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Mondeo 2007.5 (02.2007-)

Engine - 1.8L Duratorq-TDCi (Lynx) Diesel - Engine Mondeo 2007.5 (02/2007-)

Assembly

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

303-435
Mounting Stand

303-435-06
Mounting Bracket for 303-435

303-652
Aligner, Oil Pump

303-710
Timing Tool, Crankshaft
Materials
Name
Specification
Cleaner
WSK-M5B401-A1
Engine Oil - 5W-30
WSS-M2C912-A1
Sealant - Loctite 510
WSK-M2G348-A7
Silicone Sealant
WSE-M4G323-A4
  1. Coat the crankshaft main bearing journals, bearing shells and thrust half washers with clean engine oil.
    Material: Engine Oil - 5W-30

  1. CAUTION:
    CAUTION:Make sure that new bearing cap retaining bolts are installed.
    Tighten the crankshaft main bearing cap retaining bolts in the sequence shown.
    Torque:
    Stage 1:
    45 Nm
    Stage 2:
    70 Nm
    Stage 3:
    60°
  1.  
    • Coat the cylinder bores with clean engine oil.
    • The piston ring gaps and oil supply ring elements must be distributed evenly around the circumference of the piston.
    • Install the pistons with the arrows pointing towards the front of the engine.
    • Using a suitable piston ring compressor, install the pistons.

  1.  
    • Lubricate the connecting rod journals with clean engine oil.
    • The connecting rod identification marks must point towards the front of the engine.
    • CAUTION:
      CAUTION:Make sure that new connecting rod bearing caps retaining bolts are installed.
      Start tighten the connecting rod bearing caps retaining bolts finger tight.
      Torque:
      Stage 1:
      27 Nm
      Stage 2:
      60°
      Stage 3:
      20°

  1. The chain housing bottom sealing flange surfaces must be within +/- 0,26mm of the cylinder block bottom sealing flange surfaces.
    Torque: 23 Nm

  1.  
    • Align the ladder frame flush with the cylinder block.
    • Tighten the ladder frame retaining bolts in the sequence shown.
      Torque: 11 Nm

  1. Torque: 10 Nm
  1. Install the Crankshaft Rear Seal.
    Refer to: Crankshaft Rear Seal (303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).
  1. NOTE:
    NOTE:Make sure that the mating faces are clean and free of foreign material.

  1. CAUTION:
    CAUTION:Make sure that no excess sealant residue is evident.
    NOTE:
    NOTE:The component must be installed within 5 minutes of applying the sealant.
    Apply a 2.5 mm diameter bead of sealant to the edge of the Oil Pan.
    Material: Silicone Sealant

  1. Tighten the Oil Pan retaining nuts and bolts in the sequence shown.
    Torque:
    1-18 
    Stage 1:
    6.5 Nm
    Stage 2:
    14 Nm
    19 36 Nm

  1. Torque:
    1 23 Nm
    2 48 Nm

  1. Torque:
    Snug Torque 10 Nm
    Delay 2 Seconds 18 Nm
    Untighten 40°
    Final Torque 26 Nm

  1. Install a new gasket
    Torque: 23 Nm

  1. Torque:
    1 23 Nm
    2 24 Nm
    3 65 Nm

  1. Locate Alignment Tool into Oil Pump and Seal Pocket and align with Crank Sprocket. Start tighten the timing chain housing cover retaining bolts by hand, in the sequence shown.
    Special Tool(s): 303-652
    Torque:
    Alignment Tool 10 Nm
    1-5 10 Nm
    6 23 Nm
    7-19 10 Nm

  1. Torque:
    1 10 Nm
    2 23 Nm
  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. CAUTION:
    CAUTION:Make sure that new unoiled cylinder head bolts are installed.
    CAUTION:
    CAUTION:Place the two short cylinder head bolts on position 7 and 10
    NOTE:
    NOTE:The pistons must not be at TDC.
    Tighten the cylinder head retaining bolts in the sequence shown in four stages.
    Torque:
    Stage 1:
    20 Nm
    Stage 2:
    45 Nm
    Stage 3:
    100 Nm
    Stage 4:
    183 Nm

  1. 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. Make sure that the crankshaft does not rotate during installation of the special tool. Make sure that the crankshaft is at the TDC position before locking the special tool.Using the special tool, lock the crankshaft.
      Special Tool(s): 303-393

  1. Using the special tool, install the crankshaft position (CKP) sensor retaining bracket.
    Special Tool(s): 303-710
    Torque: 10 Nm

  1. NOTE:
    NOTE:Install a new crankshaft position (CKP) sensor.
    NOTE:
    NOTE:The CKP sensor must make contact with the flywheel.
    Torque: 6 Nm

  1. Attach the fuel pump pulley to the fuel pump sprocket. Apply sealant to the fuel pump pulley and to the outer edge of the fuel pump pulley retaining bolt holes.
    Material: Sealant - Loctite 510

  1. Tighten the fuel pump seal retainer retaining bolts in the sequence shown.
    Torque:
    1-7 and timing belt rear cover 10 Nm
    Engine front mount bracket 28 Nm

  1. Tighten the camshaft pulley bolt finger tight and then loosen by one-half turn.

  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.
    • 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 the special tools and install the cylinder block blanking plug.
    Special Tool(s): 303-376B, 303-193, 303-393
    Torque: 23 Nm

  1. Torque: 7 Nm

  1. Special Tool(s): 205-072
    Torque: 23 Nm

  1. Torque:
    1 23 Nm
    2 15 Nm

  1. Torque: 27 Nm

  1. Torque:
    1 27 Nm
    2 10 Nm

  1. CAUTION:
    CAUTION:Make sure that a new crankshaft pulley bolt is installed.
    Special Tool(s): 205-072
    Torque:
    1 
    Stage 1:
    100 Nm
    Stage 2:
    180°
    2 47 Nm

  1. Torque: 20 Nm

  1. NOTE:
    NOTE:Make sure that new components are installed.

  1. Torque:
    Stage 1:
    5 Nm
    Stage 2:
    90°

  1. NOTE:
    NOTE:Do not fully tighten the fuel supply manifold retaining bracket bolts at this stage.
    Torque: 23 Nm

  1. CAUTION:
    CAUTION:Use an open-ended wrench to prevent the component from turning.
    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 injector ends in sequence 4,3,2,1
      Torque: 25 Nm
    • Tighten the fuel pump end 5
      Torque: 25 Nm
    • Tighten rail end in sequence 1,2,3,4,5
      Torque: 38 Nm
    • Install a new thermostat housing gasket.
      Torque:
      thermostat housing 23 Nm
      vacuum pipe 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. Torque: 20 Nm

  1. Torque: 10 Nm

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

  1. Special Tool(s): 303-122

  1. Remove the Special Tools.
    Special Tool(s): 303-435, 303-435-06

  1. Torque:
    1 20 Nm
    2 23 Nm

  1. Make sure that the Gap between the Ears of the V-Band Clamp is between 3-6 mm.
    Torque:
    1 25 Nm
    2 45 Nm
    3 4.5 Nm
    4 10 Nm
    5 25 Nm
    6 23 Nm
    7 23 Nm
    8 35 Nm

Assembly|Installation > < General Procedures|Removal and Installation|Disassembly|Engine