MONDEO2

Engine - 1.6L/1.8L/2.
0L, Vehicles Built

Mondeo 1997 (08/1996-09/2000)
Up To: 05/1998 - Specifications
Print
Engine Data - Zetec-E
1,6 DOHC 16V 1,8 DOHC 16V 2,0 DOHC 16V

Engine management EEC V/SEFI EEC V/SEFI EEC V/SEFI
Emission standard 96 EEC 96 EEC 96 EEC
Premium 95 RON Premium 95 RON Premium 95 RON
Fuel
unleaded unleaded unleaded
Identification code L1J RKB NGA
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Bore (mm) 76,0 80,6 84,8
Stroke (mm) 88,0 88,0 88,0
Cubic capacity (cm 3) 1.598 1.796 1.989
Compression ratio 10,3:1 10,0:1 10,0:1
Engine power output (ISO)
66 85 100
(kW)
Engine power output at
5.250 5.750 6.000
(rev/min)
Torque (ISO) (Nm) 138 158 180
Torque at (rev/min) 3.500 3.750 4.000
Idle speed (rev/min) 830 800 800
Engine speed limit
7.100 7.100 7.100
(rev/min)
Engine oil - Zetec/Zetec-E
Viscosity/ambient
Type Specification
temperature
Recommended engine oil
SAE 5W-30 / below -20°C to WSS-M2C913-A or WSS-
Ford Formula E Economy Motor Oil
over +40°C M2C912-A1
Alternative engine oils
SAE 10W-30 / -20°C to over ACEA A1/B1, A2/B2 or
Ford Super Multigrade Motor Oil
+40°C A3/B3
Ford XR+ High-performance High- SAE 10W-40 / -20°C to over
ACEA A3, B3
lubricity Motor Oil +40°C
SAE 5W-40 / below -20°C to
Ford Formula S Synthetic Motor Oil ACEA A3, B3
over +40°C
Capacities
Litres
Engine oil, initial fill incl. filter 4,50
Engine oil, oil change incl. filter 4,25
Engine oil, oil change excl. filter 3,75
6,6/7,
Coolant (with manual/ automatic transmission)
1
Transmission fluid (MTX 75) 2,6
Transmission fluid (CD4E with oil cooler) * = new transmissions are already filled
9,0*
with 3,5 liters of fluid.
Lubricants, Fluids, Sealers and Adhesives
Item Specification
Transmission fluid (MTX 75) ESDM-2C186-A
Item Specification
Transmission fluid (CD4E) ESP-M2C166-H
Sealer for camshaft bearing caps WSK-M2G348-A5
Sealer for cylinder block mating face intersections WSE-M4G323-A4
Lubricant (spark plug threads - Never Seeze) ESE-M1244-A
Thread-locking compound SDM-M4G9107-A
Dimensions - cylinder block
1,6 DOHC 1,8 DOHC 2,0 DOHC

16V 16V 16V
Number of main bearings 5 5 5
m 76,000 - 80,600 - 84,800 -
Cylinder bore dia., class 1.
m 76,010 80,610 84,810
m 76,010 - 80,610 - 84,810 -
m 76,020 80,620 84,820
m 76,020 - 80,620 - 84,820 -
m 76,030 80,630 84,830
m 58,011 - 58,011 - 58,011 -
Inside dia. - main bearing shells (fitted)
m 58,038 58,038 58,038
Inside dia. - main bearing shells (fitted) (main m 58,008 - 58,008 - 58,008 -
bearing shells graded by size) m 58,031 58,031 58,031
m 0,011 - 0,011 - 0,011 -
Main bearing radial clearances
m 0,058 0,058 0,058
Main bearing radial clearances (main bearing m 0,020 - 0,020 - 0,020 -
shells graded by size) m 0,042 0,042 0,042
m 62,287 - 62,287 - 62,287 -
Main bearing parent bore
m 62,300 62,300 62,300
Dimensions - crankshaft

Main bearing journal dia. mm 57,980 - 58,000 57,980 - 58,000 57,980 - 58,000
Main bearing journal end float mm 0,09 - 0,26 0,09 - 0,26 0,09 - 0,26
Big-end bearing journal dia. mm 46,89 - 46,91 46,89 - 46,91 46,89 - 46,91
Dimensions - connecting rod

m
Bore dia., big end 49,89 - 49,91 49,89 - 49,91 49,89 - 49,91
m
m 20,589 - 20,589 - 20,589 -
Bore dia., small end
m 20,609 20,609 20,609
Inside dia. - big-end bearing shells m 46,926 - 46,926 - 46,926 -
(fitted) m 46,960 46,960 46,960
m
Big-end bearing clearances (radial) 0,016 - 0,046 0,016 - 0,046 0,016 - 0,046
m
Dimensions - piston

Piston dia., class 1. mm 75,975 - 75,985 80,570 - 80,580 84,770 - 84,780
Piston clearance in cylinder mm 0,040 - 0,060 0,040 - 0,060 0,010 - 0,030
Piston ring gaps (fitted)
Upper compression ring mm 0,30 - 0,50 0,30 - 0,50 0,30 - 0,50
Lower compression ring mm 0,30 - 0,50 0,30 - 0,50 0,30 - 0,50
Oil scraper ring mm 0,25 - 1,00 0,38 - 1,14 0,40 - 1,40
Dimensions - piston pin

Piston pin length mm 63,00 - 63,80 63,00 - 63,80 63,00 - 63,80
Piston pin dia., white mm 20,622 - 20,625 20,622 - 20,625 20,622 - 20,625
Piston pin dia., red mm 20,625 - 20,628 20,625 - 20,628 20,625 - 20,628
Piston pin dia., blue mm 20,628 - 20,631 20,628 - 20,631 20,628 - 20,631
Piston pin clearance in piston mm 0,010 - 0,0151 0,010 - 0,0151 0,010 - 0,0151
Interference fit in connecting rod mm 0,013 - 0,042 0,013 - 0,042 0,013 - 0,042
Dimensions - camshaft

Number of camshaft bearings 5 5 5
Drive Timing belt Timing belt Timing belt
Bearing journal dia. mm 25,960 - 25,980 25,960 - 25,980 25,960 - 25,980
Camshaft bearing radial clearance mm 0,020 - 0,070 0,020 - 0,070 0,020 - 0,070
Camshaft end float mm 0,080 - 0,220 0,080 - 0,220 0,080 - 0,220
Dimensions - valve

Valve clearance in valve guide
Injector mm 0,017 - 0,064 0,017 - 0,064 0,017 - 0,064
- exhaust valve mm 0,017 - 0,064 0,017 - 0,064 0,017 - 0,064
Dimensions - cylinder head

16V 16V 16V
m
Maximum distortion (mating face) 0,1 0,1 0,1
m
m 2,0 +0,12 2,0 +0,12 2,0 +0,12
Mating face height
m -0,24 -0,24 -0,24
Mating face peak-to-valley height (reference length m
R 3z = 6,0 R 3z = 6,0 R 3z = 6,0
2,5 mm at right angles to direction of grooves) m
Oil pressure, at 800 - 850 rev/min bar 1,3 - 2,5 1,3 - 2,5 1,3 - 2,5
Oil pressure, at 4000 rev/min bar 3,7 - 5,5 3,7 - 5,5 3,7 - 5,5
In the 2,0l engine, the piston cooling nozzles are fully open at 4000/min. This
results in a pressure loss of 0,3 - 0,8 bar, meaning that the 2,0l engine can be
in the lower pressure range.
Torque Specifications
lb-
Description Nm lb-ft
in
Hose clamps 4 35
Intake system
Intake manifold studs 5 44
Intake manifold bolts and nuts 18 13
Throttle body 9 80
EGR valve to intake manifold 9 80
Exhaust system
Heat shield to cylinder head (2,0 engine) 10 89
Heat shield and coolant pipe bracket to exhaust manifold (1,6 - 1,8 engine) 10 89
Heat shield and coolant pipe bracket to exhaust manifold (1,6 - 1,8 engine) 23 17
Exhaust manifold studs 6 53
Exhaust manifold nuts 15 11
lb-
in
Catalytic converter to exhaust manifold 40 30
Driveshafts
Right-hand driveshaft center bearing 27 20
Driveshaft bracket to engine 48 35
Generator
Generator to bracket 50 37
Generator bracket to cylinder block 47 35
Transmission
Transmission flange bolts 40 30
Starter motor to transmission 48 35
Transmission oil drain plug 35 26
Transmission oil check plug 35 26
Flywheel/drive plate 112 83
Clutch pressure plate 29 21
Subframe
Subframe to body 130 96
Steering gear to subframe 130 96
Radiator bracket to subframe 10 89
Air conditioning system
Air conditioning compressor to bracket 25 18
Engine mounting
Right-hand engine roll restrictor to transmission 84 62
Right-hand engine roll restrictor to subframe 48 35
Right-hand engine roll restrictor bracket to transmission (MTX 75) 84 62
Left-hand engine roll restrictor bracket to transmission (MTX 75) 84 62
Center bolt - left and right-hand engine roll restrictor 120 89
Rear engine mounting to transmission 83 61
Front engine mounting bracket to engine and engine mounting 83 61
Suspension
Hub nut 290 214
Wheel nuts 85 63
Suspension strut to body 46 34
Lower suspension arm ball joint to spindle carrier 83 61
Track rod to spindle carrier 26 19
Stabilizer link rod to suspension strut 47 35
Power steering
Power steering pump to bracket 47 35
Bracket - air conditioning compressor/power steering pump to cylinder block. 47 35
Cylinder head
Camshaft position sensor to cylinder head 21 15
Cylinder head bolts, stage 1. 25 18
105 105
Cylinder head bolts, stage 3.
° °
Camshaft bearing caps, stage 1. 10 89
Cylinder head cover, stage 1. 2 18
Spark plugs 15 11
Retaining pin for timing belt tensioner spring 10 89
Timing belt tensioner 38 28
Camshaft timing pulley 68 50
lb-
in
Upper timing belt cover 4 35
M10 x 11,5 oilway blanking plug 24 18
1/4 P.T.F. oilway blanking plug 25 18
EI ignition coil bracket to cylinder head 21 15
Power steering pump mounting plate to cylinder head 47 35
Thermostat housing 20 15
Engine lifting eye to cylinder head 16 12
Engine lifting eye to generator bracket 47 35
Bracket of oil dipstick tube 9 80
Cylinder block
Engine oil drain plug 25 18
Oil level indicator sensor 22 16
Oil pressure switch 27 20
Heater pipe bracket to oil pan 10 89
Oil pan 21 15
Oil pump 11 8
Oil splash nozzles and blanking plugs 10 89
Oil intake pipe to oil pump 10 89
Oil baffle and oil intake pipe bracket to studs 19 14
Main bearing cap bolts and studs 80 59
Big-end bearing cap bolts, stage 1. 16 12
Big-end bearing cap bolts, stage 2. 90° 90°
Coolant pump 18 13
Crankshaft rear oil seal carrier 30 22
Multi-groove belt idler pulley 48 35
Bracket for positive crankcase ventilation tube 23 17
Positive crankcase ventilation 10 89
Coolant pump belt pulley 10 89
Crankshaft belt pulley 115 85
Bracket of crankshaft position sensor 21 15
Crankshaft position sensor to bracket 8 71
Engine - 1.6L/1.8L/2.0L, Vehicles Built

Mondeo 1997 (08/1996-09/2000)
Up To: 05/1998 - Engine
Print
Description and Operation

General
Engine Variants
The Zetec-E engine (to 05/98) in the Mondeo '97 is available is three engine sizes: 1,6
(66kW), 1,8 (85 kW) and 2,0 (100kW). The transversely mounted engine is tilted
forwards by 8 degrees. As a result, a considerable space saving has been made in the
engine compartment.
Location of Engine Code on Cylinder Block

Item
Part Number
Description
1
-
Engine code
2
-
Engine serial number
Engine code:
 1,6 Zetec-E: L1J

 1,8 Zetec-E: RKB
 2,0 Zetec-E: NGA
Design of the Zetec-E engines
The Zetec-E engine is a four-cylinder in-line engine with double overhead camshafts.
The cylinder head is made of an aluminium alloy, the cylinder block is cast iron.
Valve drive
Valve Timing and Combustion Chamber
The two camshafts are driven by a single timing belt and use hydraulic tappets to
actuate the four valves of each cylinder. The camshaft cams run eccentrically over the
tappets to enable the valves to rotate. Valve rotation is further improved by seating the
valve stems in triple-grooved collets, which produce considerably less stem friction than
single-grooved collets. The spark plug which ignites the air fuel mixture is located in the
center of the pent roof combustion chamber. This central position means that the flame
can spread evenly through the combustion chamber, thus reducing the tendency of the
engine to knock.
General View - Operation of the Valves

Item
Part Number
Description
1
-
Camshaft cap bolt
2
-
Camshaft bearing cap
3
-
Camshaft front bearing cap
4
-
Camshaft front bearing cap guide sleeve
5
-
Camshaft oil seal
6
-
Exhaust camshaft
7
-
Camshaft timing pulleys
8
-
Camshaft pulley bolt
9
-
Oil gallery blanking plug
10
-
Engine lifting eye
11
-
Engine lifting eye bolt
12
-
Spark plug
13
-
Cylinder head bolt
14
-
Cylinder head
15
-
Timing cover
16
-
Bolt for timing cover
17
-
18
-
19
-
Timing belt tensioner bolt
20
-
Timing belt tensioner
21
-
Inlet valves
22
-
Exhaust valves
23
-
Bolt of camshaft position sensor (CMP sensor)
24
-
Camshaft position sensor (CMP sensor)
25
-
Valve stem seals
26
-
Valve springs
27
-
Valve spring retainers
28
-
Valve collets
29
-
Hydraulic tappets
30
-
Inlet camshaft
Crank Drive
Crankshaft
The five-bearing crankshaft is equipped with a counterweight for each cylinder. The
centre cap has two thrust half shells which guide the crankshaft in the axial direction
and also determine the end float.
Crankshaft bearings
Item
Part Number
Description
1
-
Cylinder block bearing shell
2
-
Main bearing shell with thrust half shells
3
-
Crankshaft
4
-
Timing pulley key
5
-
Main bearing shell
6
-
Main bearing cap
7
-
Main bearing cap bolt
8
-
Main bearing cap stud
The lower part of the engine consists of an aluminum oil pan. The gap between it and
the transmission is set using shims.
Differences and Special Features of the Engine Variants
Basic Engines
Differences between the basic engines:

Concept-wise, the basic engines are largely identical. The main differences lie in the
valve timing, piston diameter, compression ratios and engine tuning.
For additional information, refer to Specifications in this section.
All three engine variants have the same crankshafts and external dimensions.
 Special features of the 1,6 engine:

-
The shape of the combustion chamber in the cylinder head is different compared with
the 1,8 and 2,0 engine and is designed to produce optimum flow and swirl
characteristics. This feature also causes a reduction in emissions.
 Special features of the 1,6 and 1,8 engine:
-
Pistons are coated with molybdenum sulphite.
-
Piston crown cooled using oil spray tubes. These cool the piston crown by spraying it
with cooled, filtered engine oil from below.
-
Pistons are coated with graphite.
Ancillary Components
Differences between the ancillary components:
The 1.6l and 1.8l engines are fitted with identical ancillary components. These differ
from the 2.0l engine by having a modified exhaust system, which is also fitted with a
pulse air system in the 2.0l engine.
 Special features of the 1,6 and 1,8 engine:

-
The catalytic converter is located directly behind the exhaust manifold. As a result,
the catalytic converter responds more quickly when starting from cold and emissions
are therefore reduced.
-
The routing of the exhaust manifold is different.
-
The catalytic converter is not located in the same place as in the 1,6 and 1,8 engine,
but below the rear of the engine.
-
An additional heat exchanger is provided in the coolant circuit for oil cooling. This is
required to compensate for the greater heat load of the engine oil resulting from the
higher engine output and the piston crown cooling.
-
The exhaust manifold is equipped with a pulse air system to improve exhaust
behaviour during cold starts.
Engine Management
EEC V Module
Engine management for the Zetec-E engines is carried out by the EEC V module. The
module requires a large amount of information about the current operating conditions of
the engine and, where appropriate, the automatic transmission (CD4E). The EEC V
module obtains this information by means of sensors.
 The EEC V module controls:

-
the fully electronic ignition system (EI)
-
the sequential fuel injection (SEFI)
-
the electronically controlled exhaust gas recirculation (EGR)
-
the vacuum-controlled pulse air system
-
the air conditioning in conjunction with the cooling system
-
the transmission control for CD4E automatic transmission.
General View of Engine Management System
Item
Part Number
Description
1
-
EEC V module
2
-
In-tank fuel pump
3
-
Fuel pump relay
4
-
Fuel filter
5
-
Idle air control valve (IAC valve)
6
-
Mass air flow sensor (MAF sensor)
7
-
Air cleaner
8
-
Fuel pressure regulator
9
-
Fuel rail
10
-
Throttle position sensor (TP sensor)
11
-
Intake air temperature sensor (IAT sensor)
12
-
Injector
13
-
14
-
Carbon canister
15
-
EVAP canister purge valve
16
-
Ignition coil
17
-
Battery
18
-
EI ignition coil
19
-
Engine coolant temperature sensor (ECT sensor)
20
-
Heated oxygen sensor (HO2S), before catalytic converter
21
-
Crankshaft position sensor (CKP sensor)
22
-
Power supply relay
23
-
To the PSP switch
24
-
Magnetic clutch of air conditioning compressor
25
-
Octane adjustment service connector
26
-
Self-test connector
27
-
Data link connector (DLC) for FDS2000
28
-
Ignition switch
29
-
Inertia fuel shut-off switch (IFS switch)
30
-
Electronic pressure control
31
-
Exhaust gas recirculation valve (EGR valve)
32
-
Electronic differential pressure transducer
33
-
Differential pressure measuring point
34
-
To intake manifold
35
-
Air cleaner of pulse air system
36
-
Solenoid of pulse air system
37
-
Fan
38
-
Electronic transmission control (CD4E)
39
-
Heated oxygen sensor (HO2S), after catalytic converter
Injectors
The injection valves are installed in a fuel rail and are supplied by a central fuel inlet.
This arrangement means that the injection valves are continuously drenched with fresh
fuel and cooled. Vapour bubbles that form when the engine is switched off are flushed
into the fuel tank through the pressure regulator by the flow of fuel that occurs when
the ignition key is turned or the engine is started. This essentially prevents warm start
problems cause by vapour bubble formation. The inlet manifold design made from fibre
glass-reinforced plastic reduces injection valve heating caused by the transfer of engine
heat.
The injectors seal off the fuel-filled valve chamber to the outside with two O-rings. The
slots on the side of each injector are for entry of fuel.
The injectors are actuated sequentially.
Design of the Injectors
Item
Part Number
Description
1
-
Fuel rail
2
-
Fuel supply
3
-
Return to fuel tank
4
-
Fuel pressure regulator
5
-
Injector
6
-
Side slots for entry of fuel
7
-
Valve chamber filled with fuel
8
-
O-rings
9
-
Intake manifold
10
-
Intermediate flange
11
-
Intake port in cylinder head
12
-
Injector
Components Attached to Cylinder Head
Intake Manifold
All Zetec-E engines are equipped with intake manifolds made of glass fibre reinforced
plastic. The intake manifold ports are designed so that the intake paths are the same
length for all the cylinders.
 This gives the following advantages:

