General Specifications Mondeo 1993 (01/1993-07/1996)

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Specifications
Engine Data (Zetec)
1,6 l DOHC 16 V 1,8 l DOHC 16 V 2,0 l DOHC 16 V
Engine management EEC IV/SEFI EEC IV/SEFI EEC IV/SEFI
Bore mm 76,0 80,6 84,8
Stroke mm 88,0 88,0 88,0
Cubic capacity cm3 1597 1796 1988
Compression ratio 10,3 : 1 10,0 : 1 10,0 : 1
Engine power output (EEC) kW 65 82 97
Engine power output at rev/min 5250 5750 6000
Torque (DIN) Nm 138 158 180
Torque at rev/min 3500 3750 4000
Idle speed rev/min 830 800 800
Engine speed limit rev/min 7100 7100 7100
Engine Data (Zetec‐E)
1,6 l DOHC 16 V 1,8 l DOHC 16 V
Engine management EEC IV/SEFI EEC IV/SEFI
Bore mm 76,0 80,6 80,6
Stroke mm 88,0 88,0
Cubic capacity cm3 1597 1796
Compression ratio 10,3 : 1 10,0 : 1
Engine power output (EEC) kW 65 82
Engine power output (EEC) (PS) (88) (112)
Engine power output at rev/min 5250 5750
Torque (DIN) Nm 138 158
Torque rev/min 3500 3750
Idle speed rev/min 850 800
Engine speed limit rev/min 7100 7100
Location of Engine Code on Cylinder Block

 1. Engine code.
 1,6 litre Zetec: L1F
 1,8 litre Zetec: RKA
 2,0 litre Zetec: NGA
 1,6 litre Zetec‐E: L1J
 1,8 litre Zetec‐E: RKB
 2. Engine serial number.
 3. Engine flange.
 4. Filter of pulse air system.
A sticker on the upper timing belt cover indicates the cubic capacity (marked 1,6, 1,8, 2,0).
The cylinders must not be rebored: there are no oversize pistons.

Dimensions
1,6 l DOHC 16V 1,8 l DOHC 2,0 l
16V DOHC
16V
Cylinder Block Cylinder Block Cylinder Cylinder
Block Block
Cylinder mm 76,000 80,600 84,800 76,00 80,60 84,80 80,60 84,80 84,800
bore dia., - - - 0- 0- 0- 0- 0- -
class 1. 76,010 80,610 84,810 76,01 80,61 84,81 80,61 84,81 84,810
0 0 0 0 0
Cylinder 76,010 80,610 84,810
bore dia., mm - - -
class 2. 76,020 80,620 84,820
Cylinder 76,020 80,620 84,820
bore dia., mm - - -
class 3. 76,030 80,630 84,830
Inside dia. -
main 58,011 58,011 58,011
bearing mm - - -
shells 58,038 58,038 58,038
(fitted)
Inside dia. -
main
bearing
shells
58,008 58,008 58,008
(fitted)
mm - - -
(main
58,031 58,031 58,031
bearing
shells with
stepped
diameters)
Main
bearing 0,011 - 0,011 - 0,011 -
mm
radial 0,058 0,058 0,058
clearances
Main
bearing
radial
clearances
0,020 - 0,020 - 0,020 -
(Main mm
0,042 0,042 0,042
bearing
shells
graded by
size)
Main mm 62,287 62,287 62,287
bearing - - -
parent bore 62,300 62,300 62,300
Crankshaft
Main 57,980 57,980 57,980
bearing mm - - -
journal dia. 58,000 58,000 58,000
Main
bearing 0,09 - 0,09 - 0,09 -
mm
journal end 0,31 0,31 0,31
float
Big end
46,89 - 46,89 - 46,89 -
bearing mm
46,91 46,91 46,91
journal dia.
Connecting Rod
Bore dia., 49,89 - 49,89 - 49,89 -
mm
big end 49,91 49,91 49,91
20,589 20,589 20,589
Bore dia.,
mm - - -
small end
20,609 20,609 20,609
Inside dia. -
big end 46,926 46,926 46,926
bearing mm - - -
shells 46,960 46,960 46,960
(fitted)
Big‐end
bearing 0,016 - 0,016 - 0,016 -
mm
clearances 0,070 0,070 0,070
(radial)
Piston
75,975 80,570 84,770
Piston dia.,
mm - - -
class 1.
75,985 80,580 84,780
75,985 80,580 84,780
Piston dia.,
mm - - -
class 2.
75,995 80,590 84,790
75,995 80,590 84,790
Piston dia.,
mm - - -
class 3.
76,005 80,600 84,800
Piston ring gaps (fitted)
Upper
0,30 - 0,30 - 0,25 -
compressio mm
0,50 0,50 0,50
n ring
Lower
0,30 - 0,30 - 0,30 -
compressio mm
0,50 0,50 0,50
n ring
Oil control 0,25 - 0,38 - 0,40 -
mm
ring 1,00 1,14 1,40
The piston ring gaps
must be spaced evenly
around the
circumference of the
Ring gap
piston. This also applies
positions
to the elements of the
oil control ring. Stagger
the ring gaps at 120° to
one another.
Piston Pins
Piston pin 63,00 - 63,00 - 63,00 -
mm
length 63,80 63,80 63,80
20,622 20,622 20,622
Piston pin
mm - - -
dia., white
20,625 20,625 20,625
20,625 20,625 20,625
Piston pin
mm - - -
dia., red
20,628 20,628 20,628
20,628 20,628 20,628
Piston pin
mm - - -
dia., blue
20,631 20,631 20,631
Piston pin
0,010 - 0,010 - 0,010 -
clearance in mm
0,016 0,016 0,016
piston
Interference
fit in 0,013 - 0,013 - 0,013 -
mm
connecting 0,042 0,042 0,042
rod
Camshaft
Number of
camshaft 5 5 5
bearings
Toothe Toothe Toothe
Drive
d Belt d Belt d Belt
25,960 25,960 25,960
Bearing
mm - - -
journal dia.
25,980 25,980 25,980
Camshaft
bearing 0,020 - 0,020 - 0,020 -
mm
radial 0,070 0,070 0,070
clearances
Camshaft 0,080 - 0,080 - 0,080 -
mm
end float 0,220 0,220 0,220
Cylinder Head
Maximum
distortion
mm 0,1 0,1 0,1
(mating
face)
2,0 2,0 2,0
Mating face
mm +0,12 ‐ +0,12 ‐ +0,12 ‐
height
0,24 0,24 0,24
Mating face
peak‐to‐valley
height
(reference R3z = R3z = R3z =
length 2,5 mm 6,0 m 6,0 m 6,0 m
vertical to
direction of
grooves)
Oil pressure
at 800 - 1,3 - 1,3 - 1,3 -
bar
850 2,5 2,5 2,5
rev/min
Oil pressure
3,7 - 3,7 - 3,7 -
at 4000 bar
5,5 5,5 5,5
rev/min
In the 2,0 engine, the piston cooling
nozzles are wide open at 4000 rev/min,
causing a pressure loss of 0,3 - 0,8 bar.
In the 2,0 engine, the oil pressure may
therefore be at the lower end of the
range.

