Замена ремня ГРМ 1.8 Endura DI Ford Fiesta 1996

Removal

1. Slacken the suspension strut nuts by five turns on both sides (left-hand side shown).

2. Raise and support the vehicle.

3. Detach the lower suspension arm from the spindle carrier on both sides (left-hand side shown).

4. NOTICE: The inner joint must not be bent at more than 18 degrees.

   Detach the left-hand front drive halfshaft.

   • Detach the vibration damper.
   • Separate the clamping strap and slide back the boot.
   • Pull out the front drive halfshaft from the tripode housing.
   • Remove the grease from inside the joint.
   • Secure the front drive halfshaft.

5. NOTE: Escaping fluid.

   Remove the right-hand front drive halfshaft with intermediate shaft.

   • Remove the retaining bracket.
   • Pull the intermediate shaft from the transaxle.
   • Discard the nuts and retaining bracket.
   Seal the transaxle opening with auxiliary plugs.

6. Disconnect the starter motor.

7. Detach the generator intermediate shaft.

   1. Remove the intermediate shaft bearing retaining bolts.
   2. Remove the vibration damper retaining bolts.

8. Remove the blanking plug and insert the special tool.

   • Carefully turn the crankshaft until it touches the special tool.

9. Remove the starter motor.

10. NOTE: Make sure that the engine does not rotate during installation of the special tool.

    NOTE: Make sure that the engine is in the TDC position before the special tool is engaged.

    NOTE: Make sure that the special tool is engaged correctly.

    Install the special tool and lock the engine.

11. Detach the shift mechanism.

12. Secure the shift mechanism, using cable ties.

13. NOTICE: If the flexible pipe is bent too sharply, damage may be caused which can lead to failure of the component.

    Protect the flexible pipe with a support sleeve or suitable splints.

14. Detach the exhaust from the flexible pipe.

15. Disconnect the air conditioning (A/C) compressor electrical connector and detach it from the A/C compressor.

16. Detach the A/C compressor (four bolts) and secure it to one side.

17. Remove the engine roll restrictor.

18. Detach the accessory drive belt cover.

19. Lower the vehicle.

20. Remove the battery and the battery tray.

21. Detach the coolant expansion tank and position it to one side.

22. Install the special tools.

23. Remove the engine front mount.

24. Remove the engine rear mount.

    1. Remove the transaxle breather.
    2. Remove the three nuts.
    • Unclip the clutch pipe.

25. NOTE: Do not stress the cables and hoses.

    Using the special tool, lift the engine front and lower the engine rear.

26. Slacken the accessory drive belt and remove it.

27. Disconnect the fuel lines.

    1. Disconnect the fuel return line.
    2. Disconnect the fuel feed line.
    3. Disconnect the leak-off line.
    4. Detach the clamp.

28. Remove the timing belt lower cover (engine shown removed for clarity).

29. Detach the engine bracket (engine shown removed for clarity).

30. Remove the valve cover.

31. Insert the special tool into the camshaft groove.

32. Raise and support the vehicle.

33. Slacken the timing belt (engine shown removed for clarity).

34. Remove and discard the timing belt tensioner.

35. Remove and discard the timing belt.

36. Using the special tool, loosen the camshaft pulley retaining bolt by five turns.

37. Using the special tool, release the camshaft pulley from the taper.

Installation

1. NOTE: Use only latest level timing belts. These are identified by a laser etched Ford logo.

   Check the new timing belt.

2. Install a new, automatic timing belt tensioner.

3. Check the automatic timing belt tensioner.

   1. Make sure that the tensioner pointer rotates clockwise freely.
   2. Arrow denotes counterclockwise rotation of tensioner.

4. NOTE: Move timing belt tensioner adjustment arm to 3 o'clock position.

   Install the timing belt tensioner and tighten the bolt finger tight.

5. NOTICE:

    Never install a used timing belt.

    Install the timing belt with the direction arrows in the direction of engine rotation.

    Only install the timing belt after the engine has cooled to workshop temperature.

   NOTE: Install a new timing belt.

   Install the timing belt.

6. NOTE: The camshaft pulley must be able to turn freely on the camshaft taper.

   Tighten the camshaft pulley bolt finger tight and then loosen by 1/2 a turn.

