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Assembly|Installation > < Cylinder Head

Mondeo 2001 (10.2000-02.2007)

Engine - 2.5L Duratec-VE (VE6) - Engine Mondeo 2001 (10/2000-02/2007)
Assembly

Special Tool(s)

Universal Flange Holding Wrench

205-072 (15-030A)

Installer/Aligner, Timing Cover Seal

303-055 (21-017A)

Remover/Installer, Crankshaft Vibration Damper

303-130 (21-076)

Gauge, Bolt Angle

303-174 (21-540)

Remover/Installer, Hose Clamp

303-397 (24-003)

Mounting Bracket for 303-435

303-435-06 (21-031B)

Mounting Plate for 303-435-06

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

Installer, Camshaft Pulley

303-458 (21-192)

Adapter for 303-458

303-458-01 (21-192-01)

Installer, Crankshaft Rear Seal

303-460 (21-193A)

Socket, Spark Plug

303-499 (21-202)
Materials
Name
Specification
Silicone Sealant
WSE-M4G323-A4 
ESE-M99B144-B 
Engine Oil - 5W-30
WSS-M2C913-B 

Assembly

All vehicles
  1. Install the oil pump.
    • Tighten the bolts in the sequence shown.

  1. Install the oil pan baffle.
    • Tighten the nuts in two stages.
    • Stage 1: 5 Nm.
    • Stage 2: 45 degrees.

  1. NOTE:
    NOTE:Apply O-ring lubricant to the O-ring before installation.
    Install the oil pick-up pipe retaining nut.
    • Tighten the nut in two stages.
    • Stage 1: 5 Nm.
    • Stage 2: 45 degrees.

  1. Install the oil pick-up pipe retaining bolts.

  1. NOTE:
    NOTE:Clean the oil separator mating face with metal surface cleaner.
    NOTE:
    NOTE:Install a new oil separator gasket.
    Install the oil separator.

  1. Install the power steering pump bracket.
    • Align the bracket with the locating dowels.

  1. NOTE:
    NOTE:Install a new cylinder head gasket.
    NOTE:
    NOTE:Left-hand and right-hand cylinder head gaskets are not interchangeable.
    NOTE:
    NOTE:Align the cylinder head with the locating dowels.
    NOTE:
    NOTE:Install new cylinder head bolts with washers.
    Install the left-hand cylinder head.
    • Tighten the bolts in the sequence shown in two stages.
    • Stage 1: 40 Nm.
    • Stage 2: 90 degrees.

  1. Loosen the left-hand cylinder head bolts.
    • Loosen the cylinder head bolts one complete turn in the sequence shown.

  1. Tighten the left-hand cylinder head bolts in the sequence shown in three stages.
    • Stage 1: 40 Nm.
    • Stage 2: 90 degrees.
    • Stage 3: 90 degrees.

  1. NOTE:
    NOTE:Install a new cylinder head gasket.
    NOTE:
    NOTE:Left-hand and right-hand cylinder head gaskets are not interchangeable.
    NOTE:
    NOTE:Align the cylinder head with the locating dowels.
    NOTE:
    NOTE:Install new cylinder head bolts with washers.
    Install the right-hand cylinder head.
    • Tighten the bolts in the sequence shown in two stages.
    • Stage 1: 40 Nm.
    • Stage 2: 90 degrees.

  1. Loosen the right-hand cylinder head bolts.
    • Loosen the cylinder head bolts one complete turn in the sequence shown.

  1. Tighten the right-hand cylinder head bolts in the sequence shown in three stages.
    • Stage 1: 40 Nm.
    • Stage 2: 90 degrees.
    • Stage 3: 90 degrees.

  1. Install the crankshaft pulley retaining bolt and washer.
    • Rotate the crankshaft in a clockwise direction to position the keyway at the 11 o'clock position.

  1. NOTE:
    NOTE:Lubricate the valve tappets with clean engine oil before installation.
    Install the left-hand cylinder head valve tappets.