When reworking the cylinder head surface, the thickness must remain greater than 1,76
mm.

Engine Oil
Exterior temperature Type Specification
Ford Multigrade Super
-20 to over +40° C SAE 10W30 API/SG/CD
Engine Oil
XR+ High‐performance
-20 to over +40° C SAE 10W40 API/SG/CD
High‐lubricity Engine Oil
Semi‐synthetic and
-30 to over 40° C SAE 5W40 API/SG/CD
Synthetic Engine Oil
Ford Multigrade Super
40 to below -30° C SAE 5W30 API/SG/CD
Engine Oil
If engine oils of a different brand are used, make sure these are of an equal or higher
viscosity grade as compared with API/SG/CD.
Lubricants, Fluids and Sealers
Ford Specification
Transmission fluid (MTX‐75) ESD‐M2C186‐A
Transmission fluid (CD4E) ESP‐M2C166‐A
Coolant ESD‐M97B‐49‐A
Sealer for camshaft bearing caps: (Loctite 518) ESK‐M4G269‐A
Sealer for cylinder block: (Hylosil 502) WSK‐M4G320‐A
Spark plug lubricant: (Never Seez) ESE‐M1244‐A
Thread‐locking compound SDM‐M4G9107‐A
Fill 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
Coolant 6,6
Transmission fluid (MTX‐75) 2,6
Transmission oil (CD4E with oil cooler) * = New transmissions are
7,2*
pre‐filled with 3,5 Litres
Torques
Nm lbf.ft.
Right‐hand axle driveshaft centre bearing 27 20
Air conditioning compressor 25 18
Heater pipe bracket to sump 10 7
Subframe to body 130 96
Right‐hand engine roll restrictor to transmission (CD4E) 84 62
Right‐hand engine roll restrictor to subframe 48 35
Right‐hand engine roll restrictor to transmission (MTX 75) 49 36
Steering gear to subframe 130 96
Rear engine mounting to transmission 83 61
Front engine mounting bracket to engine and engine mounting 83 61
Centre bolt - engine roll restrictors 120 89
Lower suspension arm ball joint to spindle carrier 83 61
Track rod to spindle carrier 26 19
Stabiliser link rod to suspension strut 47 35
Gearshift linkage to body 44 32
Shift rod to transmission 23 17
Shift rod clamp bolt 16 12
Gearshift linkage stabiliser 55 41
Power steering pump to bracket 47 35
Heat shield to cylinder head 7 5
Heat shield with oil dipstick to cylinder head 10 7
Heat shield with coolant pipe bracket to exhaust manifold 23 17
Belt pulley cover 5 4
Exhaust pipe to exhaust manifold 41 30
Radiator undershield 7 5
Intake pipe to inlet manifold 4 3
Oil splash nozzles and blanking plugs 10 7
M10 x 11,5 oilway blanking plug 24 18
1/4 P.T.F. oilway blanking plug 25 18
Main bearing cap bolts and studs 80 59
Big‐end bearing cap bolts, stage 1 15 11
Big‐end bearing cap bolts, stage 2 90° 90°
Oil pump 11 8
Oil intake pipe to oil pump 10 7
Oil baffle and oil intake pipe bracket to studs 19 14
Coolant pump 18 13
Rear oil seal carrier 20 15
Bracket for crankshaft position (CKP) sensor 21 15
Sump 21 15
Flywheel 112 83
Clutch pressure plate 30 22
Cylinder head bolts, stage 1 25 18
Cylinder head bolts, stage 2 45 33
Cylinder head bolts, stage 3 105° 105°
Camshaft bearing caps, stage 1 10 7
Camshaft bearing caps, stage 2 19 14
Cylinder head cover, stage 1 2 1
Cylinder head cover, stage 2 7 5
Spark plugs 15 11
Timing belt tensioner 38 28
Camshaft timing belt cover 68 50
Upper timing belt cover 4 3
Lower timing belt cover 7 5
Coolant pump belt pulley 10 7
Crankshaft belt pulley 115 85
Crankcase breather 10 7
Crankcase breather pipe 23 17
Thermostat housing 20 15
Bracket for EI ignition coil 21 15
Air conditioning compressor bracket/power steering pump to cylinder
47 35
block
Power steering pump retaining plate to cylinder head 47 35
Heat shield bracket 32 24
Exhaust manifold nuts 16 12
Exhaust manifold studs 6 5
Inlet manifold nuts and bolts 18 13
Inlet manifold stud bolts 6 5
Throttle housing 10 7
EGR valve to inlet manifold 9 7
Pulse air system bracket to EI ignition coil bracket 10 7
Alternator bracket to cylinder block 47 35
Drive belt idler pulley 48 35
Engine lifting eye to alternator mounting 47 35
Engine lifting eye to cylinder head 16 12
Alternator to bracket 50 37
Front axle driveshaft mounting to engine 48 35
Radiator bracket to subframe 23 17
Oil pressure switch 27 20
Wheel nuts 85 63
Transmission fluid level drain plug 35 26
Transmission fluid check plug 35 26
Engine oil drain plug 25 18
Oil level indicator sensor 22 16
Suspension strut to body 46 34
Subframe to body 130 96
Centre bearing - right‐hand front axle driveshaft 27 20

