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The above application is prone to the timing belt teeth lifting off the belt in service due to operating the belt with insufficient tension. The following instructions have been produced to assist in the fitting of your new timing belt, giving simple hints and tips, which should help avoid problems caused by adopting an incorrect fitting / adjustment procedure. For instructions for the removal of the engine components required to gain access to the timing belt, please refer to the vehicle workshop manual. Note:- Incorrect tension of the timing belt, can lead to the teeth lifting from the belt, resulting in belt failure, and subsequent major engine damage. Special Tools Required: 1) Timing belt tension gauge, (accurately calibrated), Part No’s: either Rover KM4088 or Borroughs BT33-86F 2) Two 8mm Allen keys (for tensioner adjustment) 3) Short length of round steel bar (for flywheel timing location) Fitting Procedure: 1) Before the old timing belt is removed, the crankshaft should be rotated clockwise to align the timing mark on the crankshaft pulley with the edge of the metal bracket, which forms part of the lower timing belt cover (See I). To lock the crankshaft in this position, which is 90 degrees before top dead centre, insert a steel rod of the correct diameter into the hole on the gearbox / engine adaptor plate, positioned on the front facing lower edge of the cylinder block (See diagram B), and locate with the corresponding hole in the flywheel. The timing marks on the camshaft gears should now be aligned at the 3 o’clock position for the left hand gear, and the 9 o’clock position for the right hand gear (See II). Undo the timing belt tensioner Allen bolt and remove tensioner. The old timing belt can now be removed (See III). Check the condition of the geared teeth on the camshaft, crankshaft, and water pump drives. Check the tensioner, water pump, and idler bearings. Fit the new timing belt over the drive gears, ensuring the timing marks set at ‘I’and‘II’ have not moved. Refit the tensioner using the anti-slip washer ‘IV’ supplied with the new timing belt. The anti-slip washer should be fitted between the tensioner and the backplate, with the abrasive side facing towards the tensioner. Note: A new anti-slip washer must always be fitted. Non modified vehicles will not have the anti-slip washer fitted. Rotate the tensioner, using the Allen key drive to set the initial pre-load tension, sufficient to prevent the timing belt from slipping over the toothed drives, then tighten the Allen bolt to 45Nm.

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JATCO Gearbox – KV6 – NAS models Remove 1. 2. 3. 4. Position the vehicle on a twin-post lift. Tie bonnet back in upright position. Disconnect battery earth lead. Remove engine acoustic cover. 5. 6. 7. 8. Release HO2S multiplug from support bracket on LH camshaft cover, disconnect multiplug. Raise vehicle on lift. Remove rear beam. Remove RH catalytic converter. 9. Remove 2 nuts securing front pipe to manifold. 10. Release and disconnect post catalyst HO2S multiplug. 11. Release post catalyst HO2S harness from clips. 12. Remove bolt securing front pipe to bracket and remove front pipe. Discard gasket. 13. Remove 3 screws securing LH splash shield and remove shield. 14. Release HO2S lead from clip on cylinder block. Remove 4 nuts securing exhaust manifold to cylinder head, remove manifold and discard gasket. 15. Drain fluid from IRD. 16. Drain gearbox fluid. 17. FitLRT-54-026 to the RH drive shaft inboard joint. 18. Using a suitable lever, release drive shaft from IRD. 19. With assistance, pull hub outwards and release drive shaft from IRD. CAUTION: Care must be taken not to damage oil seal when removing drive shaft from IRD. CAUTION: To avoid damage to gaiter or joint, do not allow shaft to hang on joint. 20. Remove LRT-54-026 from RH drive shaft inboard joint. 21. Remove and discard drive shaft circlip. 22. Remove bolt securing lower engine steady to sump mounting bracket. 23. Remove lower engine steady noting that ‘TOP’ mark on engine steady faces uppermost. 24. Reference mark front propeller shaft for reassembly. 25. Remove 6 nuts and bolts securing propeller shaft to IRD drive flange. 26. Release propeller shaft from IRD drive flange and tie shaft aside. CAUTION: Care must be taken to support the Tripode joint when removed from the IRD unit. To avoid damage to gaiter or steel can, the joint should not be allowed to fully extend or be dropped. 27. Disconnect breather hose from IRD housing. 28. Position container to collect coolant spillage.

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Water Pump Removal 1. Drain the cooling system. Refer to Section 03-03. 2. Disconnect the battery ground cable (14301) . 3. Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05. 4. Raise and support the vehicle. 5. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts. 6. Remove the water pump pulley from the water pump (8501) . 7. Remove the crankshaft pulley (6312) . Refer to the procedure in this section 8. Remove the five lower engine front cover bolts and the lower engine front cover (6019) . NOTE: Make a note of the location of the one water pump bolt with the threads in the bolt head for ease of installation. 9. Remove the six water pump bolts. 10. Remove the water pump . Installation NOTE: Ensure the mating surfaces between the water pump and the cylinder block (6010) are cleaned of any sealant material. 1. Install a continuous 2.0-3.0mm (0.079-0.118 inch) wide bead of Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5, on the water pump and position the water pump on the cylinder block . NOTE: Refer to the note made during removal for the location of the bolt with the threads in the bolt head. 2. Install the six water pump bolts. Tighten the water pump bolts to 16-21 Nm (12-15 lb-ft). 3. Install the crankshaft pulley . Refer to the procedure in this section. 4. Position the water pump pulley on the water pump and install the four water pump pulley bolts. 5. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley , and tighten the four water pump pulley bolts to 16-21 Nm (12-15 lb-ft). 6. Install the lower engine front cover and the five lower engine front cover bolts. Tighten the five lower engine front cover bolts to 3-5 Nm (27-44 lb-in). 7. Lower the vehicle. 8. Install and adjust the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05. 9. Connect the battery ground cable . 10. Fill the cooling system. Refer to Section 03-03. 11. Start the engine (6007) and check for leaks.

