Ford 303-01A Engine 2.0L Duratec HE 125kW-170PS MI4 Instruction Manual

Ford 303-01A Engine 2.0L Duratec HE 125kW-170PS MI4

Timing Drive Components

Special Tool(s) / General Equipment

Removal

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. 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 the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

NOTE: If it is necessary to install a new timing chain tensioner, a cast iron tensioner is to be replaced with an aluminum tensioner (6K254). The existing bolts must be discarded and replaced with new bolts (6K282).

1. With the vehicle in NEUTRAL, position it on a hoist
   • Refer to: Jacking and Lifting – Overview (100-02 Jacking and Lifting, Description and Operation).
2. Remove the following items:
3. Remove the fuel injection pump.

  *  **Refer to:** Fuel Injection Pump (303-04 Fuel Charging and Controls – 2.0L Duratec-HE (125kW/170PS) – MI4) .
2.  **Remove the engine front cover.**
  *  **Refer to:** Engine Front Cover (303-01 Engine – 2.0L Duratec-HE (125kW/170PS) – MI4) .

3. Remove the nuts and position the bracket aside.

4. Remove the stud bolts and the fuel injection pump housing.

5. NOTICE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
   Install the Camshaft Alignment Tool into the rear of both of the camshaft slots as shown and tighten the retainer. Use Special Service Tool: 303-1565 Alignment Tool, Camshaft.

6. NOTICE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine  rotation can result in engine damage.
   Using the flats on the exhaust and intake camshaft to prevent camshaft rotation, loosen the exhaust and intake VCT unit bolts.

7. NOTE: If equipped with cast iron timing chain tensioner.

8. Using a small pick, release and hold the ratchet mechanism.

9. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.

10. Insert a holding pin into the hole to retain the tensioner.

11. NOTE: If it is necessary to install a new timing chain tensioner, a cast iron tensioner is to be replaced with an aluminum tensioner (6K254). The existing bolts must be discarded and replaced with new bolts (6K282).
    NOTE: If equipped with cast iron timing chain tensioner. Remove the bolts and the timing chain tensioner.

12. NOTE: If equipped with aluminum timing chain tensioner. Remove the bolts and the timing chain tensioner.

13. Remove the timing chain tensioner arm.

14. Remove the bolts and the timing chain guide.

15. Remove the timing chain.

Installation

1. Install the timing chain.

2. Install the timing chain guide and the bolts. Torque: 89 lb.in (10 Nm)

3. Install the timing chain tensioner arm.
   NOTE: If equipped with aluminum timing chain tensioner.
   NOTE: If the timing chain tensioner plunger is not pinned in the compressed position, follow the next step.

4. Reset the timing chain tensioner.

   • Position the timing chain tensioner in a soft-jawed vise.
   • Spread the ends of the ratchet wire clip apart.
   • Using the soft-jawed vise, compress the plunger to the reset position.
   • Install a locking pin in the 2 holes of the timing chain tensioner body to hold the plunger in place.

5. NOTE: If equipped with aluminum timing chain tensioner.
   NOTE: Do not remove the locking pin until the tensioner bolts are tightened.

6. Install the timing chain tensioner and the bolts.

  *  **Torque:** 89 lb.in (10 Nm)
2. Remove the locking pin.![Ford-303-01A-Engine-2-0L-Duratec-HE-125kW-170PS-MI4-FIG-17](https://manuals.plus/wp-content/uploads/2022/12/Ford-303-01A-Engine-2-0L-Duratec-HE-125kW-170PS-MI4-FIG-17.jpg) **NOTE:** If equipped with cast iron timing chain tensioner.  

NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.

6. NOTICE: Do not compress the ratchet assembly. This will damage the ratchet assembly. Using the edge of a vise, compress the timing chain tensioner plunger.

7. Using a small pick, push back and hold the ratchet mechanism.

8. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

9. Install a locking pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.

10. NOTE: If equipped with cast iron timing chain tensioner.
    NOTE: Do not remove the locking pin until the tensioner bolts are tightened.
    Install the timing chain tensioner and the bolts. Torque: 89 lb.in (10 Nm)

11. NOTE: If equipped with cast iron timing chain tensioner. Remove the locking pin.

12. NOTICE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    NOTE: Using the flats on the camshafts to prevent camshaft rotation. Tighten the exhaust and intake VCT unit bolts in 2 stages.
    Torque:

13. Stage 1: 37 lb.ft (50 Nm)

14. Stage 2: 90°

15. Remove Special Service Tool: 303-1565 Alignment Tool, Camshaft.

16. Install the fuel injection pump housing and the stud bolts in 2 stages.
    Torque:

17. Stage 1: 71 lb.in (8 Nm)

18. Stage 2: 60°

19. Position back the bracket and install the nuts. Torque: 177 lb.in (20 Nm)

20. Install the following items:

21. Install the engine front cover.
    Refer to: Engine Front Cover (303-01 Engine – 2.0L Duratec-HE (125kW/170PS) – MI4) .

22. Install the fuel injection pump.
    Refer to: Fuel Injection Pump (303-04 Fuel Charging and Controls – 2.0L Duratec-HE (125kW/170PS) – MI4) .

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