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

Mondeo 2007.5 (02.2007-)

Engine - 2.3L Duratec-HE (MI4) - Valve Clearance Adjustment Mondeo 2007.5 (02/2007-)
General Procedures

Special Tool(s)
205-072
Universal Flange Holding Wrench

205-072-02
Adapter for 205-072

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 the cam pair of the cylinder to be adjusted are pointing upwards. Using a suitable feeler gauge, measure the valave clearance.
  1. Make a note of each cylinder number with the corresponding valve clearance.
  1. Compare the measured valve clearance(s) with the specifications.
    Refer to: Spezifikationen (303-01 Motor - 2.3L 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. Special Tool(s): 205-072, 205-072-02

  1.  
    1. General Equipment: 2 mm punch
    1. NOTE:
      NOTE:Only tighten the bolt finger tight at this stage.
      Bolt M6 x 25 mm

  1. CAUTION:
    CAUTION:Counterhold the camshaft at the hexagon with a wrench to prevent the camshaft from rotating.

  1. CAUTION:
    CAUTION: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. CAUTION:
    CAUTION:Make sure that the camshafts and camshaft bearing caps are installed in their original locations.
    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:The camshaft sprocket bolt must not be tightened at this stage.
    NOTE:
    NOTE:Make sure that the camshaft sprocket can rotate on the camshaft.

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

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

  1. WARNING:
    WARNING:Only rotate the crankshaft clockwise.
    Turn the crankshaft until it stops against the special tool.

  1. CAUTION:
    CAUTION:Counterhold the camshaft at the hexagon with a wrench to prevent the camshaft from rotating.
    Torque: 72 Nm

  1. NOTE:
    NOTE:Only tighten the bolt finger tight at this stage.
    • Bolt M6 x 18 mm

  1. CAUTION:
    CAUTION:Make sure that a new bolt is installed.
    Special Tool(s): 205-072, 205-072-02
    Torque:
    Stage 1:
    100 Nm
    Stage 2:
    90°

  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.
    Turn the crankshaft until it stops against 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.
    Check that the valve clearance on all cylinders meets the specified tolerances.
  1. If necessary, repeat the steps until the valve clearance on each cylinder meets the specified tolerance.

  1. Material: Silicone Sealant

  1. Torque: 10 Nm

  1.  
    1. Torque: 10 Nm
    1. Torque: 10 Nm

  1. Torque: 10 Nm

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