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Remove the exhaust side spark plugs, outer timing belt cover, and crankshaft pulley.
Turn the crankshaft until the number one piston is at top dead center (TDC).
CAUTION The camshaft belt tensioner tool (303-097) can be damaged when trying to relieve belt tension if you attempt to remove the belt without first loosening both the timing belt tensioner adjusting bolt and the spring pivot bolt.
Loosen the timing belt spring pivot bolt, but do not remove it at this point in the procedure.
Loosen the adjusting bolt slowly and release the spring tension.
Turn the tensioner with the camshaft belt tensioner tool (303-097), against the spring pressure, clockwise to the farthest position.
While holding it in this position, tighten the adjusting bolt to hold the tensioner away from the belt.
Remove the timing belt.
To Install:
Be certain that on piston number one, the crankshaft is at TDC with the crankshaft keyway pointing straight up and the circle on the crankshaft sprocket lined up with the notch on the engine front cover.
Line up the timing marks.
Install the timing belt over the crankshaft sprocket going counterclockwise over the oil pump sprocket and over the camshaft sprocket.
Loosen the bolt allowing the tensioner pulley to press against the timing belt.
NOTE: The timing belt tensioner should not be tightened or the belt tension will not be evenly distributed over the whole belt.
Turn the crankshaft two revolutions clockwise. Next, slowly bring the crank to the number one position firing position with the keyway on the crank facing up. The dot on the crankshaft gear is lined up with the notch on the front cover.
Check the timing mark alignment again. If necessary, repeat the procedure.
Tighten the bolts. Torque the pivot bolt to 30-40 ft-lb (40-55 Nm). Torque the adjustment/locking bolt to 26-33 ft-lb (35-45 Nm).
Install the crankshaft pulley and tighten the bolt. Torque to 93-121 ft-lb (125-165 Nm).
Install the outer timing belt cover and tighten the bolt. Torque to 70-106 in-lb (8-12 Nm).
Before servicing the vehicle, refer to the precautions in the beginning of this section.
Disconnect the negative battery cable.
Remove the fan shroud.
Loosen the bolts on the water pump pulley, but do not remove them at this point in the procedure.
Remove the drive belt, the water pump pulley, and the fan and clutch assembly.
Recover the refrigerant from the A/C system.
Disconnect the A/C wiring connector.
Remove the A/C compressor from the mounting bracket then remove the A/C mounting bracket with the power steering pump still attached.
Remove the outer timing belt cover.
To Install:
Install the outer timing belt cover. Torque to 70-106 in-lb (8-12 Nm).
Install the A/C mounting bracket with the power steering pump still attached. Torque the M10 bolts and stud to 35 ft-lb (48 Nm) and torque the M8 bolt to 18 ft-lb (25 Nm).
Install the A/C compressor to the mounting bracket. Torque to 16-20 ft-lb (21-28 Nm).
Connect the A/C wiring connector.
Refill the refrigerant into the A/C system.
Install the fan and clutch assembly, the water pump pulley, and the drive belt.
Tighten the bolts on the water pump pulley. Torque to 13-17 ft-lb (17-23 Nm).
Install the fan shroud. Torque to 54-70 in-lb (6-8 Nm).
Connect the negative battery cable.
Start the engine. Check for leaks and repair as necessary.
Think you have to put a flat bar across the back of the cam shafts same as the old ZETEC ford motors. Failing that are the vernier pullies marked with eithr O T or do they have a - or a . that line up with a position on the end of the cylinder head.
This is going to be an issue. There are marks on the gears you need to line up correctly to get it right. Without a picture to look at it is very hard. You can start and get it close by rotating the crank until the number one is up all the way and the next cylinder to fire is down preparing for the compression stroke. Then you need to turn the cam shaft until all valves are closed for the number 1 and the intake valves on the next cylinder in the firing order are closing with exhaust valves closed. This should be roughly #1 TDC, close anyway. The Haynes or Chilton's repair manual will have photos of the timing chain area and what the marks look like and instructions on how to line them up. It would be a very good investment at this point.
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Sounds like the dist. could be half a tooth off. You need to bring up #1 piston to top dead center and verify the rotor in the cap is pointing to #1 in the firing order.
Try resetting the ECU. Hold both battery cables together without touching the battery, for 30 seconds. Drive normal the next 10 miles or so, the ECU will relearn all.hope this helps!
bring #1 piston to top dead center(TDC). pull #1 spark plug to sit on top of the #1 piston by inserting long screwdriver into the hole. then check the cam to the other end of the motor. there slots on both cams that should be lined up together so that can lay the bar across the end of the head to be able to insert into the hole. cam and crankshaft are lined up now to replace timing belt. and Ztech motors are no real timing marks.
set the timing mark on the crankshaft to the mark on the oil pump, then set the timing mark on the camshaft to the mark on the alternator bracket/set second camshaft mark to mark on the inner timing belt cover. line up all mark as decribed. be sure before u set anything to bring #1 piston all the way up to top. with belt on turn crankshaft 2 full turns to bring #1 piston back to top if the cams are not lined up correctly loosen belt and start over again until everything lines up correctly. you may have to do this a few times but it will work.
with the belt off; turn the crankshaft to #1 piston top-dead-center. Next turn the camshaft until both valves on the #1 piston are closed; then: check the distributor to see that the rotor is pointing to #1 spark plug wire.(if not go around again until the rotor points at the #1 wire.) If you are correct you will now see the timing marks on the cam and, the crank pulleys. line up the mark on the belt to the marks on the pulleys and, slip the belt on; then tighten the belt.
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