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Assembly|Installation > < In-vehicle Repair|Disassembly|Engine

Mondeo 2001 (10.2000-02.2007)

Engine - 1.8L Duratec-SCi (MI4) - Engine Mondeo 2001 (10/2000-02/2007)
Assembly

Special Tool(s)

Universal Flange Holding Wrench

205-072 (15-030A)

Adapter for 205-072

205-072-01

Adapter for 205-072

205-072-02 (15-030A-02)

Lifting Bracket, Engine

303-122 (21-068A)

Locking Tool, Flywheel

303-254 (21-135)

Remover/Installer, Hose Clamp

303-397 (24-003)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435-06 (21-031B)

Mounting Plate for 303-435-06

303-435-11A (21-146D)

Socket, Spark Plug

303-499 (21-202)

Timing Peg, Crankshaft TDC

303-507 (21-210)

Alignment Tool, Crankshaft Position (CKP) Sensor

303-1060

Alignment Plate, Camshaft

303-1061
General Equipment
Engine hoist
M6 x 18 mm bolt
Straightedge
Materials
Name
Specification
Silicone Sealant
WSE-M4G323-A4
Hypoid Gear Oil
SQM-2C9002-AA

Assembly
  1. NOTE:
    NOTE:Install a new oil pump gasket.
    Install the oil pump.
    • Tighten the bolts in the sequence shown in two stages.
    • Stage 1: 10 Nm.
    • Stage 2: 23 Nm.

  1. NOTE:
    NOTE:Install a new crankshaft rear seal carrier.
    Install the crankshaft rear oil seal carrier.
    • Tighten the bolts in the sequence shown.
  1. Clean the mating faces of the oil pan and the cylinder block.

  1. NOTE:
    NOTE:Install the oil pan within 10 minutes of applying the sealant and tighten the retaining bolts within a further 5 minutes.
    Apply a 3 mm bead of sealant to the oil pan.
  1. Using a suitable straightedge, align the oil pan to the cylinder block mating face on the timing chain side.

  1. Tighten the oil pan retaining bolts.
    • Tighten the bolts in the sequence shown.

  1. NOTE:
    NOTE:Install new flywheel bolts.
    Install the flywheel.

  1. Using the special tool, lock the flywheel in position.

  1. Tighten the flywheel bolts.
    • Tighten the bolts in the sequence shown in three stages.
    • Stage 1: 50 Nm.
    • Stage 2: 80 Nm.
    • Stage 3: 112 Nm.

  1. Remove the special tool.
  1. Install the clutch disc and pressure plate.
    For additional information, refer to: Clutch Disc and Pressure Plate (308-01B Clutch - Vehicles With: 6-Speed Manual Transmission (MMT6), Removal and Installation).

  1. NOTE:
    NOTE:Install a new oil filter adapter gasket.
    Install the oil filter adapter.

  1. Install the crankcase vent oil separator.

  1. NOTE:
    NOTE:Install a new thermostat housing gasket.
    Install the thermostat housing.

  1. NOTE:
    NOTE:Install a new coolant pump O-ring seal.
    Install the coolant pump.

  1. Install the knock sensors (KS).

  1. NOTE:
    NOTE:Install new cylinder head bolts and cylinder head gasket.
    Install the cylinder head.
    • Tighten the cylinder head bolts in five stages.
    • Stage 1: 5 Nm.
    • Stage 2: 15 Nm.
    • Stage 3: 45 Nm.
    • Stage 4: 90 degrees.
    • Stage 5: 90 degrees.

  1. NOTE:
    NOTE:Only rotate the crankshaft in its normal direction of rotation.
    Rotate the crankshaft until piston No. 1 is approximately 45 degrees before TDC.
  1. Install the valve tappets.

  1. CAUTION:
    CAUTION:Install the camshafts approximately at valve overlap position cylinder No. 4.
    Install the camshafts.
    • Working in several stages, evenly tighten the camshaft bearing cap bolts in the sequence shown, one half turn at a time.
    • Coat the camshaft bearing caps with oil.
    • Tighten the bolts in two stages.
    • Stage 1: 7 Nm.
    • Stage 2: 16 Nm.

  1. Install the special tool.

  1. NOTE:
    NOTE:Install a new rear friction washer.
    Install the rear friction washer.

  1. Install the crankshaft sprocket.

  1. NOTE:
    NOTE:Install a new front friction washer.
    Install the front friction washer.

  1. Install the oil pump chain.
    1. Install the oil pump chain and the oil pump sprocket.
    1. Install the oil pump sprocket retaining bolt.

  1. Using the special tools, tighten the oil pump sprocket retaining bolt.

  1. Install the oil pump chain tensioner.

  1. Install the oil pump chain guide.

  1. Install the timing chain tensioner.

  1. Install the timing chain guides.

  1. CAUTION:
    CAUTION:Do not fully tighten the camshaft sprocket retaining bolts at this stage. Make sure the camshaft sprockets rotate on the camshafts.
    Install the camshaft sprockets.
    • Install the timing chain.

