Ford Fusion Manuals

Ford Fusion: Engine - 1.5L EcoBoost (118kW/160PS) – I4 / Timing Belt. Removal and Installation

Special Tool(s) / General Equipment

Ford Fusion. Timing Belt. Removal and Installation 303-1097
Locking Tool, Variable Camshaft Timing Oil Control Unit
TKIT-2010B-FLM
TKIT-2010B-ROW
Ford Fusion. Timing Belt. Removal and Installation 303-1550
Alignment Tool, Crankshaft Vibration Damper
TKIT-2012A-FL
TKIT-2012A-ROW
Ford Fusion. Timing Belt. Removal and Installation 303-393-02
Adapter for 303-393
TKIT-2012A-FL
TKIT-2012A-ROW
Ford Fusion. Timing Belt. Removal and Installation 303-393A
Locking Tool, Flywheel
TKIT-2012A-FL
TKIT-2012A-ROW
Ford Fusion. Timing Belt. Removal and Installation 303-748
Locking Tool, Crankshaft
TKIT-2010B-FLM
TKIT-2010B-ROW
Trolley Jack
Hose Clamp Remover/Installer
Wooden Block

Removal

NOTICE: 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. With the vehicle in NEUTRAL, position it on a hoist.
    Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
  1. Remove the engine appearance cover.
Ford Fusion. Timing Belt. Removal and Installation
  1. Disconnect the PCM electrical connector.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove the engine cover.
    Detach the retainer and disconnect the electrical connector.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove the following items:
    1. Remove the degas bottle.
      Refer to: Degas Bottle (303-03A Engine Cooling - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
    2. Remove the upper air cleaner outlet pipe.
      Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
  1. Disconnect the wiring harness electrical connector, retainer and disconnect and remove the crankcase vent hose.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Timing Belt. Removal and Installation
  1. Disconnect the EVAP canister purge valve tubes from the TC inlet pipe.
Ford Fusion. Timing Belt. Removal and Installation
    • Detach the wiring harness retainers and disconnect the TC bypass hose.
      Use the General Equipment: Hose Clamp Remover/Installer
    • Loosen the TC inlet hose clamp.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove the bolts and the TC inlet pipe assembly.
Ford Fusion. Timing Belt. Removal and Installation
  1. Loosen the coolant pump pulley bolts.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove the following items:
    1. Remove the RH front wheel and tire.
      Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
    2. Remove the RH front fender splash shield.
      Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
  1. Remove the retainers and the engine undershield.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove and discard the RH halfshaft bearing retaining strap and the nuts.
Ford Fusion. Timing Belt. Removal and Installation
  1. NOTE: It may be necessary to rotate the halfshaft to remove the front lower bolt.

    Remove the RH halfshaft supports bracket bolts.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove the engine plug bolt.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove the following items:
    1. Remove the starter motor.
      Refer to: Starter Motor (303-06A Starting System - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
    2. Remove the generator.
      Refer to: Generator - 1.5L EcoBoost (118kW/160PS) – I4 (414-02 Generator and Regulator, Removal and Installation).
  1. Install the following items:
    • Use the General Equipment: Trolley Jack
      Use the General Equipment: Wooden Block
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove the nuts, bolts and the engine mount.
Ford Fusion. Timing Belt. Removal and Installation
  1. If equipped with a accessory drive belt tensioner, remove the bolts, accessory drive belt tensioner and the accessory drive belt.
Ford Fusion. Timing Belt. Removal and Installation
    • Detach the vacuum tube retainer.
    • Remove the bolt, nut and the support bracket.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove the stud bolt and the cover from front cover.
Ford Fusion. Timing Belt. Removal and Installation
    • Remove the bolts and the coolant pump pulley.
    • Detach the wiring harness retainers.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove the engine mount stud.
Ford Fusion. Timing Belt. Removal and Installation
    • Remove the wiring harness bolt.
    • Detach the wiring harness retainers and position the wiring harness aside.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove the engine front cover bolts.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove the engine front cover.
Ford Fusion. Timing Belt. Removal and Installation
  1. NOTE: Note the different lengths of the bolts for installation.

    Remove the bolts and the engine mount bracket.
Ford Fusion. Timing Belt. Removal and Installation
  1. NOTE: Only rotate the crankshaft in a clockwise direction.

    Rotate the crankshaft in a clockwise direction and position the VCT marking at 11 o'clock position.
Ford Fusion. Timing Belt. Removal and Installation
  1. 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.
Ford Fusion. Timing Belt. Removal and Installation
  1. NOTE: Only rotate the crankshaft 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.
Ford Fusion. Timing Belt. Removal and Installation
  1. Install Special Service Tool: 303-393-02  Adapter for 303-393. , 303-393A  Locking Tool, Flywheel.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove and discard the crankshaft pulley bolt. Remove the crankshaft pulley.
Ford Fusion. Timing Belt. Removal and Installation
  1. NOTE: The timing mark of each VCT unit must be at the 12 o'clock position.

