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How to change water pump & timing belt kit on FORD Transit Courier Estate – replacement guide

downloads: 2

Recommended replacement interval for the part category Water pump and timing belt kit : 70000 km

Important!

This replacement procedure can be used for:
FORD TRANSIT COURIER Kombi 1.5 TDCi, FORD TRANSIT COURIER Kombi 1.6 TDCi … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

Alternative products

Water pump and timing belt kit

Replacement: water pump & timing belt kit – FORD TRANSIT COURIER Kombi. List of the tools you'll need:

                      All-purpose cleaning spray
                    
                      WD-40 spray
                    
                      Sealant
                    
                      Combination spanner #13
                    
                      Combination spanner #15
                    
                      Combination spanner #16
                    
                      HEX bit no.H6.
                    
                      Drive socket # 7
                    
                      Drive socket # 8
                    
                      Drive socket # 10
                    
                      Drive socket # 13
                    
                      Drive socket # 15
                    
                      Drive socket # 16
                    
                      Drive socket # 18
                    
                      Torx bit T30
                    
                      Ratchet wrench
                    
                      Torque wrench
                    
                      Engine timing tool set
                    
                      Funnel
                    
                      Clip removal tool
                    
                      Flat Screwdriver
                    
                      Seal scraper
                    
                      Combination pliers
                    
                      Crow bar
                    
                      Fluid container
                    
                      Hydraulic transmission jack
                    
                      Fender cover

Buy tools

Replacement: water pump & timing belt kit – FORD TRANSIT COURIER Kombi. AUTODOC recommends:

Follow the terms, recommendations and requirements of the part operation provided by the manufacturer.
Please note: all work on the car – FORD TRANSIT COURIER Kombi – should be done with the engine switched off.

Carry out replacement in the following order:

Step 1

Open the bonnet.

Step 2

Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.

Step 3

Unscrew the fasteners of the car battery terminals. Use a drive socket #10. Use a ratchet wrench.
Step 4

Remove the battery terminals.
Step 5

Remove the engine cover.

Replacement: water pump & timing belt kit – FORD TRANSIT COURIER Kombi. Professionals recommend:
Raise the engine cover, holding it on two sides simultaneously.Do not apply excessive force when removing the part. Otherwise you may damage it.
Step 6

Detach the engine wiring harness from the upper timing cover. Use a clip removal tool.
Step 7

Unscrew the fasteners of the upper timing cover. Use a drive socket #7. Use a ratchet wrench.
Step 8

Remove the upper timing cover.
Step 9

Unscrew the fasteners of the lower serpentine belt cover. Use Torx T30. Use a ratchet wrench.
Step 10

Remove the lower serpentine belt cover.
Step 11

Pull aside the V-ribbed belt tensioner pulley. Use a combination spanner #15.
Step 12

Remove the V-ribbed belt.
Step 13

Return the tensioner pulley to its initial position.
Step 14

Disconnect the connector of the air conditioner compressor.
Step 15

Disconnect the alternator connector.
Step 16

Remove the cap from the alternator wiring harness fastener.
Step 17

Unscrew the alternator wiring harness fastener. Use a drive socket #13. Use a ratchet wrench.
Step 18

Detach the alternator wiring harness.
Step 19

Detach the alternator wiring harness clip from the bracket. Use a clip removal tool.
Step 20

Disconnect the engine wiring harness connector.
Step 21

Unscrew the fasteners of the engine wiring harness bracket. Use a drive socket #10. Use a ratchet wrench.
Step 22

Detach the engine wiring harness clip from the timing cover. Use a clip removal tool.
Step 23

Pull aside the V-ribbed belt tensioner pulley. Use a combination spanner #15.
Step 24

Unscrew the fasteners of the alternator wiring harness bracket. Use a drive socket #10. Use a ratchet wrench.
Step 25

Remove the alternator wiring harness bracket.
Step 26

Unscrew the fastener of the serpentine belt tensioner pulley. Use a drive socket #10. Use a ratchet wrench.
Step 27

Remove the serpentine belt tensioner pulley.
Step 28

Disconnect the connector of the crankshaft position sensor. Use a clip removal tool.
Step 29

Detach the crankshaft position sensor wiring. Use a clip removal tool.

