REMOVAL AND INSTALLATION: TIMING BELT (ENGINE - 1.6L ECOBOOST (132KW/180PS) - SIGMA)

Special Tool(s) / General Equipment

• 303-050 (T70P-6000): Lifting Bracket, Engine
• 303-1097: Locking Tool, Variable Camshaft Timing Oil Control Unit (TKIT-2010B-FLM, TKIT-2010B-ROW)
• 303-1502: Lifting Device Engine (TKIT-2012A-FL, TKIT-2012A-ROW)
• 303-1550: Alignment Tool, Crankshaft Vibration Damper (TKIT-2012A-FL, TKIT-2012A-ROW)
• 303-290B-18: Adapter for 303-290B (TKIT-2012A-FL, TKIT-2012A-ROW)
• 303-393-02: Adapter for 303-393 (TKIT-2012A-FL, TKIT-2012A-ROW)
• 303-393A: Locking Tool, Flywheel (TKIT-2012A-FL, TKIT-2012A-ROW)
• 303-748: Locking Tool, Crankshaft (TKIT-2010B-FLM, TKIT-2010B-ROW)
• 303-F072: Support Bar, Engine
• General Equipment: Trolley Jack
• General Equipment: Wooden Block

Removal

NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. 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.

NOTE: 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.

1. Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
2. Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
3. Illustration shows the removal of the air intake duct. Arrows indicate clips and clamps to be released.
4. Illustration shows the air intake duct being pulled away from the engine. A label 'x2' indicates two points of attachment.
5. Remove the following items:
   1. Refer to: Degas Bottle (303-03A Engine Cooling - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
   2. Remove the RH front wheel and tire. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
6. Illustration shows the RH front fender splash shield. Arrows indicate fasteners and the direction of removal. Labels 'x7' and 'x2' indicate multiple fasteners.
7. Remove the RH front fender splash shield. Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
8. Illustration shows the engine bay with the starter motor and generator components highlighted. Arrows point to fastener locations. Labels 'x4' and 'x1' indicate fastener counts.
9. Remove the following items:
   1. Refer to: Starter Motor (303-06A Starting System - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
   2. Refer to: Generator - 1.6L EcoBoost (132kW/180PS) - Sigma (414-02 Generator and Regulator, Removal and Installation).
10. Illustration shows Special Service Tool 303-1502 (Lifting Device Engine) being attached to the engine block. Label 'x2' indicates two mounting points.
11. Illustration shows Special Service Tool 303-050 (Lifting Bracket, Engine) being attached to the engine. Arrows indicate attachment points. Label 'x2' indicates two fasteners.
12. Illustration shows Special Service Tool 303-F072 (Support Bar, Engine) and 303-290B-18 (Adapter for 303-290B) installed across the engine bay, supporting the engine.
13. Remove the following items:
    • Use the General Equipment: Trolley Jack
    • Use the General Equipment: Wooden Block
14. Illustration shows the crankshaft pulley. Arrows indicate a clockwise rotation. The text specifies positioning the pulley to the '11 o'clock position'.

    NOTICE: Only rotate the crankshaft in a clockwise direction.

15. Illustration shows a component on the engine, possibly the halfshaft, with arrows indicating rotation. Label 'x3' indicates three fasteners.
16. Illustration shows a component on the engine, possibly the halfshaft, with arrows indicating rotation. Label 'x3' indicates three fasteners.

17. NOTE: The Crankshaft TDC Timing Pin will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.

    Install Special Service Tool: 303-748 Locking Tool, Crankshaft.
18. Illustration shows the crankshaft being rotated clockwise. An arrow indicates the direction. The text states to rotate until the balance weight contacts the TDC Timing Pin.

    NOTE: Only rotate the crankshaft clockwise direction.

    Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Pin. The engine is now at TDC.
19. Illustration shows Special Service Tool 303-393A (Locking Tool, Flywheel) and 303-393-02 (Adapter for 303-393) being installed on the engine.Install Special Service Tool: 303-393A Locking Tool, Flywheel . , 303-393-02 Adapter for 303-393 .
20. Illustration shows the VCT units on the camshafts. Arrows indicate timing marks. The text specifies the marks should be at the 12 o'clock position.

    NOTE: The timing mark of each VCT unit must be at the 12 o'clock position.

    NOTE: It may be necessary to rotate the camshafts slightly to install the special tool.

    Install Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit.

21. WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury.

    NOTE: Install a holding pin.

Installation

1. Illustration shows a sprocket on the engine. The text states to clean and inspect it for damage.

   NOTE: Before installation, clean and inspect the sprocket for any damage. If damage is evident, replace the sprocket. If no damage, the sprocket is to be reused.

2. Illustration shows the timing belt being routed around pulleys (labeled 1, 2, 3, 4). Arrows indicate the belt path. The text includes a warning about the tensioner spring.

   WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury.