-
reduced transfer of engine heat to the injectors, thereby preventing vapour bubbles
from forming
-
lighter weight
-
reduction of fuel deposits on the intake pipe walls during cold starts
-
less heating of the intake air when the engine is hot.
Components Attached to Intake Manifold

Item
Part Number
Description
1
-
Injector connector
2
-
Bolt of fuel pipe clamp
3
-
Fuel rail
4
-
Injector
5
-
Injector retaining ring
6
-
Intake manifold gasket
7
-
Intake manifold
8
-
Quick-release coupling of brake servo vacuum pipe
9
-
Gasket of idle air control valve
10
-
11
-
12
-
Bolt of EGR valve
13
-
EGR valve connecting pipe
14
-
Throttle plate gasket
15
-
Fuel rail bolt
16
-
Throttle body
17
-
Bolt of fuel pipe bracket
18
-
Throttle body bolt
19
-
Fuel pipe bracket
20
-
Fuel pipe clamp
Exhaust Manifold
Because the catalytic converter is located in front of the engine, the exhaust manifold
for the 1,6 and 1,8 engines has been tilted upwards slightly.
This means that, despite the confined space in the engine compartment, the exhaust
gases from all the cylinders have to travel the same distance.
Belt Tension
The ancillary components of the Zetec-E engine are driven by a maintenance-free drive
belt. An automatic spring-actuated belt tensioner ensures the correct belt tension.
Belt Routing
Engine - 1.6L/1.8L/2.0L, Vehicles Built Mondeo 1997 (08/1996-09/2000)

Up To: 05/1998 - Engine
Print
Assembly
Special Tool(s) / General Equipment
Universal flange holding wrench
15-030A
Aligner, clutch disk
16-067
Installer, oil seal
21009B
Installer, oil seal
21-093A
Locking tool, flywheel
21-135
Installer, oil seal
21-141
Timing tool, camshaft alignment
21-162B
Socket, cylinder head bolts
21-167
Angle gauge, bolt tightening
21-540
Piston ring compressor

Assembly stand
Assembly stand
Steel straightedge
Workshop hoist
Materials
Name
Specification
M10x70 bolt

Never Seeze
ESE-M1244-A
Sealer
ESK-M4G269-A
Sealer
WSE-M4G323-A4
Engine Oil
WSS-M2C912-A1
Assembly
1. Preparatory operations
 Clean all the mating faces and reusable parts thoroughly and inspect them for
damage.
2. NOTE: Use new piston cooling oil splash nozzles.
Fit the piston cooling oil splash nozzles and the blanking plugs.
3. NOTE: Main bearing shells of different thicknesses are fitted, which can also be
used in servicing.
Sizes of crankshaft main bearing shells.
 Available sizes:
1. Size A: 2,152 - 2,145 mm (green)
2. Size B: 2,147 - 2,140 mm (brown)
3. Size C: 2,142 - 2,135 mm (yellow)
4. Size D: 2,137 - 2,130 mm (blue)
4. NOTE: Use bearing shells of size "B" or "C" (refer to step ).

Measure the crankshaft radial clearance. For additional information, refer to
Section 303-00 Engine System - General Information.
 Select the bearing shell according to step to obtain a bearing clearance of
0,020 - 0,040 mm.
5. Measure the crankshaft end float. For additional information, refer to Section
303-00 Engine System - General Information.
6. Measure the camshaft radial clearance. For additional information, refer to
7. Measure the camshaft end float. For additional information, refer to Section
8. Measure the crankshaft. For additional information, refer to Section 303-00
Engine System - General Information.
9. Measure the camshafts. For additional information, refer to Section 303-00
10.Measure the big-end bearing clearance. For additional information, refer to
11.Measure the cylinder bores. For additional information, refer to Section 303-
00 Engine System - General Information.
12.Measure the pistons. For additional information, refer to Section 303-00
13.Measure the piston ring gaps. For additional information, refer to Section
14.Measure the piston ring axial clearance. For additional information, refer to
15.Check the cylinder head evenness. For additional information, refer to Section
16. NOTE: The bearing cap numbering starts at the timing belt end, to which the
arrows also point.
NOTE: Use studs for bearings '2' and '4'.
Fit the crankshaft.
 Lubricate the main bearing journals and bearing shells with engine oil.
 Fit the crankshaft main bearing caps with their associated bearing shells.
 Tighten the bolts.
17. NOTE: The connecting rod numbering starts at the timing belt end. The arrow
on the piston crown points towards the timing belt end.
Fit the pistons.
 Lubricate the pistons and cylinder liners with engine oil .
 Distribute the piston ring gaps uniformly around the circumference - this also
applies to the elements of the oil scraper ring.
 Compress the piston rings using a piston ring compressor .
 Press pistons 1 and 4 into the cylinders using the handle of a hammer. The
big-end bearing journal must be at BDC.
 Check the bearing shells are clean and dry and fit them in the associated
connecting rods and bearing caps.
 Fit the bearing caps.
 Turn the crankshaft through 180 degrees and fit pistons 2 and 3.
18. NOTICE: Only use new bolts.
NOTE: The connecting rods and big-end bearing caps have the same
numbering.
Install the bearing caps.
 Lubricate the bearing shells and journals with engine oil.
 Fit the appropriate big-end bearing caps and bearing shells and torque them
down.
19. NOTE: Use a new gasket.

Install the oil pump.
 Locate the oil pump in position.
 Align the oil pump rotor with the recesses in the crankshaft.
 Screw in the bolts finger tight.
 Align the oil pump so that the mating face of the oil pump housing is 0,3 - 0,8
mm below the cylinder block.
20. Install the oil intake pipe and the oil baffle plate.
 Fit the oil baffle.
 Install the oil intake pipe with a new gasket.
 Install the oil baffle plate with the oil intake pipe bracket.
21. Fit the oil pump seal.

 Draw in the new oil seal with the installer and the bolt of the crankshaft
pulley.
22. Fit the coolant pump with a new gasket.
23. Fit the rear oil seal carrier and the bracket of the CKP sensor.
 Locate the oil seal carrier in position with a new gasket and screw in the bolts
finger tight.
 Align the oil seal carrier so that the mating face of the oil seal carrier is 0,3 -
0,8 mm below the cylinder block.
 Tighten the four bolts.
1. Fit the CKP sensor bracket.
24. Fit the oil seal in the oil seal carrier.
 Push in the radial oil seal using the special tool and two flywheel/drive plate
bolts.
25. NOTE: The oil pan bolts must be tightened within 10 minutes of applying the
sealer.
Apply sealer to the cylinder block mating face intersections.
26. Align the oil pan.

 Locate the sump in position with a new gasket and screw the bolts in finger
tight.
 Align the oil pan using a steel straightedge so that the cylinder block and oil
pan are level.
27. Secure the oil pan.
 Tighten the ten oil pan bolts.
 Check that the oil pan is flush as in the previous step. If necessary, use
spacer sleeves to remove any step.
28. NOTE: Use new bolts.

Fit the flywheel/drive plate.
 Locate the flywheel in position and tighten the bolts finger tight.
 Immobilise the flywheel with Special Tool 21-135.
29. Center the clutch disk on the clutch pressure plate.
30. Install the clutch.

1. Locate the clutch pressure plate in position with the centered clutch disk.
2. Screw in the bolts uniformly two turns each and then to the correct torque,
working diagonally.
3. Remove the special tool.
31. NOTICE: Bring the piston of cylinder no. 1 to a point approx. 20 mm

before TDC to avoid damage when fitting the cylinder head.
NOTE: FRONT mark.
Fit the crankshaft timing pulley.
1. Thrust plate.
2. Timing pulley.
32. NOTE: 'TOP' mark and gasket identification.

Fit the cylinder head.
1. Check that the locating bushes are seated correctly.
2. Fit a new cylinder head gasket.
 Fit the cylinder head.
33. Pre-tighten the cylinder head bolts.

 Screw in new, unoiled cylinder head bolts.
 Fit cylinder head bolts in two stages in accordance with the tightening
sequence.
34. NOTICE: The cylinder head bolts must not be retorqued.
Tighten the cylinder head bolts, Stage 3.
 Tighten the cylinder head bolts in the indicated sequence.
 Lubricate the hydraulic tappets with engine oil and proceed according to the
removal sequence.
35. NOTE: The camshafts are marked. The inlet camshaft has an additional cam
for the CMP sensor at the end of the shaft.
Fit the camshafts.
 Apply sealer to the cylinder head / bearing cap mating face at the timing belt
end.
 Fit the camshafts.
36. NOTE: The numbering starts at '0' on the exhaust side and faces outwards.
Fit the camshaft bearing caps.
 Lubricate the camshaft bearing surfaces and the bearing surfaces in the
cylinder head with engine oil.
 Fit the bearing caps.
37. Fit the camshaft bearing caps.

 Screw in the bolts in pairs in the indicated sequence half a turn at a time.
 Repeat this until the bearing caps are in contact with the cylinder head.
 Tighten the bolts in pairs in the indicated sequence.
38. NOTE: The camshaft timing pulleys must be able to turn freely on the
camshafts; do not tighten the bolts.
Fit the camshaft seals.
 Lubricate the camshafts and the sealing lip of the oil seals with engine oil.
 Draw in the new oil seals using the special tool, a washer and an M10x70 bolt
.
39. NOTE: The camshaft timing pulleys must be able to turn freely on the
camshafts; do not tighten the bolts.
Install the camshaft timing belts.
40. Align the camshafts.
 Insert the special tool into the camshafts.
41. NOTICE: Install the retaining stud and spring if not present.
Tension the pulley against the spring pressure.
1. Install the spring retaining stud (if not present).
2. Hook the timing belt tensioner spring in place (if not present).
3. Tension the pulley against the spring by turning it clockwise with an Allen key
and secure it.
42. Turn the crankshaft to TDC.

 For greater accuracy, extend the mark on the oil pan with a small strip of
metal (25 mm wide) or similar.
43. NOTICE:
Use a new timing belt.
Do not kink the timing belt (bend diameter must not be less than 35 mm).
NOTE: Turn the camshaft timing pulleys so that the timing belt engages
correctly in all the timing pulleys.
NOTE: The tension side of the timing belt (between the crankshaft timing
pulley and the camshaft timing pulley) must be taut.
Lay the new timing belt in place.
 Check that the crankshaft is at TDC.
 Fit the timing belt, working in an counter-clockwise direction, starting from
the crankshaft timing pulley.
 Slacken the bolt of the tensioning pulley. The timing belt will be tensioned by
the spring.
44. Secure the timing belt tensioner.

 Secure the timing belt tensioner pulley.
NOTICE: Do not tighten the camshaft timing pulley bolts using Special Tool 21-
162B; use Special Tool 15-030A to prevent movement.
45. NOTE: The crankshaft must be at TDC.
Tighten the bolts of the camshaft timing pulleys.
 Remove Special Tool 21-162B.
46. Turn the crankshaft two turns clockwise as far as the TDC position.
47. Secure the timing belt tensioner.
 Secure the timing belt tensioner pulley.
 Check that the crankshaft and camshafts are at TDC.
 If there is a very slight error:
1. Adjust the camshaft using Special Tool 15-030A until Special Tool 21-162B
can be inserted. The crankshaft must remain at TDC.
48. NOTICE: Do not remove or tighten the camshaft timing pulley bolts using
Special Tool 21-162B; use Special Tool 15-030A to prevent movement.
NOTE: The crankshaft must remain in the TDC position.
Special tool 21-162B cannot be inserted.
 Slacken the camshaft timing pulley of the camshaft concerned. Hold the
pulley with Special Tool 15-030A.
 Turn the camshaft until Special Tool 21-162B can be inserted.
 Tighten the bolt of the camshaft timing pulley.
 Remove the special tool.
 Turn the crankshaft another two turns in the clockwise direction as far as the
TDC position and check the alignment of the camshaft.
49. NOTICE:
Use a blunt object to apply the silicone grease (e.g. a plastic cable tie) to
avoid damaging the spark plug connector seal.
Push on the spark plug connectors in a straight line with the axis of the
spark plug.
NOTE: Coat the inside of the spark plug connectors to a depth of 5-10 mm
with silicone grease.
NOTE: Use a new cylinder head cover gasket.
Install the spark plugs and cylinder head cover.
 Coat the spark plug threads with Never Seeze .
 Screw in the spark plugs and tighten them.
 Fit ten bolts.
 Connect the HT leads to the spark plugs.
50. Fit the timing belt covers.

 Make sure that the middle cover is seated correctly in the lower cover.
51. Immobilise the flywheel with Special Tool 21-135.

52. Attach the coolant pump belt pulley and the crankshaft pulley/vibration
damper.
53. Connect the PCV.
1. Screw in the three bolts.
2. PCV pipe
54. NOTICE: If the stud came out when the engine lifting eye was removed,
first fit the stud and tighten it to 6 Nm, and then secure the engine lifting eye
with the nut.
Fit the exhaust manifold, ignition coil and thermostat housing.
 Detach Special Tool 21-135 from the flywheel/drive plate.
 Engine lifting eye
 Fit the bracket of the power steering pump/air conditioning compressor (eight
bolts).
1. Fit the exhaust manifold (eight nuts)
1. Fit the ignition coil (three bolts)
1. Thermostat housing
1. Attach the coolant hose to the coolant pump
55.Suspend the engine from the workshop hoist by the engine lifting eyes and
detach it from the assembly stand .
Fit the intake manifold.
 Attach the injector wiring harness (two bolts).
57. Fit the generator bracket.

1. Fit the bolts.
2. Engine lifting eye
58. Fit the generator and the idler pulley.

1. Drive belt idler pulley
2. Generator
59. Attach the cable guide to the intake manifold.
60. Fit the center bearing bracket and the oil pressure switch.
1. Oil pressure switch
2. Tighten the three bolts.
61. Connect the plugs and fit the filter of the pulse air system.
1. Plug of CKP sensor.
2. Plug of coolant temperature sender unit.
62. Connect the plugs.