Engine – Dismantle and Reassemble (21

Mondeo 1993 (01/1993-07/1996)
134 8)
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Removal and Installation

Special Tools

15‐030 AUniversal flange

holding wrench

16‐067Clutch disc locator

 21‐009 BCamshaft radial oil
seal installer

21‐064Mounting bracket

21‐093 ACrankshaft front

radial oil seal installer

21‐141Crankshaft rear radial

oil seal installer

21‐150 AMounting plate

21‐162TDC setting tool for

camshaft

21‐167Cylinder head bolt

wrench

21‐540Angle gauge

Materials
Obtainable through:
Replacement Services
Limited, 30 Euston
Plastigage
Street, Freemans
Industrial Estate,
Leicester, LE2 7ST.
Workshop Equipment
Assembly stand 21‐187
Proprietary Tools
Dial indicator
Magnetic base for dial indicator
Piston ring compressor
Dismantle
1. Disconnect the multiplugs and disconnect the
alternator.
1. Disconnect the multiplugs of the main engine wiring
loom.
2. Disconnect the throttle position sensor (TP sensor).
3. Disconnect the camshaft position sensor (CMP
sensor).
4. Disconnect the alternator.
2. Disconnect the multiplug.
1. From the EI ignition coil.
2. From the radio interference suppressor.
3. From the engine coolant temperature sensor (ECT
sensor).

3. Disconnect the multiplugs and release the filter of

the pulse air system.
1. Disconnect the multiplug from the engine coolant
temperature sensor.
2. Disconnect the multiplug from the crankshaft
position sensor (CKP sensor).
3. Unscrew the bolt.

4. Detach the main engine wiring loom from the inlet

manifold.
• Remove the screws.
• Detach the main engine wiring loom and remove it.

5. Detach the alternator and idler pulley.

1. Detach the alternator.
2. Detach the drive belt idler pulley.

6. Remove the alternator bracket.

1. Remove the engine lifting eye bolt.
2. Remove the bracket.
7. Remove the EGR valve and bracket of the pulse air
system.
1. Detach the bracket.
2. Remove the EGR valve and the old gasket.

8. Detach the throttle housing.

9. Detach the inlet manifold.

• Disconnect the engine breather hose from the inlet
manifold.
• Remove the inlet manifold (two nuts, eight bolts).

10. Attach the engine to an assembly stand.

1. Attach the mounting plate.
2. Attach the mounting bracket.
• Attach the engine to the assembly stand.
• Drain off the engine oil.
• Detach the oil filter.

11. Remove the heat shield with the bracket.

1. Unscrew the bolts.
2. Detach the radiator hose with the coolant pipe.
12. Detach the air conditioning compressor bracket
and the power steering pump.
1. Unscrew the two bolts.
2. Remove the screws.

13. Detach the exhaust manifold.

1. Remove the oil dipstick and tube.
2. Unscrew the nine nuts.
• Carefully lay the exhaust manifold with the pulse air
system to one side.

14. Detach the EI ignition coil and the thermostat

housing.
• Disconnect the HT leads from the spark plugs.
1. Detach the bracket from the EI ignition coil.
2. Remove the thermostat housing.
15. Remove the crankcase breather.
1. Undo the pipe.
2. Unscrew the three bolts.

16. Remove the belt pulleys from the coolant pump

and crankshaft vibration damper.

17. Remove the timing belt covers.

18. Remove the timing belt.

1. Release the belt tensioner pulley.
2. Back off the belt tensioner pulley using an Allen
key.
• Secure the belt tensioner pulley.
• Remove the timing belt.
 19. Remove the crankshaft timing belt pulley.
1. Pull off the timing belt pulley.
2. Remove the thrust washer.