Step 30

Detach the engine wiring harness.
Step 31

Unscrew the fasteners of the engine wiring harness bracket. Use a drive socket #8. Use a ratchet wrench.
Step 32

Remove the crankshaft pulley cap. Use a flat screwdriver.
Step 33

Turn the crankshaft pulley. Use a drive socket #18. Use a ratchet wrench.

Please note!
The piston should be at its bottom dead centre (BDC).Adjust the valve timing according to the factory marks.
Step 34

Install the flywheel locking tool according to the factory marks. Use an engine timing tool set.
Step 35

Unscrew the crankshaft pulley fastener. Use a drive socket #18. Use a ratchet wrench.
Step 36

Remove the crankshaft pulley.
Step 37

Unscrew the fasteners of the lower timing cover. Use a drive socket #7. Use a ratchet wrench.
Step 38

Remove the lower timing cover.
Step 39

Unscrew the fastener of the crankshaft position sensor. Use a drive socket #8. Use a ratchet wrench.
Step 40

Remove the crankshaft position sensor.
Step 41

Unscrew the coolant reservoir cap.
Step 42

Prepare a container for fluids.
Step 43

Clean the coolant drain plug. Use all-purpose cleaning spray.
Step 44

Remove the coolant drain plug retaining clip.
Step 45

Remove the coolant drain plug.
Step 46

Drain the coolant from the engine.

Replacement: water pump & timing belt kit – FORD TRANSIT COURIER Kombi. AUTODOC recommends:
Caution! The coolant can be very hot.Wear gloves to prevent contact with hot liquid.All work should be done with the engine stopped.
Step 47

Clean the connectors of the coolant hoses. Use all-purpose cleaning spray.
Step 48

Detach the coolant hoses from the coolant reservoir.
Step 49

Detach the clamp of the lower coolant pipe. Use combination pliers.
Step 50

Detach the lower coolant pipe.
Step 51

Unscrew the fasteners of the air conditioner piping bracket. Use a drive socket #10. Use a ratchet wrench.
Step 52

Release the coolant reservoir retainers. Use a clip removal tool.
Step 53

Remove the coolant reservoir.
Step 54

Remove the flywheel locking tool. Use an engine timing tool set.
Step 55

Turn the crankshaft gear. Use a drive socket #18. Use a ratchet wrench.

Please note!
The piston should be at its top dead centre (TDC).
Step 56

Install the crankshaft gear locking tool according to the factory marks. Use an engine timing tool set.
Step 57

Install the camshaft gear locking tool according to the factory marks. Use an engine timing tool set.
Step 58

Support the engine in the oil pan area. Use a hydraulic transmission jack.
Step 59

Clean the engine mount fasteners. Use WD-40 spray.
Step 60

Unscrew the upper fastener of the engine mount. Use a drive socket #15. Use a ratchet wrench.
Step 61

Unscrew the engine mount fasteners. Use a drive socket #16. Use a ratchet wrench.
Step 62

Remove the fastening bolts.
Step 63

Remove the engine mount.
Step 64

Loosen the fastener of the timing belt tensioner pulley. Use a combination spanner #13. Use HEX No.H6.
Step 65

Pull aside the timing belt tensioner pulley.
Step 66

Install the timing belt tensioner pulley locking tool. Use an engine timing tool set.
Step 67

Unscrew the fastener of the timing belt idler pulley. Use a combination spanner #16.
Step 68

Remove the timing belt idler pulley from its mounting seat.
Step 69

Remove the timing belt.
Step 70

Remove the timing belt tensioner pulley.
Step 71

Unscrew the water pump fasteners. Use a drive socket #8. Use a ratchet wrench.
Step 72

Remove the water pump. Use a crowbar.