1. Ignition coil (EI)
2. Radio interference suppressor.
3. ECT sensor.
63. Connect the plugs and the generator.

1. Plug of engine main wiring harness.
2. TP sensor.
3. CMP sensor.
4. Connect the generator.
64. Attach the catalytic converter to the exhaust manifold (2,0 engine shown).
65. NOTICE: Support the engine with wooden wedges and secure it with
clamping straps.
Place the engine on the assembly table .
66. Install the oil filter.
 Lubricate the gasket with engine oil.
 Tighten it half to three-quarters of a turn after it touches the mating face.
67. Finishing operations.
 Top up the engine with engine oil .
For additional information, refer to Specifications in this section.
Engine - 2.5L - Specifications Mondeo 1997 (08/1996-09/2000)
Print
Engine data
2,5L 2,5 ST 200

Engine Management EEC V EEC V
D3/Stage
Emission standard up to 99,75 MY D4
II
Emission standard from 2000 MY (vehicles with manual
E3/D3 D4
transmission)
Emission standard from 2000 MY (vehicles with automatic
E3/D3 -
transmission)
Engine code from 97 MY SEA -
Engine code from 99.75 MY - SGA
Engine code from 2000 MY SEB -
Engine code from 2000.5 MY SEC -
1-4-2-5-3- 1-4-2-5-3-
Firing order
6 6
Bore (mm), up to 99.75 MY 82.4 -
Bore (mm), from 99.75 MY 81.66 81.66
Stroke (mm) 79.5 79.5
Engine capacity (cm 3) up to 99.75 MY 2543 -
Engine capacity (cm 3) from 99.75 MY 2499 2499
Compression ratio 9.7:1 10.25:1
Engine power output (ISO) (kW) 125 151
at (rev/min) 6250 6700
Torque (ISO) (Nm) 220 229
Torque at (rev/min) 4250 5500
Idle speed (rev/min) 725±50 725±50
Engine speed limit (rev/min) 6925 6925
Cylinder head and valve train, 2.5l engine
Item Detail
Combustion chamber volume 44.5±1.5 cc
Combustion chamber bottom to cylinder head mating
14.875 mm
face
Maximum distortion (mating face) 0.05 mm on 150 mm x x150 mm
Valve seat width, inlet 1.1-1.4 mm
Item Detail
Width, outlet 1.4-1.7 mm
Angle 44.75 degrees
Max. out-of-round (T.I.R.) 0.04 mm
Valve stem clearance, inlet 0.020-0.069 mm
Valve stem clearance, outlet 0.045-0.094 mm
Valve head diameter, inlet 32 mm
Valve head diameter, outlet 26 mm
31 and 24.5mm (1.22 and 0.96
Diameter
in)
Out-of-round limit, valve seat 0.05 mm
Valve seat angle 45.5 degrees
Valve stem diameter (STD), inlet 5.975-5.995 mm
Valve stem diameter (STD), outlet 5.950-5.970 mm
Valve spring preload (N/spec. length) - inlet 680 N/30.19 mm
Valve spring preload (N/spec. length) - outlet 680 N/30.19 mm
Free length (approximate), inlet 46.8 mm
Free length (approximate), outlet 46.8 mm
Spring force, installed (N/spec. length) - inlet 228 N/39.99 mm
Spring force, installed (N/spec. length) - outlet 228 N/39.99 mm
Service limit 10 % pressure loss/30.09
Limit value for deviation from box form 1%
Cam follower ratio 1.8:1
Hydraulic valve tappet diameter (STD) 16-15.988 mm
Clearance to bore 0.018-0.069 mm
Service limit 0.016 mm
Pressure loss 5-25 seconds
Desired clearance with valve tappet pressed in 0.50-1.11 mm
Camshaft, 2.5l engine
Item Detail
Lobe lift
Inlet (primary) 4.79 mm
Inlet (secondary) 4.79 mm
Outlet 4.79 mm
Permitted cam lift loss 0 mm
Theoretical valve lift without play
Inlet (primary) 9.80 mm
Inlet (secondary) 9.80 mm
Outlet 9.80 mm
End float
Standard 0.025-0.165 mm
Play between bearing journal and bearing
Bearing journal diameter (all) 26.926-26.936 mm
Bearing inside diameter (all) 27.012-26.897 mm
Cylinder block, 2.5l engine
Item Detail
Surface, cylinder block mating face
Warpage, cylinder block mating face 0,025/25x25/150x150
Warpage, cylinder block face 0,025/25x25,050/x150
Item Detail
Main bearing bore diameter 68.998-69.022 mm
Bore diameter
Diameter, oversize 1 82.4-82.410 mm
Surface (RMS) 0.2-0.6 micrometers
Out-of-round limit value 0.015 mm
Out-of-round limit value 0.020 mm
Taper wear limit 0.006 mm
Crankshaft, 2.5l engine
Item Detail
62.968-62.992
Main bearing journal diameter
mm
49.970-49.990
Connecting rod bearing journal diameter
mm
Crankshaft endplay 0.110-0.232 mm
0.050mm Max
Crankshaft lateral run-out on rear side of cylinder block
(0.001 in)
Connecting rod bearings
Clearance to crankshaft 0.028-0.066 mm
Add bearing wall thickness (STD) 0.250 mm undersize - 0.125 mm to
1.503
standard thickness or thickness class 2
Main bearings
Desired clearance to crankshaft 0.025-0.045 mm
Permitted clearance to crankshaft 0.025-0.050 mm
Bearing wall thickness, class 1 2.501 mm
Connecting rod, 2.5l engine
Item Detail
Piston pin bore
21.071-21.032 mm
diameter
Length (centre-
138.06-138.4 mm
centre)
Pivot shaft hole and crankshaft bearing bore must be parallel and on
Axial warpage
the same vertical plane within the specified total difference if 101.5 mm
(max. bore-bore
is measured on each side of the centre line at the ends of a 203 mm
difference)
long bar.
Flexing 0.050 mm to 25 mm
Band 0.038 mm to 25 mm
Side play (mounted
on crankshaft)
Service limit 0.35mm Max (0.0137 in)
Piston, 2.5l engine
Item Detail
Measured 43 mm from the outside edge on the upper
Diameter
piston to the axis.
Code class 1 82.390-82.410 mm
Item Detail
Code class 2 82.398-82.442 mm
Code class 3 82.410-82.430 mm
Play between piston and eye 0.012-0.022 mm
Pin eye diameter 21.008-21.012 mm
Ring groove width
Compression ring groove (top)
Compression ring groove (bottom)
Oil scraper ring groove 3.030-3.055 mm
Gudgeon pin
Length 55.05-55.47 mm
Diameter 21.011-21.013 mm
Pin to rod clearance -0.005 to +0.001 mm
Play between pin and small end
Side play
Compression ring (top) 0.04-0.075 mm
Compression ring (bottom) 0.040-0.085 mm
Oil control 'scraper' ring Snug fit
Operating limit value 0.10 mm
Piston ring gap Specification 82.4 mm measured diameter
Measured diameter, compression ring
0.100-0.250 mm
(top)
Measured diameter, compression ring
0.27-0.42 mm
(bottom)
Measured diameter, oil scraper ring
0.15-0.65 mm
(steel rail)
Operating limit value, compression
0.50mm Max (0.0196 in)
ring (top)
Operating limit value, compression
0.65mm Max (0.0255 in)
ring (bottom)
Operating limit value, oil scraper ring
max. 0.90
(steel rail)
Lubrication, 2.5l engine
Detail
Oil pressure (warm, 1500 rpm) 138-310 kPa (20-45 psi)
Drive belt tension, 2.5l engine
Detail
The specified belt tensions differ depending on whether the belts are Automatic
newly installed or used. Tensioners
Automatic
6-fin water pump belt, front end accessory drive (FEAD)
Tensioners
No adjustment
3-fin water pump belt, rear end accessory drive (FEAD)
necessary
Item Detail
ESD-
Coolant
M97B49-A
ESP-M2C166-
Transmission fluid (CD4E)
H
Transmission fluid (MTX 75) ESD-
Item Detail
M2C186-A
ESP-M2C166-
Power steering hydraulic fluid
H
Sealer - lower crankcase to cylinder block, mating faces - oil pan to lower
WSK-
crankcase, mating faces - cylinder head covers to cylinder heads, keyway -
M4G320-A
crankshaft vibration damper.
ESK-
Sealer - coolant plug to cylinder block
M4G260-A
SM-4G-4644-
Sealer - oil pressure switch, blanking plugs - oil and coolant passages.
AA/AB
SDM-
Sealer - flywheel bolts
M4G9107-A
SQM-
Lubricant - camshaft bearings
2C9002-AA
SQM-
Lubricant - piston running surfaces, bearing running surfaces, cam followers
2C9002-AA
ESD-
Lubricant - O rings - coolant connecting pipe
M97B49-A
Lubricant - spark plugs (Never Seeze) ESE-M1244-A
Engine oil
Item Viscosity/Ambient temperature Detail

SAE 5W-30 / below -20°C to WSS-M2C913-A or
over +40°C WSS-M2C912-A1
SAE 10W-30 / -20C to over ACEA A1/B1, A2/B2 or
Ford Super Multigrade Engine Oil
+40C A3/B3
Ford XR+ High-performance High- SAE 10W-40 / -20°C to over
ACEA A3, B3
lubricity Motor Oil +40°C
SAE 5W-40 / under -20 °C to
over + 40 °C
Capacities
Liters
Engine oil, initial fill with filter 5.85
Engine oil, with filter change 5.5
Engine oil, without filter change 5.0
Coolant (MTX 75) 9.5
Coolant (CD4E) 9.7
Transmission fluid (CD4E with oil cooler), total capacity 10.0*
Transmission fluid level (CD4E with oil cooler) Mark on the dipstick
Transmission fluid (MTX 75), total capacity 2.6
* = New transmissions are already pre-filled with 3.5 litres
lb-
in
Air conditioning compressor 25 18
Tie-rod end 26 19
Stabiliser bar link rod to suspension strut 47 35
Brake calliper 120 88
Heat shield - right-hand front driveshaft center bearing 27 20
lb-
in
Oil pipe - oil cooler to automatic transmission 23 17
Center bolt in subframe gauge 30 22
Front engine mounting 83 61
Rear engine mounting (CD4E) 48 35
Rear engine mounting (MTX-75) 83 61
Rear engine roll restrictor to subframe 48 35
Center bolt to rear engine roll restrictor 120 88
Front engine roll restrictor to subframe 48 35
Center bearing - right-hand front driveshaft to transmission 27 20
Center bolt to front engine roll restrictor 120 88
Torque converter to engine drive plate 36 27
Selector mechanism to body 44 32
Stabiliser bracket 55 41
Air conditioning dehydrator to subframe 11 8
Shift rod bracket 23 17
Shift linkage clamp bolt 16 12
Front exhaust pipe 40 30
Rear catalytic converter 40 30
Left and right-hand top suspension struts 46 34
Flange bolts 40 30
Starter motor retaining bracket 48 35
Ground cable to automatic transmission housing 40 30
Wheel nuts 85 63
Driveshaft stub nuts 340 251
Mounting plate to cylinder block 47 35
Blanking plugs of oil and coolant passages, 1/4" 14 10
Blanking plugs of oil and coolant passages, 1" 90 66
Blanking plug - oil pump 10 89
Oil pump cover to oil pump 10 89
Oil pump to cylinder block 10 89
Oil baffle to lower crankcase 10 89
Oil intake pipe to lower crankcase, M6 10 89
Oil intake pipe to lower crankcase, M8 25 18
Oil line to radiator 23 17
Oil separator to cylinder block 10 89
Engine mount bracket to cylinder block 47 35
Cylinder head bolts, stage 2. 90° 90°
-360° -360°
Cylinder head bolts, stage 3.
(undo) (undo)
Lower crankcase to cylinder block - pre-tighten all bolts 4 35
Lower crankcase to cylinder block, Stage 1: Bolts 1 to 8 25 18
Lower crankcase to cylinder block - Stage 2: Bolts 9 to 16 40 30
Lower crankcase to cylinder block - Stage 3: Bolts 1 to 16 90° 90°
lb-
in
Lower crankcase to cylinder block - Stage 4: Bolts 17 to 22: 25 18
Connecting rod bearing caps, stage 1 23 17
Connecting rod bearing caps, stage 2 43 32
Connecting rod bearing caps, stage 3 90° 90°
Camshaft bearing caps to cylinder head 10 89
Camshaft oil seal housing to cylinder head 10 89
Fixed timing chain guide to cylinder block 25 18
Timing chain tensioner to cylinder block 25 18
Timing case cover to cylinder block 25 18
Wiring harness bracket to timing case cover 10 89
Camshaft position sensor to timing case cover 10 89
Crankshaft position sensor to timing case cover 10 89
Pulley/vibration damper to crankshaft, stage 1 120 88
-360° -360°
Pulley/vibration damper to crankshaft, stage 2
(undo) (undo)
Pulley/vibration damper to crankshaft, stage 3 50 37
Pulley/vibration damper to crankshaft, stage 4 90° 90°
Power steering pump to carrier of engine mounting bracket 25 18
Power steering pump bracket to timing case cover 10 89
Belt pulley to power steering pump 25 18
Stud of the power steering pump 10 89
Spark plugs 14 10
Cylinder head cover to cylinder head 10 89
Wiring harness retaining plate to cylinder head cover 10 89
Engine lifting eye 112 83
Oil baffle to oil pan 10 89
Oil drain plug to oil pan 26 19
Oil pan to lower crankcase 25 18
Heat shields to oil pan 10 89
Oil cooler to cylinder block 57 42
Oil pressure switch to cylinder block 14 10
Exhaust manifold to cylinder head 20 15
Knock sensor to cylinder head 34 25
Generator bracket to cylinder block/lower crankcase 25 18
Generator mounting bolts 47 35
Bracket to generator 25 18
Engine drive plate to crankshaft 80 59
Flywheel to crankshaft 80 59
Camshaft oil seal carrier 10 89
Water pump to cylinder head, stage 1 10 89
Water pump to cylinder head, stage 2 90° 90°
Coolant connecting pipe to cylinder head 10 89
Positive crankcase ventilation bracket to coolant connecting
6 53
pipe
Coolant distribution pipe to cylinder head 6 53
Oil dipstick tube bracket to coolant distribution pipe 10 89
Wiring harness to cylinder head cover 5 44
Generator power connection 10 89
Lower intake manifold to cylinder heads 10 89
Intake manifold runner control actuator 10 89
Upper intake manifold to cylinder head cover 10 89
EI coil to cylinder head cover 6 53
lb-
in
Ground cable to EI coil 6 53
Front driveshaft intermediate shaft bracket to cylinder block 47 35
Exhaust gas recirculation pipe to EGR valve 40 30
Unspecified screw connections: M5 x 0,8 6 53
Unspecified screw connections: M6 x 1 10 89
Unspecified screw connections: M14 x 2 132 97
Engine - 2.5L - Engine Mondeo 1997 (08/1996-09/2000)
Print
The 2,5 liter Duratec-VE engine (DURAble TEChnique V Engine) is made entirely of
aluminium, and its two-part cylinder block is manufactured in a special casting process.
Weighing just 165 kg, the engine meets the strict emission requirements of the
emission standard for 1996 (EEC V).
The 2,5 liter 24-valve V6 engine develops 125 kW at 6250 rev/min with an electronically
controlled intake manifold switching system to optimise torque and power output.
Four overhead camshafts are driven by two timing chains. State of the art technology is
used, featuring electronic engine management with a fully electronic ignition system,
sequential electronic fuel injection, electronically controlled exhaust gas recirculation
(EGR) and two catalytic converters on the exhaust manifolds.
The 2,5 liter 24-valve V6 engine develops 125 kW at 6250 rev/min with an electronically
controlled intake manifold runner control system to optimise torque and power output.
The engine fitted to the Mondeo ST200 is distinguished from the 2,5 Duratec-VE engine
by the following features:
 Higher power output: 151 kW (205 PS)

 Revised camshafts with modified valve timing
 Revised intake pipe
 Modified exhaust pipes
 Compression ratio 10,25:1
 Sintered and forged connecting rods
 Emissions standard D4
Item
Part Number
Description
1
-
EI ignition coil
2
-
Electronic vacuum regulator
3
-
4
-
5
-
Electronic differential pressure sensor (DPFE sensor), mounted on bracket at the rear of the
right-hand cylinder head
6
-
Knock sensor
7
-
Intake air temperature sensor (IAT sensor)
8
-
Air cleaner
9
-
Battery junction box
10
-
Mass air flow sensor (MAF sensor)
11
-
Engine coolant temperature sensor (ECT sensor), in engine coolant distribution pipe between
cylinder heads.
12
-
Upper engine cover
13
-
One heated oxygen sensor (HO2S) for each cylinder bank, in exhaust manifold
14
-
One start-up catalytic converter per cylinder bank (one unit in each exhaust manifold)
15
-
Throttle housing with throttle position sensor (TP sensor)
16
-
Electric IMRC actuator
17
-
Upper intake manifold
18
-
Camshaft position sensor (CMP sensor), on engine front cover (exhaust camshaft - left-hand
cylinder head)
19
-
Crankshaft position sensor (CKP sensor), on lower engine front cover
20
-
Hydraulic engine mounting
21
-
Engine mounting bracket
22
-
Power steering pressure switch (PSPS)
23
-
Powertrain control module (PCM) EEC V
24
-
Service plug (octane adjustment)

Item
Part Number
Description
1
-
Electronic vacuum regulator
2
-
3
-
IAC valve seal
4
-
Throttle body gasket
5
-
Throttle body
6
-
EGR valve seal
7
-
EGR valve
8
-
Exhaust back pressure transducer
9
-
Positive crankcase ventilation hose
10
-
PCV valve
11
-
Fuel injection wiring
12
-
Electronic intake manifold runner control (IMRC) switching module
13
-
Cylinder head cover gasket (left-hand)
14
-
Oil filler cap
15
-
Water pump drivebelt
16
-
Water pump belt pulley
17
-
Camshaft rear oil seal
18
-
Camshaft oil seal carrier gasket
19
-
Oil seal carrier
20
-
Alignment dowel (2 off)
21
-
Water pump drivebelt tensioner
22
-
Coolant pump
23
-
Engine lifting eye (LH)
24
-
Exhaust manifold (LH)
25
-
Exhaust manifold gasket (LH)
26
-
Cylinder head gasket (LH)
27
-
Cylinder head (LH)
28
-
A/C compressor
29
-
Exhaust camshaft (LH)
30
-
Intake camshaft (LH)
31
-
Camshaft thrust bearing cap (LH) (2 off)
32
-
Adapter plate
33
-
Camshaft bearing cap (LH) (7 off)
34
-
Flywheel
35
-
Cylinder head cover (LH)
36
-
Water pump pulley cover
37
-
EGR valve pipe
38
-
Fuel injector retainer (6 off)
39
-
Fuel injector (6 off)
40
-
Upper intake manifold
41
-
Intake manifold gasket, upper (2 off)
42
-
Lower intake manifold
43
-
Intake manifold gasket, lower (2 off)
44
-
Fuel injector seal (6 off)
45
-
Fuel rail
46
-
Oil separator
47
-
Oil separator to cylinder block gasket
48
-
Coolant hose
49
-
Oil dipstick
50
-
Crankshaft rear oil seal
51
-
Oil dipstick tube
52
-
Oil cooler
53
-
Oil filter
54
-
Oil pan
55
-
Cylinder block
56
-
Oil pan gasket
57
-
Crankshaft position sensor (CKP sensor)
58
-
59
-
Crankshaft front oil seal
60
-
Drivebelt tensioner
61
-
Dust cover
62
-
Drivebelt idler pulley
63
-
Power steering pump
64
-
Power steering pump bracket
65
-
Generator
66
-
Generator mounting bracket
67
-
Timing chain cover
68
-
Cylinder head gasket (RH)
69
-
Cylinder block
70
-
Power steering pump bracket
71
-
Intake camshaft
72
-
Generator bracket
73
-
Exhaust manifold (RH)
74
-
Exhaust manifold gasket (RH)
75
-
Engine lifting eye (RH)
76
-
Crankshaft timing sprocket
77
-
Exhaust camshaft (RH)
78
-
Camshaft thrust bearing cap (RH) (2 off)
79
-
Cylinder head cover (RH)
80
-
Inline connector bracket
81
-
Radio ignition interference capacitor
82
-
EI ignition coil
83
-
Spark plug connectors (6 off)
84
-
HT lead
85
-
Spark plug (6 off)
86
-
Coolant connecting pipe
87
-
Camshaft bearing cap (6 off)
88
-
Cylinder head (RH)
Item
Part Number
Description
1
-
Oil separator
2
-
Oil separator gasket
3
-
Coolant hose
4
-
Cylinder block
5
-
Crankshaft rear oil seal
6
-
Valve stem seal (12 on each side)
7
-
Valve spring retainer (12 on each side)
8
-
Valve collet (24 on each side)
9
-
Valve spring (12 on each side)
10
-
Valve tappet (12 on each side)
11
-
Cam follower (12 on each side)
12
-
Cylinder head
13
-
Intake valve (6 on each side)
14
-
Exhaust valve (6 on each side)
15
-
Crankshaft thrust half rings
16
-
Crankshaft
17
-
Lower crankshaft thrust main bearing shell
18
-
Lower crankshaft main bearing shell (3 off)
19
-
Lower crankcase
20
-
Oil baffle plate
21
-
Oil pump intake pipe
22
-
Crankshaft timing sprocket (2 required up to 99.5 MY)
23
-
Crankshaft position sensor pulse ring
24
-
Crankshaft bolt and washer
25
-
Crankshaft pulley
26
-
Timing chain (2 off)
27
-
Oil pump
28
-
Big-end bearing bolt (12 off)
29
-
Big-end bearing cap (6 off)
30
-
Big-end bearing shell (12 off)
31
-
Connecting rod (6 off)
32
-
Piston pin retainer (12 off)
33
-
Piston pin (6 off)
34
-
Piston (6 off)
35
-
Timing chain tensioner (RH)
36
-
Cylinder head (RH)
37
-
Timing chain guide (RH)
38
-
Cylinder head gasket (RH)
39
-
Timing chain tensioner (RH)
40
-
Timing chain tensioner (LH)
41
-
Timing chain tensioner
42
-
Timing chain guide (LH)
43
-
Cylinder head gasket (LH)
44
-
Upper crankshaft main bearing shell (4 off)
45
-
Piston ring set (6 off)
46
-
Adapter plate for chain tensioner
47
-
Adapter plate for right-hand chain tensioner
Print
Disassembly
Universal Flange Holding Wrench
205-072 (15-030 A)
Remover, Seal
303-112 (21-051)
Remover, Crankshaft Seal
303-293 (21-143)
Remover, Crankshaft Vibration Damper
303-338 (21-153 B)
Adapter for 303-338
303-338-02 (21-153 A02)
Remover/Installer, Hose Clamp
303-397 (24-003)
Mounting Bracket for 303-435
303-435-06 (21-031 B)
Mounting Plate for 303-435-06
303-435-11A (21-146 C)
Socket, Spark Plug
303-499 (21-202)
Lengths of rubber hosing
Disassembly
All vehicles
1. Drain off the engine.
2. Disconnect the exhaust gas recirculation (EGR) pipe from the EGR valve.
1. Detach the hoses.
2. Unscrew the pipe.
3. NOTE: Loosening sequence.

