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Exhaust Manifold > < Camshaft Seal

Mondeo 1997 (08.1996-09.2000)

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

Special Tool(s)

Universal flange holding wrench

205-072 (15030A)

Alignment Plate, Camshaft

303-376 (21162B)

Timing Peg, Crankshaft TDC

303-574 (21163)

Pliers, Spark Plug Connector

303-622 (21226)
General Equipment
Workshop jack
Wooden block
Materials
Name
Specification
Silicone grease for spark plug connector seals
A969-M1C171-AA 
Never Seez
ESE-M1244-A 
Sealer
WSK-M2G348-A5 

Removal

  1. General Notes.
    • Request the radio keycode.
    • Make a note of the pre-set radio stations.
    • 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.
    • If necessary, cut the cable ties and renew them on installation.
  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Detach the engine undershield (nine bolts) (if equipped).

  1. Detach the right-hand lower wheel housing cover (shown with the front wheel removed).

  1. NOTE:
    NOTE:Mark the running direction of the drive belt.
    Remove the drive belt.
    1. Loosen the coolant pump pulley bolts.
    1. Slacken the drive belt in the clockwise direction and remove it.
    • Detach the coolant pump pulley.
    1. Remove the drive belt idler pulley.

  1. Detach the crankshaft pulley/vibration damper.

  1. CAUTION:
    CAUTION:Always remove the timing belt cover to avoid damaging the timing belt.
    Remove the lower timing belt cover.

  1. Detach the coolant recovery tank and lay it to one side.
    • Detach the cruise control system cable from the coolant expansion tank (if equipped).
  1. CAUTION:
    CAUTION:Insert the wooden block between the oil pan and the trolley jack.
    Position the trolley jack with the wooden block under the oil pan and raise so that the front engine mounting is free from load.

  1. NOTE:
    NOTE:Mark the installation position of the engine mounting.
    Remove the front engine mounting.
  1. NOTE:
    NOTE:This step only applies to vehicles with liquid propane gas (LPG) drive.
    Detach the LPG fuel rail.
    For additional information, refer to: Fuel Injection Supply Manifold (303-04E Fuel Charging and Controls - Liquified Petroleum Gas (LPG), Removal and Installation).

  1. Detach the bracket for the power steering fluid line from the engine lifting eye.

  1. NOTE:
    NOTE:Leave the timing belt cover in installation position.
    Remove the timing belt upper cover.

  1. Detach the timing belt center cover/front engine mounting bracket.
    • Remove the upper timing belt cover.
  1. Unclip the accelerator cable and cruise control system cable from the cylinder head cover.

  1. CAUTION:
    CAUTION:Do not pull on the cable when detaching the spark plug connector. If necessary, remove the ignition cable from the ignition coil to avoid kinking the cable. Turn the spark plug connector slightly before detaching it in order to loosen the seal.
    CAUTION:
    CAUTION:Disconnect the spark plug connectors in line with the spark plugs (for angled spark plug connectors, use Special Tool 303-622).
    Remove the cylinder head cover.
    1. Detach the spark plug connectors.
    1. Detach the crankcase ventilation hose.
    1. Remove the 10 bolts.
  1. CAUTION:
    CAUTION:Must be done in order to set the valve timing.
    Remove the spark plugs.

  1. Turn the engine to ignition point for cylinder no. 1 and insert the special tool into the camshaft.
    • Insert the special tool.

  1. Slacken the timing belt.
    1. Loosen the bolt and slacken the timing belt tensioner by turning clockwise.
    1. Unscrew the bolt four turns and detach the timing belt tensioner.
    • Remove the timing belt.

Installation
  1. Release the camshaft timing pulleys; counterhold using Special Tool 205-072.

  1. Set the crankshaft to TDC on cylinder no. 1.

  1. Remove the blanking plug and fully screw in the special tool.

  1. CAUTION:
    CAUTION:Use a new timing belt.
    CAUTION:
    CAUTION:Do not kink the timing belt (bend diameter must not be less than 35 mm).
    CAUTION:
    CAUTION:Do not turn the crankshaft. If necessary check whether the crankshaft is touching Special Tool 303-620.
    NOTE:
    NOTE:Version with lower idler pulley shown (built until approx. 01/99).
    NOTE:
    NOTE:The tab on the timing belt tensioner must not be hooked into the metal cover.
    Fit a new timing belt (shown on a removed engine).
    • Starting at the crankshaft timing pulley and working anti-clockwise, fit the timing belt. Pull the belt tight as you proceed.