   Remove the holding pin.
3. Illustration shows Special Service Tool 303-1550 (Alignment Tool, Crankshaft Vibration Damper) being installed. Arrows indicate attachment points and rotation. Labels '2', '3', '1' refer to steps or components.Install Special Service Tool: 303-1550 Alignment Tool, Crankshaft Vibration Damper.Rotate crankshaft pulley to align the Special Tool:Use Special Service Tool: 303-1550 Alignment Tool, Crankshaft Vibration Damper.Finger tight at this stage.Using a new bolt, finger tight at this stage.
4. Illustration shows Special Service Tool 303-1550 (Alignment Tool, Crankshaft Vibration Damper) being removed.Remove Special Service Tool: 303-1550 Alignment Tool, Crankshaft Vibration Damper.
5. Torque specifications are provided:
   • Stage 1: 74 lb.ft (100 Nm)
   • Stage 2: 90°
   • Stage 3: Wait 2s
   • Stage 4: 15°
6. Illustration shows Special Service Tool 303-748 (Locking Tool, Crankshaft) being removed.Remove Special Service Tool: 303-748 Locking Tool, Crankshaft.
7. Illustration shows Special Service Tools 303-393-02 (Adapter for 303-393) and 303-393A (Locking Tool, Flywheel) being removed.Remove Special Service Tool: 303-393-02 Adapter for 303-393 . , 303-393A Locking Tool, Flywheel.
8. Illustration shows Special Service Tool 303-1097 (Locking Tool, Variable Camshaft Timing Oil Control Unit) being removed.Remove Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit.
9. Illustration shows the crankshaft being rotated clockwise. An arrow indicates the direction. The text specifies rotating about 1 3/4 turns.

   NOTE: Only rotate the crankshaft in a clockwise direction.

   Rotate about 1 3/4 turns.
10. Illustration shows Special Service Tool 303-748 (Locking Tool, Crankshaft) being installed.Install Special Service Tool: 303-748 Locking Tool, Crankshaft.
11. Illustration shows the crankshaft being rotated clockwise. An arrow indicates the direction. The text states to rotate until the balance weight contacts the crankshaft locking tool.

    NOTE: Only rotate the crankshaft in a clockwise direction.

    Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the crankshaft locking tool. The engine is now at TDC.
12. Illustration shows the VCT units on the camshafts. Arrows indicate timing marks. The text specifies the marks should be at the 12 o'clock position.

    NOTE: The timing mark of each VCT unit must be at the 12 o'clock position.

    NOTE: It may be necessary to rotate the camshafts slightly to install the special tool.

    If the special tool cannot be installed, repeat the adjustment according to the preceding steps.Install Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit.
13. Illustration shows Special Service Tool 303-1097 (Locking Tool, Variable Camshaft Timing Oil Control Unit) being removed.Remove Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit.
14. Illustration shows Special Service Tool 303-748 (Locking Tool, Crankshaft) being removed.Remove Special Service Tool: 303-748 Locking Tool, Crankshaft.
15. Torque specification:Torque: 177 lb.in (20 Nm)
16. Torque specification:Torque: 89 lb.in (10 Nm)
17. Torque specification:Torque: 35 lb.ft (48 Nm)
18. Torque specifications:
    • 1. Torque: 44 lb.in (5 Nm)
    • 2. Torque: 18 lb.ft (25 Nm)
    • 3. Torque: 18 lb.ft (25 Nm)
19. Illustration shows the installation of general equipment: Trolley Jack and Wooden Block.Install the following items:
    • Use the General Equipment: Trolley Jack
    • Use the General Equipment: Wooden Block
20. Illustration shows Special Service Tools 303-F072 (Support Bar, Engine), 303-290B-18 (Adapter for 303-290B), and 303-050 (T70P-6000) (Lifting Bracket, Engine) being removed.Remove Special Service Tool: 303-F072 Support Bar, Engine., 303-290B-18 Adapter for 303-290B., 303-050 (T70P-6000) Lifting Bracket, Engine.
21. Torque specification:Torque: 41 lb.ft (55 Nm)
22. Illustration shows fasteners being tightened. Labels indicate torque values and tightness levels.1. Torque: 89 lb.in (10 Nm)2. Finger tight.3. Finger tight.
23. Torque specification:Torque: 89 lb.in (10 Nm)
24. Torque specification:Torque: 35 lb.ft (48 Nm)
25. Torque specification:Torque: 89 lb.in (10 Nm)
26. Torque specification:Torque: 59 lb.ft (80 Nm)
27. Refer to: Generator - 1.6L EcoBoost (132kW/180PS) - Sigma (414-02 Generator and Regulator, Removal and Installation).
28. Remove the following items:
    • Use the General Equipment: Trolley Jack
    • Use the General Equipment: Wooden Block
29. Refer to: Starter Motor (303-06A Starting System - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
30. Torque: 177 lb.in (20 Nm)
31. Install the RH front fender splash shield. Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
32. Illustration shows the RH front fender splash shield being installed. Arrows indicate attachment points. Labels 'x7' and 'x2' indicate multiple fasteners.
33. Install the RH front wheel and tire. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
34. Torque: 44 lb.in (5 Nm)
35. Torque: 44 lb.in (5 Nm)
36. Refer to: Degas Bottle (303-03A Engine Cooling - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
37. Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
38. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.