Remove the right-hand exhaust manifold.
 Discard the gasket.
4. Remove the intermediate driveshaft bracket.

5. Attach the special tool to the engine.
6. Install the mounting bracket to the mounting plate.

7. Mount the engine on the mounting stand.
8. Disconnect off the plugs and detach the wiring harness.
1. Generator cable.
2. Differential pressure feedback EGR (DPFE) plug.
3. Electronic vacuum regulator.
4. ECT sensor on coolant distribution pipe.
5. Detach the wiring rail.
9. Disconnect the intake manifold runner control (IMRC) cable.

 Unhook from the bracket.
 Detach from the IMRC.
10. Remove the IMRC actuator.
1. Disconnect the IMRC multiplug.
2. Unscrew the bolts.
11. Disconnect the spark plug connectors.

12. Detach the EI coil with the high tension leads and the spark plug
connectors.
1. Disconnect the EI ignition coil multiplug.
2. Detach the ground cable.
3. Detach the condenser.
4. Remove the remaining bolts and the EI coil.
13. Disconnect the vacuum hoses.
1. From the upper intake manifold.
2. From the electronic vacuum regulator.
3. From the fuel pressure regulator.
4. From the DPFE.
5. From the EGR valve.
14. Pull off the hoses and the electrical plugs.

1. Throttle position (TP) sensor plug.
2. Positive crankcase ventilation hose.
3. Idle air control valve (IAC valve) plug.
15. NOTE: Loosening sequence
Remove the upper intake manifold.
 Discard the gaskets.
16. Disconnect the heated oxygen sensor (H02S) plug.

17. Disconnect the plugs.
1. Oil pressure switch.
2. Crankshaft position (CKP) sensor.
3. Camshaft position (CMP) sensor.
 Unclip the wiring harness.
18. Detach the fuel injection system wiring harness.

1. Pull off the engine coolant temperature sensor (ECT sensor) plug.
2. Pull off the EGR back pressure transducer plug.
3. Pull off the fuel injector plugs.

Remove the lower intake manifold.
20. Using the special tool, remove the thermostat housing with the coolant
hoses.
21. Detach the coolant distribution pipe, the engine lifting eye and the oil
dipstick.
1. Unscrew the nuts.
2. Detach the left-hand engine lifting eye.
3. Withdraw the engine oil dipstick.
22. Remove the coolant pump drivebelt.

 Rotate the belt tensioner clockwise to relieve tension on the drivebelt.
23. Remove the hose and the positive crankcase ventilation valve.
1. Unscrew the nut.
2. Detach the hose and the positive crankcase ventilation valve.
24. Remove the coolant connecting pipe.
25. Remove the coolant pump.

2. Disconnect the coolant hose.
3. Detach the coolant hose from the oil cooler.
Vehicles with manual transaxle
26.Remove the clutch disc and pressure plate. For additional information, refer to
Section 308-01 Clutch.
27. Remove the flywheel.
1. Remove the flywheel retaining bolts.
2. Remove the adapter plate.
Vehicles with automatic transaxle

28. Remove the flexplate.
1. Remove the flexplate retaining bolts.
2. Remove the adapter plate.
All vehicles
29. NOTICE:
Do not scratch or damage the seal sealing surfaces on the crankshaft and
cylinder block. Use a 0,25 mm brass or copper shim to protect the sealing
surface.
Only insert the special tool by hand.

Remove the crankshaft rear seal.
30. Remove the generator.

1. Remove the bracket bolt.
2. Remove the generator bolts.
31. Remove the generator bracket.
32. Remove the oil filter.

Remove the left-hand exhaust manifold.
34. Remove the oil cooler and the oil pressure switch.
1. Unscrew the bolt and remove the oil cooler.
2. Remove the oil pressure switch.
35. Remove the studs and take off the oil pan heat shields.

Remove the oil pan.
 Check the oil pan and the cylinder block for damage.
37. Remove the wiring harness retaining plate.
2. Take off the retaining plate.
38. Detach the right-hand engine lifting eye.

1. Remove the bolt.
2. Take off the engine lifting eye.
39. NOTE: Slackening sequence.
Remove the valve covers.
40. Remove the camshaft pulley.
41. NOTICE: Only insert the special tool by hand.

Using the special tool, remove the camshaft seal.
42. NOTICE: Protect the camshaft when removing the seal carrier.
Remove the camshaft seal carrier.
 Discard the seal.
43. Remove the power steering pump pulley (four bolts).

44. Remove the power steering pump and bracket.
45. Using the special tool, remove the crankshaft pulley retaining bolt.
46. Using the special tool, remove the crankshaft pulley.

47. Remove the sensors and wiring brackets.
1. CKP sensor.
2. CMP sensor.
3. Wiring bracket.
4. Wiring bracket.

Remove the timing chain cover.
49. NOTICE: Protect the surface of the crankshaft while removing the seal.
Using the special tool, remove the crankshaft front seal (engine shown
installed).
50. Position the crankshaft.

1. Remove the CKP sensor pulse ring.
2. Screw in the crankshaft pulley/vibration damper bolt and turn the crankshaft
clockwise until the Woodruff key is in the 3 o'clock position. Undo the bolt.
51. Install the crankshaft pulley retaining bolt and washer.
52. Using the special tool, remove the right-hand spark plugs.
53. Using the special tool, remove the left-hand spark plugs.
54. Rotate the crankshaft in a clockwise direction to position number one

cylinder at top dead center (TDC) with the crankshaft keyway at the 11
o'clock position.
 If the camshafts are not positioned as shown, rotate the crankshaft one
complete revolution.
55. Rotate the crankshaft in a clockwise direction to position the crankshaft

keyway at the 3 o'clock position.
 The right-hand camshafts will be in the neutral position.
56. NOTE: Mark the position of all timing chain tensioner components to make
sure they are assembled in their original positions.
Remove the right-hand timing chain tensioner and timing chain tensioner arm.
1. Remove the bolts.
2. Remove the timing chain tensioner.
3. Remove the timing chain tensioner arm.
57. Remove the right-hand timing chain.

1. Remove the right-hand timing chain guide.
2. Remove the right-hand timing chain.
58. NOTICE:
The cylinder head and the camshaft bearing caps are numbered and
marked for left-hand and right-hand cylinder heads.
Remove camshaft bearing thrust caps No. 1R and 5R first. Do not loosen
any other retaining bolts until the thrust caps are removed.
NOTE: Camshaft bearing caps are dowelled to the cylinder head. If necessary,
use a plastic mallet to loosen the caps.
NOTE: Loosen the retaining bolts and bearing caps in the indicated sequence
in several passes to allow the camshafts to gradually rise from the cylinder
head.
NOTE: If the cam followers and valve tappets are to be re-used, mark their
position to make sure they are assembled in the original location.
Remove the right-hand cylinder head camshafts.
 Remove the cam followers.
 Remove the valve tappets.
59. NOTICE: Remove the right-hand cylinder head bolts in the sequence
shown in several passes.
Remove the right-hand cylinder head.
 Discard the cylinder head bolts, washers and gasket.
60. Rotate the crankshaft in a clockwise direction approximately 600 degrees

and position the crankshaft keyway at the 11 o'clock position.
61. Remove the crankshaft pulley retaining bolt and washer.
62. NOTE: Mark the position of all timing chain tensioner components to make
sure they are assembled in their original positions.
Remove the left-hand timing chain tensioner and timing chain tensioner arm.
1. Remove the bolts.
2. Remove the timing chain tensioner.
3. Remove the timing chain tensioner arm.
63. Remove the left-hand timing chain.
1. Remove the left-hand timing chain guide.
2. Remove the left-hand timing chain.
64. NOTICE:
The cylinder head and the camshaft bearing caps are numbered and
marked for left-hand and right-hand cylinder heads.
Remove camshaft bearing thrust caps No. 1L and 5L first. Do not loosen
any other retaining bolts until the thrust caps are removed.
NOTE: Loosen the retaining bolts and bearing caps in the sequence shown in
several passes to allow the camshafts to gradually rise from the cylinder head.
NOTE: Camshaft bearing caps are dowelled to the cylinder head. If necessary,
use a plastic mallet to loosen the caps.
NOTE: If the cam followers and valve tappets are to be re-used, mark their
position to make sure they are assembled in the original location.
Remove the left-hand camshafts.
 Remove the cam followers.
 Remove the valve tappets.
65. NOTICE: Remove the left-hand cylinder head bolts in the sequence shown
in several passes.
Remove the left-hand cylinder head.
 Discard the cylinder head bolts, washers and gasket.
66. Remove the bracket for the power steering pump.

67. Remove the oil separator.
68. Remove the oil intake pipe.
69. Remove the oil pan baffle.

Remove the oil pump.
Engine - 2.5L - Cylinder Head Mondeo 1997 (08/1996-09/2000)
Print
Disassembly and Assembly of Subassemblies

Special Tool(s)
Installer, Intake Valve Stem Seal
303-247 (21-130A)
Compressor, Valve Spring
303-361A (21-155)
Adapter for 303-361A
303-361-02 (21-155-02A)
Pliers, Valve Stem Seal
303-508 (21-211)
Materials
Name
Specification
Engine Oil - 5W-30
WSS-M2C913-B
Disassembly
1. NOTICE: Mark the installation position of any valve train components that
are to be re-used so that they are installed in the correct position.
Using the special tools, remove the valve collets, the valve springs and the
valve spring retainers.
2. Remove the valves.

3. Using the special tool, remove the valve stem seals.
4. Check the cylinder heads and related components for wear or damage.
 Discard components if damaged.
Assembly
1. WARNING: Use eye protection when using compressed air. Failure to do

so may result in personal injury.
NOTICE: The cylinder head surface is measured in microns. For proper

head gasket sealing, avoid any contact of the surface with hard objects.
NOTE: Install new components if necessary.
Remove gasket material, dirt and debris from the cylinder heads. Wash with a
suitable soap solution and dry completely using compressed air if the blanking
plugs have been removed.
 If gasket material remains on the cylinder head after cleaning, use a plastic
scraper to remove the remaining material.
2. Using the special tool, install new valve stem seals.
3. Install the valves.
 Coat the valve stems and guides with engine oil prior to installation.
4. Using the special tools, install the valve spring retainers, the valve springs and
the valve collets.
Print
Assembly
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)
Mounting Bracket for 303-435
303-435-06 (21-031B)
Mounting Plate for 303-435-06
303-435-11 (21-146C)
Installer, Camshaft Pulley
303-458 (21-192)
Adapter for 303-458
303-458-01 (21-192-01)
Remover/Installer, Hose Clamp
303-397 (24-003)
Installer, Crankshaft Rear Seal
303-460 (21-193A)
Socket, Spark Plug
303-499 (21-202)
Assembly stand
Materials
Name
Specification
Silicone Sealant
WSE-M4G323-A4
Engine Oil - 5W-30
WSS-M2C912-A1
Lubricant
ESE-M1244-A (Never Seeze)
Sealer
SM-4G-4644-AA/AB
Sealant - Loctite 270
SD-M4G9107-A
Antifreeze - Super Plus 4
ESD-M97B49-A
Assembly
All vehicles
1. NOTE: Tightening sequence.
Install the oil pump.
2. Install the oil pan baffle.

 Tighten the nuts in two stages.
 Stage 1: 5 Nm.
 Stage 2: 45 degrees.
3. 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.
4. Install the oil pick-up pipe retaining bolts.
5. NOTE: Install a new oil separator gasket.

Install the oil separator.
6. Install the bracket for the power steering pump.
 Align the bracket with the locating sleeves.
7. NOTE: Install a new cylinder head gasket.

NOTE: Left-hand and right-hand cylinder head gaskets are not
interchangeable.
NOTE: Align the cylinder head with the locating dowels.
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.
8. Loosen the left-hand cylinder head bolts.
 Loosen the cylinder head bolts one complete turn in the sequence shown.
9. Tighten the left-hand cylinder head bolts in the sequence shown in three
stages.
 Stage 1: 40 Nm.
10. NOTE: Install a new cylinder head gasket.
NOTE: Left-hand and right-hand cylinder head gaskets are not
interchangeable.
NOTE: Align the cylinder head with the locating dowels.
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.
11. Loosen the right-hand cylinder head bolts.

 Loosen the cylinder head bolts one complete turn in the sequence shown.
12. Tighten the right-hand cylinder head bolts in the sequence shown in three
stages.
 Stage 1: 40 Nm.

 Rotate the crankshaft in a clockwise direction to position the keyway at the 11
o'clock position.
14. NOTE: Lubricate the valve tappets with clean engine oil before installation.
Install the left-hand cylinder head valve tappets.
15. NOTICE: The cam followers must be installed in their original positions.
NOTE: Lubricate the cam followers with clean engine oil before installation.
Install the left-hand cylinder head cam followers.
16. NOTE: Lubricate the camshafts with clean engine oil before installation.
Install the left-hand camshafts.
17. Position the left-hand camshafts as shown.
1. The mark on the intake camshaft at the 9 o'clock position.
2. The mark on the exhaust camshaft at the 12 o'clock position.
18. NOTICE:
The camshaft journal caps must be installed in their original positions.
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: 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.
20. NOTICE: Make sure vise jaw protectors are used.

Loosely mount the left-hand timing chain tensioner in a vise.
21. NOTICE: 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.
22. 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.
23. 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.
24. 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.
2. Count 29 links from the crankshaft timing mark and mark this link as the
exhaust camshaft sprocket timing mark.
3. Continue counting to link 42. Mark this link as the intake camshaft sprocket
timing mark.
25. NOTE: Install the crankshaft sprockets with the timing marks facing outwards.
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.
2. Install the crankshaft sprockets.
3. Install the left-hand timing chain.
26. Install the left-hand timing chain tensioner.

1. Install the left-hand timing chain tensioner arm.
2. Position the timing chain tensioner.
3. Install the bolts.
27. Remove the left-hand timing chain tensioner piston retaining wire.
28. NOTE: Lubricate the valve tappets with clean engine oil before installation.
Install the right-hand cylinder head valve tappets.
29. NOTICE: The cam followers must be installed in their original position.
NOTE: Lubricate the cam followers with clean engine oil before installation.
Install the right-hand cylinder head cam followers.
30. NOTE: Lubricate the camshafts with clean engine oil before installation.
Install the right-hand camshafts.
31. Position the right-hand camshafts as shown.
1. The mark on the exhaust camshaft at the 12 o'clock position.
2. The mark on the intake camshaft at the 3 o'clock position.
32. NOTICE:
The camshaft journal caps must be installed in their original position.
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: 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.
 Rotate the crankshaft in a clockwise direction to position the keyway at the 3
o'clock position.