Camshaft - Remove
20. Remove the cylinder head cover and the camshaft
pulleys.
• Remove the cylinder head cover.
• Remove the camshaft pulleys, holding them with the
special tool.

21. Remove the camshafts.

• Slacken the bearing cap bolts in pairs in the
indicated sequence half a turn at a time.
• Repeat this until the bearing caps are released
completely.
• Remove the bearing caps, camshafts and radial oil
seals.

22. Remove the cylinder head.

• Slacken and unscrew the cylinder head bolts in the
indicated sequence.
• Remove the cylinder head and set it down on
wooden blocks.

23. Remove the coolant pump.

24. Remove the clutch (six bolts).

25. Remove the flywheel (six bolts).

NOTE:
Remove the sump downwards so that no oil
sludge or abraded particles get into the
engine.
26. Remove the sump (ten bolts).

27. Remove the bracket of the CKP sensor and the

rear oil seal carrier.
1. Remove the bracket.
2. Detach the oil seal carrier together with the oil seal.
• Press the oil seal out of the carrier.

28. Remove the oil intake pipe and oil baffle.

1. Detach the oil intake pipe from the oil pump.
2. Unscrew the four nuts.
 29. Remove the oil pump.

30. Remove the pistons.

CAUTION:
Do not damage the cylinder liners.

• Remove the ring of carbon around the upper edge of

the cylinders.
NOTE:
Place the big‐end bearing shells in order to
one side.
• Detach the big‐end bearing caps.
• Push the pistons, connecting rods and bearing shells
out of their bores.
NOTE:
Remove the bearing shells and keep them in
order.
31. Remove the crankshaft.
• Remove the main bearing caps.
• Remove the crankshaft.

32. Remove the oil splash nozzles for cooling the

pistons, and the blanking plugs.

Assemble
33. Preparatory operations
   Thoroughly clean all mating faces and parts to be
reused and check them for damage.
NOTE:
Use new oil splash nozzles.

34. Fit the oil splash nozzles for cooling the pistons,
and the blanking plugs.
 35. Measure the diameter of the main and big‐end
bearing journals using a proprietary micrometer.
• Repeat the measurement at 90° intervals.
• If the measured values do not correspond to the
values specified in the Technical Data, the crankshaft
must be reworked or renewed.

36. Availability of main bearing shells.

NOTE:
From 8/93, main bearing shells graded
according to size will be fitted, and these may
also be used when servicing. They can be
identified by their colour.
• Sizes available:
   Grade A: 2.1445 mm (green)
   Grade B: 2.1415 mm (brown)
   Grade C: 2.1365 mm (yellow)
   Grade D: 2.1315 mm (blue)
CAUTION:
Do not damage the crankshaft bearings when
installing the crankshaft.
37. Fit the crankshaft.
• Fit bearing shells of size `B' or `C' (see sub‐
operation ).
• Place the crankshaft in the cylinder block without
lubrication.

Measure the bearing clearances

CAUTION:
Crankshaft must not be rotated during
measurement!
NOTE:
The measurement point should be free of oil.

38. Measure the clearances of the crankshaft main

bearings.
• Lay the Plastigage thread on the bearing journal
across the bearing.
• Fit the bearing cap (see sub‐operation ).
NOTE:
Measure the bearing clearances one after
the other in numerical order (one to five).
39. Measure the clearances of the crankshaft main
bearings (continued).
NOTE:
The bearing caps are numbered starting
from the timing belt end.
• Fit the cap with its associated bearing shell, with the
arrow pointing towards the timing belt and torque it
down.
• Remove the bearing cap.
40. Measure the clearances of the crankshaft main
bearings (continued).
• Compare the Plastigage thread with the Plastigage
scale.
• The reading corresponds to the bearing clearance.
• Select the bearing shell according to sub-operation
so as to obtain a bearing clearance of 0,020 - 0,040
mm.

41. Fit the crankshaft.

NOTE:
The bearing cap numbering starts at the
timing belt end to which the arrows also
point.
• Lubricate the main bearing journals and bearing
shells with engine oil.
• Fit the crankshaft main bearing caps with their
associated bearing shells.
NOTE:
Use studs for bearings 2 and 4.

• Tighten the bolts.

42. Check the crankshaft end float.
• Set up the dial indicator.
• Measure the end float by lifting the crankshaft by
means of a screwdriver.
• Rectify the end float as necessary by fitting flanged
bearing shells to main bearing No. 3.

43. Fit the pistons.

• Lubricate the pistons and cylinder bores with engine
oil.
• Distribute the piston ring gaps uniformly around the
circumference – this also applies to the elements of
the oil control ring.
NOTE:
The numbering on the connecting rods starts
at the timing belt end. The arrow on the
piston crown points towards the timing belt
end.
• Compress the piston rings using a proprietary 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 that 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° and fit pistons 2
and 3.
44. Measure the big‐end bearing clearances.
   Measure the big‐end bearing clearances as described
in sub‐operations to
 45. Fit the bearing caps.
CAUTION:
Only use new bolts.

