4.6
Release and remove the crankshaft pulley bolt and discard. Remove the crankshaft pulley.
5.5
Final Tension Position
Use an Allen key on the tensioner to maintain tension on the timing belt. Slacken the tensioner retaining bolt and position the pointer
CENTRALLY within the window of the tensioner. Tighten the tensioner bolt.
5.5.1
Install the crankshaft pulley with a new centre bolt and tighten in 2 stages – 70Nm. + 62 degrees.
5.5.2
Remove all tools.
Fig.12
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be
sorted, taken to a recycling centre and disposed of in a manner which is compatible with the environment.
NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.
IMPORTANT: No liability is accepted for incorrect use of this product.
WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required for any claim.
© Jack Sealey Limited
Environmental Protection
Sole UK Distributor, Sealey Group,
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk,
IP32 7AR
Original Language Version
01284 757500
01284 703534
VS4830 Issue: 2(I) - 27/07/15
Fig.13
www.sealey.co.uk
sales@sealey.co.uk
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