35. NOTICE: Make sure vise jaw protectors are used.
Loosely mount the right-hand timing chain tensioner in a vise.
36. NOTICE: 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.
37. 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.
38. 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.
39. 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.
2. Count 29 links from the crankshaft timing mark and mark this link as the
exhaust camshaft sprocket timing mark.
3. Continue counting to link 42. Mark this link as the intake camshaft sprocket
timing mark.
40. 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.
2. Install the right-hand timing chain.
41. Install the right-hand timing chain tensioner.
1. Install the right-hand timing chain tensioner arm.
2. Position the timing chain tensioner.
3. Install the bolts.
42. Remove the right-hand timing chain tensioner piston retaining wire.
44. NOTE: Ignore the timing flags on the rear of the camshaft sprockets.
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.
2. There should be 27 chain links between the camshaft and crankshaft timing
marks.
3. There should be 30 chain links between the camshaft and crankshaft timing
marks.

46. NOTICE: 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.
47. NOTE: Install the engine front cover within six minutes of applying the sealant.
Apply a 6 mm dot of sealant to the mating faces in the positions shown.
48. NOTE: Install new engine front cover gaskets.

Install the engine front cover.
 Tighten the studs in the sequence shown.

Tighten the remaining engine front cover bolts and studs.
50. NOTE: Coat the new O-rings with engine oil.

Install the sensors and wiring brackets.
1. CKP sensor.
2. CMP sensor.
3. Wiring bracket.
4. Wiring bracket.
51. NOTE: Install a new crankshaft front seal.
Using the special tool, install the crankshaft front seal.
 Lubricate the outer ring and the sealing lip of the seal with engine oil.
 Draw in the crankshaft front seal using the special tool and the washer of the
crankshaft pulley/vibration damper bolt.
52. Using the special tool, install the crankshaft pulley/vibration damper.
53. Remove the special tool and the crankshaft pulley retaining washer.
Using the special tool, install the crankshaft pulley/vibration damper.
 Seal off the Woodruff key in the crankshaft pulley/vibration damper with
silicone sealer and sealant.
 Tighten the bolt in four stages.
 Stage 1: 120 Nm.
 Stage 2: Turn the bolt back a full turn.
 Stage 3: 50 Nm.
55. NOTE: Do not tighten the power steering pump bracket retaining bolts and
nuts at this stage.
Install the power steering pump and bracket.
56. NOTE: The longer 84 mm retaining bolts should be tightened first.

Tighten the 84 mm power steering pump retaining bolts.
57. Tighten the power steering pump retaining nuts.
58. NOTE: The indentation on the pulley must face towards the front of the
engine.
Install the pulley to the power steering pump.
59. Install the camshaft seal carrier.
60. NOTICE: Do not damage the running surface of the camshaft.

Using the special tools, install the camshaft seal.
 Lubricate the outside of the seal with engine oil.
61. Using the special tool, install the camshaft pulley.

 Heat the belt pulley, locate it in position and draw it on as far as it will go.
62. Using the special tool, install the left-hand spark plugs.
63. Using the special tool, install the right-hand spark plugs.
64. NOTE: Clean the mating faces with metal surface cleaner.
Apply sealant to the mating faces of the cylinder head in the positions shown.
65. NOTE: Install new valve cover gaskets.

NOTE: Tightening sequence
Install the valve covers.
66. Install the wiring harness retaining plate and the right-hand engine lifting
eye.
67. 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.
68. NOTE: Location of the studs.

NOTE: Tightening sequence.
NOTE: Install the oil pan within six minutes of applying the sealant.
Install the oil pan with a new gasket.
69. Install the oil pan heat shields.
70. Install the oil cooler and the oil pressure switch.
1. Install the oil cooler retaining bolt.
2. Apply sealer to the thread of the oil pressure switch and install the switch.
 Coat the oil cooler seal, the O-ring and the oil filter seal with engine oil.
 Use oil/coolant passage sealer .
71. NOTE: Install a new left-hand exhaust manifold gasket.
Install the left-hand exhaust manifold.
72. Install the oil filter.
73. Install the generator bracket.

74. Install the generator.
1. Generator bolts.
2. Bracket bolt.
75. Using the special tool, install the crankshaft rear seal.
 Lubricate the outer ring and sealing lip with engine oil.
76. Install the flywheel.
1. Install the adapter plate.
2. Apply sealer to the bolts and tighten them working diagonally.
 Use sealant.
 Using the special tool 205-072, hold the crankshaft by the vibration damper.
Vehicles with automatic transaxle

Install the adapter plate and the flexplate.
All vehicles
78. NOTE: Tightening sequence
Install the coolant pump.
1. Tighten the new bolts in two stages.
1. Stage 1: 10 Nm.
2. Stage 2: 90 degrees.
2. Connect the coolant hose.

79. Install the coolant connecting pipe between the cylinder heads.
 Use new O-rings and coat them with antifreeze.
80. Install the positive crankcase ventilation (PCV) valve and hose.
1. Attach the PCV valve and hose.
2. Tighten the nut.
81. Install the water pump drive belt.

 Rotate the belt tensioner clockwise to release the tension on the drive belt.
82. Attach the coolant distribution pipe, the engine lifting eye and the oil
dipstick.
1. Install the engine lifting eye.
2. Install the dipstick with a new oiled O-ring.
3. Screw on the nuts.
83. Using the special tool, install the thermostat housing with the coolant
hoses.
84. NOTE: Install new gaskets with the locating lugs facing downwards.
Install the lower intake manifold.
85. Install the fuel injection system wiring harness.
1. ECT sensor plug.
2. DPFE sensor plug.
3. Fuel injector connector.
86. Connect the plugs.

1. Oil pressure switch.
2. CKP sensor.
3. CMP sensor.
 Clip the wiring harness in place.
87. Connect the HO2S plug.
88. NOTE: Install new gaskets with the locating lugs pointing downwards.
Install the upper intake manifold.
89. Connect the hoses and plugs

1. Plug to the TP sensor.
2. Positive crankcase ventilation hose.
3. Plug to the IAC valve.
90. Connect the vacuum hoses.

1. To the upper part of the intake manifold.
2. To the electronic vacuum regulator.
3. To the fuel pressure regulator.
4. To the DPFE.
5. To the EGR valve.
91. Install the electronic ignition (EI) coil.
 Connect the electrical connectors.
92. Install the IMRC actuator.

1. Install the retaining bolts.
2. Connect the IMRC electrical connector.
93. Install the IMRC cable.
94. Install the wiring harness and connect the electrical conectors.
1. Attach the wiring rail.
2. Generator cable.
3. DPFE sensor plug.
4. Electronic vacuum regulator plug.
5. ECT sensor to coolant connection pipe.
95. Remove the special tools.

96. Install the intermediate driveshaft bracket.
97. NOTE: Install a new right-hand exhaust manifold gasket.

Install the right-hand exhaust manifold.
98. Connect the EGR pipe to the EGR valve.
1. Screw on the EGR pipe.
2. Connect the hoses to the EGR pipe.
99. Finishing operations.

 Fill the engine with engine oil.
100. Install the clutch disc and pressure plate. For additional information, refer
to Section 308-01 Clutch.
Engine - 1.8L Diesel - Specifications Mondeo 1997 (08/1996-09/2000)
Print
Engine Data
Description TCI diesel

Engine management EEC V
Emission standard 96 EC
Fuel Diesel
Engine code RFN
Injection sequence 1-3-4-2
Bore mm 82,5
Stroke mm 82,0
Cubic capacity (effective) cm 3 1753
Compression ratio 21,5 : 1
Compression pressure at starter motor speed bar 28-34
Engine power output (EEC) kW 66
Engine power output (EEC) at rev/min 4500
Torque (EEC) Nm 180
Torque (EEC) at rev/min 2250
Idle speed rev/min 850 - 860
Maximum engine speed - continuous rev/min 4500
Maximum engine speed - intermittent (without load) rev/min 5200 - 5300
Item Specification
Coolant ESD-M97B49-A
Transmission fluid (MTX) ESD-M2C168-A
Power steering hydraulic fluid ESPM-2C-166-H
Sealer for camshaft bearing cap No. 1; oil pan to cylinder block SPM-4G-9112-F/G
Sealer for blanking plugs, oil pressure switch, oil passages SM-4G-4644-AA/AB
Sealer for coolant pump hose connections SM-1C-1022-A
Engine oil up to 1999 MY
Specificatio
Viscosity / ambient temperature Designation
n
Ford XR+ High-performance High-lubricity
SAE10W-40 / -20°C to over +40°C ACEA A3, B3
Motor Oil
Alternative engine oil
SAE 5W-40 / below -20°C to over
+40°C
If engine oils of this specification are not available, only use engine oils which
conform to specifications API SH/CD EC (energy conserving) and CCMC PD2 or
better.
Engine oil from 1999 MY
Ambient
Type Specification
temperature/viscosity
SAE 10W-40 / -20°C to over WSS-M2C912-A1 or
Ford Formula E Motor Oil
+40°C WSS-M2C913-A
Alternative engine oil
SAE 5W-40 / below -20°C to Ford Formula S Synthetic Motor
ACEA A3, B3
over +40°C Oil
SAE 10W-40 / -20°C to over Ford XR+ High-performance
ACEA A3, B3
+40°C High-lubricity Motor Oil
If engine oils of this specification are not available, only use engine oils which
conform to specifications API SH/CD EC (energy conserving) and CCMC PD2 or
better.
Capacities
Litres
Engine oil, initial fill 5,2
Engine oil change, incl. change of oil filter 5,1
Engine oil, oil change without change of oil filter 4,5
Coolant 9,3
Drivebelt Tension
Description mm
Generator (new) 1-2
Description mm
Generator (used) 1-3
Power steering (new) 1-2
Power steering (used) 1-3
Air conditioning compressor (new) 1-3
Air conditioning compressor (used) 2-4
Dimensions
Cylinder block TCI diesel

Number of main bearings 5
Cylinder bore diameter, class A mm 82,500-82,515
Cylinder bore diameter, class B mm 82,515-82,530
Cylinder bore diameter, class C mm 82,660-82,675
Cylinder bore diameter, class D mm 82,675-82,690
Main bearing radial clearance mm 0,015-0,062
Main bearing parent bore dia. mm 57,683-57,696
Dimensions
Crankshaft TCI diesel

Main bearing journal diameter, standard mm 53,970-53,990
Main bearing journal diameter, 1st undersize 0,25 mm 53,720-53,740
Main bearing journal diameter, 2nd undersize 0,50 mm 53,470-53,490
Big-end bearing journal diameter, standard mm 48,970-48,990
Big-end bearing journal diameter, 1st undersize 0,25 mm 48,720-48,740
Big-end bearing journal diameter, 2nd undersize 0,50 mm 48,470-48,490
Big-end bearing clearance mm 0,025-0,085
Crankshaft end float mm 0,11-0,37
Dimensions
Connecting rods TCI diesel

Bore diameter, big end mm 52,000-52,020
Bore diameter, small end mm 26,012-26,020
Distance between connecting rod small and big ends, class A mm 129,872-129,948
Distance between connecting rod small and big ends, class B mm 129,932-130,008
Distance between connecting rod small and big ends, class C mm 129,992-130,068
Distance between connecting rod small and big ends, class D mm 130,052-130,128
Big-end bearing radial clearance mm 0,016-0,074
Dimensions
Pistons TCI diesel

Piston diameter (measured
m
at right angles to piston 82,463-82,477
m
pin bore), class A
m
m
pin bore), class B
m
m
pin bore), class C
m
m
pin bore) class E
m
m
pin bore), class F
Pistons TCI diesel
Piston clearance (initial m
0,021-0,054
installation), classes A-F m
m
Piston protrusion at TDC 0,500-0,840
m
Piston ring gap (fitted), m
0,310-0,500
upper compression ring m
Piston ring gap (fitted), m
0,310-0,500
lower compression ring m
Piston ring gap (fitted), oil m
0,250-0,580
control ring m
Piston ring clearance in
m
piston groove, upper 0,090-0,122
m
compression ring
m
piston groove, lower 0,070-0,102
m
compression ring
m
piston groove, oil control 0,050-0,082
m
ring
The piston ring gaps must be distributed evenly around the
circumference of the piston. This also applies to the
Ring gap position
elements of the oil scraper ring. Offset the gaps by 120
degrees to each other.
Dimensions - piston pin TCI diesel
Piston pin diameter mm 25,996-26,000
Piston pin type Floating fit in piston and connecting rod
Piston pin retention Snap-ring
Dimensions
Cylinder head TCI diesel

m
Camshaft bearing diameter, standard 30,500-30,525
m
m
Camshaft bearing diameter, oversize 30,575-30,600
m
m
Valve tappet bore diameter, standard 35,000-35,030
m
m
Valve tappet bore diameter, oversize 35,500-35,530
m
m
Valve guide bore diameter, standard 8,000-8,025
m
m
Valve guide bore diameter, 1st oversize 8,263-8,288
m
m
Valve guide bore diameter, 2nd oversize 8,463-8,488
m
Thickness of cylinder head gasket with piston protrusion of 0,500 m 1,36 (two tooth
- 0,680 mm m marks)
Thickness of cylinder head gasket with piston protrusion of 0,681 m 1,42 (three tooth
- 0,740 mm m marks)
Thickness of cylinder head gasket with piston protrusion of 0,741 m 1,52 (four tooth
- 0,840 mm m marks)
m
Max. permissible unevenness over entire head mating face 0,08
m
Dimensions
Camshaft TCI diesel

Valve timing, inlet valve opens before TDC °CS 6
Camshaft TCI diesel
Valve timings, inlet valve closes after BDC °CS 32
Valve timings, exhaust valve opens before BDC °CS 57
Valve timings, exhaust valve closes after TDC °CS 7
Cam lift, inlet mm 8,99
Cam lift, exhaust mm 10,0
End float mm 0,100-0,240
Bearing journal diameter mm 27,9995 - 28,055
Bearing clearance mm 0,016-0,075
Valve clearance (cold), inlet mm 0,30-0,40
Valve clearance (cold), exhaust mm 0,45-0,55
Thickness of valve adjustment shims mm 3,00-4,75
Thickness of valve adjustment shims, in steps of mm 0,05
Dimensions
Engine lubrication TCI diesel

Oil pressure (minimum, oil temperature approx. 80° C), with engine idling bar 0,75
Oil pressure (minimum, oil temperature approx. 80° C), at 2000 1/min bar 1,50
Pressure relief valve opening pressure bar 2,0-4,0
Oil pump, max. clearance between inner/outer rotors mm 0,174
Description Nm lb-ft lb-in

Wheel nuts 85 63
Axle nuts 290 214
Bumper reinforcement strut 10 89
Tie-rod end to spindle carrier 26 19
Stabiliser bar link rod to suspension strut 47 35
Center bearing of front driveshaft to bracket 27 20
Center bearing bracket to cylinder block 48 35
Bracket of front engine mounting to engine mounting 83 61
Bracket of front engine mounting to engine bracket 83 61
Engine mounting to body 83 61
Wiring loom bracket to transmission 12 9
Bracket of rear engine roll restrictor to subframe 48 35
Center bolt of rear engine roll restrictor 120 89
Bracket of rear engine roll restrictor to transmission 84 62
Bracket of front engine roll restrictor to transmission 84 62
Bracket of front engine roll restrictor to subframe 48 35
Center bolt of front engine roll restrictor 120 89
Coolant drain plug 23 17
Radiator to subframe 10 89
Coolant pump 23 17
Vacuum line bracket to thermostat housing 9 80
Air conditioning dehydrator 7 62
Condenser to radiator 7 62
Intercooler to bracket 18 13
Turbocharger bracket to cylinder block 24 18
Bracket of power steering line to body 10 89
Power steering drivebelt cover 10 89
Power steering drivebelt tensioner to timing cover 23 17
Power steering drivebelt tensioner to power steering pump bracket 24 18
Power steering line bracket to subframe 12 9
Power steering pump belt cover 10 89
Engine mounting/power steering pump bracket to cylinder block 47 35
Engine lifting eye to engine mounting/power steering pump bracket 23 17
Exhaust manifold to catalytic converter 40 30
Catalytic converter to exhaust system 40 30
Catalytic converter to bracket 24 18
Vacuum line to vacuum pump 16 12
Vacuum pump to cylinder head 22 16
Transmission flange bolts 40 30
Starter motor to engine 20 15
Starter motor bracket to engine 20 15
Wiring to glow plugs 3 27
Glow plugs 20 15
Wiring loom bracket to lifting eye 23 17
Fuel filter to bracket 23 17
Oil pressure switch to cylinder head 20 15
Oil intake pipe bracket to cylinder block 22 16
Oil pan 11 8
Clip of turbocharger oil return hose 5 44
Oil dipstick tube 10 89
Main bearing caps, stage 1 27 20
Main bearing caps, stage 2 75° 75°
Big-end bearing caps, stage 1 25 18
Big-end bearing caps, stage 2 60° 60°
Big-end bearing caps, stage 3 20° 20°
Timing cover to cylinder block 24 18
Flywheel, stage 1 18 13
Flywheel, stage 2 45° 45°
Flywheel, stage 3 45° 45°
Clutch pressure plate to flywheel 30 22
Crankshaft position sensor bracket 21 15
Auxiliary shaft thrust plate 9 80
Auxiliary shaft oil seal carrier 23 17
Generator to bracket (M8) 24 18
Generator to bracket (M10) 50 37
Tensioning pulley bracket to generator bracket 24 18
Bolt of generator tensioning pulley 24 18
Cylinder head bolts, stage 1 10 89
Cylinder head bolts, stage 3 (wait three minutes first) -180° -180°
Cylinder head bolts, stage 5 120° 120°
Vacuum line bracket to cylinder head 22 16
Camshaft oil baffle 20 15
Camshaft bearing caps 23 17
Cylinder head cover 5 44
Injectors 95 70
Fuel-injection pump to timing cover 24 18
Fuel-injection pump bracket to cylinder block 23 17
Fuel filter bracket to cylinder head 23 17
Fuel-injection lines to injectors 25 18
Fuel-injection lines to fuel-injection pump 25 18
Fuel-injection pump pulley 25 18
Adjusting cam to cylinder head 45 33
Camshaft timing belt pulley to camshaft (M8) 35 26
Camshaft timing belt pulley to camshaft (M10) 48 35
Camshaft timing belt tensioner to cylinder head (M8) 10 89
Camshaft timing belt tensioner to cylinder head (M12) 50 37
Rear timing belt cover to cylinder block 24 18
Auxiliary shaft timing pulley 45 33
Fuel-injection pump timing pulley to flange 23 17
Fuel-injection pump timing belt tensioner to cylinder block 45 33
Blanking plug - TDC setting 24 18
Pulley/vibration damper flange bolt to crankshaft, stage 1 (degrees) 150 111
Pulley/vibration damper flange bolt to crankshaft, stage 2 -90° -90°
Pulley/vibration damper flange bolt to crankshaft, stage 3 120 89
Vibration damper flange to crankshaft, stage 4 60° 60°
Oil feed pipe - turbocharger 18 13
Bracket of turbocharger oil feed pipe 23 17
Catalytic converter bracket 24 18
Bracket for glow plug power supply 10 89
Covers - timing belt 8 71
Coolant pipe bracket 25 18
Oil pump to cylinder block 23 17
Intake manifold to cylinder head 23 17
Exhaust to cylinder head 23 17
Coolant recovery tank 10 89
Oil return pipe to vacuum pump 16 12
Wheel arch trim panel 11 8
EGR pipe 15 11
Air cleaner bracket 23 17
Pulley/vibration damper to vibration damper flange 35 26
Engine - 1.8L Diesel - Cylinder Head Mondeo 1997 (08/1996-09/2000)
Print
Disassembly and Assembly of Subassemblies

Special Tool(s)
Installer, valve stem oil seal
303-037 (21-007A)
Compressor, valve spring
303-060 (21-024)
Adapter for 303-060
303-060-02 (21-024-05)
Installer, valve collets
303-362 (21-156)
Pliers, valve stem oil seal
303-390 (21-165)
Socket, injectors (27 mm)
310-051 (23-045)
Materials
Name
Specification
Shims

Sealer
SM-4G-4644-AA/BB
Sealer
SPM-4G-9112-F/G
Hypoid oil
SQM-2C-9002-AA
Engine oil 5W-30
WSS-M2C912-A1
Disassembly
1. Detach the exhaust gas recirculation pipe (EGR pipe) and the exhaust
manifold.
1. EGR pipe
2. Exhaust manifold
 Remove the gasket.
2. Detach the intake manifold.

