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Mondeo 2007.5 (02.2007-)

Engine - 1.8L Duratorq-TDCi (Lynx) Diesel - Cylinder Head Mondeo 2007.5 (02/2007-)
Removal and Installation

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

303-122
Lifting Bracket, Engine

303-193
Timing Peg, Crankshaft TDC

303-376B
Alignment Plate, Camshaft

303-393
Locking Tool, Flywheel

303-651
Remover, Camshaft Sprocket
Materials
Name
Specification
Cleaner
WSK-M5B401-A1
Engine Oil - 5W-30
WSS-M2C912-A1
General Equipment
Cable ties
Trolley jack

Removal

WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation).
WARNING:
WARNING:Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient temperature.
  1. Disconnect the battery ground cable.
    Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

  1. Drain the cooling system.
    Refer to: Cooling System Draining, Filling and Bleeding (303-03D Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel, General Procedures).
  1. Remove the Air Cleaner.
    Refer to: Air Cleaner (303-12D Intake Air Distribution and Filtering - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1. Remove the Fuel Filter.
    Refer to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).

  1. NOTE:
    NOTE:Only rotate the camshaft in the normal direction of rotation.
    Using the camshaft groove as a guide, rotate the crankshaft to 5 degrees before top dead center (TDC).

  1. CAUTION:
    CAUTION:Make sure that the area around the component is clean and free of foreign material.
    Refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel, General Procedures).

  1. CAUTION:
    CAUTION:Use an open-ended wrench to prevent the component from turning.
    CAUTION:
    CAUTION:Make sure that all openings are sealed. Use new blanking caps.
    Discard the high-pressure fuel supply lines.

  1. Discard the thermostat housing gasket.
  1. Remove the front right wheel.
    Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

  1. CAUTION:
    CAUTION:Make sure that the exhaust flexible pipe is not forcibly bent.

  1. CAUTION:
    CAUTION:Twisting the exhaust flexible pipe more than 2 degrees may cause damage resulting in failure.

  1. Refer to: Accessory Drive Belt (303-05D Accessory Drive - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1. Secure the A/C compressor to one side.
    General Equipment: Cable ties
  1. Remove the starter motor.
    Refer to: Starter Motor (303-06D Starting System - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1. CAUTION:
    CAUTION:Make sure that the crankshaft is not rotated while the special tool is installed.
    NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    1. Remove the cylinder block blanking plug and install the special tool.
      Special Tool(s): 303-193
    1. Rotate the crankshaft slowly until the crankshaft stops.
    1. Using the special tool, lock the crankshaft.
      Special Tool(s): 303-393

  1. Loosen the charge air cooler outlet pipe and put it aside.

  1. General Equipment: Trolley jack

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

  1. Torque: 20 Nm

  1. Discard the timing belt.

  1. Loosen the camshaft pulley retaining bolt by 5 turns.
    Special Tool(s): 205-072

  1. Special Tool(s): 303-651

  1. NOTE:
    NOTE:Note the different lengths of the bolts.

  1. Special Tool(s): 303-122
  1. Position the cylinder head on wooden blocks.

Installation

  1. Clean the mating faces of the cylinder head and cylinder block with cleaner.
    Material: Cleaner

  1. NOTE:
    NOTE:The thickness and position of the new cylinder head gasket must be the same as that of the old one (hole/tooth and TOP/OBEN marked).

  1. NOTE:
    NOTE:The pistons must not be at TDC. Make sure that the special tool is engaged in the camshaft groove.
    Special Tool(s): 303-122

  1. CAUTION:
    CAUTION:Make sure that new bolts are installed.
    CAUTION:
    CAUTION:Make sure that the component is clean, free of foreign material and lubricant.
    Torque:
    Stage 1:
    20 Nm
    Stage 2:
    54 Nm
    Stage 3:
    90°
    Stage 4:
    (M12x137) 70°, (M12x177) 90°

  1. Torque: 10 Nm

  1.  
    • Check the timing belt tensioner and make sure that the timing belt tensioner pointer rotates clockwise freely.
    • Move the timing belt tensioner adjustment arm to the 3 o'clock position.
    • Do not fully tighten the timing belt tensioner retaining bolt at this stage.

