Continental: Expert Tips for Changing Timing Belts

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Detailed instructions for timing belt kit CT1092WP1 in a Ford Focus II (DA), 1.6-liter TDCI, MY 2005 with engine code HHDA
Continental shows how to avoid errors when changing belts

Significant errors are frequently committed when changing the timing belt.
To ensure that the belt change operation goes smoothly, the Continental provides fitters with a detailed installation guide. In this, experts provide a step-by-step explanation of the correct change procedure.

The manufacturer recommends changing the timing belt up to 12/2005 every 240,000 km/10 years.

The labor time is 1.7 hours.

Tip: The multi V-belt must be changed at the same time as the timing belt. The manufacturer recommends changing the multi V-belt up to 12/2005 every 240,000 km/10 years.

Fitters need the special tools specified below for the procedure. You will also find the tools in the Tool Box V04.

1. 2x crankshaft centering tool OE (303-732), Tool Box V04/18

2. Crankshaft locking pin OE (303-734), Tool Box V04/17

3. Camshaft centering tool OE (303-735), Tool Box V04/19

Preparatory work:

Identify the vehicle using the engine code.

Disconnect the vehicle battery. Do not turn the crankshaft and camshaft once the timing belt has been removed. Turn the engine in the normal direction of rotation (clockwise) unless otherwise specified.

Turn the engine only at the crankshaft sprocket and not at other sprockets. Only carry out checks and adjustments when the engine is cold. Avoid contact between the belt and harmful substances, such as engine oil, fuel or coolant.

Comply with all the tightening torques specified by the vehicle manufacturer.

Removal:

Remove ancillary drive belt, drain coolant at expansion reservoir hose, cover alternator in advance.
Support engine securely using jack and pad.
After unscrewing 4 nuts, remove front engine mount (nuts must be changed: 80 Nm top and 90 Nm bottom).
Remove upper guard, then unscrew 4 horizontal bolts of engine mount flange (55 Nm), loosen CS vibration damper using impact wrench and remove, then finally remove lower guard and re-fit vibration damper (Figs. 1, 2, 3).

Ford Focus II (DA), 1.6-liter TDCI, MY 2005 with engine code HHDA — Continental AG

1. Set valve timings to TDC mark of cylinder 1.

2. Camshaft sprocket bore (at approx. 10 o’clock position) must be aligned with bore in cylinder head (Fig. 4) such that locking tool OE (303-735), Tool Box V03/19 can be inserted into bore (Fig. 5).

3. Check position of crankshaft. To do so, turn round bore of crankshaft timing belt sprocket/sensor sprocket to 12 o’clock position until it is aligned with bore behind it. Insert crankshaft centering tool OE (303-732), Tool Box V04/18 into bore of crankshaft timing belt sprocket/sensor sprocket and engine block bore (Figs. 6, 7).

4. Lock timing belt sprocket of high-pressure pump in approx. 5 o’clock position with crankshaft centering tool OE (303-732), Tool Box V04/18 (Figs. 8, 9).

5. Remove timing belt guide on crankshaft timing belt sprocket/sensor sprocket (approx. 5 o’clock position) and sensor (approx. 7 o’clock position) (Fig. 10).

6. Loosen tensioning pulley nut and release tension on timing belt.

7. Timing belt can now be removed.

1. Crankshaft timing belt sprocket/sensor sprocket can slide off crankshaft when removing timing belt! Before fitting new timing belt, check that pulley spring for crankshaft timing belt sprocket/sensor sprocket is correctly positioned (Fig. 11). Fit components contained in timing belt kit. Check remaining sprockets such as camshaft sprocket and crankshaft sprocket for damage. When fitting tensioning pulley, ensure that tensioning pulley fork is installed centrally above cam (Fig. 12).

2. Fit timing belt in direction of crankshaft rotation. Take care to ensure that timing belt is not kinked during fitting! Timing belt must be tight between sprockets on tight side.

3. Tension timing belt via tensioning pulley. To do so, turn tensioning pulley eccentric counterclockwise using hex key and tension until marks (Figs. 12, 13) align. Tighten tensioning pulley nut (23 Nm).

4. Remove locking and centering tools.

5. Re-install timing belt guide on crankshaft timing belt sprocket/sensor sprocket (approx. 5 o’clock position) and sensor (approx. 7 o’clock position) (Figs. 14, 15). Ensure, as you do so, that sensor does not touch sensor ring (Figs. 16, 17).

6. Turn engine through 10 revolutions at crankshaft in direction of engine rotation.

7. Set valve timings to TDC mark of cylinder 1. Setting as specified in Removal above. It must be possible to insert locking and centering tools again. Tensioning pulley marks (Fig. 13) must be aligned. If marks are not aligned, repeat setting process as described in items 3-6. Then remove all locking and centering tools again.

8. Assembly and finalization in reverse order to removal. Fit new crankshaft bolt and tighten in two stages. Stage 1: 30 Nm, stage 2: 180 degrees. To do so, lock flywheel using crankshaft locking pin OE (303-734), Tool Box V04/17, turn crankshaft until locking tool is aligned with one of slots in flywheel (Fig. 18). Then remove locking tool again.