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303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel|Specifications > < Engine - Vehicles With: 6-Speed Manual Transmission (MMT6)

Mondeo 2007.5 (02.2007-)

Engine - 1.8L Duratorq-TDCi (Lynx) Diesel - Engine Accessories Mondeo 2007.5 (02/2007-)

Installation

Special Tool(s)
205-072
Universal Flange Holding Wrench

303-122
Lifting Bracket, Engine

303-193
Timing Peg, Crankshaft TDC

303-376B
Alignment Plate, Camshaft

303-393
Locking Tool, Flywheel

303-435
Mounting Stand

303-435-06
Mounting Bracket for 303-435

303-710
Timing Tool, Crankshaft
Materials
Name
Specification
Sealant - Loctite 510
WSK-M2G348-A7
  1. CAUTION:
    CAUTION:Make sure that new bolts are installed.
    Special Tool(s): 303-393
    Torque:
    Stage 1:
    35 Nm
    Stage 2:
    45°
  1. Install the clutch disc and pressure plate.
    Refer to: Clutch Disc and Pressure Plate (308-01 Clutch - Vehicles With: 6-Speed Manual Transmission (MMT6), Removal and Installation).

  1. NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    1. Remove the cylinder block blanking plug and install the special tool.
      Special Tool(s): 303-193
    1. Rotate the crankshaft slowly until the crankshaft stops.
    1. Make sure that the crankshaft does not rotate during installation of the special tool. Make sure that the crankshaft is at the TDC position before locking the special tool.Using the special tool, lock the crankshaft.
      Special Tool(s): 303-393

  1. Using the special tool, install the crankshaft position (CKP) sensor retaining bracket.
    Special Tool(s): 303-710
    Torque: 10 Nm

  1. NOTE:
    NOTE:Install a new crankshaft position (CKP) sensor.
    NOTE:
    NOTE:The CKP sensor must make contact with the flywheel.
    Torque: 6 Nm

  1.  
    • 1.
      Torque:
      Snug Torque 10 Nm
      Delay 2 Seconds 18 Nm
      Untighten 40°
      Final Torque 26 Nm
    • 2.
      Torque: 33 Nm

  1. Install a new gasket
    Torque: 23 Nm

  1. Attach the fuel pump pulley to the fuel pump sprocket. Apply sealant to the fuel pump pulley and to the outer edge of the fuel pump pulley retaining bolt holes.
    Material: Sealant - Loctite 510

  1. Tighten the fuel pump seal retainer retaining bolts in the sequence shown.
    Torque:
    1-7 and timing belt rear cover 10 Nm
    Engine front mount bracket 28 Nm

  1. Tighten the camshaft pulley bolt finger tight and then loosen by one-half turn.

  1.  
    • Check the timing belt tensioner and make sure that the timing belt tensioner pointer rotates clockwise freely.
    • Move the timing belt tensioner adjustment arm to the 3 o'clock position.
    • Do not fully tighten the timing belt tensioner retaining bolt at this stage.

  1.  
    • The camshaft pulley must be able to rotate freely on the camshaft taper.
    • Install the timing belt with the direction arrows in the direction of engine rotation.

  1. Tension the timing belt counterclockwise until the pointer is positioned between the sides of the window.
    Torque: 50 Nm

  1. Special Tool(s): 205-072
    Torque: 50 Nm
  1. Remove the special tools.
    Special Tool(s): 303-376B, 303-193, 303-393
  1.  
    1. Rotate the crankshaft 2 revolutions. Replace the Timing Peg just before TDC on the second revolution.
      Special Tool(s): 303-193
    1. Rotate the crankshaft slowly until the crankshaft stops at TDC.
  1. Check that the timing belt tensioner pointer is positioned in the window, otherwise the timing belt tensioning steps must be repeated.

  1. NOTE:
    NOTE:If the special tool cannot be installed, the timing belt tensioning steps must be repeated.
    Install the special tool.
    Special Tool(s): 303-376B
  1. Remove the special tools and install the cylinder block blanking plug.
    Special Tool(s): 303-376B, 303-193, 303-393
    Torque: 23 Nm

  1. Torque: 7 Nm

  1. Special Tool(s): 205-072
    Torque: 23 Nm

  1. Torque:
    1 23 Nm
    2 15 Nm

  1. Torque: 27 Nm

  1. Torque:
    1 27 Nm
    2 10 Nm

  1. CAUTION:
    CAUTION:Make sure that a new crankshaft pulley bolt is installed.
    Special Tool(s): 205-072
    Torque:
    1 
    Stage 1:
    100 Nm
    Stage 2:
    180°
    2 47 Nm

  1. Torque:
    Glow plugs 15 Nm
    Glow plug wire electrical connector retaining nuts  2,5 Nm

  1. NOTE:
    NOTE:Make sure that new components are installed.

  1. CAUTION:
    CAUTION:Make sure that new bolts are installed.
    NOTE:
    NOTE:Make sure that these components are installed to the noted removal position.
    Torque: 37 Nm

  1. Push the fuel injector fuel return line gently into the fuel injector. Make sure that new fuel injector fuel return line clips are installed. Do not distort the fuel injector fuel return line retaining clip when installing it to the fuel injector. Failure to follow this instruction may result in fuel leaks.

  1. Torque: 23 Nm

  1. Tighten the common rail support bracket retaining bolts in the sequence shown. Do not fully tighten the fuel supply manifold retaining bracket bolts at this stage.
    Torque:
    1-2 23 Nm
    3 24 Nm

  1. CAUTION:
    CAUTION:Use an open-ended wrench to prevent the component from turning.
    NOTE:
    NOTE:The fuel supply line must be installed with the yellow identification collar adjacent to the fuel injector and the blue identification collar adjacent to the fuel rail.
    NOTE:
    NOTE:The fuel supply line must be installed with the yellow identification collar adjacent to the fuel pump and the blue identification collar adjacent to the fuel rail.
    NOTE:
    NOTE:The high-pressure fuel supply lines must be connected immediately after removing the blanking plugs.
    NOTE:
    NOTE:Do not allow the unions to hit the ends of the high-pressure fuel supply line. To aid installation of the new high-pressure fuel supply lines, the unions at the fuel rail end are colored gold.
    Tighten the fuel injector high-pressure fuel supply lines in the sequence shown.
    Torque:
    1-5 25 Nm
    6-10 38 Nm

  1. Torque: 5 Nm

  1. Torque: 3 Nm

  1. Torque: 24 Nm

  1. Torque: 20 Nm

  1. Torque: 23 Nm

  1. Torque:
    1 23 Nm
    2 23 Nm

  1. Torque:
    1 7 Nm
    2 20 Nm
    3 20 Nm
  1. Install the Fuel Filter.
    Refer to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).

  1. Torque:
    1 23 Nm
    2 10 Nm

  1. Special Tool(s): 303-122

  1. Remove the Special Tools.
    Special Tool(s): 303-435, 303-435-06

  1. Torque:
    1 20 Nm
    2 23 Nm

  1. Make sure that the Gap between the Ears of the V-Band Clamp is between 3-6 mm.
    Torque:
    1 25 Nm
    2 45 Nm
    3 4.5 Nm
    4 10 Nm
    5 25 Nm
    6 23 Nm
    7 35 Nm

  1. Torque:
    1 15 Nm
    2 4 Nm

303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel|Specifications > < Engine - Vehicles With: 6-Speed Manual Transmission (MMT6)