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Mondeo 1997 (08.1996-09.2000)

Engine - Vehicles Built Up To: 05/1998 1.6L/1.8L/2.0L - Engine Mondeo 1997 (08/1996-09/2000)
Assembly

Special Tool(s)

Universal flange holding wrench

15-030A

Aligner, clutch disk

16-067

Installer, oil seal

21009B

Installer, oil seal

21-093A

Locking tool, flywheel

21-135

Installer, oil seal

21-141

Timing tool, camshaft alignment

21-162B

Socket, cylinder head bolts

21-167

Angle gauge, bolt tightening

21-540
General Equipment
Piston ring compressor
Assembly stand
Assembly stand
Steel straightedge
Workshop hoist
Materials
Name
Specification
M10x70 bolt
 
Never Seeze
ESE-M1244-A 
Sealer
ESK-M4G269-A 
Sealer
WSE-M4G323-A4 
Engine Oil
WSS-M2C912-A1 

Assembly

  1. Preparatory operations
    • Clean all the mating faces and reusable parts thoroughly and inspect them for damage.

  1. NOTE:
    NOTE:Use new piston cooling oil splash nozzles.
    Fit the piston cooling oil splash nozzles and the blanking plugs.
  1. NOTE:
    NOTE:Main bearing shells of different thicknesses are fitted, which can also be used in servicing.
    Sizes of crankshaft main bearing shells.
    • Available sizes:

        • 1. Size A: 2,152 - 2,145 mm (green)

        2. Size B: 2,147 - 2,140 mm (brown)

        3. Size C: 2,142 - 2,135 mm (yellow)

        4. Size D: 2,137 - 2,130 mm (blue)
  1. NOTE:
    NOTE:Use bearing shells of size "B" or "C" (refer to step ).
    Measure the crankshaft radial clearance. For additional information, refer to Section  303-00 Engine System - General Information.
    • Select the bearing shell according to step to obtain a bearing clearance of 0,020 - 0,040 mm.
  1. Measure the crankshaft end float. For additional information, refer to Section  303-00 Engine System - General Information.
  1. Measure the camshaft radial clearance. For additional information, refer to Section  303-00 Engine System - General Information.
  1. Measure the camshaft end float. For additional information, refer to Section  303-00 Engine System - General Information.
  1. Measure the crankshaft. For additional information, refer to Section  303-00 Engine System - General Information.
  1. Measure the camshafts. For additional information, refer to Section  303-00 Engine System - General Information.
  1. Measure the big-end bearing clearance. For additional information, refer to Section  303-00 Engine System - General Information.
  1. Measure the cylinder bores. For additional information, refer to Section  303-00 Engine System - General Information.
  1. Measure the pistons. For additional information, refer to Section  303-00 Engine System - General Information.
  1. Measure the piston ring gaps. For additional information, refer to Section  303-00 Engine System - General Information.
  1. Measure the piston ring axial clearance. For additional information, refer to Section  303-00 Engine System - General Information.
  1. Check the cylinder head evenness. For additional information, refer to Section  303-00 Engine System - General Information.

  1. NOTE:
    NOTE:The bearing cap numbering starts at the timing belt end, to which the arrows also point.
    NOTE:
    NOTE:Use studs for bearings '2' and '4'.
    Fit the crankshaft.
    • Lubricate the main bearing journals and bearing shells with engine oil.
    • Fit the crankshaft main bearing caps with their associated bearing shells.
    • Tighten the bolts.

  1. NOTE:
    NOTE:The connecting rod numbering starts at the timing belt end. The arrow on the piston crown points towards the timing belt end.
    Fit the pistons.
    • Lubricate the pistons and cylinder liners with engine oil .
    • Distribute the piston ring gaps uniformly around the circumference - this also applies to the elements of the oil scraper ring.
    • Press pistons 1 and 4 into the cylinders using the handle of a hammer. The big-end bearing journal must be at BDC.
    • Check the bearing shells are clean and dry and fit them in the associated connecting rods and bearing caps.
    • Fit the bearing caps.
    • Turn the crankshaft through 180 degrees and fit pistons 2 and 3.

  1. CAUTION:
    CAUTION:Only use new bolts.
    NOTE:
    NOTE:The connecting rods and big-end bearing caps have the same numbering.
    Install the bearing caps.
    • Lubricate the bearing shells and journals with engine oil.
    • Fit the appropriate big-end bearing caps and bearing shells and torque them down.

  1. NOTE:
    NOTE:Use a new gasket.
    Install the oil pump.
    • Locate the oil pump in position.
    • Align the oil pump rotor with the recesses in the crankshaft.
    • Screw in the bolts finger tight.
    1. Align the oil pump so that the mating face of the oil pump housing is 0,3 - 0,8 mm below the cylinder block.
    1. Tighten the bolts.

  1. Install the oil intake pipe and the oil baffle plate.
    • Fit the oil baffle.
    1. Install the oil intake pipe with a new gasket.
    1. Install the oil baffle plate with the oil intake pipe bracket.

