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Valve Seals > < Crankshaft Front Seal

Mondeo 1997 (08.1996-09.2000)

Engine - Vehicles Built Up To: 05/1998 1.6L/1.8L/2.0L - Intake Manifold Mondeo 1997 (08/1996-09/2000)
In-vehicle Repair

General Equipment
Trolley jack
Materials
Name
Specification
Cable ties
 

Removal

  1. General Notes.
    • The positions of the engine mountings are described looking from the transmission towards the engine.
    • Owing to special model variants, some job steps do not apply to all vehicles. These are clearly marked in the text.
  1. Standard preparatory measures
    • Make a note of the radio keycode.
    • Make a note of the preset radio stations.
      CAUTION:
      CAUTION:Disconnect the battery negative lead.
    • Cut the cable ties where necessary and renew them on installation.

  1. Remove the intake pipe.
    1. Pull out the plug of the mass air flow sensor (MAF sensor).
    1. Disconnect the intake air temperature (IAT) sensor multiplug.
    1. Remove the bolt and the two nuts.
    1. Open the clips.
  1. Raise the vehicle.

  1. Detach the engine undershield (nine bolts).

  1. Detach the right-hand front wheelhouse cover.

  1. Remove the drive belt.
    1. Slacken the drive belt.
    1. Remove the drive belt.

  1. Detach the generator at the bottom.

  1. Detach the brake booster vacuum pipe from the intake manifold.
    • Unlock the quick-release coupling and disconnect the pipe.
    • Disconnect the PCV hose from the intake manifold.
  1. Lower the vehicle.
  1. CAUTION:
    CAUTION:Insert the wooden block between the oil pan and the trolley jack.
    Lift the engine with the trolley jack to take the weight off the front engine mounting.

  1. NOTE:
    NOTE:Mark the position of the front engine mounting bracket in relation to the power steering pump bracket.
    Detach the front engine mounting bracket.

  1. Disconnect the vacuum hoses from the intake manifold.

  1. Pull out the plug of the cylinder head wiring harness and detach the engine wiring harness from the intake manifold.
    1. Plug.
    1. Wiring harness.

  1. Detach the accelerator cable.
    • Unhook the cable.
    • Pull off the plastic clip and lay the accelerator cable to one side.

  1. Detach the generator and lay it to one side.

  1. Detach the exhaust gas recirculation (EGR valve) system.
    1. EGR pipe
    1. EGR valve

  1. Detach the EGR line bracket.

  1. Detach the throttle position sensor (TP) multiplug.

  1. Remove the throttle housing.

  1. Disconnect the camshaft position (CMP) sensor multiplug.
  1. Release fuel pressure. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.

  1. WARNING:
    WARNING:Escaping fuel. Observe the safety regulations when handling fuel.
    Disconnect the fuel pipes.
    • Detach the fuel line bracket from the intake manifold.

  1. Disconnect the fuel injector plug.

  1. Disconnect the idle air control (IAC) valve connector.

  1. Remove the intake manifold (eight bolts, two nuts).
    • Detach the injector wiring harness (two bolts).

Installation
  1. NOTE:
    NOTE:Only use a new gasket when the old is faulty.
    Install the intake manifold (eight bolts, two nuts).
    • Attach the injector wiring harness (two bolts).

  1. Connect the idle air control (IAC) valve connector.

  1. Push on the fuel injector connector.

  1. NOTE:
    NOTE:The pipes are marked.
    Connect the fuel pipes.
    • Attach the fuel pipe bracket to the intake manifold.

  1. Connect the CMP sensor plug.

  1. Install the throttle housing with a new gasket.

  1. Connect the TP sensor multiplug.

  1. Install the EGR system.
    1. EGR Valve
    1. EGR pipe

  1. Attach the bracket to the EGR line.

  1. Install the generator.

  1. Install the accelerator cable and adjust it.
    1. Install the cable in the bracket and slide on the plastic clip.
    • Hook the cable in place.
    1. Pull the clip off the accelerator cable.
    • Pull the inner cable a few clicks out from the outer cable.
    • Fully depress the accelerator pedal once and slide the clip back on.
    • Check that the throttle plate opens fully when the accelerator pedal is depressed. If not, repeat the adjustment procedure.

  1. Attach the engine wiring harness to the intake manifold and connect the plug of the cylinder head wiring harness.
    1. Wiring harness.
    1. Plugs.

  1. Connect the vacuum hoses to the intake manifold.

  1. NOTE:
    NOTE:Use new self-locking nuts.
    NOTE:
    NOTE:The markings on the front engine mounting bracket and power steering pump bracket must line up.
    Install the front engine mounting bracket.
    1. Tighten four nuts.
    1. Tighten the nut on the engine mounting.
  1. Remove the trolley jack .

  1. NOTE:
    NOTE:Engage the vacuum pipe properly.
    Attach the brake booster vacuum pipe to the intake manifold.
    • Guide the vacuum pipe into the quick-release coupling and lock it in place.
    • Press the PCV hose into place on the intake manifold.

  1. Tighten the lower generator bolt.

  1. Install the drive belt and tension it.
    • The diagram shows the routing of the drive belt with and without an air conditioning compressor.

  1. Install the right-hand front wheelhouse cover.

  1. Attach the engine undershield (nine bolts).
  1. Lower the vehicle.

  1. Install the intake pipe.
    1. Connect the plug of the MAF sensor.
    1. Connect the IAT sensor plug at the intake pipe.
    1. Install the bolt and the two nuts.
    1. Close the clips.
  1. Standard finishing operations.
    • Connect the negative lead to the battery.
    • Check the fluid levels and correct as necessary.
    • Check the routing of the vacuum hoses and wiring and secure them with cable ties.
    • Enter the radio keycode.
    • Reset the clock.
    • Reprogram the preset radio stations.
    • Carry out a road test to enable the powertrain control module (PCM) to collect data.
    • Check the fluid levels again and correct as necessary.

Valve Seals > < Crankshaft Front Seal