    NOTE: It may 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.
Ford Fusion. Timing Belt. Removal and Installation
  1. Ford Fusion. Timing Belt. Removal and Installation  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.

    • Rotate the timing belt tensioner clockwise.
    • Install a holding pin.
    • Remove the timing belt.
Ford Fusion. Timing Belt. Removal and Installation
  1. NOTE: Clean and inspect the sprocket for any damage. If damage is evident, replace the sprocket. If no damage, the sprocket is to be reused.

    Remove and inspect the timing belt sprocket.
Ford Fusion. Timing Belt. Removal and Installation
    • Disconnect the CKP sensor electrical connector.
    • Remove the bolt and the CKP sensor.
Ford Fusion. Timing Belt. Removal and Installation

Installation

  1. 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.

    Install the crankshaft sprocket.
Ford Fusion. Timing Belt. Removal and Installation
  1. Install the timing belt in the following sequence.
Ford Fusion. Timing Belt. Removal and Installation
  1. Ford Fusion. Timing Belt. Removal and Installation  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.
Ford Fusion. Timing Belt. Removal and Installation
  1. Install the crankshaft pulley.
Ford Fusion. Timing Belt. Removal and Installation
    1. Install Special Service Tool: 303-1550  Alignment Tool, Crankshaft Vibration Damper.
    1. Rotate crankshaft pulley to align the Special Tool:
      Use Special Service Tool: 303-1550  Alignment Tool, Crankshaft Vibration Damper.
    1. Finger tight at this stage.
    1. Using a new bolt, finger tight at this stage.
Ford Fusion. Timing Belt. Removal and Installation
  1. NOTE: Make certain the special tools that secure the flywheel from rotating are still installed prior to performing this step. Failure to secure the flywheel may cause misalignment of the crankshaft pulley to the crankshaft resulting in driveability concerns.

    Tighten the crankshaft pulley bolt in 4 stages.
    Torque:
      Stage 1:  74 lb.ft (100 Nm)
      Stage 2:  90°
      Stage 3:  Wait 2s
      Stage 4:  15°
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove Special Service Tool: 303-1550  Alignment Tool, Crankshaft Vibration Damper.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove Special Service Tool: 303-748  Locking Tool, Crankshaft.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove Special Service Tool: 303-393-02  Adapter for 303-393. , 303-393A  Locking Tool, Flywheel.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove Special Service Tool: 303-1097  Locking Tool, Variable Camshaft Timing Oil Control Unit.
Ford Fusion. Timing Belt. Removal and Installation
  1. NOTE: Only rotate the crankshaft in a clockwise direction.

    Rotate about 1 3/4 turns.
Ford Fusion. Timing Belt. Removal and Installation
  1. Install Special Service Tool: 303-748  Locking Tool, Crankshaft.
Ford Fusion. Timing Belt. Removal and Installation
  1. 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.
Ford Fusion. Timing Belt. Removal and Installation
  1. NOTE: The timing mark of each VCT unit must be at the 12 o'clock position.

