Sunday, October 30, 2011

Timing Chain components dis-assembly on 2003 Ford Focus?


Timing Chain Cover, Chain, Sprockets, & Seal




Removal & Installation



2.3L (VIN Z) Engine

CAUTION
The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Negative battery cable
    Accessory belt splash shield
    Accessory drive belt
    Cylinder head cover
  3. Using the crankshaft pulley bolt, rotate the crankshaft clockwise to the No. 1 piston at Top Dead Center (TDC).
  4. Install the camshaft alignment plate 303-465 to the rear of the camshafts.
    CAUTION
    The special tool Camshaft Alignment Plate (T94P-6256-CH) is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.


    NOTE
    The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
  5. Remove the plug bolt and install Special Tool Crankshaft Timing Peg 303-507 to prevent the engine from being rotated in the clockwise direction.

    Click image to see an enlarged view
    Fig. Plug bolt location-2.3L (VIN Z) engine,
  6. Install the special tools Holding Fixture (205-126) and Adapter (205-072-02) to the crankshaft pulley.

    Click image to see an enlarged view
    Fig. Using crankshaft holding fixture 205-126-2.3L engine
  7. Remove or disconnect the following

    Crankshaft pulley bolt
    Crankshaft pulley
    Crankshaft Position (CKP) sensor
    Accessory drive belt tensioner
    Power steering pressure (PSP) switch
    PSP tube bracket
    Power steering pump pulley, using Special Tool 211-016
    PSP tube
    Power steering pump mounting bolts and position the pump aside
    Water pump pulley
  8. Support the engine from above with a suitable support fixture.
  9. Remove or disconnect the following:

    Engine mounts
    Idler pulley
    Front cover
  10. Compress the timing chain tensioner and insert a paper clip into the hole to secure the piston.
  11. Remove or disconnect the following:
    NOTE
    Use a wrench on the flats of the camshaft to prevent camshaft rotation. Do not rely on the Camshaft Alignment Plate to prevent rotation. Damage to the camshaft can occur.



    Timing chain tensioner
    Right hand timing chain guide
    Timing chain
    Camshaft sprockets



    Click image to see an enlarged view
    Fig. Power steering pump removal tool 211-016.


    Click image to see an enlarged view
    Fig. Securing the timing chain tensioner piston with a paper clip.
To install:
  1. Remove the Camshaft Alignment tool.
    CAUTION
    Do not rotate the camshafts. Damage to the valves and pistons can occur. If the camshaft sprockets were not removed, use the flats on the camshafts to prevent camshaft rotation and loosen the sprocket bolts.
  2. Install or connect the following:

    Camshaft sprockets and the bolts. Do not tighten the bolts at this time.
    LH timing chain guide and tighten the bolts to 89 inch lbs. (10 Nm)
    Timing chain
    RH timing chain guide
    Timing chain tensioner and tighten the bolts to 89 inch lbs. (10 Nm). Remove the paper clip to release the piston.
  3. Install the Camshaft Alignment tool.
  4. Using a wrench on the flats on the camshafts to prevent camshaft rotation, tighten the bolts to 48 ft. lbs. (65 Nm).
    CAUTION
    Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
  5. Clean and inspect the mounting surfaces of the engine and the front cover.
    NOTE
    The engine front cover must be installed and the bolts tightened within four minutes of applying the silicone gasket and sealant.
  6. Apply a 0.10 inch (2.5 mm) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 0.10 inch (2.5 mm) bead of silicone gasket and sealant to the front cover.
  7. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:
    1. Tighten the 8 mm bolts to 89 inch lbs. (10 Nm).
    2. Tighten the 13 mm bolts to 35 ft. lbs. (48 Nm).
      NOTE
      Lubricate the oil seal with clean engine oil.



      Click image to see an enlarged view
      Fig. Front cover torque sequence-2.3L (VIN Z) engine
  8. If a new seal is being installed, use the special tool Front Seal Installer 303-096 to install the crankshaft front oil seal.
  9. Position the power steering pump and tighten the four bolts to 18 ft. lbs. (25 Nm).
  10. Using the special tool Teflon Seal Installer 211-D027, install a new O-ring on the PSP tube fitting.
  11. Install or connect the following:
    NOTE
    Apply clean engine oil on seal area before installing.



    PSP tube fitting and tighten to 15 ft. lbs. (20 Nm)
    PSP tube bracket and tighten the nut to 10 ft. lbs. (13 Nm)
    PSP switch
    Water pump pulley and tighten the bolts to 18 ft. lbs. (25 Nm)
    Accessory drive belt idler pulley and tighten the bolt to 18 ft. lbs. (25 Nm)
    Accessory drive belt tensioner and tighten the bolts to 18 ft. lbs. (25 Nm)
  12. Install the crankshaft pulley and hand-tighten the bolt.
    NOTE
    Do not reuse the crankshaft damper bolt.


    CAUTION
    Only hand-tighten the bolt or damage to the front cover can occur.


    NOTE
    This step will correctly align the crankshaft pulley to the crankshaft.
  13. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
  14. Rotate the pulley as necessary to align the bolt holes.
    CAUTION
    Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover.
  15. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt as follows:
    1. Step 1: Tighten to 74 ft. lbs. (100 Nm).
    2. Step 2: Tighten an additional 90 degrees.
  16. Remove the special tools.
  17. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
  18. Remove the Crankshaft Timing Peg.
  19. Remove the Camshaft Alignment tool.
  20. Turn the engine two complete revolutions.
  21. Install the Crankshaft Timing Peg.
    NOTE
    Only turn the engine in the normal direction of rotation.
  22. Turn the crankshaft until the No. 1 piston is at top dead center (TDC).
    CAUTION
    Only hand-tighten the bolt or damage to the front cover can occur.
  23. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, correct the engine timing.
  24. Using the Camshaft Alignment tool, check the position of the camshafts. If it is not possible to install the special tool, correct the engine timing.
  25. Remove the Camshaft Alignment tool.
  26. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
  27. Remove the Crankshaft Timing Peg.
  28. Install or connect the following:

    Engine plug bolt and tighten it to 15 ft. lbs. (20 Nm)
    Engine mounts and tighten the bolts to 35 ft. lbs. (48 Nm)
    CKP sensor
    Cylinder head cover
    Accessory drive belt
    Accessory drive belt splash shield
    Negative battery cable
  29. Fill and purge the power steering fluid.
  30. Fill the cooling system to the correct level.
  31. Fill the engine with oil.
  32. Start then engine and check for leaks.