  1. CAUTION:
    CAUTION:The cam followers must be installed in their original positions.
    NOTE:
    NOTE:Lubricate the cam followers with clean engine oil before installation.
    Install the left-hand cylinder head cam followers.
  1. NOTE:
    NOTE:Lubricate the camshafts with clean engine oil before installation.
    Install the left-hand camshafts.

  1. Position the left-hand camshafts as shown.
    1. The mark on the intake camshaft at the 9 o'clock position.
    1. The mark on the exhaust camshaft at the 12 o'clock position.

  1. CAUTION:
    CAUTION:The camshaft journal caps must be installed in their original positions.
    CAUTION:
    CAUTION:Do not install the camshaft journal thrust caps until all the camshaft bearing caps have been installed, or damage to the thrust caps may occur.
    NOTE:
    NOTE:Lubricate the camshaft journal caps with clean engine oil before installation.
    Install the left-hand camshaft journal caps.
    • Tighten the bolts in the sequence shown in several stages.

  1. Remove the crankshaft pulley retaining bolt and washer.

  1. CAUTION:
    CAUTION:Make sure vise jaw protectors are used.
    Loosely mount the left-hand timing chain tensioner in a vise.

  1. CAUTION:
    CAUTION:During tensioner compression, do not release the ratchet stem until the tensioner piston is fully retracted into its bore or damage to the ratchet stem will result.
    Using a suitable pin, release the the left-hand timing chain tensioner piston.
  1. NOTE:
    NOTE:The piston should retract with minimal force. If binding occurs, reposition the tensioner in the vise to eliminate side loading.
    Slowly compress the left-hand timing chain tensioner, by tightening the vise.

  1. NOTE:
    NOTE:The retaining wire or paper clip must remain in position until the timing chain tensioner has been installed.
    Using suitable 1.5 mm diameter wire or a paper clip, lock the left-hand timing chain tensioner piston in position.

  1. If the timing marks on the timing chain are not evident, use a permanent marker to mark the crankshaft and camshaft timing marks on the left-hand timing chain.
    1. Mark any link to use as the crankshaft timing mark.
    1. Count 29 links from the crankshaft timing mark and mark this link as the exhaust camshaft sprocket timing mark.
    1. Continue counting to link 42. Mark this link as the intake camshaft sprocket timing mark.

  1. NOTE:
    NOTE:Install the crankshaft sprockets with the timing marks facing outwards.
    NOTE:
    NOTE:Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
    Install the left-hand timing chain.
    1. Install the left-hand timing chain guide.
    1. Install the crankshaft sprockets.
    1. Install the left-hand timing chain.

  1. Install the left-hand timing chain tensioner.
    1. Install the left-hand timing chain tensioner arm.
    1. Position the timing chain tensioner.
    1. Install the bolts.
  1. Remove the left-hand timing chain tensioner piston retaining wire.

  1. NOTE:
    NOTE:Lubricate the valve tappets with clean engine oil before installation.
    Install the right-hand cylinder head valve tappets.

  1. CAUTION:
    CAUTION:The cam followers must be installed in their original position.
    NOTE:
    NOTE:Lubricate the cam followers with clean engine oil before installation.
    Install the right-hand cylinder head cam followers.
  1. NOTE:
    NOTE:Lubricate the camshafts with clean engine oil before installation.
    Install the right-hand camshafts.

  1. Position the right-hand camshafts as shown.
    1. The mark on the exhaust camshaft at the 12 o'clock position.
    1. The mark on the intake camshaft at the 3 o'clock position.

  1. CAUTION:
    CAUTION:The camshaft journal caps must be installed in their original position.
    CAUTION:
    CAUTION:Do not install the camshaft journal thrust caps until all the camshaft bearing caps have been installed, or damage to the thrust caps may occur.
    NOTE:
    NOTE:Lubricate the camshaft journal caps with clean engine oil before installation.
    Install the right-hand camshaft journal caps.
    • Tighten the bolts in the sequence shown in several stages.

  1. Install the crankshaft pulley retaining bolt and washer.
    • Rotate the crankshaft in a clockwise direction to position the keyway at the 3 o'clock position.