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CAUTION: Syncro Positioning Tool T95T-12200-A (3.0L, 4.0L) or T96T-12200-A (5.0L) must be obtained prior to installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine (6007), possibly causing engine damage. CAUTION: Prior to the removal of the camshaft position sensor (CMP sensor) (12A112), set No. 1 cylinder to 0 degrees top dead center (TDC) of compression stroke. Then note the position of the camshaft position sensor electrical connector. The installation procedure requires that the electrical connector be located in the same position. Removal 1. Disconnect battery ground cable (14301). 2. Disconnect fuel charging wiring electrical connector from camshaft position sensor. 3. Remove the CMP sensor screws and camshaft position sensor from camshaft synchronizer. CAUTION: Do not move crankshaft (6303) until entire installation procedure is complete. Doing so will result in the fuel system being out of time with the engine resulting in possible emissions fault. NOTE: If camshaft synchronizer is to be removed from the cylinder block (6010), proceed with Step 4. If the camshaft synchronizer is not being removed, proceed to installation Step 8. 4. Remove hold-down clamp (12270). 5. Remove camshaft synchronizer from cylinder block. Installation 1. Attach Syncro Positioning Tool T95T-12200-A (3.0L, 4.0L) or T96T-12200-A (5.0L). Camshaft Synchronizer — 3.0L, 4.0L Camshaft Synchronizer — 5.0L 2. Align the synchronizer vane with the radial slot of the Syncro Positioning Tool T95T-12200-A (3.0L) or T96T-12200A (5.0L). 3. Rotate the tool on the synchronizer base until the tool’s boss engages the base notch. 4. Dip gear end into ESE-M2C123-A oil or equivalent to coat gear, thrust washer and lower bearing. Syncro Positioning Tool — 3.0L, 4.0L 5. CAUTION: Do not rotate crankshaft when syncro positioning tool is on the camshaft synchronizer. Armature tab will be damaged and synchronizer timing may be shifted. On 3.0L engines, install camshaft synchronizer so that drive gear engagement occurs when arrow on Syncro Positioning Tool T95T-12200-A is pointed approximately 75 degrees (3.0L), 60 degrees (4.0L) counterclockwise off the centerline of the engine. This step will locate camshaft position sensor electrical connector to the original position. Syncro Positioning Tool — 5.0L On 5.0L engines, install camshaft synchronizer into cylinder block making sure that arrow on Syncro Positioning Tool T96T-12200-A is pointing forward parallel to center line of crankshaft. This step will locate camshaft position sensor electrical connector to the pre-removal position. 6. CAUTION: If camshaft position sensor electrical connector is not positioned properly, DO NOT reposition the connector by rotating the synchronizer assembly. This will result in the fuel system being out of time with the engine, possibly causing engine damage. Remove the synchronizer assembly and repeat Step 5. Install hold-down clamp and tighten to 19-30 Nm (14-22 lb-ft) on 3.0L, 4.0L and 23-34 Nm (17-25 lb-ft) on 5.0L. 7. Remove Syncro Positioning Tool. 8. Install CMP sensor and CMP sensor screws. Tighten to 2.5-3.5 Nm (23-30 lb-in). 9. Connect fuel charging wiring electrical connector to camshaft position sensor (CMP sensor). 10. NOTE: When battery voltage is removed from the powertrain control module (PCM) (12A650), all learned values will be cleared and reset to predetermined values. When battery voltage is restored to the PCM, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Connect battery ground cable. Camshaft Position (CMP) Sensor — 3.0L Shown, 4.0L, 5.0L Similar

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Special tools, testers and auxiliary items required Jointed wrench 3185 Socket T10058 Torque wrench V.A.G 1331 Hand drill with plastic brush Protective goggles Flat scraper Silicone sealing compound D 176 404 A2 Locking fluid D 000 600 A2 Removing Remove center and right sound insulation Engines with oil pan protection Body Exterior – Repair Group 50. Remove bolts – 2 – and take sleeves – 3 – off front and rear parts of oil pan protection. Press spreader pin out upward and remove spreader rivets – 4 – . Remove oil pan protection – 1 – . Engines with LongLife Service Pull 3-pin connector off Oil level thermal sensor -G266-. Continuation for all engines Drain engine oil. Note: Observe disposal regulations! Remove oil pan bolts. Note: Loosen oil pan bolts with jointed wrench 3185 and remove with socket T10058. Remove oil pan. Loosen pan with light blows of a rubber headed hammer if necessary. Remove sealant residue on cylinder block with a flat scraper.