7. NOTE: Using an allen key, maintain tension until tensioner bolt is tightened.

   Tension the timing belt.

   1. Turn the timing belt tensioner adjustment arm counter-clockwise to tension the timing belt slightly.
   2. The pointer must be positioned between the sides of the window.
   3. Tighten the timing belt tensioner retaining bolt.

8. Using the special tool, tighten the camshaft pulley retaining bolt.

9. Remove the special tool.

10. Raise and support the vehicle.

11. Release the special tool.

12. Remove the special tool.

13. NOTE: Only turn the engine in the normal direction of rotation.

    NOTE: Using paint or typing correction fluid, mark the crankshaft pulley to show TDC.

    Turn the engine six revolutions.

14. Install the special tool.

15. NOTE: Only turn the engine in the normal direction of rotation.

    Turn the engine to TDC.

    • Turn the engine slowly until the crankshaft stops.

16. NOTICE:

     Make sure that the engine does not rotate during installation of the special tool.

     Make sure engine is at the TDC position before locking the special tool.

     Make sure that the special tool engages correctly.

    Using the special tool, lock the engine.

17. Lower the vehicle.

18. NOTE: The auto tensioner pointer may move slightly upwards in the window.

    Check that the autotensioner pointer is positioned in between the sides of the window.

    1. If the pointer is in the window, go to following step.
    2. If the pointer is not in the window, repeat the procedure.

19. Install the special tool.

    • If the special tool cannot be installed, repeat the procedure.

20. Remove the special tools.

21. NOTE: Check the valve cover gasket and install a new if necessary.

    Install the valve cover.

22. NOTE: Position the bolts in the bracket before installing the bracket.

    Install the engine bracket lower retaining bolts (shown on removed engine for clarity).

23. Install the engine bracket upper retaining bolts (shown on removed engine for clarity).

24. Install the timing belt lower cover (shown on removed engine for clarity).

25. Install the accessory drive belt.

26. Using the special tool, position the engine, so the engine mounts can be installed.

27. NOTE: Do not fully tighten the nuts at this stage.

    Install the engine rear mount.

    1. Install the transaxle breather.
    2. Tighten the nuts finger tight.
    • Clip the clutch pipe.

28. NOTE: Do not fully tighten the nuts and bolts at this stage.

    Install the engine front mount.

29. Raise and support the vehicle.

30. Install the engine roll restrictor.

31. Install the shift mechanism.

32. Install the A/C compressor.

    1. Install the electrical connector
    2. Install the four bolts.

33. Attach the accessory drive belt cover.

34. Lower the vehicle.

35. NOTICE: Always tighten the engine front mounting bracket before the engine rear mounting bracket so that the studs can be seated in the elongated holes of the engine rear mounting bracket.

    Tighten the bolts and nuts of the engine front mounting bracket.

36. Tighten the nuts of the engine rear mount.

37. Remove the special tools.

38. Connect the fuel lines.

    1. Connect the fuel return line.
    2. Connect the fuel supply line.
    3. Connect the leak-off line.
    4. Attach the clamp.

39. Tighten the fuel pipe bracket retaining nut.

40. Install the coolant expansion tank.

41. Install the battery and the battery tray.

42. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

43. NOTE: Install a new intermediate shaft bracket and nuts.

    NOTE: Do not damage the oil seal when inserting the intermediate shaft.

    Install the right-hand intermediate halfshaft.

44. Guide the front left-hand and right-hand drive halfshafts into the tripode bells. Assemble the tripode joint with high-durability grease(fill quantity 125 g).

45. Make a clamp head for Special Tool 204-169.

    • Material: aluminium or steel plate

46. Position the tripode joint boot and secure it with clamping straps.

    • Apply the special tool so that the clamp head is vertical to the clamping strap head.
    • Tighten the clamping strap using the special tool.

47. Attach the vibration damper.

48. Install the flexible pipe on the exhaust pipe.

49. Detach the support sleeve from the flexible pipe.

50. Fit the starter motor.

51. Connect the starter motor.

52. Attach the lower suspension arm to the spindle carrier on both sides (left-hand side shown).

53. Lower the vehicle.

54. Tighten the suspension strut nuts on both sides (left-hand side shown).

55. Standard finishing operations.

    • Check the transmission fluid level.
    • Enter the radio keycode.
    • Reprogram the preset radio stations.