  1. Fit the oil pump seal.
    • Draw in the new oil seal with the installer and the bolt of the crankshaft pulley.

  1. Fit the coolant pump with a new gasket.

  1. Fit the rear oil seal carrier and the bracket of the CKP sensor.
    • Locate the oil seal carrier in position with a new gasket and screw in the bolts finger tight.
    1. Align the oil seal carrier so that the mating face of the oil seal carrier is 0,3 - 0,8 mm below the cylinder block.
    1. Tighten the four bolts.
    1. Fit the CKP sensor bracket.

  1. Fit the oil seal in the oil seal carrier.
    • Push in the radial oil seal using the special tool and two flywheel/drive plate bolts.

  1. NOTE:
    NOTE:The oil pan bolts must be tightened within 10 minutes of applying the sealer.
    Apply sealer to the cylinder block mating face intersections.

  1. Align the oil pan.
    • Locate the sump in position with a new gasket and screw the bolts in finger tight.
    • Align the oil pan using a steel straightedge so that the cylinder block and oil pan are level.

  1. Secure the oil pan.
    • Tighten the ten oil pan bolts.
    • Check that the oil pan is flush as in the previous step. If necessary, use spacer sleeves to remove any step.

  1. NOTE:
    NOTE:Use new bolts.
    Fit the flywheel/drive plate.
    • Locate the flywheel in position and tighten the bolts finger tight.
    • Immobilise the flywheel with Special Tool 21-135.
    • Tighten the bolts.

  1. Center the clutch disk on the clutch pressure plate.

  1. Install the clutch.
    1. Locate the clutch pressure plate in position with the centered clutch disk.
    1. Screw in the bolts uniformly two turns each and then to the correct torque, working diagonally.
    1. Remove the special tool.

  1. CAUTION:
    CAUTION:Bring the piston of cylinder no. 1 to a point approx. 20 mm before TDC to avoid damage when fitting the cylinder head.
    NOTE:
    NOTE:FRONT mark.
    Fit the crankshaft timing pulley.
    1. Thrust plate.
    1. Timing pulley.

  1. NOTE:
    NOTE:'TOP' mark and gasket identification.
    Fit the cylinder head.
    1. Check that the locating bushes are seated correctly.
    1. Fit a new cylinder head gasket.
    • Fit the cylinder head.

  1. Pre-tighten the cylinder head bolts.
    • Screw in new, unoiled cylinder head bolts.
    • Fit cylinder head bolts in two stages in accordance with the tightening sequence.

  1. CAUTION:
    CAUTION:The cylinder head bolts must not be retorqued.
    Tighten the cylinder head bolts, Stage 3.
    • Tighten the cylinder head bolts in the indicated sequence.
    • Lubricate the hydraulic tappets with engine oil and proceed according to the removal sequence.

  1. NOTE:
    NOTE:The camshafts are marked. The inlet camshaft has an additional cam for the CMP sensor at the end of the shaft.
    Fit the camshafts.
    • Apply sealer to the cylinder head / bearing cap mating face at the timing belt end.
    • Fit the camshafts.

  1. NOTE:
    NOTE:The numbering starts at '0' on the exhaust side and faces outwards.
    Fit the camshaft bearing caps.
    • Lubricate the camshaft bearing surfaces and the bearing surfaces in the cylinder head with engine oil.
    • Fit the bearing caps.

  1. Fit the camshaft bearing caps.
    • Screw in the bolts in pairs in the indicated sequence half a turn at a time.
    • Repeat this until the bearing caps are in contact with the cylinder head.
    • Tighten the bolts in pairs in the indicated sequence.

  1. NOTE:
    NOTE:The camshaft timing pulleys must be able to turn freely on the camshafts; do not tighten the bolts.
    Fit the camshaft seals.
    • Lubricate the camshafts and the sealing lip of the oil seals with engine oil.
    • Draw in the new oil seals using the special tool, a washer and an M10x70 bolt .
  1. NOTE:
    NOTE:The camshaft timing pulleys must be able to turn freely on the camshafts; do not tighten the bolts.
    Install the camshaft timing belts.

  1. Align the camshafts.
    • Insert the special tool into the camshafts.

  1. CAUTION:
    CAUTION:Install the retaining stud and spring if not present.
    Tension the pulley against the spring pressure.
    1. Install the spring retaining stud (if not present).
    1. Hook the timing belt tensioner spring in place (if not present).
    1. Tension the pulley against the spring by turning it clockwise with an Allen key and secure it.

  1. Turn the crankshaft to TDC.
    • For greater accuracy, extend the mark on the oil pan with a small strip of metal (25 mm wide) or similar.