• Lubricate the bearing shells and journals with

engine oil.
NOTE:
The connecting rods and big‐end bearing
caps have the same numbering.
• Fit the appropriate big‐end bearing caps and bearing
shells and torque them down.
Align the Oil Pump
46. Fit the oil pump.
• Align the oil pump rotor with the recesses in the
crankshaft.
• Screw in the bolts loosely.
1. Align the oil pump so that the mating face of the oil
pump housing is 0,3 to 0,8 mm below the cylinder
block.
2. Tighten the bolts.

47. Fit the oil intake pipe and oil baffle.

• Fit the oil baffle.
1. Fit the oil intake pipe using a new seal.
2. Fit the oil baffle with the oil intake pipe bracket
(four nuts).

Fit the Oil Pump Radial Oil Seal

48. Fit the Oil Pump Radial Oil Seal
   Draw in the radial oil seal using the special tool and
the crankshaft belt pulley retaining bolt.

49. Fit the coolant pump with a new gasket.

Align the Rear Oil Seal Carrier

 50. Fit the oil seal carrier.
• Locate the oil seal carrier in position with a new
gasket and screw in the bolts loosely.
1. Align the oil seal carrier so that the mating face of
the oil seal carrier is 0,3 to 0,8 mm below the cylinder
block.
2. Tighten the four bolts.
3. Fit the CKP sensor bracket.

Fit the Radial Oil Seal in the Rear Oil Seal Carrier.
51. Fit the radial oil seal in the oil seal carrier.
   Draw in the radial oil seal using the special tool and
two flywheel bolts.

52. Coat the joins in the cylinder block mating face

with sealer.
   The sump bolts must be tightened within 20 minutes
of applying the sealer.

Align the Sump

53. Align the sump.
• Locate the sump in position with a new gasket and
screw in the bolts loosely.
• Align the sump using a steel straight edge so that
the cylinder block and sump are level.

54. Secure the sump.

• Tighten the ten sump bolts.
• Check the alignment of the sump as described in
sub‐operation and eliminate any discrepancy with
spacer sleeves if necessary.
 NOTE:
Use new bolts.

55. Fit the flywheel.

56. Centre the clutch disc on the pressure plate.

57. Fit the clutch.

1. Locate the clutch pressure plate in position with
the centred clutch disc.
2. Tighten the six bolts uniformly working diagonally.
3. Remove the special tool.

CAUTION:
Bring the piston of cylinder No. 1 to a point
approx. 20 mm before TDC to avoid damage
when fitting the cylinder head.
58. Fit the crankshaft timing belt pulley.
1. Fit the thrust washer.
NOTE:
FRONT mark.

2. Fit the timing belt pulley.

59. Fit the cylinder head.

NOTE:
TOP mark and gasket identification.

1. Fit a new cylinder head gasket.

2. Check that the locating bushes are seated
correctly.
• Fit the cylinder head.
 60. Tighten the cylinder head bolts, Stages 1 and 2.
• Screw in new un‐oiled cylinder head bolts.
• Tighten the cylinder head bolts in two stages in the
indicated sequence.

CAUTION:
Must not be re‐tightened.

61. Tighten the cylinder head bolts, Stage 3.

   Tighten the cylinder head bolts in the indicated
sequence.

Camshaft – Install
62. Fit the camshafts.
• Apply sealer to the mating face of the bearing cap
with the cylinder head at the timing belt end.
NOTE:
The camshafts are marked. The inlet
camshaft has an additional cam for the CMP
sensor at the end of the shaft.
• Lubricate the camshafts with engine oil and lay them
in place.

63. Fit the camshaft bearing caps.

NOTE:
The numbering starts on the exhaust side
with ”0" and faces outwards.
   Fit the bearing caps.

64. Tighten the camshaft bearing caps in two stages.

• Screw in the retaining 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.

Fit the Camshaft Radial Oil Seals

65. Fit the camshaft radial oil seals.
• Draw in the new radial oil seals using the special
tool, a washer and an M10 x 70 bolt.
• Fit the camshaft pulleys.
• The pulleys must be able to turn freely on the
camshafts.

66. Align the camshafts.

   Fit the special tool in the camshafts.

67. Turn the crankshaft to the TDC position.

   For greater accuracy, extend the mark on the sump
using a small strip of metal (25 mm wide) or similar.

68. Pretension the timing belt tensioner and tighten it.

   Tension the pulley against the spring by turning it
clockwise with an Allen key and tighten it.
69. Fit the timing belt.
1. Fit the timing belt in an anti‐clockwise direction,
starting at the crankshaft pulley.
2. Release the belt tensioner pulley.

70. Secure the camshaft pulleys.

NOTE:
The crankshaft must not be turned in the
process.
• Secure the camshaft pulleys.
• Remove the Special Tool 21-162.
• Turn the crankshaft two revolutions in a clockwise
direction to the TDC position.

71. Secure the timing belt tensioner.

• Secure the belt tensioner pulley.
• Check the crankshaft and camshafts are at TDC
using Special Tool 21-162.
• If there is a very tiny error:
• Align the camshaft using 15‐30 A so that aligning
tool 21-162 can be inserted. The crankshaft must
remain in the TDC position.

72. Special Tool 21-162 cannot be inserted.

• Undo the camshaft pulley on the affected camshaft,
using flange‐holding wrench 15-030 A to stop it from
turning.
• Rotate the camshaft until aligning tool 21-162 can be
inserted.
NOTE:
The crankshaft must remain in the TDC
position.
• Secure the camshaft pulley.
73. Fit the cylinder head cover.
• Coat the spark plug threads with ”Never‐Seez".
1. Screw in the spark plugs and tighten them.
2. Fit the cylinder head cover with a new gasket and
tighten the bolts in two stages.

