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Camshaft Seal > < In-vehicle Repair|Valves

Mondeo 1997 (08.1996-09.2000)

Engine - Vehicles Built Up To: 05/1998 1.6L/1.8L/2.0L - Camshafts Mondeo 1997 (08/1996-09/2000)
In-vehicle Repair

Special Tool(s)

Universal flange holding wrench

15-030A

Installer, oil seal

21009B

Timing tool, camshaft alignment

21-162B
General Equipment
Transmission jack
Trolley jack
Materials
Name
Specification
Never Seeze
ESE-M1244-A 
Bolt
M10x70 
Sealer
ESK-M4G269-A 
Cable ties
 
Engine Oil
WSS-M2C912-A1 

Removal

  1. General notes.
    • The positions of the engine mountings and engine roll restrictors are described looking from the transmission towards the engine.
    • Owing to special model variants, some job steps do not apply to all vehicles. These are clearly marked in the text.
  1. Standard preparatory measures
    • Make a note of the radio keycode.
    • Open up the coolant expansion tank.
    • Make a note of the preset radio stations.
    • Undo the right-hand front wheel nuts.
      CAUTION:
      CAUTION:Disconnect the battery negative lead.
    • Cut the cable ties where necessary and renew them on installation.

  1. Remove the intake pipe.
    1. Pull out the plug of the mass air flow sensor (MAF sensor).
    1. Disconnect the plug of the intake air temperature sensor (IAT sensor) from the intake pipe.
    1. Remove the bolt and the two nuts.
    1. Release the retaining clips.

  1. Detach the accelerator cable.
    • Unhook the cable.
    • Pull off the plastic clip and lay the accelerator cable to one side.

  1. Disconnect the plug, the ground lead and the high-pressure pipe.
    1. Pull out the plug of the power steering pressure switch (PSP switch).
    1. Detach the ground lead from the engine lifting eye.
    1. Disconnect the power steering high-pressure pipe.

  1. Detach the plug of the heated oxygen sensor (HO2S) from the engine mounting.
  1. Remove the timing belt.
    For additional information, refer to Timing belt in this section.

  1. Remove the camshaft timing pulleys.
    • Detach the crankshaft timing belts, using the special tool to prevent movement.

  1. Remove the camshafts.
    • Slacken the bearing cap bolts in pairs in the indicated sequence half a turn at a time.
    • Repeat this until the bearing caps are completely loose.
    • Remove the bearing caps, camshafts and oil seals.

Installation
  1. NOTE:
    NOTE:The camshafts are marked. The inlet camshaft has an additional cam for the CMP sensor at the end of the shaft.
    Fit the camshafts.
    • Apply sealer to the bearing cap / cylinder head mating face at the timing belt end.
    • Fit the camshafts.

  1. NOTE:
    NOTE:The numbering starts at '0' on the exhaust side and faces outwards.
    Install the camshaft bearing cap.
    • Fit the bearing caps.

  1. Install the camshaft bearing caps.
    • Screw in the bolts in pairs in the indicated sequence half a turn at a time.
    • Repeat this until the bearing caps are in contact with the cylinder head.
    • Tighten the bolts in pairs in the indicated sequence.

  1. Fit the camshaft oil seals.
    • Lubricate the camshaft and the sealing lip of the oil seal with engine oil .
    • Draw in the new oil seals using the special tool, a washer and an M10x70 bolt .
      NOTE:
      NOTE:The camshaft timing pulleys must be able to turn freely on the camshafts. Do not tighten the bolts.
    • Fit the camshaft timing pulleys.

  1. Align the camshafts.
    • Insert the special tool.
  1. Install the timing belt.
    For additional information, refer to Timing belt in this section.

  1. Fit the HO2S plug to the engine mounting.

  1. Connect the plug, the ground lead and the high-pressure pipe.
    1. Connect the plug to the PSP switch.
    1. Attach the ground lead to the engine lifting eye.
    1. Fit the power steering high-pressure pipe.

  1. Attach the accelerator cable and adjust it.
    1. Fit the cable in the bracket and slide on the plastic clip.
    • Hook the cable in place.
    1. Pull the clip off the accelerator cable.
    • Pull the inner cable a few clicks out from the outer cable.
    • Fully depress the accelerator pedal once and slide the clip back on.
    • Check that the throttle plate opens fully when the accelerator pedal is depressed. If not, repeat the adjustment procedure.

  1. Fit the intake pipe.
    1. Fit the retaining clips.
    1. Fit the bolt and the two nuts.
    1. Connect the plug of the IAT sensor at the intake pipe.
    1. Connect the MAF sensor plug.

        2. 1. Connect the cylinder head vent hose.
  1. Standard finishing operations.
    • Connect the negative lead to the battery.
    • Check the fluid levels and correct as necessary.
    • Pressure-test the cooling system for leaks.
    • Check the routing of the vacuum hoses and wiring and secure them with cable ties.
    • Enter the radio keycode.
    • Reset the clock.
    • Reprogram the preset radio stations.
    • Carry out a road test to enable the powertrain control module (PCM) to collect data.
      NOTE:
      NOTE:The engine oil temperature must be at least 80°C.
    • Change the engine oil and the oil filter.
    • Check the fluid levels again and correct as necessary.

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