  1. CAUTION:
    CAUTION:Use a new timing belt.
    CAUTION:
    CAUTION:Do not kink the timing belt (bend diameter must not be less than 35 mm).
    CAUTION:
    CAUTION:Do not turn the crankshaft. If necessary check whether the crankshaft is touching Special Tool 303-620.
    NOTE:
    NOTE:Version without lower idler pulley shown (built from approx. 01/99).
    NOTE:
    NOTE:The tab on the timing belt tensioner must not be hooked into the metal cover.
    Fit a new timing belt (shown on a removed engine).
    • Starting at the crankshaft timing pulley and working anti-clockwise, fit the timing belt. Pull the belt tight as you proceed.

  1. CAUTION:
    CAUTION:Tension the timing belt working counter-clockwise.
    NOTE:
    NOTE:The valve timing will be incorrect and there will be timing belt noise if the timing belt is not correctly tensioned.
    Tension the timing belt.
    1. Hook the timing belt tensioner into the metal cover and loosely install the bolt.
    1. Tension the timing belt by turning the tensioner counter-clockwise until the arrow and the marking line up.

  1. CAUTION:
    CAUTION:Do not tighten the camshaft timing pulley bolts against Special Tool 303-376; counterhold using Special Tool 205-072.
    NOTE:
    NOTE:The crankshaft must remain at TDC.
    Tighten the camshaft timing pulley bolts.

  1. Remove Special Tool 303 -574.

  1. Remove Special Tool 303 -376 from the camshafts.
  1. NOTE:
    NOTE:Turn the engine by the crankshaft two turns in the normal direction of rotation.
    Check the valve timing by inserting the special tool. Correct adjustment if necessary.
    • Attach Special Tool 303-574 and make sure that the crankshaft is resting against the special tool.
    • Insert Special Tool 303-376 into the camshafts; if necessary loosen the timing pulleys, correct the camshaft setting and re-check.
    • Remove the special tools.

  1. Install the blanking plug.

  1. Apply sealer to the camshaft bearing caps.

  1. CAUTION:
    CAUTION:When applying silicone grease, use a blunt object (e.g. a plastic cable tie), to prevent damaging the spark plug connector seal.
    CAUTION:
    CAUTION:Push on the spark plug connector in line with the spark plug axis.
    NOTE:
    NOTE:Coat the inner side of the spark plug connector down to a depth of 5 to 10 mm with silicone grease.
    Install the cylinder head cover and the spark plugs.
    • Coat the spark plug threads with Never Seez.
    1. Screw in the spark plugs.
    1. Screw in the cylinder head cover bolts in two stages.
    • Stage 1: 2 Nm
    • Stage 2 (metal cylinder head cover): 7 Nm
    • Stage 2 (plastic cylinder head cover). 9 Nm
    • Push on the spark plug connectors until they engage.
  1. Clip the accelerator cable and cruise control system cable to the cylinder head cover.

  1. NOTE:
    NOTE:Install the upper timing belt cover together with the center timing belt cover.
    Attach the center timing belt cover/front engine mounting.

  1. NOTE:
    NOTE:Check the seating of the timing belt upper cover gasket and correct it if necessary.
    Attach the timing belt upper cover.

  1. Attach the bracket for the power steering fluid line to the engine lifting eye.
  1. NOTE:
    NOTE:This step only applies to vehicles with liquid propane gas (LPG) drive.
    Attach the LPG fuel rail.
    For additional information, refer to: Fuel Injection Supply Manifold (303-04E Fuel Charging and Controls - Liquified Petroleum Gas (LPG), Removal and Installation).

  1. NOTE:
    NOTE:If the engine mounting cannot be easily reinstalled, the engine must be aligned to the subframe.
    Install the front engine mounting.
  1. Pull the trolley jack out from the front of the vehicle.

  1. Attach the coolant expansion tank.
    • Attach the cruise control system cable to the coolant expansion tank (if equipped).

  1. NOTE:
    NOTE:Correct seating of the lower in the middle cover.
    Attach the timing belt lower cover.

  1. Attach the crankshaft pulley/vibration damper.

  1. NOTE:
    NOTE:Ensure correct seating.
    NOTE:
    NOTE:Observe the running direction markings for used drive belts.
    NOTE:
    NOTE:Screw the bolts fully home but do not tighten them.
    Attach the drive belt.
    1. Install the drive belt idler pulley.
    • Install the coolant pump pulley.
    1. Tension the belt tensioner clockwise and lay it onto the drive belt.
    1. Tighten the coolant pump pulley bolts.

  1. Attach the right lower wheel housing cover (shown with the front wheel removed).

  1. Attach the engine undershield (nine bolts) (if removed).
  1. Lower the vehicle.
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Standard finishing operations.
    • Check fluid levels and correct if necessary.
    • Check the routing of the vacuum hoses and 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.

Exhaust Manifold > < Camshaft Seal