74. Fit the timing belt covers.

   Make sure that the middle cover is seated correctly
in the lower cover.

75. Attach the coolant pump pulley and the crankshaft

vibration damper.

76. Fit the PCV.

1. Tighten the three bolts.
2. Fit the pipe.
77. Attach the EI ignition coil and the thermostat
housing.
1. Fit the thermostat housing with a new oil seal.
2. Fit the EI ignition coil bracket.
• Connect the HT leads to the spark plugs.

78. Fit the exhaust manifold.

1. Fit the exhaust manifold with a new gasket (nine
nuts).
2. Fit the oil dipstick with the tube.

79. Fit the air conditioning compressor bracket and the

power steering pump.
1. Tighten the eight bolts.
2. Tighten the bolts.
80. Fit the heat shield with the bracket.
1. Fit the bracket.
2. Connect the radiator hose with the coolant pipe.

81. Fit the inlet manifold.

• Detach the engine from the engine stand; detach the
mounting bracket and the mounting plate.
• Fit the inlet manifold with a new gasket (eight bolts,
two nuts).
• Push the PCV hose onto the inlet manifold.

82. Fit the throttle housing with a new gasket.

83. Fit the EGR valve and the bracket of the pulse air
system.
1. Fit the EGR valve with a new gasket.
2. Fit the bracket.

84. Fit the alternator bracket.

1. Fit the bracket.
2. Fit the engine lifting eye.
85. Fit the alternator and idler pulley.
1. Fit the drive belt idler pulley.
2. Fit the alternator.

86. Attach the main engine wiring loom to the inlet

manifold.

87. Fit the driveshaft bracket and oil pressure switch.

1. Fit the oil pressure switch.
2. Fit the bracket (three bolts).

88. Connect the multiplugs and fit the filter of the

pulse air system.
1. Tighten the retaining bolt of the filter of the pulse
air system.
2. Connect the multiplug to the CKP sensor.
3. Connect the engine coolant temperature sensor
multiplug.

89. Connect the multiplugs.

1. To the EI ignition coil.
2. To the radio interference suppressor.
3. To the ECT sensor.
 90. Connect the multiplugs and the alternator.
1. Connect the multiplugs of the main engine wiring
loom.
2. Connect the multiplug to the TP sensor.
3. Connect the multiplug to the CMP sensor.
4. Connect the alternator.

Cylinder Head – Remove and Install (21

Mondeo 1993 (01/1993-07/1996)
163 0)
 Print

Removal and Installation

Special Tools

15‐030 AUniversal flange

holding wrench

15‐097Subframe locating pins

21‐009 BCamshaft radial oil

seal installer

21‐068 AEngine lifting tackle

21‐140Engine support bar

21‐140‐01Adaptor

21‐140‐02Adaptor

21‐140‐03Adaptor

21‐162Timing tool, camshaft

alignment
 21‐167Cylinder head bolt
wrench

21‐172Installation gauge for

engine/transmission assembly

21‐540Angle gauge

24‐003Radiator hose clip

remover and installer

Workshop Equipment
Workshop hoist
Remove
1. Preparations.
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
CAUTION:
Disconnect the battery ground lead.

• Cable ties should be cut when necessary and

renewed when assembling.
• Slacken the right‐hand front wheel nuts.
2. Remove the intake pipe.
1. Disconnect the mass air flow (MAF) sensor
multiplug.
2. Disconnect the intake air temperature sensor (IAT
sensor) multiplug.
3. Remove one bolt and two nuts.
4. Release the retaining clips.

3. Remove the air cleaner.

1. Detach the positive crankcase ventilation (PCV)
hose.
2. Unhook the rubber ring.
3. Pull the air cleaner out from the rubber mountings
and take it out.
4. Disconnect the fuel pipes and detach the throttle
cable.
1. Compress the plastic lugs and pull the hoses off the
fuel pipes.
2. Pull off the throttle cable retaining clip.
3. Unhook the throttle cable and move it to the rear.

5. Disconnect the multiplug, the ground cable and the

high‐pressure pipe.
1. Disconnect the multiplug from the power steering
pressure (PSP) switch.
2. Detach the ground lead from the engine lifting eye.
3. Detach the power steering high‐pressure pipe.

6. Disconnect the vacuum hoses and the multiplug.

1. From the intake pipe.
2. From the fuel pressure regulator.
3. Disconnect the multiplug of the main engine wiring
loom.

7. Disconnect the vacuum hoses.

NOTE:
Mark the vacuum hoses.

1. From the exhaust gas recirculation valve (EGR

valve).
2. From the pipe of the pulse air system.
3. From the positive crankcase ventilation.

8. Disconnect the plug of the ignition coil.

1. Disconnect the plug from the EI coil.
2. Disconnect the multiplug of the radio interference
suppressor.
3. Disconnect the multiplug of the engine coolant
temperature sensor (ECT sensor).
• Unclip the wiring and lay it to one side.
• Raise the vehicle.
9. Remove the radiator undershield and drain off the
coolant.
1. Remove the bolts (x9).
2. Open the coolant drain plug. Drain off the coolant
and refit the plug when finished.

