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Exhaust Manifold > < Camshaft Seal

Mondeo 2007.5 (02.2007-)

Engine - 2.0L Duratorq-TDCi (DW) Diesel - Timing Belt Mondeo 2007.5 (02/2007-)
Removal and Installation

Special Tool(s)
303-1059
Alignment Peg, Crankshaft

303-393
Locking Tool, Flywheel

303-393-01
Adapter for 303-393

303-396-01
Adapter for 303-396

303-735
Alignment Peg, Camshaft
General Equipment
Trolley jack

Removal

  1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Remove the following items:
    1. Refer to: Accessory Drive Belt (303-05E Accessory Drive - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
    1. Refer to: Starter Motor (303-06E Starting System - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).

  1. General Equipment: Trolley jack

  1. CAUTION:
    CAUTION:Make sure that the crankshaft is not rotated while the special tool is installed.
    Install the Special Tool(s): 303-1059

  1. Install the Special Tool(s): 303-735

  1. Install the Special Tool(s): 303-393, 303-393-01

  1. CAUTION:
    CAUTION:Take extra care when handling the crankshaft position (CKP) sensor ring.

Installation
  1.  
    1. NOTE:
      NOTE:Make sure that a new component is installed.
    1. Torque: 56 Nm

  1.  
    1. NOTE:
      NOTE:Make sure that a new component is installed.
    1. NOTE:
      NOTE:Make sure that a new component is installed.
    1. NOTE:
      NOTE:Only tighten the bolt finger tight at this stage.
    1. CAUTION:
      CAUTION:Take extra care when handling the crankshaft position (CKP) sensor ring.

  1.  
    1. Allen key, 6mm
    1. Torque: 21 Nm

  1. Torque: 50 Nm

  1. Remove the Special Tool(s): 303-396-01, 303-1059

  1. Remove the Special Tool(s): 303-735
  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Rotate the crankshaft 4 revolutions.

  1. Install the Special Tool(s): 303-1059

  1. Install the Special Tool(s): 303-393, 303-393-01

  1. NOTE:
    NOTE:The special tool can only be installed if the valve timing is correct.
    Install the Special Tool(s): 303-735

  1. Remove the Special Tool(s): 303-735

  1. Torque: 7 Nm

  1.  
    1. Torque: 10 Nm
    1. NOTE:
      NOTE:Only tighten the bolts finger tight at this stage.
    1. Torque: 133 Nm

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

  1. Torque: 90 Nm

  1.  
    1. Torque: 7 Nm
    1. NOTE:
      NOTE:Make sure that a new component is installed.
      Torque:
      Stage 1:
      70 Nm
      Stage 2:
      60°

  1. Remove the special tools.
    Special Tool(s): 303-1059, 303-393, 303-393-01
  1. Install the following items:
    1. Refer to: Accessory Drive Belt (303-05E Accessory Drive - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
    1. Refer to: Starter Motor (303-06E Starting System - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
  1. Connect the battery.
    Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

Exhaust Manifold > < Camshaft Seal