  1. Remove the crankshaft pulley retaining bolt and washer.

  1. CAUTION:
    CAUTION:Make sure vise jaw protectors are used.
    Loosely mount the right-hand timing chain tensioner in a vise.

  1. CAUTION:
    CAUTION:During tensioner compression, do not release the ratchet stem until the tensioner piston is fully retracted into its bore or damage to the ratchet stem will result.
    Using a suitable pin, release the the right-hand timing chain tensioner piston.
  1. NOTE:
    NOTE:The piston should retract with minimal force. If binding occurs, reposition the tensioner in the vise to eliminate side loading.
    Slowly compress the right-hand timing chain tensioner, by tightening the vise.

  1. NOTE:
    NOTE:The retaining wire or paper clip must remain in position until the timing chain tensioner has been installed.
    Using suitable 1.5 mm diameter wire or a paper clip, lock the left-hand timing chain tensioner piston in position.

  1. If the timing marks on the timing chain are not evident, use a permanent marker to mark the crankshaft and camshaft timing marks on the right-hand timing chain.
    1. Mark any link to use as the crankshaft timing mark.
    1. Count 29 links from the crankshaft timing mark and mark this link as the exhaust camshaft sprocket timing mark.
    1. Continue counting to link 42. Mark this link as the intake camshaft sprocket timing mark.

  1. NOTE:
    NOTE:Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
    Install the right-hand timing chain.
    1. Install the right-hand timing chain guide.
    1. Install the right-hand timing chain.

  1. Install the right-hand timing chain tensioner.
    1. Install the right-hand timing chain tensioner arm.
    1. Position the timing chain tensioner.
    1. Install the bolts.
  1. Remove the right-hand timing chain tensioner piston retaining wire.

  1. Install the crankshaft pulley retaining bolt and washer.

  1. NOTE:
    NOTE:Ignore the timing flags on the rear of the camshaft sprockets.
    NOTE:
    NOTE:Check the number of timing chain links between the camshaft front timing marks and between the camshaft front timing marks and timing marks on the crankshaft sprockets.
    Rotate the crankshaft approximately 120 degrees in a counterclockwise direction and check the timing.
    1. There should be 12 chain links between the camshaft timing marks.
    1. There should be 27 chain links between the camshaft and crankshaft timing marks.
    1. There should be 30 chain links between the camshaft and crankshaft timing marks.

  1. Remove the crankshaft pulley retaining bolt and washer.

  1. CAUTION:
    CAUTION:The pulse wheel has two keyway slots and is used in several different engines.
    Install the pulse wheel in the keyway slot stamped 25, color coded blue.

  1. NOTE:
    NOTE:Install the engine front cover within six minutes of applying the sealer.
    Apply a 6 mm dot of sealant to the mating faces in the positions shown.

  1. CAUTION:
    CAUTION:The engine front cover must be installed in two stages.
    NOTE:
    NOTE:Note the position of the locating dowels and studs.
    NOTE:
    NOTE:Install new engine front cover gaskets.
    Install the engine front cover.
    • Install the engine front cover retaining bolts and studs in the sequence shown.

  1. NOTE:
    NOTE:1, 3, 4, 8, 10, 11, 14, 15 and 16 are stud locations.
    Install the remaining engine front cover retaining bolts and studs.
    • Tighten the bolts and studs in the sequence shown.

  1. Install the crankshaft position sensor (CKP), the camshaft position sensor (CMP) and wiring brackets.
    • Lubricate the O-ring with sealer before installation.

  1. NOTE:
    NOTE:Install the a new crankshaft front seal
    Using the special tools, install the crankshaft front seal.
    • Lubricate the outer ring with clean engine oil before installation.
  1. Remove the special tools.
  1. Apply sealant to the front of the crankshaft on the inside diameter surface of the crankshaft pulley at the keyway.
    • Before applying the sealant, clean the sealing surfaces to remove all residue.

  1. NOTE:
    NOTE:Use the crankshaft pulley retaining bolt washer for installation.
    Using the special tool, install the crankshaft pulley.
  1. Remove the special tools and the crankshaft pulley retaining bolt washer.