10. Disconnect the multiplug and the vacuum hose.

1. Disconnect the multiplug of the oxygen sensor
(HO2S) and release it from the retainer.
2. Disconnect the vacuum hose from the filter of the
pulse air system.

11. Disconnect the exhaust pipe from the exhaust

manifold.
   Unscrew the nuts and remove them with the springs.

12. Detach the lower wheel arch trim panel.

• Remove the front wheels.
1. Undo the upper wheel arch trim panel.
2. Detach the lower wheel arch trim panel.

13. Undo the bolts on the coolant pump pulley.

14. Remove the drive belt.
1. Slacken the drive belt.
2. Take off the drive belt.

15. Undo the bolts on the right‐hand engine roll

restrictor.
1. Slacken the centre bolt two turns.
2. Slacken the three bolts two turns.

16. Remove the left‐hand engine roll restrictor.

1. Remove the centre bolt.
2. Detach the engine roll restrictor from the subframe
and remove it (two bolts).

17. Fit the gauge in place of the left‐hand engine roll

restrictor.
1. Attach the gauge to the subframe.
2. Screw in the centre bolt.
• Lower the vehicle.

18. Detach the main engine wiring loom and the brake
servo vacuum line from the inlet manifold.
1. Unlock the quick release coupling and pull off the
line.
2. Unscrew the bolt.
• Lower the vehicle.
19. Detach the main engine wiring loom from the inlet
manifold.
• Remove the screws.
• Open the coolant expansion tank.

20. Remove the heat shield.

21. Disconnect the coolant hoses from the thermostat

housing.

22. Release the filter of the pulse air system and

disconnect the multiplugs.
1. Disconnect the multiplug from the engine coolant
temperature sensor.
2. Disconnect the multiplug of the crankshaft position
sensor (CKP sensor).
3. Remove the bolt.

NOTE:
Use a block of wood to prevent damage.

23. Support the engine with a jack.

24. Detach the front engine mounting bracket.
25. Detach the left‐hand retaining plate from the
cylinder head.
1. Remove the bolts in the cylinder head.
2. Remove the bolt from the power steering pump
bracket.

26. Remove the middle and the upper timing belt

covers.
1. Detach the drive belt idler pulley.
2. Remove the upper timing belt cover.
3. Remove the middle timing belt cover.

27. Remove the cylinder head cover.

• Disconnect the HT leads from the spark plugs.
1. Remove the cylinder head cover (10 bolts).
2. Remove the spark plugs.

28. Remove the timing belt.

1. Release the belt tensioner pulley.
2. Back off the belt tensioner pulley using an Allen
key.
• Secure the belt tensioner pulley.
CAUTION:
Do not kink the timing belt.

• Remove the timing belt.

29. Remove the camshaft pulleys.

   Detach the camshaft pulleys, using a flange‐holding
wrench to stop them from turning.
 30. Remove the camshafts.
• Slacken the bearing cap bolts in pairs in the
indicated sequence half a turn at a time.
• Repeat this until the bearing caps are completely
loosened.
• Remove the bearing caps, camshafts and radial oil
seals.

31. Remove the cylinder head bolts.

• Slacken and unscrew the cylinder head bolts in the
indicated sequence.
• Remove the oil dipstick and tube.

32. Lift off the cylinder head.

   Attach the lifting tackle to the engine lifting eyes, lift
the cylinder head with the workshop hoist and set it
down on wooden blocks.

Install
33. Preparations.
• Make up two locating studs as shown in the sketch.
• Clean all the mating faces thoroughly.
• Use new self‐locking nuts.
• Turn the crankshaft so that the piston of cylinder
No. 1 is roughly 20 mm before TDC to avoid damage
to valves and pistons.

34. Fit the cylinder head gasket and insert the

locating studs.
NOTE:
TOP mark, gasket identification.

1. Fit a new cylinder head gasket.

2. Insert the two workshop fabricated locating studs.
3. Check the locating bushes are seated correctly.
35. Fit the cylinder head.
• With the aid of the workshop hoist, guide the
cylinder head over the locating studs and into position.
Detach the lifting tackle.
• Unscrew the locating studs and remove them.

36. Pre‐tighten the cylinder head bolts. (Stages 1 and

2).
• Screw in new un‐oiled cylinder head bolts.
• Pre‐tighten the cylinder head bolts in 2 stages in the
indicated sequence.

CAUTION:
Must not be re‐tightened.

37. Tighten the cylinder head bolts.

• Tighten the cylinder head bolts in the indicated
sequence.
• Fit the oil dipstick and tube.

38. Fit the camshafts.

• Apply sealer to the mating face area for the bearing
cap on the cylinder head at the timing belt end.
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.

39. Fit the camshaft bearing caps.

NOTE:
The numbering starts on the exhaust side
with ”0" and faces outwards.
   Fit the bearing caps.
 40. Tighten the camshaft bearing caps in two stages.
• Screw in the retaining 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 retaining bolts in pairs in the indicated
sequence.

41. Fit the camshaft radial oil seals.

• Draw in the new radial oil seals using the special
tool, a washer and an M10 x 70 bolt.
• Fit the camshaft pulleys.
• The pulleys must be able to turn freely on the
camshafts.

