cool these are the instructions for the tensioner.

REVISED TIMING BELT & TENSION SETUP ON 2.0L

Shop manuals are indispensable tools for looking up disassembly/ installation procedures, specifications, diagnostic and service information. But sometimes errors occur in printed manuals, which makes life interesting for the poor guy who doesn't know the manual is incorrect. An example here is the timing belt and tensioner setup procedure that Ford originally published for the 1998-2000 Contour, Escort ZX2, 2000 Focus, 1998-2000 Mercury Mystique and 1999-2000 Mercury Cougar with 2.0L engine. Ford TSB 99-25-4 provides the following corrected information:

To achieve proper timing belt tension on this engine, Ford says the camshaft sprocket bolts should be loosened enough to permit the sprockets to turn freely on the camshafts. Once this has been done, rotate the crankshaft clockwise so cylinder No. 1 is at top dead center. Then, install the camshaft alignment tool in the camshaft slots to hold the cams in place.

Back out the tensioner bolt four full turns and position the tensioner so the locating tab is at approximately the 4 o'clock position. Line up the hex key slot in the tensioner-adjusting washer with the pointer that is located behind the pulley.

Working counterclockwise from the crank sprocket, install the timing belt.

Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover.

Position the hex key slot in the tensioner-adjusting washer to the 4 o'clock position.p>

Tighten the attaching bolt enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 6 mm hex key.

Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab. (The pointer will move in a clockwise direction during adjustment).

While holding the adjusting washer in position, torque the attaching bolt to 18 lb-ft (25 N.m).

Note: If the pointer does not remain centered over the index line during final tightening, loosen the bolt and repeat the procedure beginning with step 4.



As for the exhuast, its not that hard, just move the exhaust cam 1 tooth up or down after turning the engine over a few times by hand. You will see at the TDC position, if they dont match up then u need to adjust the exhaust once again.

The car will start with an exhaust error but run rough, so just turn it over by hand until they match up perfectly. you will see that the exhaust cam shaft stops to load up which the intake moves all the time, just make sure u compare them at TDC. Then u are ready to assemble it and give it a test start.

Over tension will make the belt run offcenter and hit, thats what mine did.

Make sure u inspect all idlers because once they go ure done, my belt got stripped when the bottom (little idler) broke apart and stripped the walls. MAke sure u spend the extra cash and do the job once. The offcenter thing is more of a long term effect, the car will run fine but the belt will feel excess stress if the belt is running into the outer walls (never runs into the block for some reason LOL).

Good luck,
Ciprian