  1. CAUTION:
    CAUTION:Install a new crankshaft pulley retaining bolt.
    Using the special tool, install the crankshaft pulley.
    • Tighten the bolt in four stages.
    • Stage 1: 120 Nm.
    • Stage 2: Loosen one turn.
    • Stage 3: 50 Nm.
    • Stage 4: 90 degrees.

  1. NOTE:
    NOTE:Do not fully tighten the power steering pump bracket retaining bolts and nuts at this stage.
    Install the power steering pump and bracket.

  1. NOTE:
    NOTE:The longer 84 mm retaining bolts should be tightened first.
    Tighten the 84 mm power steering pump retaining bolts.

  1. Tighten the power steering pump retaining nuts.

  1. NOTE:
    NOTE:The dimple on the pulley must face towards the front of the engine.
    Install the power steering pump belt pulley.

  1. NOTE:
    NOTE:Install a new gasket.
    Install the camshaft seal retainer.
    • Align the retainer on the locating dowels and tighten the retaining bolts.

  1. CAUTION:
    CAUTION:Do not damage the camshaft seal surface.
    Using the special tools, install the camshaft seal.
    • Lubricate the camshaft seal with clean engine oil before installation.

  1. Using the special tool, install the camshaft pulley.

  1. Using the special tool, install the left-hand spark plugs.

  1. Using the special tool, install the right-hand spark plugs.

  1. NOTE:
    NOTE:Clean the cylinder head mating face with metal surface cleaner.
    Apply sealant to the mating faces of the cylinder heads in the position shown.

  1. NOTE:
    NOTE:Install new gaskets.
    Install the valve covers.
    • Tighten the valve cover retaining bolts in the sequence shown.

  1. Install the engine wiring bracket to the right-hand valve cover.

  1. NOTE:
    NOTE:Install the oil pan within six minutes of applying the sealant.
    Apply a 10 mm bead of sealant to the cylinder block in the positions shown.

  1. NOTE:
    NOTE:Install the stud bolts in position 5, 6, 7, 12, 14, 15.
    Install the oil pan.
    • Tighten the bolts and studs in the sequence shown.

  1. Install the oil pressure switch.

  1. NOTE:
    NOTE:If studs were removed, install short end of studs into the cylinder head.
    NOTE:
    NOTE:Install a new gasket and retaining nuts.
    Install the left-hand exhaust manifold.
    • Tighten the nuts in the sequence shown.

  1. Install a new oil filter.

  1. NOTE:
    NOTE:If studs were removed, install short end of studs into the cylinder head.
    NOTE:
    NOTE:Install a new gasket and retaining nuts.
    Install the right-hand exhaust manifold.
    • Tighten the nuts in the sequence shown.

  1. Install the generator mount bracket.

  1. Install the generator.

  1. CAUTION:
    CAUTION:Tighten the bolts in several stages to correctly seat the crankshaft rear seal until it is flush with the cylinder block.
    Using the special tool, install the crankshaft rear seal.
    • Lubricate the outer ring with clean engine oil before installation.
Vehicles with manual transaxle
  1. NOTE:
    NOTE:Use a suitable strap wrench to hold the crankshaft pulley.
    Install the flywheel.
    1. Install the adapter plate.
    1. Install the flywheel retaining bolts.
Vehicles with automatic transaxle
  1. NOTE:
    NOTE:Use a suitable strap wrench to hold the crankshaft pulley.
    Install the adapter plate and the flexplate.
    • Tighten the flexplate retaining bolts in the sequence shown.
All vehicles
  1. NOTE:
    NOTE:Install a new gasket.
    Install the coolant pump.
    • Tighten the bolts in two stages.
    • Stage 1: 10 Nm.
    • Stage 2: 90 degrees.

  1. Using the special tool, connect the coolant hoses to the coolant pump.

  1. NOTE:
    NOTE:Install new O-ring seals.
    Install the cooling system bypass assembly.
    • Lubricate the O-ring seals with sealer before installation.

