Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake2B•6 CVH and PTE engine in-car repair procedures8.13 Checking the tension of the timingbeltof the crankshaft sprocket, and then pull thebelt vertically upright on its right-hand run.Keep it taut, and engage it with the teeth ofthe camshaft sprocket. If the original belt isbeing refitted, check that the belt’s directionof travel is correct, and realign the belt-tosprocketmarks made during removal, toensure that the exact original engagementpositions are retained. When the belt is fullyfitted on the sprockets, check that thesprocket positions have not altered.9 Carefully manoeuvre the belt around thetensioner, and engage its teeth with the waterpump sprocket, again ensuring that the TDCpositions of the crankshaft and camshaftare not disturbed as the belt is finallylocated.10 Refit the lower timing belt cover, andtighten its retaining bolts to the specifiedtorque setting. Refit the crankshaft pulley, andtighten its retaining bolt to the specifiedtorque setting.11 To take up belt slack, loosen off thetensioner and move it towards the front of thecar to apply an initial tension to the belt.Secure the tensioner in this position, thenremove the flywheel ring gear locking device.12 Rotate the crankshaft through two fullrevolutions in (the normal direction of travel),returning to the TDC position (camshaftsprocket-to-cylinder head). Check that thecrankshaft pulley notch is aligned with theTDC (0) mark on the lower half of the timingbelt cover.13 Grasp the belt between the thumb andforefinger, at the midway point between thecrankshaft and camshaft sprockets on theright-hand side. If the belt tension is correct, itshould just be possible to twist the beltthrough 90º at this point (see illustration). Toadjust the belt, loosen off the tensionerretaining bolts, move the tensioner asrequired using a suitable screwdriver as alever, then retighten the retaining bolts. Rotatethe crankshaft to settle the belt, thenrecheck the tension. It may take two or threeattempts to get the tension correct. Oncompletion, tighten the tensioner bolts to thespecified torque wrench setting.14 It should be noted that this setting isapproximate, and the belt tension should berechecked by a Ford dealer with the specialtensioner-setting tool at the earliestopportunity.15 Refit the starter motor (refer to Chapter5A).16 Refit the rocker cover (see Section 4) andthe upper timing belt cover (see Section 7).17 Refit the auxiliary drivebelt, adjust itstension as described in Chapter 1, then refitthe crankshaft pulley lower cover.18 On completion, reconnect the batteryearth lead.9 Timing belt tensioner andsprockets - removal,inspection and refitting3Tensioner1 Set the engine at TDC for No 1 piston oncompression as described in Section 3, thenrefer to Section 7 and remove the timing beltupper cover.2 Loosen off the two bolts securing the timingbelt tensioner. Using a large screwdriver, prisethe tensioner to one side to release the timingbelt tension.3 Remove the two tensioner bolts, andwithdraw the tensioner from behind the timingbelt.4 Check the condition of the tensioner,ensuring that it rotates smoothly on itsbearings, with no signs of roughness orexcessive free play. Renew the tensioner if indoubt about its condition.5 To refit the tensioner, first check that theengine is still positioned at TDC for No 1piston on compression, with both thecamshaft and crankshaft sprocket timingmarks correctly aligned as described inSection 3.6 Refit the tensioner, guiding it in positionaround the timing belt, and secure with thetwo bolts. Move the tensioner towards thefront of the car, to apply an initial tension tothe belt. Secure the tensioner in this position.7 Adjust the timing belt tension as describedin Section 8, paragraphs 12 to 14.8 Refit the timing belt upper cover oncompletion.9.13a Refit the camshaft sprocket . . .Camshaft sprocket9 Set the engine at TDC for No 1 piston oncompression as described in Section 3, thenrefer to Section 7 and remove the timing beltupper cover.10 Loosen off the two bolts securing thetiming belt tensioner. Using a largescrewdriver, prise the tensioner to one side torelease the timing belt tension. Slip the timingbelt off the camshaft sprocket.11 Pass a bar through one of the holes in thecamshaft sprocket to prevent the camshaftfrom rotating, then unscrew and remove thesprocket retaining bolt. Note that this boltmust be renewed when refitting the camshaftsprocket. Remove the sprocket, noting theWoodruff key fitted to the camshaft; if the keyis loose, remove it for safekeeping.12 Check the condition of the sprocket,inspecting carefully for any wear grooves,pitting or scoring around the teeth.13 Install the Woodruff key, then fit thecamshaft sprocket with a new retaining bolt.The threads of the bolt should be smearedwith thread-locking compound prior to fitting.Tighten the retaining bolt to the specifiedtorque wrench setting (see illustrations).14 Check that the engine is still positioned atTDC for No 1 piston on compression, withboth the camshaft and crankshaft sprockettiming marks correctly aligned as described inSection 3.15 Slip the timing belt over the camshaftsprocket, then move the tensioner towardsthe front of the car to apply an initial tension tothe belt. Secure the tensioner in this position.16 Adjust the timing belt tension asdescribed in Section 8, paragraphs 12 to 14.17 Refit the timing belt upper cover oncompletion.Crankshaft sprocket18 Remove the timing belt as described inSection 8.19 The crankshaft sprocket can now bewithdrawn. If it is a tight fit on the crankshaft,a puller or two large screwdrivers can be usedto release its grip. Withdraw the thrustwasherand the Woodruff key from the crankshaft.20 Check the condition of the sprocket,9.13b . . . and tighten the retaining bolt tothe specified torque whilst retaining thesprocket as shown