Replacement: water pump & timing belt kit – FORD TRANSIT COURIER Kombi. AUTODOC experts recommend:
Caution! Coolant may come out from the water pump channels and body.
Step 73

Clean the water pump mounting seat. Use a seal scraper. Use all-purpose cleaning spray.
Step 74

Install the water pump gasket.
Step 75

Install the new water pump.
Step 76

Tighten the water pump fasteners. Use a drive socket #8. Use a torque wrench. Tighten it to 10 Nm torque.
Step 77

Treat the fastening bolt. Use a sealant.
Step 78

Install the timing belt tensioner pulley.
Step 79

Screw in the fastener of the timing belt tensioner pulley. Use a combination spanner #13.
Step 80

Install the timing belt idler pulley.
Step 81

Treat the fastening bolt. Use a sealant.
Step 82

Tighten the fastener of the timing belt idler pulley. Use a drive socket #16. Use a torque wrench. Tighten it to 37 Nm torque.
Step 83

Install the new timing belt.

Replacement: water pump & timing belt kit – FORD TRANSIT COURIER Kombi. Tip from AUTODOC:
Be careful not to damage the timing belt.
Step 84

Adjust the timing belt tension by moving the tensioner pulley.

AUTODOC recommends:
Make sure that the timing belt is properly tensioned.
Step 85

Tighten the fastener of the timing belt tensioner pulley. Use a combination spanner #13. Use HEX No.H6. Use a torque wrench. Tighten it to 30 Nm torque.
Step 86

Remove the timing belt tensioner pulley locking tool.
Step 87

Remove the camshaft gear locking tool.
Step 88

Remove the crankshaft gear locking tool.
Step 89

Turn the crankshaft pulley. Use a drive socket #18. Use a ratchet wrench.

Replacement: water pump & timing belt kit – FORD TRANSIT COURIER Kombi. Professionals recommend:
Make sure all the timing belt components are mounted correctly.
Step 90

Install the engine mount to its mounting seat.
Step 91

Treat the engine mount fasteners. Use a sealant.
Step 92

Install the fastening bolts.
Step 93

Tighten the engine mount fastening bolts. Use a drive socket #16. Use a torque wrench. Tighten it to 55 Nm torque.
Step 94

Treat the fastening bolts. Use a sealant.
Step 95

Screw in the upper fasteners of the engine mount. Use a drive socket #15. Use a ratchet wrench.
Step 96

Tighten the upper fastener of the engine mount. Use a drive socket #15. Use a torque wrench. Tighten it to 50 Nm torque.
Step 97

Remove the support from under the engine.

AUTODOC recommends:
FORD TRANSIT COURIER Kombi – Do not lower the transmission jack sharply to avoid damaging components and mechanisms of the car.
Step 98

Install the crankshaft position sensor.
Step 99

Tighten the fastener of the crankshaft position sensor. Use a drive socket #8. Use a torque wrench. Tighten it to 9 Nm torque.
Step 100

Install the lower timing cover.
Step 101

Tighten the fasteners of the lower timing cover. Use a drive socket #7. Use a torque wrench. Tighten it to 6 Nm torque.
Step 102

Turn the crankshaft gear. Use a drive socket #18. Use a ratchet wrench.

Please note!
The piston should be at its bottom dead centre (BDC).Adjust the valve timing according to the factory marks.
Step 103

Install the flywheel locking tool according to the factory marks. Use an engine timing tool set.
Step 104

Unscrew the crankshaft pulley fastener. Use a drive socket #18. Use a ratchet wrench.
Step 105

Install the crankshaft pulley according to the factory marks.
Step 106

Tighten the crankshaft pulley fastener. Use a drive socket #18. Use a torque wrench. Tighten it to 35 Nm torque.+190°

AUTODOC recommends:
Important! Be sure to use new fasteners.
Step 107

Remove the flywheel locking tool.
Step 108

Install the serpentine belt tensioner pulley.
Step 109

Install the alternator wiring harness bracket.
Step 110

Screw in the fasteners of the engine wiring harness bracket. Screw in the fasteners of the alternator wiring harness bracket. Use a drive socket #10. Use a ratchet wrench.
Step 111

Pull aside the V-ribbed belt tensioner pulley. Use a combination spanner #15.
Step 112

Screw in the fastener of the serpentine belt tensioner pulley. Use a drive socket #10. Use a ratchet wrench.
Step 113

Tighten the fasteners of the engine wiring harness bracket. Tighten the fasteners of the alternator wiring harness bracket. Use a drive socket #10. Use a torque wrench. Tighten it to 14 Nm torque.
Step 114