3. Remove the injectors.
4. Remove the oil pressure switch.

5. NOTE: Put the bearing caps and shells down in order.
Remove the camshaft.
1. Remove bearing caps nos. 2 and 4.
NOTICE: Slacken the nuts one turn at a time.

2. Slacken the nuts of bearing caps nos. 1, 3 and 5 uniformly, one turn at a
time.
 Take out the camshaft with the oil seal.
 Remove the plunger of the vacuum pump.
6. NOTE: Keep them in order.

Remove the valve tappets and shims .
7. Remove the valve springs.
 Place the cylinder head on wooden blocks.
 Release the collets by tapping on the valve spring retainers with a copper
hammer.
NOTE: Keep them in order.
 Compress the valve springs and take out the collets, valve springs and
retainers.
8. Extract the valve stem seals.

9. Remove the swirl chambers.
Assembly
1. Preparatory operations
 Clean all parts thoroughly and check them for wear.
2. Measure the camshaft. For additional information, refer to Section 303-00
3. Regrind the valves.
4. Fit the swirl chambers into place.
5. NOTICE: Mask the collet grooves with adhesive tape.

Fit new valve stem seals.
 Lubricate the valves with hypoid oil SQM-2C-9002-AA and fit them.
 Lubricate the valve stem seals with engine oil .
6. Install the valve springs.
 Install the valve springs with the valve spring retainers.
 Compress the valve springs using the valve spring compressor.
 Insert the collets in the collet grooves.
7. Measure the radial clearance of the camshaft. For additional information, refer
to Section 303-00 Engine System - General Information.
8. NOTE: The lettering on the shims faces downwards.
Coat the valve tappets and adjustment shims with 5W-30 engine oil and insert
them.
9. Install the camshaft.
 Coat the bearing shells and bearing journals with 5W-30 engine oil .
 Insert the plunger of the vacuum pump.
 Fit the camshaft with the camshaft groove parallel with the top edge of the
cylinder head.
10. Install the camshaft (continued).

1. Apply sealer to bearing cap no. 1 in the areas shown.
2. Coat bearing caps one, three and five with 5W-30 engine oil . Fit the bearing
shells and the nuts.
NOTICE: Tighten them one turn at a time.

3. Tighten the nuts one turn at a time in the indicated sequence until they reach
the specified torque.
11.Seal the join between the bearing cap and cylinder head with a thin bead of
sealer on both sides.
12. Install the oil pressure switch.

 Apply sealer to the thread of the oil pressure switch.
13. NOTE: Use new heat shields.
Install the injectors.

Attach the intake manifold.

Attach the exhaust manifold and the EGR pipe.
1. Attach the exhaust manifold.
2. Connect the EGR pipe.
Engine - 1.8L Diesel - Engine Mondeo 1997 (08/1996-09/2000)
Print
Assembly
Universal flange holding wrench
205-072 (15-030A)
Aligner, clutch disk
308-205 (16-067)
Timing pin, crankshaft TDC position
303-193 (21-104)
Aligner/installer, crankshaft front oil seal
303-318 (21-148A)
Alignment tool, camshaft alignment
303-376 (21-162B)
Socket, cylinder head bolts
303-377 (21-164)
Locking tool, flywheel
303-393 (21-168)
Aligner, crankshaft rear oil seal
303-513 (21-217)
Angle gauge, bolt tightening
303-174 (21-540)
Timing pin, injection pump timing
303-018 (23-019)
Timing pin, crankshaft position sensor (CKP sensor)
310-057 (23-049)
Micrometer
Feeler gauge
Internal gauge
Dial gauge fixture
Dial gauge
Materials
Name
Specification
Sealer
SM-4G-9112-F/G
Plastigage

Engine oil 5W-30
WSS-M2C912-A1
Assembly
1. Clean all mating faces and reusable parts thoroughly and check them for
damage.
2. Clean the oil splash nozzles for piston cooling and the oilways.
3. Measure the cylinder bore with an internal gauge For additional information,
refer to Section 303-00 Engine System - General Information.
4. Measure the crankshaft with a micrometer . For additional information, refer
to Section 303-00 Engine System - General Information.
5. Measure the main bearing clearance with Plastigage . For additional
information, refer to Section 303-00 Engine System - General Information.
6. NOTE: The bearing cap numbering begins at the timing belt end, to which the
arrows also point.
Install the crankshaft.
 Lubricate the main bearing journals, the bearings shells and the thrust half
rings with engine oil .
 Insert the thrust half rings into main bearing no. 3 with their lubricating
grooves facing outwards.
 Fit the crankshaft main bearing caps with their associated bearing shells.
7. Measure the crankshaft end float using a dial gauge and dial gauge fixture .
For additional information, refer to Section 303-00 Engine System - General
Information.
8. Measure the piston diameter with a micrometer. For additional information,
9. Measure the piston ring gaps with feeler gauges . For additional information,
10.Measure the piston ring end float using the feeler gauges. For additional
11. NOTE: The connecting rod numbering starts at the timing belt end. The arrow
on the piston crown points towards the timing belt end.
Install the pistons.
 Distribute the piston ring gaps evenly around the circumference. The same
applies to the elements of the oil scraper ring.
 Compress the piston rings using a piston ring compressor .
 Press the pistons into the cylinders using the handle of a hammer while
guiding the connecting rods onto the big-end bearing journals.
 Fit the appropriate bearing shells, clean and dry, in the connecting rods.
12.Measure the big-end bearing clearances with Plastigage . For additional
13. Fit the oil intake pipe with its bracket.
NOTE: Make sure that the O-ring is seated correctly.
1. Fit the oil intake pipe, using a new O-ring.
2. Fit the bracket.
14. Attach the timing cover.

 Fit the timing cover with a new gasket and new rubber oilway seals.
NOTE: The mating face of the timing cover must be flush with the lower
edge of the cylinder block (tolerance +/- 0,1 mm).
 Center the timing cover with the aligner and installer.
1. Tighten the bolts of the crankshaft pulley/vibration damper.

1. Remove the aligner/installer and the bolt of the crankshaft pulley/vibration
damper.
15. NOTICE: Fit the oil seal without lubrication.
Fit the crankshaft front oil seal using the crankshaft pulley/vibration damper
bolt.
16. NOTICE: Carry out step 16 immediately after step 15 to prevent the oil
seal from contracting.
NOTE: Make sure that the O-ring in the timing pulley is in perfect condition. It
must be possible to insert the roll pin in the crankshaft bore.
Fit the crankshaft timing pulley.
NOTICE: Do not lubricate the crankshaft spigot with engine oil.

 Coat the O-ring with 5W-30 engine oil .
 Carefully slide on the timing pulley as far as its stop.
17. NOTICE: The oil pan bolts must be tightened within 20 minutes of
applying the sealer.
Apply sealer to the cylinder block mating face intersections.
18. Fit the oil pan.

 Fit the oil pan with a new gasket and screw in the bolts (x14) finger tight.
 Align the oil pan so that it is flush.
19. NOTICE: Fit the oil seal without lubrication. The support ring will fall out
by itself when the crankshaft oil seal carrier is fitted. Do not remove it
beforehand.
Fit the crankshaft rear oil seal carrier.
 Locate the new crankshaft oil seal carrier with the integrated oil seal and the
bolts in position.
 Screw in the bolts.
 Fit the aligner and center the oil seal carrier on the crankshaft.
20. NOTICE: If the special tool cannot be removed, the oil pan must be
realigned.
Tighten the bolts of the crankshaft rear oil seal carrier.
 Remove the aligner/installer.
21. Tighten the oil pan bolts (x14).
22. NOTICE: Use new bolts.

Fit the flywheel.
23. Center the clutch disk on the clutch pressure plate.

24. Fit the clutch pressure plate with the centered clutch disk.
1. Fit the clutch pressure plate in position with the centered clutch disk.
2. Tighten the bolts uniformly, working diagonally.
3. Remove the aligner.
25. NOTICE: Use a new gasket.

Fit the coolant pump.
26. NOTE: The lubricating grooves on the thrust plate must face outwards.
Fit the auxiliary shaft.
 Coat the auxiliary shaft, the bearing bush in the cylinder block and the
retaining plate with 5W-30 engine oil .
 Fit the auxiliary shaft with the thrust plate and tighten the bolts.
27. NOTICE: Use a new oil seal carrier.

Fit the auxiliary shaft oil seal carrier.
 Coat the auxiliary shaft spigot with 5W-30 engine oil .
 Slide the auxiliary shaft oil seal carrier with the integrated oil seal and plastic
fitting sleeve onto the auxiliary shaft spigot.
NOTE: Remove the plastic fitting sleeve after installation and check that
the seal is seated correctly.
 Tighten the bolts of the oil seal carrier.
28.Measure the piston protrusion with a dial gauge and a dial gauge fixture . For
additional information, refer to Section 303-00 Engine System - General
Information.
29. Align the crankshaft and the camshaft.
 Turn the crankshaft until cylinder no. 1 is at TDC.
 Turn the camshaft until the offset groove on the end is parallel with the upper
edge of the cylinder head (larger semi-circle uppermost).
1. Insert the timing tool in the offset groove on the camshaft.
 The crankshaft and camshaft must not be turned any more.
30. NOTE: Use a new cylinder head gasket. "TOP/OBEN" mark.

Fit the cylinder head gasket.
1. Check that the guide sleeves are correctly seated.
2. Check that the thickness markings correspond to the piston protrusion
measurement.
31. NOTE: The turbocharger oil return hose must be connected when the cylinder
head is fitted.
Fit the cylinder head.
32. NOTICE: Use new unoiled cylinder head bolts. It is not permitted to
retighten the cylinder head bolts.
Tighten the cylinder head bolts.
 Tighten the cylinder head bolts in two stages in the specified sequence using
a socket wrench.
 Stage 1: 10 Nm
 Stage 2: 100 Nm
33. NOTICE: For stage 3, first slacken the cylinder head bolt, then tighten it to
the specified torque and angle in accordance with the tightening sequence.
Then move on to the next bolt.
NOTE: It is not permitted to retighten the cylinder head bolts.
Wait three minutes and then tighten the cylinder head bolts.
 Stage 3: undo the bolt 180 degrees.
 Stage 4: tighten the bolt to 70 Nm.
 Stage 5: tighten the bolt through 120 degrees.
34. NOTICE: Use a new gasket.

Attach the thermostat housing.
35. Attach the bracket of the engine mounting and power steering pump.
2. Bracket to cylinder block.
3. Attach the bracket to the lifting eye.
36. Fit the vacuum pump.

1. Connect the oil return hose.
NOTE: Fit the lower bolt first.
2. Tighten the bolts.
1. Fit the vacuum pump with a new O-ring, the bracket and the bolts.
3. Attach the PCV hose.

37. Fit the injection pump.
38. Fit the injection pump bracket.

1. Attach the bracket for the boost pressure pipe.
 Attach the boost pressure pipe to the injection pump.
2. Fit the bracket (two bolts/three nuts).
39. Fit the fuel filter with its bracket.
1. Fit the fuel filter and bracket in position and tighten the nuts.
2. Attach the bracket for the boost pressure pipe.
3. Connect the vacuum pipe to the turbocharger.
40. NOTE: Use new clips.

Fit the fuel heater and the fuel pipes.
1. Fit the fuel heater to the bracket.
2. Connect the fuel pipes to the fuel filter.
41. Connect the injection pipes to the injectors and injection pump and
connect the leak-off hoses.
42. NOTE: Hold it with the old timing belt.

Fit the auxiliary shaft timing pulley.
43. Fit the rear timing belt covers.

44. NOTE: Center the bolts in the slots; do not tighten the bolts.
Fit the injection pump timing pulley.
45. Fit the injection pump timing belt tensioner.

 Compress the tensioner spring and lock it with the bolt.
46. Fit the flange of the crankshaft pulley/vibration damper.

 Stage 1: 150 Nm
 Stage 2: -90 degrees
NOTE: Use Special Tool 21-540.
 Stage 3: 120 Nm
 Stage 4: 60 degrees
47. Align the camshaft.

 Insert the special tool into the slot of the camshaft.
48. Align the injection pump timing pulley and turn the crankshaft to TDC.
1. Align the injection pump timing pulley by inserting Special Tool 308-018 (23-
019) through the slot in the pulley and through the hole in the injection pump
housing.
 Unscrew the blanking plug from the opening in the cylinder block for setting
TDC.
NOTE: Special Tool 303-193 (21-104) must be screwed in as far as it
will go. The crankshaft must be resting against the timing pin.
2. Screw Special Tool 303-193 (21-104) into the cylinder block.
 Turn the crankshaft carefully to TDC.
49. NOTICE: The camshaft timing belt and injection pump timing belt must be
renewed each time they are slackened. Re-tensioning of the timing belt is not
permitted.
NOTE: Make sure that the belt is correctly seated.
NOTE: The bolts must not be at the ends of the slots.
Fit the injection pump timing belt.
 Fit the new timing belt with the slack side facing the timing belt tensioner.
 Slacken the bolt of the timing belt tensioner and allow the tensioner to snap
against the belt.
 Tighten the bolt of the timing belt tensioner.
 Tighten the bolts of the timing pulley.
50.Install the camshaft timing belt.

For additional information, refer to Timing belt in this section.
51.Check valve clearance and adjust if necessary.
For additional information, refer to Valve Clearances in this section.
52. NOTICE: The setting of 10 degrees for the adjustment of the start of fuel
delivery on the fuel pump must be strictly adhered to.
NOTE: When using angle gauge 303-174 (21-540), make sure that the dial
does not move because of the movement of the special tool. Pressure must be
constantly applied to the special tool. If the setting of 10 degrees is not
achieved exactly, rotate the dial completely out of the measuring range and
carry out the adjustment again.
Set the crankshaft to 10 degrees after TDC on cylinder no. 1.
 Locate the CKP sensor bracket without the sensor in position and attach it
loosely.
 Place the angle gauge on the pulley/vibration damper and set the dial to 10
degrees.
 Turn the pulley/vibration damper until the arrows on the angle gauge line up.
53. Align the CKP sensor bracket.

 Insert Special Tool 310-057 (23-049) in the CKP sensor bracket and center it
in the hole on the flywheel.
 Tighten the bolts of the CKP sensor bracket and remove the special tool.
54. Check the alignment of the CKP sensor.

 Set the crankshaft to 10 degrees after TDC on cylinder no. 1 as described in
the two previous steps.
NOTE: If the special tool cannot be inserted in the hole in the flywheel,
the adjustment procedure must be repeated as described in the two
previous steps. Check the alignment again.
 It must be possible to insert the special tool into the flywheel.
55. Fit the oil baffle.
56. NOTE: Clean and inspect the gasket and renew it if necessary (it can be
reused several times). Coat the gasket with engine oil prior to installation.
Attach the cylinder head cover.
57. Attach the PCV hoses.
1. To the cylinder block.
2. To the turbocharger.
58. Fit the crankshaft pulley/vibration damper.
59. Fit the timing belt covers.

60. Fit the injection pump pulley and the coolant hose.
61. Fit the generator bracket.

62. Fit the generator and the drive belt tensioner pulley.
1. Fit the generator (two bolts).
2. Fit the generator (one bolt).
3. Fit the idler pulley (two bolts).
4. Screw in the bolt of the tensioner pulley.
63. Fit the generator drive belt and tension it.

1. Fit the drive belt and tension it with the adjusting bolt.
2. Check the drive belt tension.
1. 1 - 2 mm for new drive belts
2. 2 - 4 mm for used drive belts
3. Tighten the tensioner pulley bolt.

