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In-vehicle Repair|Oil Pan > < Timing Chain

Mondeo 2001 (10.2000-02.2007)

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

Special Tool(s)

Flange Holding Wrench, Universal

205-072 (15-030A)

Adapter for 205-072

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

Timing Plate, Camshaft Alignment

303-376 (21-162B)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)

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)
General Equipment
Trolley Jack
M6 x 18 mm bolt
Materials
Name
Specification
Loctite 7070
 
Hypoid oil
SQM-2C9002-AA 
Silicone sealant
WSE-M4G323-A6 

Removal

  1. WARNING:
    WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
    Drain the cooling system. For additional information, refer to Section  303-03 Engine Cooling.
  1. Remove the intake manifold.
    For additional information, refer to Intake Manifold in this section.

  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. Loosen the water pump pulley retaining bolts by three turns.
  1. Remove the power steering pump. For additional information, refer to Section  211-02 Power Steering.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Disconnect the exhaust front pipe.
    1. Remove the exhaust manifold heat shield lower retaining bolts.
    1. Detach the exhaust manifold from the retaining bracket.
    1. Detach the exhaust front pipe from the exhaust manifold.

  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. Remove the engine front cover lower retaining bolts.

  1. Disconnect the crankshaft position (CKP) sensor electrical connector.

  1. Disconnect the heated oxygen sensor (HO2S) electrical connector.
  1. Lower the vehicle.

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

  1. Remove the exhaust manifold upper heat shield.

  1. Detach the exhaust manifold retaining bracket.

  1. Remove the generator upper retaining bolt.

  1. Detach the ground lead from the cylinder head.

  1. Remove the water pump pulley.

  1. Using the special tool, disconnect the coolant hose from the coolant expansion tank.

  1. Detach the coolant expansion tank and position it to one side.
  1. NOTE:
    NOTE:Support the engine with suitable wooden blocks.
    Position a trolley jack with the wooden block under the oil pan and raise the engine so that the engine front mount is free from load.

  1. Remove the engine front mount.

  1. Remove the accessory drive belt idler.

  1. Remove the engine front cover upper retaining bolts.
    • Remove the engine front cover.

  1. Detension the timing chain (engine shown removed for clarity).
    1. Unlock the timing chain tensioner ratchet.
    1. Apply pressure to the timing chain guide.
    1. Fix the timing chain tensioner with a suitable pin punch.

  1. NOTE:
    NOTE:Hold the camshafts by the hexagon with an open-ended wrench to prevent them from turning.
    Remove the camshaft sprockets.
    • Detach the timing chain from the camshaft sprockets.

  1. Remove the timing chain guides.

  1. CAUTION:
    CAUTION:Keep the camshaft bearing caps, valve tappets and the camshafts in order for installation.
    CAUTION:
    CAUTION:Remove the camshaft bearing caps in the sequence shown.
    NOTE:
    NOTE:Working in several stages, release each camshaft bearing cap retaining bolt two turns at a time.
    Remove the camshaft bearing caps.
    • Remove the valve tappets.

  1. Disconnect the fuel supply line. For additional information, refer to Section  310-00 Fuel System - General Information.

  1. CAUTION:
    CAUTION:Remove the cylinder head bolts in the sequence shown.
    Remove the cylinder head.
    • Discard the gasket.
    • Discard the bolts.

Installation

  1. Clean the engine front cover mating faces with Loctite 7070.
  1. Check the cylinder head for distortion. For additional information, refer to Section  303-00 Engine System - General Information.

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

  1. Connect the fuel supply line. For additional information, refer to Section  310-00 Fuel System - General Information.
  1. Install the valve tappets.

  1. CAUTION:
    CAUTION:Working in several stages, evenly tighten the camshaft bearing cap bolts in the sequence shown, one half turn at a time.
    Install the camshafts.
    • Tighten the bolts in the sequence shown in two stages:
    • Stage 1: 7 Nm
    • Stage 2: 16 Nm
  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. 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 turn on the camshafts.
    Install the camshaft sprockets.
    • Install the timing chain.

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

  1. CAUTION:
    CAUTION:Hold the camshafts by the hexagon with an open-ended wrench to prevent them from turning.
    Tighten the camshaft sprocket retaining bolts.

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

  1. Install the engine front cover (engine shown removed for clarity).
    • 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. Install the accessory drive belt idler.

  1. Install the engine front mount.
  1. Remove the trolley jack.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Connect the CKP sensor electrical connector.

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

  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: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 engine 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 engine 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. Connect the HO2S sensor electrical connector.

  1. Connect the exhaust front pipe.
    1. Attach the exhaust front pipe to the exhaust manifold.
    1. Attach the exhaust manifold to the retaining bracket.
    1. Install the exhaust manifold heat shield lower retaining bolts.
  1. Lower the vehicle.

  1. Attach the coolant expansion tank.

  1. Using the special tool, connect the coolant hose to the coolant expansion tank.

  1. NOTE:
    NOTE:Do not fully tighten the water pump pulley retaining bolts at this stage.
    Install the water pump pulley.

  1. Attach the ground lead to the cylinder head.

  1. Install the generator upper retaining bolt.

  1. Attach the exhaust manifold bracket.

  1. Install the exhaust manifold upper heat shield.

  1. Using the special tool, connect the coolant hoses.
  1. Install the power steering pump. For additional information, refer to Section  211-02 Power Steering.

  1. Tighten the water pump pulley retaining bolts.

  1. Apply a small bead of silicone 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. Install the intake manifold.
    For additional information, refer to Intake Manifold in this section.
  1. Fill and bleed the cooling system. For additional information, refer to Section  303-03 Engine Cooling.
  1. Fill and bleed the power steering system. For additional information, refer to Section  211-02 Power Steering.
  1. Initialize the door window motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

In-vehicle Repair|Oil Pan > < Timing Chain