Tighten the fastener of the serpentine belt tensioner pulley. Use a drive socket #10. Use a torque wrench. Tighten it to 16 Nm torque.
Step 115

Install the coolant reservoir. Make sure you hear a click indicating that it is locked in place.
Step 116

Screw in the fasteners of the air conditioner piping bracket. Use a drive socket #10. Use a ratchet wrench.
Step 117

Attach the coolant hoses to the coolant reservoir.
Step 118

Clean the lower coolant pipe mounting seat. Use all-purpose cleaning spray.
Step 119

Attach the lower coolant pipe.
Step 120

Attach the clamp of the lower coolant pipe. Use combination pliers.
Step 121

Install the coolant drain plug.
Step 122

Install the coolant drain plug retaining clip.
Step 123

Install the crankshaft pulley cap.
Step 124

Screw in the fasteners of the engine wiring harness bracket. Use a drive socket #8. Use a ratchet wrench.
Step 125

Attach the engine wiring harness.
Step 126

Attach the alternator wiring harness.
Step 127

Attach the engine wiring harness clip to the timing cover.
Step 128

Attach the alternator wiring harness clip to the bracket.
Step 129

Connect the connector of the crankshaft position sensor.
Step 130

Attach the crankshaft position sensor wiring.
Step 131

Screw in the alternator wiring harness fastener. Use a drive socket #13. Use a ratchet wrench.
Step 132

Install the cap on the alternator wiring harness fastener.
Step 133

Connect the connector of the air conditioner compressor.
Step 134

Connect the alternator connector.
Step 135

Install the V-ribbed belt.

Replacement: water pump & timing belt kit – FORD TRANSIT COURIER Kombi. Tip from AUTODOC experts:
Make sure that the V-ribbed belt fits all pulleys snugly.
Step 136

Pull aside the V-ribbed belt tensioner pulley. Use a combination spanner #15.
Step 137

Place the V-ribbed belt on the tensioner pulley.
Step 138

Return the tensioner pulley to its initial position. Use a combination spanner #15.
Step 139

Install the lower serpentine belt cover.
Step 140

Screw in the fasteners of the lower serpentine belt cover. Use Torx T30. Use a ratchet wrench.
Step 141

Install the upper timing cover.
Step 142

Screw in the fasteners of the upper timing cover. Use a drive socket #7. Use a ratchet wrench.
Step 143

Attach the engine wiring harness to the upper timing cover.
Step 144

Connect the engine wiring harness connector.
Step 145

Remove the coolant reservoir cap.
Step 146

Insert the funnel.
Step 147

Pour coolant in the coolant reservoir.

Replacement: water pump & timing belt kit – FORD TRANSIT COURIER Kombi. Tip:
Only use the coolant recommended by the manufacturer.The coolant level should be at the MAX mark.Wait until the air goes out of the system.
Step 148

Install the coolant reservoir cap.
Step 149

Screw on the coolant reservoir cap.
Step 150

Attach the terminals to the battery.

Replacement: water pump & timing belt kit – FORD TRANSIT COURIER Kombi. AUTODOC experts recommend:
Be careful! Do not mix up the positive and the negative terminals of the car battery.
Step 151

Screw in the fasteners of the battery terminals. Use a drive socket #10. Use a ratchet wrench.
Step 152

Install the engine cover and secure it.

AUTODOC recommends:
Make sure the engine cover is properly seated. It should not be displaced with respect to the guiding fasteners.Warning! To avoid damaging the fasteners of the car during installation, do not use excessive force. FORD TRANSIT COURIER Kombi
Step 153

Run the engine for a few minutes. This should be done in order to remove residual air from the cooling system and to check if the components are operating correctly.
Step 154

Shut off the engine.

Step 155

Check the coolant level. If necessary, top up to the required level.

Please note!
The coolant level should be at the MAX mark.
Step 156

Remove the fender protection cover.

Step 157

Close the hood.

Replacement: water pump & timing belt kit – FORD TRANSIT COURIER Kombi. Professionals recommend:
Be sure to record the mileage at which you replaced the timing belt and water pump kits.

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