64. Fit the oil dipstick tube with its bracket and a new O-ring.
65. Detach the engine from the assembly stand.

66. NOTE: Fill the oil pump with engine oil and lubricate the gears.
Fit the oil pump.
1. Fit the oil pump with a new gasket and a new oil filter.
2. Tighten the oil pump bolts.
3. Connect the oil feed pipe to the turbocharger.
4. Tighten the oil feed pipe bolt.
67. Connect the coolant pipe to the oil cooler.
1. Connect the coolant pipe to the oil cooler.
2. Tighten the bracket bolt.

Mondeo 1997 (08/1996-09/2000)
From: 05/1998 - Specifications
Print
Engine Data - Zetec-E

Engine management EEC V/SEFI EEC V/SEFI EEC V/SEFI
Engine code L1N/L1Q RKF/RKH NGB/NGC
Emission standard EC Stage llE4 EC Stage llE4 D3/E4
Premium 95 RON Premium 95 RON Premium 95 RON
Fuel
unleaded unleaded unleaded
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Bore (mm) 76,0 80,6 84,8
Stroke (mm) 88,0 88,0 88,0
Cubic capacity (cm 3) 1.598 1.796 1.989
Compression ratio 10,3:1 10,0:1 10,0:1
Engine power output (ISO)
66 85 96
(kW)
Engine power output at
5.250 5.750 6.000
(rev/min)
Torque (ISO) (Nm) 138 158 180
Torque at (rev/min) 3.500 3.750 4.000
Idle speed (rev/min) 830 800 800
Engine speed limit
7.100 7.100 7.100
(rev/min)
Engine oil - Zetec/Zetec-E
Viscosity/ambient
Type Specification
temperature
SAE 5W-30 / from -20 °C to WSS-M2C913-A or WSS-
over +40 °C M2C912-A1
SAE 10W-30 / -20 °C to over ACEA A1/B1, A2/B2 or
Ford Super Multigrade Engine Oil
+40 °C A3/B3
Ford XR+ High Performance High SAE 10W-40 / -20 °C to over
ACEA A3, B3
Lubricity Engine Oil +40 °C
Ford Formula S Synthetic Engine SAE 5W-40 / under -20 °C to
ACEA A3, B3
Oil over + 40 °C
If these engine oils are not available, only engine oils which comply with the
minimum API SH/EC (Energy Conserving) specification must be used.
Capacities
Litres
Engine oil, initial fill incl. filter 4,50
Engine oil, oil change incl. filter 4,25
Engine oil, oil change excl. filter 3,75
6,6/7,
Coolant (with manual/ automatic transmission)
1
Transmission fluid (iB5) 2,3
Transmission fluid (CD4E with oil cooler) * = new transmissions are already filled
8,5*
with 3,5 liters of fluid.
Item Specification
Transmission fluid (MTX 75) ESDM-2C186-A
Transmission fluid (CD4E) ESP-M2C166-H
Sealer, camshaft bearing cap WSK-M2G348-A5
Sealer for cylinder block mating face intersections WSE-M4G323-A4
Lubricant (spark plug threads - Never Seeze) ESE-M1244-A
Thread-locking compound SDM-M4G9107-A
Silicone grease, spark plug connector seal A696-M1C171-AA
Dimensions - cylinder block

16V 16V 16V
Number of main bearings 5 5 5
m 76,000 - 80,600 - 84,800 -
m 76,010 80,610 84,810
m 76,010 - 80,610 - 84,810 -
m 76,020 80,620 84,820
m 76,020 - 80,620 - 84,820 -
m 76,030 80,630 84,830
m 58,011 - 58,011 - 58,011 -
Inside dia. - main bearing shells (fitted)
m 58,038 58,038 58,038
16V 16V 16V
Inside dia. - main bearing shells (fitted) (main m 58,008 - 58,008 - 58,008 -
bearing shells graded by size) m 58,031 58,031 58,031
m 0,011 - 0,011 - 0,011 -
Main bearing radial clearances
m 0,058 0,058 0,058
Main bearing radial clearances (main bearing m 0,020 - 0,020 - 0,020 -
shells graded by size) m 0,042 0,042 0,042
m 62,287 - 62,287 - 62,287 -
Main bearing parent bore
m 62,300 62,300 62,300
Dimensions - crankshaft

Main bearing journal dia. mm 57,980 - 58,000 57,980 - 58,000 57,980 - 58,000
Main bearing journal end float mm 0,09 - 0,26 0,09 - 0,26 0,09 - 0,26
Big-end bearing journal dia. mm 46,89 - 46,91 46,89 - 46,91 46,89 - 46,91
Dimensions - connecting rod
Bore diameter, big end mm 49,89 - 49,91

Bore diameter, small end mm 18,958 - 18,982
Inside dia. - big-end bearing shells (fitted) mm 46,926 - 46,960
Big-end bearing/rod bearing radial clearance mm 0,016 - 0,070
Big-end bearing clearance (axial) mm 0,090 - 0,320
Dimensions - pistons (when new)

Piston clearance in cylinder mm 0,040 - 0,060 -0,010 - 0,030 -0,010 - 0,030
Piston ring gaps (fitted)
Upper compression ring mm 0,30 - 0,50 0,25 - 0,36 0,22 - 0,37
Lower compression ring mm 0,30 - 0,50 0,70 - 0,9 0,70 - 0,9
Oil scraper ring mm 0,25 - 1,00 0,38 - 1,14 0,20 - 0,70
Dimensions - piston pin

Piston pin length mm 49,85 - 50,15 54,70 - 55,00
Piston pin diameter mm 18,997 - 19,000 18,995 - 19,000
Piston pin clearance in piston mm 0,010 - 0,017 0,010 - 0,017 0,010 - 0,016
Dimensions - camshaft

Number of camshaft bearings 5 5 5
Drive Timing belt Timing belt Timing belt
Bearing journal dia. mm 25,960 - 25,980 25,960 - 25,980 25,960 - 25,980
Camshaft bearing radial clearance mm 0,020 - 0,070 0,020 - 0,070 0,020 - 0,070
Camshaft end float mm 0,080 - 0,220 0,080 - 0,220 0,080 - 0,220
Dimensions - valve

Valve clearance in valve guide
Injector mm 0,017 - 0,064 0,017 - 0,064 0,017 - 0,064
- exhaust valve mm 0,017 - 0,064 0,017 - 0,064 0,017 - 0,064
Valves
Description Petrol engine Liquid propane gas (LPG) drive

Valve control Bucket tappets
m
Valve clearance (engine cold); intake 0,11 - 0,18 0,07 - 0,22
m
m
Valve clearance (engine cold); exhaust 0,27 - 0,34 0,23 - 0,38
m
Dimensions - cylinder head

16V 16V 16V
m
Maximum distortion (mating face) 0,1 0,1 0,1
m
m 2,0 +0,12 2,0 +0,12 2,0 +0,12
Mating face height
m - 0,24 - 0,24 - 0,24
Mating face peak-to-valley height (reference length
µm R 3z = 6,0 R 3z = 6,0 R 3z = 6,0
2,5 mm at right angles to direction of grooves)
Oil pressure, at 800 - 850 rev/min bar 1,3 - 2,5 1,3 - 2,5 1,3 - 2,5
Oil pressure, at 4000 rev/min bar 3,7 - 5,5 3,7 - 5,5 3,7 - 5,5
On the 2,0l engine the piston cooling oil nozzles are fully opened at 4000
rev/min. This produces a pressure loss of 0,3 - 0,8 bar, which may cause the
2,0l engine to go into the lower pressure range.

Hose clamps 4 35
Intake system
Intake manifold studs 5 44
Intake manifold bolts and nuts 18 13
Throttle body 9 80
EGR valve to intake manifold 9 80
Exhaust system
Heat shield to cylinder head (2,0 engine) 10 89
Heat shield and coolant pipe bracket to exhaust manifold (1,6 - 1,8l engine) 10 89
Heat shield and coolant pipe bracket to exhaust manifold (1,6 - 1,8l engine) 23 17
Exhaust manifold studs 6 53
Exhaust manifold nuts 16 12
Catalytic converter to exhaust manifold 40 30
EGR pipe to EGR valve 29 21
Bracket - EGR pipe to ignition coil 6 53
EGR pipe to exhaust manifold 29 21
Driveshafts
Center bearing - right-hand front driveshaft 27 20
Front driveshaft bracket to engine 48 35
Generator
Generator to bracket 50 37
Transmission
Transmission/engine flange bolts 40 30
Starter motor to transmission 48 35
Transmission oil drain plug 35 26
Transmission oil check plug 35 26
Flywheel/drive plate 112 83
Clutch pressure plate 29 21
Subframe
Radiator bracket to subframe 10 89
Air conditioning system
Engine mounting
Right-hand engine roll restrictor to transmission 84 62
Right-hand engine roll restrictor to subframe 48 35
Right-hand engine roll restrictor bracket to transmission (MTX 75) 84 62
Left-hand engine roll restrictor bracket to transmission (MTX 75) 84 62
Center bolt - left and right-hand engine roll restrictor 120 89
Rear engine mounting to transmission 83 61
Front engine mounting bracket to engine and engine mounting 83 61
Suspension
Hub nut 290 214
Wheel nuts 85 63
Suspension strut to body 46 34
Stabilizer link rod to suspension strut 47 35
Power steering
A/C compressor bracket/power steering pump to cylinder block 48 35
Cylinder head
Camshaft position sensor to cylinder head 21 15
Metal cylinder head cover, 2nd stage 7 62
Plastic cylinder head cover, 2nd stage 9 80
Spark plugs 15 11
Timing belt tensioner 38 28
Camshaft timing pulley 68 50
Upper timing belt cover 10 89
M10 x 11,5 oilway blanking plug 24 18
1/4 P.T.F. oilway blanking plug 25 18
EI ignition coil bracket to cylinder head 21 15
Retaining plate for power steering pump to cylinder head 47 35
Engine lifting eye to cylinder head 16 12
Engine lifting eye to generator bracket 47 35
Bracket for oil dipstick tube 9 80
Cylinder block
Oil level indicator sensor 22 16
Oil pressure switch 27 20
Heater pipe bracket to oil pan 10 89
Oil pan 21 15
Oil pump 11 8
Piston cooling oil nozzles or blanking plugs 10 89
Oil intake pipe to oil pump 10 89
Oil baffle and oil intake pipe bracket to studs 19 14
Main bearing cap bolts and studs 83 61
Big-end bearing cap bolts, stage 1. 15 11
Big-end bearing cap bolts, stage 2. 90° 90°
Coolant pump 18 13
Multi-groove belt idler pulley 48 35
Bracket for positive crankcase ventilation pipe 23 17
Positive crankcase ventilation 10 89
Coolant pump belt pulley 10 89
Crankshaft belt pulley 115 85
Bracket of crankshaft position sensor 21 15
Crankshaft position sensor to bracket 8 71

Mondeo 1997 (08/1996-09/2000)
From: 05/1998 - Engine
Print

The Cougar is now equipped with the new 2,0L Zetec-E engine familiar from Mondeo.
Location of the engine number on the cylinder block

Item
Part Number
Description
1
-
Engine code
2
-
Engine serial number
Engine codes
The engine codes for the 2.0L Zetec-E engines are:
 2,0L Zetec-E-Motor (D3) - EDBA

 2,0L Zetec-E-Motor (E4) - EBBC
 2,0L Zetec-E-Motor (Stage II) - EBBD
 2,0L Zetec-E-Motor (Stage III) - EDBB
Construction of the Zetec-E engine
Basic concept
The Zetec-E engine is an in-line four cylinder engine with two overhead camshafts and
16 valves. The 16 valve cylinder head achieves a better cylinder charge particularly at
high engine speeds.
The cylinder head is made of aluminum alloy and the cylinder block of cast iron.
Timing belt center cover/front engine mounting bracket
The new timing belt cover has a vertical rib to increase its rigidity. This means that both
the timing belt centre cover and the front engine mounting must be removed at the
same time in order to change the timing belt.
Cylinder head
Combustion chamber
The centrally positioned spark plug in the roof shaped combustion chamber causes the
mixture found in the combustion chamber to ignite. Positioning the spark plug centrally
causes an even spread of the flame front through the combustion chamber and thus at
the same time reduces the tendency of the engine to knock.
Valve gear
The two camshafts are driven by one common drive belt and operate four valves per
cylinder through adjustable tappets. Because of the exhaust gas stream flowing past
them, the exhaust valves are subjected to particularly high temperatures. The exhaust
valves are specially coated so that they are better able to dissipate heat. Each valve is
closed by its own single valve spring. Adjustment shims in the valve tappets are
changed in order to adjust the valve clearance. These are available in 52 different
thicknesses. The thickness of the adjusting shim is stamped on the back face as a
numerical value accurate to a hundredth of a millimetre (example: the number 222 =
2,22 mm). Because of the limited space in the cylinder head the camshaft must be
removed in order to change the adjusting shims. Absolute accuracy is therefore
necessary during the adjustment procedure in order to avoid having to remove and
install the camshaft more than once. The cams on the camshaft run off-centre on the
valve tappets. Because of this, from an engine speed of about 3000 rev/min the tappets
are caused to rotate, and they transmit this turning movement to the valves. Turning of
the valves is desirable because this leads to an even seating of the valves on their seats
and prevents the valves from bedding in at one position and leaking.
Valve gear
Item
Part Number
Description
1
-
Bolt - camshaft bearing cap
2
-
Camshaft bearing cap
3
-
Inlet camshaft
4
-
Exhaust camshaft
5
-
Oil gallery blanking plug
6
-
Valve clearance adjusting shim
7
-
Tappet
8
-
Valve collets
9
-
Valve spring retainers
10
-
Valve spring
11
-
Valve stem seals
12
-
Exhaust valves
13
-
Inlet valves
14
-
Cylinder Head
15
-
Cylinder head bolt
16
-
Spark plug
17
-
Engine lifting eye bolt
18
-
Engine lifting eye
19
-
Timing pulley bolt
20
-
Camshaft timing belt pulleys.
21
-
Camshaft oil seals
22
-
Front camshaft bearing cap guide sleeve
23
-
Front camshaft bearing cap
Timing belt tensioner
NOTICE: Only tension the timing belt tensioner anticlockwise.

Correct timing belt tension is ensured by the automatic timing belt tensioner. To do this
it is set to its base position when a new timing belt is put in place (arrow point (3) and
marking (2) line up). This base setting is taken over by a cam (4). A further cam which
is under spring pressure ensures the correct timing belt tension during operation. The
working range of the timing belt tensioner is 30° either side of the centre position.
NOTE: The timing belt must not be re-tensioned because there is a danger that the
working range would be exceeded in one direction. The base setting of the timing belt
tensioner is only valid for new timing belts. Re-tensioning can therefore lead to
splitting or run-out of the timing belt.
After removing the adjusting tool and the alignment pin the base setting can no longer
be checked (the force of the valve springs puts pressure on the timing belt and alters
the position of the timing belt tensioner).
Automatic timing belt tensioner
Item
Part Number
Description
1
-
Clip hooked into the pressed steel cover
2
-
Marking.
3
-
Arrow point
4
-
Cam for base setting
Components Attached to Cylinder Head
Intake manifold
The new Zetec-E engines are equipped with an inlet manifold made of glass fibre
reinforced plastic. The channels of the inlet manifold are arranged in such a way that
the inlet paths for all cylinders are the same length.
 This gives the following advantages:

-
reduced heat transfer to the fuel injectors and therefore prevention of vapor bubbles,
-
lighter weight
-
reduction of fuel deposits on the intake pipe walls during cold starts
-
less heating of the intake air when the engine is hot.
Components attached to the inlet manifold
Item
Part Number
Description
1
-
Fuel injectors plug
2
-
Bolt of fuel pipe clamp
3
-
Fuel rail
4
-
Injector
5
-
Injector retaining ring
6
-
Intake manifold gasket
7
-
Intake manifold
8
-
Quick-release coupling of brake servo vacuum pipe
9
-
Idle speed control valve gasket (ISC valve)
10
-
ISC valve
11
-
Throttle Body Gasket
12
-
Fuel rail bolt
13
-
Throttle body
14
-
Fuel pipe bracket bolt
15
-
Throttle body bolt
16
-
Fuel pipe bracket
17
-
Fuel pipe clamp.
Cylinder block
Crankshaft
The five main bearing crankshaft has a counterbalance weight for each cylinder. The
centre main bearing is provided with two bearing half shells which take the axial thrust
of the crankshaft and are also used to adjust the end float.
Crankshaft bearings
Item
Part Number
Description
1
-
Cylinder block main bearing shell
2
-
Main bearing shell with thrust half shells
3
-
Crankshaft
4
-
Crankshaft timing pulley Woodruff key
5
-
Bearing cap main bearing shell
6
-
Main bearing caps
7
-
Bolt - main bearing cap
Big end bearings
The connecting rods are numbered from one to four in sequence on the side nearest the
timing belt. Mixing up the big end bearing caps and connecting rods is almost impossible
because the bearing caps are broken away from the connecting rods during production.
The fracture profile of the bearing cap therefore only matches one particular connecting
rod.
Lower crankcase
Lower crankcase
View of lower crankcase
The purpose of the lower crankcase is to dampen the engine vibrations. This leads to a
further reduction in the noise level in the passenger compartment. The joint between
the lower crankcase and the cylinder block is sealed using a rubber gasket (from
01/1999 a steel carrier plate gasket is used).
Lower crankcase shims

Shims are to be installed at the lower crankcase in order to level out the gap between
the transmission and the lower crankcase if it is too large (see Technical Data and
Specifications).
Oil pan
The assembly is closed at the bottom by a pressed steel sump which is attached directly
to the lower crankcase. Sealing is achieved using a 3 mm wide bead of sealer.
Engine management
EEC V Module
Engine management of the Zetec-E engines is handled by the EEC V module. To do this
it requires a great deal of information about the current operating parameters of the
engine and the automatic transmission (CD4E). The EEC V module obtains this
information through sensors.
 The EEC V module controls:

-
the fully electronic ignition system (EI)
-
sequential fuel injection (SEFI),
-
the air conditioning system together with the cooling system and
-
transmission control of the CD4E automatic transmission (if equipped).

