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In-vehicle Repair|Valves > < Valve Seals

Mondeo 1997 (08.1996-09.2000)

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

Special Tool(s)

Installer, Oil Seal

303-039 (21009B)

Alignment Plate, Camshaft - TDC position

303-376 (21162B)
Materials
Name
Specification
Cable ties
 
Sealer - Camshaft bearing cap
WSK-M2G348-A2/A5 
Engine oil
WSS-M2C912-A1 

Removal

  1. General Notes.
    • The position markings for the engine mountings and engine roll restrictors are described looking from the transmission towards the engine.
    • Any steps which only apply to certain variants and not to all vehicles are clearly indicated.
  1. Standard preparatory measures
    • Request the radio keycode.
    • Make a note of the pre-set radio stations.
      CAUTION:
      CAUTION:Disconnect the battery ground cable.
    • Cable ties : cut if necessary and renew on installation.

  1. Detach the pulley cover (if equipped).
  1. Lower the vehicle.

  1. Remove the intake pipe.
    1. Disconnect the mass air flow (MAF) sensor multiplug.
    1. Disconnect the intake air temperature (IAT) sensor multiplug (if equipped).
    1. Remove one bolt and two nuts.
    1. Release the retaining clips.

  1. Detach the cruise control cable (if equipped).
    1. Cable from throttle valve
    1. Pull the cable out of the bush while gently moving it up and down.
    1. Press the bush out of the bracket.

  1. Detach the accelerator cable.
    • Disconnect the cable.
    • Pull off the plastic clip and lay the accelerator cable to one side.
  1. Remove the timing belt.
    For additional information, refer to: Zahnriemen (303-01D Motor - gebaut ab 05/1998 1.6L/1.8L/2.0L, In-vehicle Repair).

  1. NOTE:
    NOTE:Loosening sequence
    Unscrew the bolts of the camshaft bearing caps evenly and in several stages, two turns at a time.
    • Remove the oil seals.
    • Remove the camshafts.

Installation
  1. NOTE:
    NOTE:The identification numbers are located on the outside of the camshaft bearing caps.
    Apply sealant to camshaft bearing caps nos. 0 and 5, in the areas shown.
  1. Turn the crankshaft to approx. 60° BTDC.

  1. NOTE:
    NOTE:Lay the camshafts in place with none of the cams at full lift.
    Lubricate the camshaft and camshaft bearing caps with engine oil .

  1. NOTE:
    NOTE:Work through the tightening sequence several times and tighten the camshaft bearing caps evenly a half a turn at a time, and then tighten them down in two stages.
    Tighten the camshaft bearing caps.

  1. Install the camshaft oil seals.
    • Lubricate the camshafts and the sealing lip of the oil seals with engine oil .
    • Draw in the new oil seals using the special tool, a washer and an M10x70 bolt.

  1. NOTE:
    NOTE:Do not tighten the bolts. The timing pulleys must be free to turn on the camshafts.
    Turn the camshafts to ignition point on cylinder no. 1 and insert the special tool into the camshafts.
  1. Install the timing belt.
    For additional information, refer to: Zahnriemen (303-01D Motor - gebaut ab 05/1998 1.6L/1.8L/2.0L, In-vehicle Repair).

  1. Attach the accelerator cable and adjust it.
    1. Attach 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. Install the cruise control system cable (if equipped).
    1. Press the bush into the bracket.
      NOTE:
      NOTE:An audible click indicates proper engagement.
    1. Cable in bush
    1. Cable on throttle valve

  1. Install the intake pipe.
    1. Secure the retaining clips.
    1. Install a bolt and two nuts.
    1. Connect the plug for the IAT sensor (if equipped).
    1. Connect the MAF multiplug.
  1. Standard finishing operations.
    • Connect the battery ground cable.
    • Check fluid levels and correct if necessary.
    • Check the routing of vacuum hoses and the wiring and secure them with cable ties.
    • Enter the radio keycode.
    • Reprogram the pre-set radio stations.
    • Reset the clock.
    • Carry out a road test to enable the PCM to collect data.
    • Check the fluid levels again and correct as necessary.

In-vehicle Repair|Valves > < Valve Seals