Timing belt replacement for 2.2L duratorq-tdci engine

You will need: all the tools to remove and install wheel mudguards and fender liner, as well as special clamps to fix the crankshaft and exhaust camshaft pulley.

NOTE: Work on a manhole, overpass or, if possible, on a lift.

1. Disconnect wires from the plug "minus" of the storage battery.

2. Securely support the engine.

3. Remove the right front wheel.

4. Remove the right front wheel liner (see Removal and installation of wheel mudguards and fender liner).

5. Remove the right suspension bracket of the power unit (refer to Right Powertrain Mount Replacement).

6. Remove the front timing cover.

7. Remove the starter (see Removing and installing the starter).

Pic. 5.51. Fixing the crankshaft of the engine from turning.

8. Fix the crankshaft from turning by installing a special clamp (pic. 5.51) into the hole on the cylinder block, aligning the holes on the cylinder block and flywheel.

Pic. 5.52. Fixing the exhaust camshaft pulley.

9. Fix the exhaust camshaft pulley from turning by installing a special clamp (pic. 5.52) into the hole on the pulley, aligning the holes on the pulley and the cylinder head.

10. Loosen the timing belt tension by loosening the central tensioner bolt by inserting the hexagon into the adjusting hole and turning the tensioner pulley counterclockwise.

11. Remove the belt.

WARNING: When removing the timing belt, do not rotate the crankshaft or camshaft of the engine.

12. Put on a new belt.

13. Set the position of the tension roller depending on the temperature of the engine (see fig. 5.42) and tighten the center bolt of the timing belt tensioner. The tension roller spring will set the required tension.

14. Remove the clamps that fixed the position of the crankshaft (see fig. 5.51), and the exhaust camshaft pulley (see fig. 5.52).

15. Turn the crankshaft four turns clockwise.

16. Check up correctness of installation of a belt of a drive of the gas-distributing mechanism. To check, insert a special tool into the hole on the camshaft pulley (see fig. 5.52 and 8), by aligning the holes on the pulley and cylinder head. The special tool can only be installed with correctly set valve timing.

17. If the timing belt is installed correctly, install all removed parts in the reverse order of removal.