    NOTE: It may 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.
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove Special Service Tool: 303-1097  Locking Tool, Variable Camshaft Timing Oil Control Unit.
Ford Fusion. Timing Belt. Removal and Installation
  1. Install the engine mount bracket and the bolts.
    Torque: 41 lb.ft (55 Nm)
Ford Fusion. Timing Belt. Removal and Installation
  1. Install the engine front cover.
Ford Fusion. Timing Belt. Removal and Installation
  1. Install the engine front cover bolts.
    Torque: 89 lb.in (10 Nm)
Ford Fusion. Timing Belt. Removal and Installation
    • Attach the wiring harness retainers.
    • Install the wiring harness bolt.
      Torque: 89 lb.in (10 Nm)
Ford Fusion. Timing Belt. Removal and Installation
  1. Install the engine mount stud finger tight.
Ford Fusion. Timing Belt. Removal and Installation
    • Attach the wiring harness retainers.
    • Install the coolant pump pulley and bolts finger tight.
Ford Fusion. Timing Belt. Removal and Installation
  1. Position the cover to engine front cover and install the stud bolt.
    Torque: 89 lb.in (10 Nm)
Ford Fusion. Timing Belt. Removal and Installation
    • Install the support bracket, nut and the bolt.
      Torque:
         1:   17 lb.ft (23 Nm)
         2:   62 lb.in (7 Nm)
    • Attach the vacuum tube retainer.
Ford Fusion. Timing Belt. Removal and Installation
  1. If equipped with a accessory drive belt tensioner, install the accessory drive belt, accessory drive belt idler pulley and the bolts.
    Torque: 35 lb.ft (48 Nm)
Ford Fusion. Timing Belt. Removal and Installation
  1. Tighten the engine mount studs.
    Torque: 89 lb.in (10 Nm)
Ford Fusion. Timing Belt. Removal and Installation
  1. Install the engine mount, nuts and the bolts.
    Torque:
       1:   85 lb.ft (115 Nm)
       2:   66 lb.ft (90 Nm)
Ford Fusion. Timing Belt. Removal and Installation
  1. Remove the following items:
    • Use the General Equipment: Trolley Jack
      Use the General Equipment: Wooden Block
Ford Fusion. Timing Belt. Removal and Installation
  1. Install the following items:
    1. Install the generator.
      Refer to: Generator - 1.5L EcoBoost (118kW/160PS) – I4 (414-02 Generator and Regulator, Removal and Installation).
    2. Install the starter motor.
      Refer to: Starter Motor (303-06A Starting System - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
  1. Remove Special Service Tool: 303-748  Locking Tool, Crankshaft.
Ford Fusion. Timing Belt. Removal and Installation
  1. Install the engine plug bolt.
    Torque: 177 lb.in (20 Nm)
Ford Fusion. Timing Belt. Removal and Installation
    • Install the CKP sensor and the bolt.
      Torque: 89 lb.in (10 Nm)
    • Connect the CKP sensor electrical connector.
Ford Fusion. Timing Belt. Removal and Installation
  1. Position the RH halfshaft support bracket and install the bolts.
    Torque: 35 lb.ft (48 Nm)
Ford Fusion. Timing Belt. Removal and Installation
    1. Install the RH halfshaft retaining strap and the nuts.
      Torque: 44 lb.in (5 Nm)
    1. Tighten the RH halfshaft retaining strap nut.
      Torque: 18 lb.ft (25 Nm)
    1. Tighten the RH halfshaft retaining strap nut.
      Torque: 18 lb.ft (25 Nm)
Ford Fusion. Timing Belt. Removal and Installation
  1. Install the engine undershield and the retainers.
Ford Fusion. Timing Belt. Removal and Installation
  1. Install the following items:
    1. Install the RH front fender splash shield.
      Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
    2. Install the RH front wheel and tire.
      Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
  1. Tighten coolant pump pulley bolts.
    Torque: 18 lb.ft (24 Nm)
Ford Fusion. Timing Belt. Removal and Installation
  1. Install the TC inlet pipe assembly and the bolts.
    Torque: 71 lb.in (8 Nm)
Ford Fusion. Timing Belt. Removal and Installation
    • Tighten the TC inlet pipe clamp.
      Torque: 44 lb.in (5 Nm)
    • Connect the TC bypass hose and attach the wiring harness retainers.
      Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Timing Belt. Removal and Installation
  1. Connect the EVAP canister purge valve tubes to the TC inlet pipe.
Ford Fusion. Timing Belt. Removal and Installation
  1. Install and connect the crankcase vent hose and attach the wiring harness electrical connector and retainer.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Timing Belt. Removal and Installation
  1. Install the following items:
    1. Install the upper air cleaner outlet pipe.
      Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
    2. Install the degas bottle.
      Refer to: Degas Bottle (303-03A Engine Cooling - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
  1. Connect the electrical connector and attach the wiring harness retainer.
Ford Fusion. Timing Belt. Removal and Installation
  1. Connect the PCM electrical connector.
Ford Fusion. Timing Belt. Removal and Installation
  1. Install the engine appearance cover.
Ford Fusion. Timing Belt. Removal and Installation
  1. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.

    Oil Pump. Removal and Installation

    Special Tool(s) / General Equipment 303-1097Locking Tool, Variable Camshaft Timing Oil Control UnitTKIT-2010B-FLMTKIT-2010B-ROW Materials Name Specification Motorcraft® Metal Brake Parts CleanerPM-4-A, PM-4-B -  Removal Remove the crankshaft front seal...

    Valve Cover. Removal and Installation

    Special Tool(s) / General Equipment Hose Clamp Remover/Installer Materials Name Specification Flange SealantCU7Z-19B508-A WSS-M2G348-A11  Motorcraft® Metal Surface Prep WipesZC-31-B -  Engine Oil - SAE 5W-20 - Synthetic Blend Motor OilXO-5W20-Q1SP WSS-M2C945-B1  Removal Release the fuel system pressure...

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    Ford Fusion 2013–2020 Service Manual: Intake Air Distribution and Filtering - Component Location. Description and Operation


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