  1. CAUTION:
    CAUTION:Use a new timing belt.
    CAUTION:
    CAUTION:Do not kink the timing belt (bend diameter must not be less than 35 mm).
    NOTE:
    NOTE:Turn the camshaft timing pulleys so that the timing belt engages correctly in all the timing pulleys.
    NOTE:
    NOTE:The tension side of the timing belt (between the crankshaft timing pulley and the camshaft timing pulley) must be taut.
    Lay the new timing belt in place.
    • Check that the crankshaft is at TDC.
    1. Fit the timing belt, working in an counter-clockwise direction, starting from the crankshaft timing pulley.
    1. Slacken the bolt of the tensioning pulley. The timing belt will be tensioned by the spring.

  1. Secure the timing belt tensioner.
    • Secure the timing belt tensioner pulley.
CAUTION:
CAUTION:Do not tighten the camshaft timing pulley bolts using Special Tool 21-162B; use Special Tool 15-030A to prevent movement.
  1. NOTE:
    NOTE:The crankshaft must be at TDC.
    Tighten the bolts of the camshaft timing pulleys.
    • Remove Special Tool 21-162B.
  1. Turn the crankshaft two turns clockwise as far as the TDC position.

  1. Secure the timing belt tensioner.
    • Secure the timing belt tensioner pulley.
    • Check that the crankshaft and camshafts are at TDC.
    • If there is a very slight error:

        • 1. Adjust the camshaft using Special Tool 15-030A until Special Tool 21-162B can be inserted. The crankshaft must remain at TDC.

  1. CAUTION:
    CAUTION:Do not remove or tighten the camshaft timing pulley bolts using Special Tool 21-162B; use Special Tool 15-030A to prevent movement.
    NOTE:
    NOTE:The crankshaft must remain in the TDC position.
    Special tool 21-162B cannot be inserted.
    • Slacken the camshaft timing pulley of the camshaft concerned. Hold the pulley with Special Tool 15-030A.
    • Turn the camshaft until Special Tool 21-162B can be inserted.
    • Tighten the bolt of the camshaft timing pulley.
    • Remove the special tool.
    • Turn the crankshaft another two turns in the clockwise direction as far as the TDC position and check the alignment of the camshaft.

  1. CAUTION:
    CAUTION:Use a blunt object to apply the silicone grease (e.g. a plastic cable tie) to avoid damaging the spark plug connector seal.
    CAUTION:
    CAUTION:Push on the spark plug connectors in a straight line with the axis of the spark plug.
    NOTE:
    NOTE:Coat the inside of the spark plug connectors to a depth of 5-10 mm with silicone grease.
    NOTE:
    NOTE:Use a new cylinder head cover gasket.
    Install the spark plugs and cylinder head cover.
    1. Screw in the spark plugs and tighten them.
    1. Fit ten bolts.
    • Connect the HT leads to the spark plugs.

  1. Fit the timing belt covers.
    • Make sure that the middle cover is seated correctly in the lower cover.
  1. Immobilise the flywheel with Special Tool 21-135.

  1. Attach the coolant pump belt pulley and the crankshaft pulley/vibration damper.

  1. Connect the PCV.
    1. Screw in the three bolts.
    1. PCV pipe

  1. CAUTION:
    CAUTION:If the stud came out when the engine lifting eye was removed, first fit the stud and tighten it to 6 Nm, and then secure the engine lifting eye with the nut.
    Fit the exhaust manifold, ignition coil and thermostat housing.
    • Detach Special Tool 21-135 from the flywheel/drive plate.
    1. Engine lifting eye
    1. Fit the bracket of the power steering pump/air conditioning compressor (eight bolts).
    1. Fit the exhaust manifold (eight nuts)
    1. Fit the ignition coil (three bolts)
    1. Thermostat housing
    1. Attach the coolant hose to the coolant pump
  1. Suspend the engine from the workshop hoist by the engine lifting eyes and detach it from the assembly stand .

  1. NOTE:
    NOTE:Use a new gasket.
    Fit the intake manifold.
    • Attach the injector wiring harness (two bolts).

  1. Fit the generator bracket.
    1. Fit the bolts.
    1. Engine lifting eye

  1. Fit the generator and the idler pulley.
    1. Drive belt idler pulley
    1. Generator

  1. Attach the cable guide to the intake manifold.

  1. Fit the center bearing bracket and the oil pressure switch.
    1. Oil pressure switch
    1. Tighten the three bolts.

  1. Connect the plugs and fit the filter of the pulse air system.
    1. Plug of CKP sensor.
    1. Plug of coolant temperature sender unit.

  1. Connect the plugs.
    1. Ignition coil (EI)
    1. Radio interference suppressor.
    1. ECT sensor.

  1. Connect the plugs and the generator.
    1. Plug of engine main wiring harness.
    1. TP sensor.
    1. CMP sensor.
    1. Connect the generator.

  1. Attach the catalytic converter to the exhaust manifold (2,0 engine shown).

  1. CAUTION:
    CAUTION:Support the engine with wooden wedges and secure it with clamping straps.
    Place the engine on the assembly table .
  1. Install the oil filter.
    • Lubricate the gasket with engine oil.
    • Tighten it half to three-quarters of a turn after it touches the mating face.
  1. Finishing operations.

Assembly|Installation > < In-vehicle Repair|Disassembly|Engine