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Valve Seals > < Intake Manifold

Mondeo 2001 (10.2000-02.2007)

Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) - Crankshaft Front Seal Mondeo 2001 (10/2000-02/2007)
In-vehicle Repair

Special Tool(s)

Adapter for 205-071 (15-026A)

205-071-02 (15-026-51)

Flange Holding Wrench, Universal

205-072 (15-030A)

Adapter for 205-072

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

Remover, Crankshaft Oil Seal

303-293(21-143)

Timing Plate, Camshaft Alignment

303-376 (21-162B)

Installer, Crankshaft Oil Seal

303-395 (21-171)

Remover/Installer, Spark Plug

303-499 (21-202)

Timing Peg, Crankshaft TDC

303-507 (21-210)

Pliers, Valve Stem Oil Seal

303-508 (21-211)

Remover, Halfshaft Oil Seal

308-208 (16-074)
General Equipment
M6 x 18 mm bolt

Removal
  1. Detach the positive crankcase ventilation (PCV) hose and the vacuum hose from the engine upper cover.

  1. Remove the engine upper cover.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Disconnect the camshaft position (CMP) sensor electrical connector.

  1. Detach the engine wiring harness electrical connector from the valve cover.

  1. Detach the PCV hose from the valve cover.

  1. Remove the engine upper cover retaining brackets.

  1. Using the special tool, disconnect the spark plug electrical connectors.

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

  1. Remove the valve cover.
  1. Remove the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine until piston No. 1 is approximately 45 degrees before top dead center (TDC).

  1. NOTE:
    NOTE:Do not discard the crankshaft pulley retaining bolt.
    Using the special tools, prevent the crankshaft pulley from rotating and remove the crankshaft pulley

  1. Using the special tool, remove the crankshaft front oil seal.
    • Discard the oil seal.

Installation
  1. Measure the thickness of the crankshaft pulley retaining bolt washer.

  1. NOTE:
    NOTE:If the thickness of the crankshaft pulley retaining bolt washer is less then 5.5 mm, a friction washer must be installed.
    Install a friction washer to the crankshaft (engine shown removed for clarity).

  1. NOTE:
    NOTE:Install a new crankshaft front oil seal.
    Using the special tools, install the crankshaft front oil seal.
  1. Lower the vehicle.
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Using an open-ended wrench, carefully turn the camshafts until the cams of cylinder No. 4 are at valve overlap position.

  1. Install the special tool.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

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

  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Using the crankshaft pulley retaining bolt, turn the engine 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 onto the crankshaft 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. Lower the vehicle.

  1. Remove the special tool.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the special tool.
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine two revolutions.

  1. Install the special tool.
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine 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, correct the valve timing.
    Using a M6 x 18 mm bolt, check the position of the crankshaft pulley.
  1. Lower the vehicle.

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

  1. Remove the special tool.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the crankshaft pulley securing bolt.

  1. Remove the special tool.

  1. Install the cylinder block lower blanking plug.
  1. Install the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. Apply a small bead of silicon 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, connect the spark plug electrical connectors.

  1. Install the engine upper cover retaining brackets.

  1. Attach the PCV hose to the valve cover.

  1. Connect the CMP sensor electrical connector.

  1. Attach the engine wiring harness electrical connector to the valve cover.
  1. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Install the engine upper cover.

  1. Attach the PCV hose and the vacuum hose to the engine upper cover.
  1. Initialize the door window motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

Valve Seals > < Intake Manifold