Mondeo 1997 (08/1996-09/2000)
From: 05/1998 - Engine
Print
Assembly
205-072 (15030A)
Installer, Oil Seal
303-039 (21009B)
Installer, Oil Seal
303-291 (21141)
Locking Tool, Flywheel
303-254 (21135)
Alignment Plate, Camshaft
303-376 (21162B)
Timing Peg, Crankshaft TDC
303-574 (21163)
Aligner, Clutch Disk
308-204 (16067)

Spatula
Steel straightedge
Workshop hoist
Studs (M6 x 20)
Materials
Name
Specification
High-temperature grease
ESD-M1C220-A
Sealer remover
WSK-M2G348-A4
Sealer - joins between cylinder block and oil pump/oil seal carrier
WSK-M4G320-A
Sealer - Camshaft bearing cap
WSK-M2G348-A5
Sealer
WSS-M4G323-A7
Engine oil
WSS-M2C912-A1
Silicone grease, spark plug connector seal
A696-M1C171-AA
Never Seez
ESE-M1244-A
Assembly
All vehicles
1. Preparatory operations.
NOTICE: Do not damage the cylinder liners.

 Remove the carbon deposits from the upper edge of the cylinder.
 Clean all parts to be reused using a spatula and seal remover and check for
damage.
 Thoroughly clean all threaded bores.
2. Available main bearing shell sizes.
NOTE: The main bearing shells are color coded.
 Stage A: 2.145 - 2.152 mm (green)
 Stage B: 2.140 -2.147 mm (brown)
 Stage C: 2.135 -2.142 mm (brown)
 Stage D: 2.130 - 2.137 mm (brown)
3. NOTE: Use main bearing shells of size "B" or "C" (refer to the previous step).
Measure the crankshaft main bearing journal clearance.
For additional information, refer to: Spiel - Kurbelwellenhauptlagerzapfen
(303-00 Motor - Allgemeine Informationen, General Procedures).
 In accordance with preceding work step, select a bearing shell to obtain an
end float of 0.020 - 0.040 mm.
4. Measure the crankshaft end float.
For additional information, refer to: Axialspiel - Kurbelwelle (303-00 Motor -
Allgemeine Informationen, General Procedures).
5. Measure the camshaft bearing journal clearance.
For additional information, refer to: Spiel – Nockenwellenlagerzapfen (303-00
Motor - Allgemeine Informationen, General Procedures).
6. Measure the camshaft end float.
For additional information, refer to: Axialspiel - Nockenwelle (303-00 Motor -
7. Measure the crankshaft.
For additional information, refer to: Durchmesser -
Kurbelwellenhauptlagerzapfen (303-00 Motor - Allgemeine Informationen,
General Procedures).
8. Measure the camshaft bearing journal diameter.
For additional information, refer to: Durchmesser – Nockenwellenlagerzapfen
(303-00 Motor - Allgemeine Informationen, General Procedures).
9. Measure the piston diameter.
For additional information, refer to: Durchmesser - Kolben (303-00 Motor -
10. Measure the cylinder bore taper.
For additional information, refer to: Konizität - Zylinderbohrung (303-00 Motor
- Allgemeine Informationen, General Procedures).
11. Measure the piston ring end gap clearance.
For additional information, refer to: Kolbenringstoß (303-00 Motor -
12. Measure the piston ring clearance.
For additional information, refer to: Kolbenringspiel (303-00 Motor -
13. Check for cylinder head distortion.
For additional information, refer to: Zylinderkopfverzug (303-00 Motor -
14. Install the crankshaft.
 Lay the main bearing shells in the cylinder block and main bearing caps and
coat them with engine oil.
 Coat the crankshaft main bearing with engine oil.
 Insert the crankshaft.
NOTE: Do not tighten the main bearing cap bolts yet.
 Attach the main bearing caps.
15. NOTE: The connecting rods are numbered consecutively from the timing belt
end. The recesses in the piston crown point towards the inlet side (1.8l only),
the arrow points towards the timing belt end.
Install the piston.
 Distribute the piston ring gaps and the elements of the oil scraper ring evenly
around the circumference (120 degrees).
 Compress the piston rings using a piston ring compressor.
 Press pistons one and four into the cylinders using a hammer handle. Big-end
bearing journals one and four must be in the BDC position.
NOTE: The Ford trademark on the connecting rod points towards the
drive belt side.
 Check the bearing shells are clean and dry and install them in the associated
connecting rods and bearing caps.
NOTE: Use new big-end bearing cap bolts.
NOTE: Do not yet tighten the big-end bearing cap bolts.
 Coat the big-end bearing journals and big-end bearing shells with engine oil.
 Install the bearing caps.
 Rotate the crankshaft through 180 degrees and insert pistons two and three.
16. NOTE: The crankshaft must turn freely, if necessary check and adjust the end
float.
Tighten the main bearings and the big-end bearings.
1. Tighten the main bearing cap bolts to 83 Nm.
2. Tighten big-end bearing nuts in two stages.
 Stage 1: 15 Nm
 Stage 2: 90 degrees
17. Attach the rear oil seal housing and the CKP sensor with its bracket.
 Position the oil seal housing with a new oil seal and install the bolts finger
tight.
 Align the oil seal carrier so that the sealing face of the oil seal carrier is 0.3 to
0.8 mm below the cylinder block.
 Tighten the four bolts.
1. Install the CKP sensor bracket.
18. NOTICE: The oil seal must be inserted as far as its stop into Special Tool
303 -291.
NOTE: Coat the crankshaft oil seal with engine oil.
Install the new crankshaft rear seal in the special tool.
 To install it correctly, place the special tool in a vise and press in the seal
using the handle of a hammer.
 Incorrect position
 Correct position
19. Draw in the oil seal.

 Draw in the oil seal with the special tool and two flywheel bolts.
20. Align the oil pump.

 Position the oil pump with a new gasket and tighten the bolts finger tight.
 Align the oil pump on both sides so that the mating face is 0.3 to 0.8 mm
above the lower edge of the cylinder block.
21. NOTE: Coat the crankshaft oil seal with engine oil.
Attach the oil pump with a new crankshaft front oil seal.
 Tighten bolts and check alignment in accordance with preceding work step;
correct if necessary.
22. Align the lower crankcase.

 Coat the joints between the cylinder block and the oil pump/oil seal housing
with sealant .
 Position the lower crankcase with a new gasket and tighten the bolts finger
tight.
NOTE: If the permissible limits for protrusion and gaps are exceeded,
install spacer shims as described in the next step.
 Align the lower crankcase with a steel straightedge so that the cylinder block
and the lower crankcase are flush, or the following tolerances are not exceed:
1. MTX 75 manual transmission: 0.10 mm projection to 0.25 mm gap.
2. CD4E automatic transmission: 0.00 mm projection to 0.25 mm gap.

23. NOTE: From 01/99 onwards only round spacer shims will be used.
If necessary, install lower crankcase spacer shims.
 Use 0.25 mm spacer shims for a gap of 0.26 to 0.50 mm.
 Use 0.50 mm spacer shims for a gap of 0.51 to 0.75 mm.
24. Attach the lower crankcase using a new gasket.

1. Tighten bolts and check alignment as described previously; correct if
necessary.
2. Attach the oil intake pipe.
25. NOTICE: Use studs. The lower crankcase may be damaged if sealer enters
the blind holes.
10 Screw studs (M6 x 20) into the indicated blind holes.
26. NOTE: Once contact is made with the lower crankcase, do not remove the oil
pan again.
NOTE: Attach the oil pan within 10 minutes of applying the sealer.
Apply a 3 mm bead of sealer to the oil pan mating surface.
Attach the oil pan and tighten in two stages.
 Stage 1: 6 Nm
 Stage 2: 10 Nm
28. NOTE: Use new bolts.

NOTE: Remove any residue of thread-locking compound from the threaded
bores.
Attach the flywheel/drive plate.
29. NOTE: Apply high-temperature grease thinly enough to ensure that no grease
emerges from the splines when the clutch disk is pushed onto the transmission
input shaft.
Coat the clutch plate splines evenly with high-temperature grease .
30. Centre the clutch disk on the pressure plate.
31. Attach the clutch.

1. Locate the clutch pressure plate in position with the centered clutch disk.
2. Screw in the bolts uniformly two turns each and then to the correct torque,
working diagonally.
3. Check that the clutch disk is properly centered.
32. NOTICE: The choice of cylinder head gasket depends on the number of
the cast cylinder block.
Install the cylinder head.
1. Cylinder block number
2. Install a new cylinder head gasket onto the cylinder block.
3. Screw in the guide pegs.
4. Insert guide sleeves.
 Suspend the cylinder head by the engine lifting eyes from the workshop hoist
and position on the cylinder block in the installation position.
33. NOTICE: The cylinder head bolts must not be retightened.

Attach the cylinder head.
NOTE: Screw in the cylinder head bolts unoiled.
 Tighten the cylinder head bolts in three stages in accordance with the
tightening sequence.
 Stage 1: Tighten the bolts to 15 Nm.
 Stage 2: Tighten the bolts to 40 Nm.
 Stage 3: Tighten the bolts by 90 degrees.
34. NOTE: The identification numbers are located on the outside of the camshaft
bearing caps.
Apply sealant to camshaft bearing caps nos. 0 and 5, in the areas shown.
35. Turn the crankshaft to approx. 60° BTDC.
36. NOTE: Lay the camshafts in place with none of the cams at full lift.
Coat the camshafts and camshaft bearing caps with engine oil.
37. NOTE: Work through the tightening sequence several times and tighten the
camshaft bearing caps evenly a half a turn at a time, and then tighten them
down in two stages.
Tighten the camshaft bearing caps.
38. Install the camshaft oil seals.
 Lubricate the camshafts and the sealing lip of the oil seals with engine oil.
 Draw in the new oil seals using the special tool, a washer and an M10x70
bolt.
39. NOTE: Do not tighten the bolts. The timing pulleys must be free to turn on the
camshafts.
Turn the camshafts to ignition point on cylinder no. 1 and insert the special
tool into the camshafts.
40. Set the crankshaft to just before TDC on cylinder no. 1.
41. Remove the blanking plug and align the crankshaft to TDC on cylinder no.
1 using the special tool.
42. NOTE: Do not tighten the bolts. The camshaft timing pulleys must be able to
turn freely on the camshafts.
Slide the timing pulleys onto the camshafts and screw in the bolts.
43. Install a new gasket to the coolant pump.
1. Lay the gasket in place.
2. Secure the gasket by bending over the tabs.
Vehicles built up to 1/1999
44. NOTICE:
Do not turn the crankshaft, if necessary check whether the crankshaft is

resting against the special tool 303-620.
NOTE: The tab on the timing belt tensioner must not be hooked into the metal
cover.
Fit the new timing belt.
1. Slide the crankshaft timing pulley and the thrust washer onto the crankshaft.
2. Attach the coolant pump.
3. Attach the lower idler pulley.
4. Attach the upper idler pulley.
5. Starting from the crankshaft timing pulley and working counter-clockwise, put
the timing belt in place. Pull the belt tight as you proceed.
6. Attach the timing belt tensioner and screw in the bolt 5 turns.
Vehicles built from 1/1999
45. NOTICE:
Do not turn the crankshaft, if necessary check whether the crankshaft is

resting against the special tool 303-620.
NOTE: The tab on the timing belt tensioner must not be hooked into the metal
cover.
Fit the new timing belt.
1. Push crankshaft pulley hub, together with thrust washer, onto crankshaft.
2. Attach the coolant pump.
3. Install the idler pulley.
4. Put the timing belt in place, starting from the crankshaft pulley hub and
working counter-clockwise. Keep the timing belt taut at all times.
5. Install the timing belt tensioner and screw in the bolts five turns.
All vehicles
46. NOTICE: Tension the timing belt working counter-clockwise.

NOTE: The valve timing will be incorrect and there will be timing belt noise if
the timing belt is not correctly tensioned.
Tension the timing belt.
1. Hook the timing belt tensioner into the metal cover and loosely install the
bolt.
2. Tension the timing belt by turning the tensioner counter-clockwise until the
arrow and the marking line up.
47. NOTICE: Do not tighten against Special Tool 303-376.

NOTE: Use Special Tool 205-072 to hold the timing pulleys.
Tighten the timing pulleys.
48. Remove Special Tool 303 -574.
49. Remove Special Tool 303 -376 from the camshafts.

50. NOTE: Turn the engine by the crankshaft two turns in the normal direction of
rotation.
Check the valve timing by inserting the special tools, if necessary correct the
adjustment.
 Install Special Tool 303-574 and make sure that the crankshaft is resting
against the special tool.
 Insert Special Tool 303-376 into the camshafts; if necessary loosen the timing
pulleys, correct the camshaft setting and re-check.
 Remove the special tools.
51. Install the blanking plug.
52. NOTICE:
When applying silicone grease, use a blunt object (e.g. a plastic cable tie),
to prevent damaging the spark plug connector seal.
Push on the spark plug connector in line with the spark plug axis.
NOTE: Coat the inner side of the spark plug connector down to a depth of 5 to
10 mm with silicone grease.
Install the cylinder head cover and the spark plugs.
 Coat the spark plug threads with Never Seez.
 Screw in the spark plugs.
 Screw in the cylinder head cover bolts in two stages.
 Stage 1: 2 Nm
 Stage 2 (metal cylinder head cover). 7 Nm
 Stage 2 (plastic cylinder head cover). 9 Nm
 Push on the spark plug connectors until they engage.
53. Attach the timing belt cover.
1. Attach the timing belt lower cover.
2. Attach the crankshaft pulley/vibration damper.
NOTE: Check the seat of the seal and correct as necessary.
3. Attach the timing belt upper cover.
NOTE: Correct seating of the lower in the middle cover.
4. Install the middle timing belt cover.
5. Install the drive belt idler pulley.
6. Attach the coolant pump pulley.
54. Attach the positive crankcase ventilation using a new gasket.

1. Install the three bolts.
2. Install the positive crankcase ventilation pipe.
55. Attach the ancillary components on the exhaust side.
1. A/C compressor bracket.
2. Power steering pump bracket to cylinder head.
3. Power steering pump bracket to cylinder head.
4. Coolant hose to thermostat housing and coolant pump.
56.Suspend the engine by the engine lifting eyes from the workshop hoist and
detach it from the assembly stand.
 Place the engine on the assembly table and leave it attached to the workshop
hoist.
57. Attach the ancillary components on the intake side.
1. Oil pressure switch
2. KS
 Attach a new oil filter. Coat the seal with engine oil .
 Generator bracket
1. Generator bracket
58. Install the intake manifold.
1. Install the seven bolts and two nuts.
2. Connect the solenoid valve plug and press in the rubber seal.
59. Install the generator.

 Insert the generator into the bracket.
 Tighten the bolt.
 Install and tighten the bolt.
1. Attach the positive cable.
1. Attach the connectors.
60. Connect the oil pressure switch plug and the knock sensor.
61. Connect the CMP sensor plug and the ECT sensor plug.
 Connect the wiring to the EI coil.

MONDEO2

Uploaded by

Copyright:

Available Formats

MONDEO2

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MONDEO2

Uploaded by

Copyright:

Available Formats

Engine - 1.6L/1.8L/2.

0L, Vehicles Built

Engine Data - Zetec-E

1,6 DOHC 16V 1,8 DOHC 16V 2,0 DOHC 16V

1,6 DOHC 1,8 DOHC 2,0 DOHC

1,6 DOHC 16V 1,8 DOHC 16V 2,0 DOHC 16V

1,6 DOHC 16V 1,8 DOHC 16V 2,0 DOHC 16V

1,6 DOHC 16V 1,8 DOHC 16V 2,0 DOHC 16V

1,6 DOHC 16V 1,8 DOHC 16V 2,0 DOHC 16V

1,6 DOHC 16V 1,8 DOHC 16V 2,0 DOHC 16V

1,6 DOHC 16V 1,8 DOHC 16V 2,0 DOHC 16V

1,6 DOHC 1,8 DOHC 2,0 DOHC

Engine - 1.6L/1.8L/2.0L, Vehicles Built

Description and Operation

Location of Engine Code on Cylinder Block

 1,6 Zetec-E: L1J

Valve Timing and Combustion Chamber

General View - Operation of the Valves

Differences and Special Features of the Engine Variants

Differences between the basic engines:

 Special features of the 1,6 engine:

Differences between the ancillary components:

 Special features of the 1,6 and 1,8 engine:

 The EEC V module controls:

The injectors are actuated sequentially.

Design of the Injectors

 This gives the following advantages:

Engine - 1.6L/1.8L/2.0L, Vehicles Built Mondeo 1997 (08/1996-09/2000)

Aligner, clutch disk

Installer, oil seal

Installer, oil seal

Locking tool, flywheel

Installer, oil seal

Timing tool, camshaft alignment

Socket, cylinder head bolts

Angle gauge, bolt tightening

Piston ring compressor

2. Size B: 2,147 - 2,140 mm (brown)

3. Size C: 2,142 - 2,135 mm (yellow)

4. Size D: 2,137 - 2,130 mm (blue)

4. NOTE: Use bearing shells of size "B" or "C" (refer to step ).

19. NOTE: Use a new gasket.

21. Fit the oil pump seal.

26. Align the oil pan.

28. NOTE: Use new bolts.

30. Install the clutch.

31. NOTICE: Bring the piston of cylinder no. 1 to a point approx. 20 mm

32. NOTE: 'TOP' mark and gasket identification.

33. Pre-tighten the cylinder head bolts.

37. Fit the camshaft bearing caps.

42. Turn the crankshaft to TDC.

Use a new timing belt.

44. Secure the timing belt tensioner.

50. Fit the timing belt covers.

51. Immobilise the flywheel with Special Tool 21-135.

57. Fit the generator bracket.

58. Fit the generator and the idler pulley.

62. Connect the plugs.

63. Connect the plugs and the generator.