1/26/2018 Ford Workshop Manuals > Mondeo 2007.5 (02.

2007-) > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01E Engine - 1.8L Durator…

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Mondeo 2007.5 (02.2007-)

Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01E Engine - 1.8L Duratorq-TD
Operation > Diagnosis and Testing > General Procedures > Removal and Installation >
Engine

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Engine - 1.8L Duratorq-TDCi (Lynx) Diesel - Engine
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Assembly
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
303-652
Aligner, Oil Pump
303-710
Timing Tool, Crankshaft

Materials
Name Specification
Cleaner WSK-M5B401-A1
Engine Oil - 5W-30 WSS-M2C912-A1
Sealant - Loctite 510 WSK-M2G348-A7
Silicone Sealant WSE-M4G323-A4

1. Coat the crankshaft main bearing journals, bearing shells and thrust half w

Material: Engine Oil - 5W-30

2.

CAUTION:Make sure that new bearing cap retaining bolts are installed.
Tighten the crankshaft main bearing cap retaining bolts in the sequence sh

Torque:
Stage 1:45 Nm
Stage 2:70 Nm
Stage 3:60°

3.
Coat the cylinder bores with clean engine oil.
The piston ring gaps and oil supply ring elements must be distribu
Install the pistons with the arrows pointing towards the front of t
Using a suitable piston ring compressor, install the pistons.

4.
Lubricate the connecting rod journals with clean engine oil.
The connecting rod identification marks must point towards the fr

CAUTION:Make sure that new connecting rod bearing caps retaini

Start tighten the connecting rod bearing caps retaining bolts finge

Torque:
Stage 1:27 Nm
Stage 2:60°
Stage 3:20°

5. The chain housing bottom sealing flange surfaces must be within +/- 0,26

Torque: 23 Nm

6.

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7.
Align the ladder frame flush with the cylinder block.
Tighten the ladder frame retaining bolts in the sequence shown.

Torque: 11 Nm

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Mondeo 2007.5 (02.2007-) Workshop Manual

Mechanical Repairs
1 General Information
2 Chassis 8. Torque: 10 Nm
3 Powertrain
303 Engine
303-00 Engine System - General Informat
303-01A Engine - 1.6L Duratec-16V Ti-V
303-01B Engine - 2.0L Duratec-HE (MI4)
303-01C Engine - 2.3L Duratec-HE (MI4)
303-01D Engine - 2.5L Duratec (VI5)
303-01E Engine - 1.8L Duratorq-TDCi (L
Description and Operation
Engine
Diagnosis and Testing
Engine
General Procedures
Valve Clearance Adjustment
Removal and Installation
Valve Cover 9. Install the Crankshaft Rear Seal.
Crankshaft Front Seal
Valve Stem Seals
Camshaft Refer to: Crankshaft Rear Seal (303-01E Engine - 1.8L Duratorq-TDCi (Lynx
Camshaft Seal
Timing Belt
Exhaust Manifold 10.
Cylinder Head
Oil Pump
Oil Pan NOTE:Make sure that the mating faces are clean and free of foreign materi
Crankshaft Rear Seal
Removal
Engine - Vehicles Wit 11.
Engine - Vehicles Wit
Engine Accessories
Disassembly CAUTION:Make sure that no excess sealant residue is evident.
Engine
Assembly
>>Engine <<
Installation NOTE:The component must be installed within 5 minutes of applying the se
Specifications Apply a 2.5 mm diameter bead of sealant to the edge of the Oil Pan.
303-01F Engine - 2.0L Duratorq-TDCi (D
303-01G Engine - 2.2L Duratorq-TDCi (D
Material: Silicone Sealant
303-03A Engine Cooling - 1.6L Duratec-1
303-03B Engine Cooling - 2.0L Duratec-H
303-03C Engine Cooling - 2.5L Duratec (
303-03D Engine Cooling - 1.8L Duratorq
303-03E Engine Cooling - 2.0L Duratorq-
303-03F Engine Cooling - 2.2L Duratorq-
12. Tighten the Oil Pan retaining nuts and bolts in the sequence shown.
303-04A Fuel Charging and Controls - 1.6
303-04B Fuel Charging and Controls - 2.0
303-04C Fuel Charging and Controls - 2.5 Torque:
303-04D Fuel Charging and Controls - 1.8 1-18
303-04E Fuel Charging and Controls - 2.0 Stage 1:6.5 Nm
303-04F Fuel Charging and Controls - 2.2 Stage 2:14 Nm
303-04G Fuel Charging and Controls - Tu 19 36 Nm
303-04H Fuel Charging and Controls - Tu
303-04I Fuel Charging and Controls - Tur
303-04J Fuel Charging and Controls - Tur
303-05A Accessory Drive - 1.6L Duratec-
303-05B Accessory Drive - 2.0L Duratec-
303-05C Accessory Drive - 2.5L Duratec
303-05D Accessory Drive - 1.8L Duratorq
303-05E Accessory Drive - 2.0L Duratorq
303-05F Accessory Drive - 2.2L Duratorq
303-06A Starting System - 1.6L Duratec- 13. Torque:
303-06B Starting System - 2.0L Duratec-H 1 23 Nm
303-06C Starting System - 2.5L Duratec ( 2 48 Nm
303-06D Starting System - 1.8L Duratorq
303-06E Starting System - 2.0L Duratorq-
303-07A Engine Ignition - 1.6L Duratec-1
303-06F Starting System - 2.2L Duratorq-
303-07B Engine Ignition - 2.0L Duratec-H
303-07C Engine Ignition - 2.5L Duratec (V
303-07D Glow Plug System - 1.8L Durato
303-07E Glow Plug System - 2.0L Durato
303-07F Glow Plug System - 2.2L Durato
303-08A Engine Emission Control - 1.6L
303-08B Engine Emission Control - 2.0L
303-08C Engine Emission Control - 2.5L
303-08D Engine Emission Control - 1.8L
303-08E Engine Emission Control - 2.0L
303-08F Engine Emission Control - 2.2L 14. Torque:
303-12A Intake Air Distribution and Filte Snug Torque 10 Nm
303-12B Intake Air Distribution and Filter Delay 2 Seconds 18 Nm
303-12C Intake Air Distribution and Filter Untighten 40°
Final Torque 26 Nm
303-12D Intake Air Distribution and Filte
303-12E Intake Air Distribution and Filter
303-12F Intake Air Distribution and Filter