  1. Install the positive crankcase ventilation (PCV) valve and hoses.
    1. Connect the PCV valve and hoses.
    1. Install the bracket retaining nut.
Vehicles with coolant pump belt tensioner
  1. Detension the coolant pump belt tensioner, install the coolant pump belt.
Vehicles without coolant pump belt tensioner
  1. NOTE:
    NOTE:Install a new coolant pump belt.
    Install the coolant pump belt around the coolant pump pulley and the top of the camshaft pulley.
  1. Make sure that the coolant pump belt is correctly positioned into the grooves of the pulleys.

  1. NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Guide the coolant pump belt onto the pulleys as the engine is rotated.
  1. NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Rotate the crankshaft through 360 degrees.
  1. Check that the coolant pump belt is correctly positioned in the grooves of the pulleys.
    • Repeat the installation procedure if the coolant pump belt is misaligned.
All vehicles
  1. NOTE:
    NOTE:Install the O-ring seal on the oil level indicator tube and lubricate with clean engine oil before installation.
    Install the oil level indicator tube.
    • Locate the oil level indicator tube using a twisting motion.

  1. Install the coolant distribution tube.

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

  1. CAUTION:
    CAUTION:Install new gaskets with the locating lugs facing downwards.
    Install the lower intake manifold.
    • Tighten the bolts in the sequence shown.

  1. Connect the fuel injector electrical connectors.
    • Attach the wiring harness.

  1. Connect the CKP sensor electrical connector.
    1. Attach the wiring harness to the retaining stud.
    1. Connect the CKP sensor electrical connector.

  1. Connect the CMP sensor electrical connector.
    • Attach the wiring harness to the retaining stud.

  1. Connect the oil pressure switch electrical connector.

  1. Connect the heated oxygen sensor (HO2S) electrical connector.

  1. CAUTION:
    CAUTION:Install new gaskets with the locating lugs pointing downwards.
    NOTE:
    NOTE:Clean the upper intake manifold mating face with metal surface cleaner.
    Install the upper intake manifold.
    • Tighten the bolts in the sequence shown.

  1. Connect the throttle position (TP) sensor electrical connector.

  1. Connect the PCV hose to the throttle body.

  1. Connect the idle air control (IAC) valve electrical connector.
Vehicles with EGR
  1. Connect the electronic vacuum regulator (EVR) hoses.
    • Install the vacuum hose harness.

  1. Connect the vacuum hoses to the upper intake manifold, the EGR valve and the fuel pressure regulator.

  1. Connect the differential pressure feedback EGR electrical connector.

  1. Connect the EGR pipe to the EGR valve.
    1. Attach the tube fitting.
    1. Connect the hoses.
All vehicles
  1. Install the electronic ignition (EI) coil.
    • Install the EI coil, make sure the radio suppressor and ground cable are connected. Connect the EI coil electrical connector.

  1. Connect the right-hand spark plug electrical connectors.
    • Attach the bracket.

  1. Connect the left-hand spark plug electrical connectors.
    • Attach the bracket.

  1. Install the intake manifold runner control (IMRC) actuator and mounting bracket.
    1. Install the retaining bolts.
    1. Connect the IMRC electrical connector.
    1. Install a new cable tie.

  1. Attach the IMRC cable to the throttle body.

  1. Attach the wiring harness bracket to the right-hand valve cover (two nuts).

  1. Attach the wiring harness in-line electrical connectors to the mounting bracket.

  1. Connect the EVR solenoid valve electrical connector.

  1. Connect the generator electrical connectors.
  1. Using a suitable engine hoist, remove the engine from the mounting stand.

  1. Remove the special tools.

  1. Install the intermediate drive shaft bracket.

  1. NOTE:
    NOTE:Install a new gasket and retaining nuts.
    Install the right-hand exhaust manifold.
    • Tighten the nuts in the sequence shown.
  1. Fill the engine with clean engine oil.
Vehicles with manual transaxle
  1. Install the clutch disc and pressure plate.
    For additional information, refer to: Clutch Disc and Pressure Plate (308-01A Clutch - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal and Installation).

Assembly|Installation > < Cylinder Head