  1. Tension the timing chain.
    • Apply pressure to the timing chain and remove the securing pin.

  1. CAUTION:
    CAUTION:Hold each camshaft by the hexagon with an open-ended wrench to prevent it from rotating.
    Tighten the camshaft sprockets retaining bolts.
  1. Clean the engine front cover mating faces.

  1. NOTE:
    NOTE:Install the engine front cover within 10 minutes of applying the sealant.
    Apply a 3 mm bead of sealant to the engine front cover.

  1. Install the engine front cover.
    • Tighten the bolts in the sequence shown.
    • Bolts 1 through 8 to 10 Nm.
    • Bolt 9: 48 Nm.
    • Bolts 10 through 19 to 10 Nm.
    • Bolts 20 through 22 to 48 Nm.

  1. Remove the cylinder block lower blanking plug from the cylinder block and install the special tool.

  1. NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Using the crankshaft pulley retaining bolt, rotate the crankshaft until piston No. 1 is at TDC.
  1. Remove the crankshaft pulley retaining bolt.
    • Discard the bolt.

  1. CAUTION:
    CAUTION:Only tighten the crankshaft pulley securing bolt finger tight.
    Install the crankshaft pulley and secure the crankshaft pulley to the front cover using a M6 x 18 mm bolt.

  1. NOTE:
    NOTE:Install a new crankshaft pulley retaining bolt.
    Using the special tools, prevent the crankshaft pulley from rotating and tighten the crankshaft pulley retaining bolt.
    • Tighten the bolt in two stages.
    • Stage 1: 100 Nm.
    • Stage 2: 90 degrees.

  1. Remove the crankshaft pulley securing bolt.

  1. Remove the special tool.

  1. Remove the special tool.
  1. NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Rotate the crankshaft two revolutions.

  1. Install the special tool.
  1. NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Rotate the crankshaft until piston No. 1 is at TDC.

  1. CAUTION:
    CAUTION:Only tighten the crankshaft pulley securing bolt finger tight.
    NOTE:
    NOTE:If it is not possible to install the crankshaft pulley securing bolt, repeat the valve timing.
    Using a M6 x 18 mm bolt, check the position of the crankshaft pulley.

  1. NOTE:
    NOTE:If it is not possible to install the special tool, repeat the valve timing.
    Using the special tool, check the position of the camshafts.

  1. Remove the special tool.

  1. Remove the crankshaft pulley securing bolt.

  1. Remove the special tool.

  1. Install the cylinder block lower blanking plug.

  1. NOTE:
    NOTE:Do not tighten the crankshaft position (CKP) sensor bracket retaining bolts at this stage.
    Install the CKP sensor bracket.

  1. Install the special tool so that it is engaged in the crankshaft pulley teeth.

  1. Tighten the CKP sensor bracket retaining bolts.
    • Remove the special tool.

  1. Install the CKP sensor.

  1. Install the coolant pump pulley.

  1. Install the accessory drive belt idler pulley.

  1. Apply a small bead of sealant to the areas as shown.

  1. Apply a small bead of sealant to the areas as shown.

  1. NOTE:
    NOTE:Install a new valve cover gasket if necessary.
    Install the valve cover.
    • Tighten the bolts in the sequence shown.

  1. Using the special tool, install the spark plugs.

  1. Using the special tool, install the coolant hoses.

  1. NOTE:
    NOTE:Install a new fuel pump drive assembly gasket.
    Install the fuel pump drive assembly.

  1. Install the fuel pump tappet.

  1. NOTE:
    NOTE:Install a new fuel pump O-ring seal.
    Install the fuel pump.

  1. Attach the high-pressure fuel supply line to the fuel pump.

  1. Install the fuel return line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Connect the positive crankcase ventilation (PCV) hose to the intake manifold.

  1. NOTE:
    NOTE:Install a new intake manifold gasket.
    Install the intake manifold.

  1. Install the power steering pump.

  1. Using the special tool, connect the coolant hose to the throttle body.

  1. NOTE:
    NOTE:Install new exhaust gas recirculation (EGR) pipe gaskets.
    Install the EGR pipe.

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket.
    NOTE:
    NOTE:Do not tighten the nuts at this stage.
    Install the exhaust manifold.

  1. NOTE:
    NOTE:Install new EGR valve to exhaust manifold pipe gaskets.
    Install the EGR valve to exhaust manifold pipe.

  1. Install the exhaust manifold retaining bracket retaining bolts.

  1. Install the exhaust manifold lower heat shield.

  1. Tighten the exhaust manifold retaining nuts.

  1. Install the exhaust manifold upper heat shield.

  1. Install the ignition coils on plug.

  1. Install the oil level indicator and oil level indicator

  1. Using the special tool and an engine hoist, support the engine.

  1. Remove the special tools.

Assembly|Installation > < In-vehicle Repair|Disassembly|Engine