15. Install a new gasket

Torque: 23 Nm

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16.

17. Torque:
1 23 Nm
2 24 Nm
3 65 Nm

18.

19. Locate Alignment Tool into Oil Pump and Seal Pocket and align with Crank

Special Tool(s): 303-652

Torque:
Alignment Tool 10 Nm
1-5 10 Nm
6 23 Nm
7-19 10 Nm

20. Torque:
1 10 Nm
2 23 Nm

21. Clean the mating faces of the cylinder head and cylinder block with cleane

Material: Cleaner

22.

NOTE:The thickness and position of the new cylinder head gasket must be

23.

CAUTION:Make sure that new unoiled cylinder head bolts are installed.

CAUTION:Place the two short cylinder head bolts on position 7 and 10

NOTE:The pistons must not be at TDC.

Tighten the cylinder head retaining bolts in the sequence shown in four sta

Torque:
Stage 1:20 Nm
Stage 2:45 Nm
Stage 3:100 Nm
Stage 4:183 Nm

24.

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

2. Rotate the crankshaft slowly until the crankshaft stops.
3. Make sure that the crankshaft does not rotate during installation of

Special Tool(s): 303-393

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25. Using the special tool, install the crankshaft position (CKP) sensor retainin

Special Tool(s): 303-710

Torque: 10 Nm

26.

NOTE:Install a new crankshaft position (CKP) sensor.

NOTE:The CKP sensor must make contact with the flywheel.

Torque: 6 Nm

27. Attach the fuel pump pulley to the fuel pump sprocket. Apply sealant to th

Material: Sealant - Loctite 510

28. 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

29. Tighten the camshaft pulley bolt finger tight and then loosen by one-half t

30.
Check the timing belt tensioner and make sure that the timing bel
Move the timing belt tensioner adjustment arm to the 3 o'clock po
Do not fully tighten the timing belt tensioner retaining bolt at this

31.
The camshaft pulley must be able to rotate freely on the camshaft
Install the timing belt with the direction arrows in the direction of

32. Tension the timing belt counterclockwise until the pointer is positioned be

Torque: 50 Nm

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33. Special Tool(s): 205-072

Torque: 50 Nm

34. Remove the special tools.

Special Tool(s): 303-376B, 303-193, 303-393

35.
1. Rotate the crankshaft 2 revolutions. Replace the Timing Peg just b

Special Tool(s): 303-193

2. Rotate the crankshaft slowly until the crankshaft stops at TDC.

36. Check that the timing belt tensioner pointer is positioned in the window, o

37.

NOTE:If the special tool cannot be installed, the timing belt tensioning ste
Install the special tool.

Special Tool(s): 303-376B

38. Remove the special tools and install the cylinder block blanking plug.

Special Tool(s): 303-376B, 303-193, 303-393

Torque: 23 Nm

39. Torque: 7 Nm

40. Special Tool(s): 205-072

Torque: 23 Nm

41. Torque:
1 23 Nm
2 15 Nm

42. Torque: 27 Nm

43. Torque:
1 27 Nm
2 10 Nm

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44.

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

45. Torque: 20 Nm

46.

NOTE:Make sure that new components are installed.

47. Torque:
Stage 1:5 Nm
Stage 2:90°

48.

NOTE:Do not fully tighten the fuel supply manifold retaining bracket bolts
Torque: 23 Nm

49.

CAUTION:Use an open-ended wrench to prevent the component from turni

NOTE:The high-pressure fuel supply lines must be connected immediately

NOTE:Do not allow the unions to hit the ends of the high-pressure fuel sup
Tighten the injector ends in sequence 4,3,2,1

Torque: 25 Nm
Tighten the fuel pump end 5

Torque: 25 Nm
Tighten rail end in sequence 1,2,3,4,5

Torque: 38 Nm
Install a new thermostat housing gasket.

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Torque:
thermostat housing 23 Nm
vacuum pipe 18 Nm

50. Torque:
1 7 Nm
2 23 Nm
3 23 Nm

51. Install the Fuel Filter.

Refer to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel (310-01 Fuel Tank

52. Torque: 23 Nm

53.

54. Torque: 20 Nm

55. Torque: 10 Nm

56.
1. Torque: 3 Nm
2. Torque: 5 Nm

57. Special Tool(s): 303-122

58. Remove the Special Tools.

Special Tool(s): 303-435, 303-435-06

59. Torque:
1 20 Nm
2 23 Nm

60. Make sure that the Gap between the Ears of the V-Band Clamp is between

Torque:
1 25 Nm
2 45 Nm
3 4.5 Nm
4 10 Nm

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5 25 Nm
6 23 Nm
7 23 Nm
8 35 Nm

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Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01E Engine - 1.8L Duratorq-TD
Operation > Diagnosis and Testing > General Procedures > Removal and Installation >
Engine

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