  1.  
    • The camshaft pulley must be able to rotate freely on the camshaft taper. Tighten the camshaft pulley bolt finger tight and then loosen by one-half turn.
    • Install the timing belt with the direction arrows in the direction of engine rotation.

  1. Tension the timing belt counterclockwise until the pointer is positioned between the sides of the window.
    Torque: 50 Nm

  1. Special Tool(s): 205-072
    Torque: 50 Nm
  1. Remove the special tools.
    Special Tool(s): 303-376B, 303-193, 303-393
  1.  
    1. Rotate the crankshaft 2 revolutions. Replace the Timing Peg just before TDC on the second revolution.
      Special Tool(s): 303-193
    1. Rotate the crankshaft slowly until the crankshaft stops at TDC.
  1. Check that the timing belt tensioner pointer is positioned in the window, otherwise the timing belt tensioning steps must be repeated.

  1. NOTE:
    NOTE:If the special tool cannot be installed, the timing belt tensioning steps must be repeated.
    Install the special tool.
    Special Tool(s): 303-376B
  1. Remove all special tools and install the cylinder block blanking plug.
    Torque: 23 Nm

  1. Torque: 20 Nm

  1. Torque: 7 Nm

  1. Torque: 23 Nm

  1.  
    1. Torque: 12 Nm
    1. Torque: 80 Nm
    1. NOTE:
      NOTE:Only tighten the bolts finger tight at this stage.

  1. Lower and remove the Trolley jack.
    General Equipment: Trolley jack

  1. Torque: 90 Nm

  1. Install the starter motor.
    Refer to: Starter Motor (303-06D Starting System - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1. Torque: 25 Nm

  1. Torque:
    driveshaft intermediate bearing retaining bolts 27 Nm
    vibration damper retaining bolts 10 Nm

  1. Torque:
    1 25 Nm
    2 9.8 Nm
    3 35 Nm
    4 23 Nm

  1. CAUTION:
    CAUTION:Twisting the exhaust flexible pipe more than 2 degrees may cause damage resulting in failure.
    Tighten all retaining nuts in the sequence shown.
    Torque:
    1-5 25 Nm
    6 51 Nm

  1. Remove the exhaust flexible pipe support wrap.

  1.  
    1. Torque: 35 Nm
    1. Loosen: 360°
    1. Torque: 85 Nm

  1. Install the front right wheel.
    Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

  1. Tighten the common rail support bracket retaining bolts in the sequence shown. Do not fully tighten the fuel supply manifold retaining bracket bolts at this stage.
    Torque:
    1-2 23 Nm
    3 24 Nm

  1. CAUTION:
    CAUTION:Use an open-ended wrench to prevent the component from turning.
    NOTE:
    NOTE:The fuel supply line must be installed with the yellow identification collar adjacent to the fuel injector and the blue identification collar adjacent to the fuel rail.
    NOTE:
    NOTE:The fuel supply line must be installed with the yellow identification collar adjacent to the fuel pump and the blue identification collar adjacent to the fuel rail.
    NOTE:
    NOTE:The high-pressure fuel supply lines must be connected immediately after removing the blanking plugs.
    NOTE:
    NOTE:Do not allow the unions to hit the ends of the high-pressure fuel supply line. To aid installation of the new high-pressure fuel supply lines, the unions at the fuel rail end are colored gold.
    Tighten the fuel injector high-pressure fuel supply lines in the sequence shown.
    Torque:
    1-5 25 Nm
    6-10 38 Nm
    11 23 Nm
    12 18 Nm

  1. Torque:
    1 7 Nm
    2 23 Nm
    3 23 Nm
  1. Install the Fuel Filter.
    Refer to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).

  1. Torque: 23 Nm

  1.  
    1. Torque: 3 Nm
    1. Torque: 5 Nm

  1. Torque: 10 Nm

  1. Torque: 23 Nm

  1. Torque: 24 Nm
  1. Install the Air Cleaner.
    Refer to: Air Cleaner (303-12D Intake Air Distribution and Filtering - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).
  1. Connect the battery ground cable.
    Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).
  1. Change the engine oil and the oil filter.
    Material: Engine Oil - 5W-30
  1. Bleed the cooling system.
    Refer to: Cooling System Draining, Filling and Bleeding (303-03D Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel, General Procedures).

Oil Pump > < Exhaust Manifold