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General Procedures|Removal and Installation > < Diagnosis and Testing|Engine

Mondeo 2007.5 (02.2007-)

Engine - 2.0L Duratec-HE (MI4) - Valve Clearance Adjustment Mondeo 2007.5 (02/2007-)
General Procedures

Special Tool(s)
303-376B
Alignment Plate, Camshaft

303-499
Socket, Spark Plug

303-748
Locking Tool, Crankshaft
Materials
Name
Specification
Adhesive - Loctite 243
WSK-M2G349-A7
Hypoid Gear Oil
SQM-2C9002-AA
Silicone Sealant
WSE-M4G323-A4
General Equipment
2 mm punch

  1. NOTE:
    NOTE:The gasket is to be reused unless damaged.

  1. Special Tool(s): 303-499

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Rotate the crankshaft until each piston is at top dead center (TDC) and measure the valve clearance(s) using a suitable set of feeler gauges.
  1. Note down each cylinder number and the valve clearance(s) measured.
  1. Compare the measured valve clearance(s) with the specifications.
    Refer to: Specifications (303-01B Engine - 2.0L Duratec-HE (MI4), Specifications).
  1. NOTE:
    NOTE:Only carry out the following steps when the valve clearance(s) require adjustment.

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Rotate the crankshaft until piston No. one is approximately 45 degrees before top dead center (TDC).

  1.  
    1. General Equipment: 2 mm punch
    1. Open ended wrench
    1. Bolt M6 x 25 mm

  1. CAUTION:
    CAUTION:Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

  1. CAUTION:
    CAUTION:Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
    Loosen: 5 turn(s)

  1. NOTE:
    NOTE:Note the position of each component before removal.
  1.  
    • Remove the valve tappet and read the thickness from the underside.
    • The number on the valve tappet indicates the thickness of the bottom of the tappet. However, the number only indicates the digits after the decimal point (example: .650 = 3,650).
  1.  
    • Calculate the required thickness of the valve tappet with the following formula: X = S + M - V
    • Required thickness of tappet = X
    • Thickness of currently fitted tappet = S
    • Measurement of existing valve clearance (actual value) = M
    • Desired valve clearance = V
  1. Install the correct valve tappet.

  1. NOTE:
    NOTE:Make sure that these components are installed to the noted removal position.
    Coat the camshaft bearing caps with oil.
    Material: Hypoid Gear Oil
  1. Install the camshafts approximately at valve overlap position cylinder No. 4.
    Torque:
    Stage 1:
    7 Nm
    Stage 2:
    16 Nm

  1. NOTE:
    NOTE:Only tighten the bolt finger tight at this stage.
    NOTE:
    NOTE:Make sure that the camshaft sprockets can rotate on the camshafts.

  1. Install the Special Tool(s): 303-376B

  1.  
    • Bolt M6 x 25 mm

  1. Install the Special Tool(s): 303-748

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Rotate the crankshaft until it contacts the special tool.

  1. CAUTION:
    CAUTION:Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
    Torque: 72 Nm

  1. Remove the Special Tool(s): 303-376B

  1. Remove the Special Tool(s): 303-748

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Rotate the crankshaft one and three quarters until piston No. 1 is approximately 45 degrees before top dead center (TDC).

  1. Install the Special Tool(s): 303-748

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Rotate the crankshaft until it contacts the special tool.

  1. NOTE:
    NOTE:Only tighten the bolt finger tight at this stage.
    NOTE:
    NOTE:The bolt can only be installed if the valve timing is correct.
    • Bolt M6 x 18 mm

  1. NOTE:
    NOTE:The special tool can only be installed if the valve timing is correct.
    Install the Special Tool(s): 303-376B

  1. Remove the Special Tool(s): 303-376B

  1. Remove the Special Tool(s): 303-748

  1. Torque: 20 Nm

  1.  
    1. Material: Adhesive - Loctite 243
      Torque: 10 Nm
    1. Material: Adhesive - Loctite 243
      Torque: 12 Nm
  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Rotate the crankshaft until the piston is at TDC and measure the valve clearance.
  1. Repeat the procedure as necessary until all valve clearances are within the specified tolerance.

  1. Special Tool(s): 303-499
    Torque: 12 Nm

  1. Material: Silicone Sealant

  1. Torque: 10 Nm

  1. Torque: 10 Nm

  1. Torque: 10 Nm

General Procedures|Removal and Installation > < Diagnosis and Testing|Engine