Adjust the Valve Timing

42. Align the camshafts.
   Place the aligning tool on the camshafts.

43. Turn the crankshaft to the TDC position.

   For greater accuracy, extend the mark on the sump
with a small strip of metal (25 mm wide) or similar.

44. Pretension the timing belt tensioner and tighten it.

   Tension the pulley against the spring by turning it
clockwise with an Allen key and secure it.
45. Fit the timing belt.
1. Fit the timing belt in an anti‐clockwise direction,
starting at the crankshaft pulley.
2. Release the belt tensioner pulley.

46. Secure the camshaft pulleys.

NOTE:
The crankshaft must not be turned in the
process.
• Secure the camshaft pulleys.
• Remove the aligning tool
• Turn the crankshaft two revolutions in a clockwise
direction to the TDC position.

47. Secure the timing belt tensioner.

• Secure the belt tensioner pulley.
• Check the crankshaft and camshafts are at TDC.
• If there is a very tiny error:
• Align the camshaft using 15‐30 A so that alignment
tool 21‐162 can be inserted. The crankshaft must
remain in the TDC position.

48. Aligning tool 21‐162 cannot be inserted.

• Undo the camshaft pulley on the affected camshaft,
using a flange‐holding wrench to stop it from turning.
• Rotate the camshaft until the aligning tool can be
inserted.
NOTE:
The crankshaft must remain in the TDC
position.
• Secure the camshaft pulley.
49. Fit the cylinder head cover.
• Coat the spark plug threads with ”Never‐Seez".
1. Screw in the spark plugs and tighten them.
2. Fit the cylinder head cover with a new gasket and
tighten the bolts in two stages.
• Connect the HT leads to the spark plugs.

50. Fit the middle and the upper timing belt covers.
1. Fit the middle timing belt cover.
• Make sure that the middle cover is seated correctly
in the lower cover.
2. Fit the upper timing belt cover.
3. Fit the drive belt idler pulley.

51. Attach the left‐hand retaining plate to the cylinder

head.
1. Tighten the bolt on the power steering pump
bracket.
2. Tighten bolts on the cylinder head.

NOTE:
Do not tighten yet.

52. Fit the front engine mounting bracket using new

self‐locking nuts.
53. Remove the jack.

54. Fit the filter of the pulse air system and connect
the multiplugs.
1. Tighten the pulse air system filter retaining bolt.
2. Connect the multiplug to the CKP sensor.
3. Connect the multiplug to the engine coolant
temperature sensor.
 55. Connect the coolant hoses to the thermostat
housing.

56. Fit the heat shield.

   Attach the bracket of the oil dipstick and coolant
pipe at the same time.

57. Attach the main engine wiring loom to the inlet

manifold.
   Raise the vehicle.

58. Attach the main engine wiring loom and the brake
servo vacuum line to the inlet manifold.
1. Tighten the bolt.
CAUTION:
Make sure the vacuum line engages correctly.

2. Guide the vacuum line into the quick release

coupling and lock it in place.

Lay the drive belt in place.

59. Lay the drive belt in place and tension it.
   The diagram shows the routing with and without an
air conditioning compressor.
60. Fit the lower wheel arch trim panel.
1. Fit the lower wheel arch trim panel.
2. Fit the upper wheel arch trim panel.
61. Attach the front wheel.

62. Connect the exhaust pipe.

   Fit the nuts with the springs and tighten them.
63. Align the engine and transmission assembly as
described in Operation No. 21 133 0.

64. Connect the multiplug and the vacuum hose.

1. Connect the multiplug of the oxygen sensor and
secure it in the retainer.
2. Connect the vacuum hose to the filter of the pulse
air system.

65. Connect the vacuum hoses.

NOTE:
The hoses were marked prior to removal.

1. To the EGR valve.

2. To the pipe of the pulse air system.
3. To the positive crankcase ventilation.

66. Connect the multiplugs.

1. EI ignition coil multiplug.
2. Radio interference suppression filter multiplug.
3. ECT sensor multiplug.
67. Connect the vacuum hoses and multiplug.
1. To the intake pipe.
2. To the fuel pressure regulator.
3. Connect the multiplug of the main engine wiring
loom.

68. Connect the multiplug, ground cable and high‐

pressure pipe.
1. Push on the PSP switch multiplug.
2. Connect the ground lead to the engine lifting eye.
3. Connect the power steering high‐pressure pipe.

69. Attach the throttle cable and connect the fuel

pipes.
1. Attach the throttle cable.
2. Fit the throttle cable retaining clip.
NOTE:
The fuel pipes are colour coded.

3. Connect the fuel pipes (quick release couplings).

70. Fit the air cleaner.

1. Press the air cleaner into the rubber mountings and
hook in the rubber ring.
2. Attach the intake hose.
3. Attach the PCV hose to the cylinder head cover.

71. Install the intake pipe.

1. Close the retaining clips.
2. Tighten the bolt and the two nuts.
3. Connect the IAT sensor multiplug.
4. Connect the MAF multiplug.
 72. Tighten the front wheel nuts.
73. Finishing operations.
• Connect the battery ground lead.
• Fill up with coolant.
• Warm the engine up and check the fill capacities,
correcting as necessary.
• Pressure test the cooling system for leaks.
• Enter the radio keycode.
• Reprogramme the preset radio stations.
• Reset the clock.
• Carry out a road test to enable the powertrain
control module (PCM) to gather data.

Camshafts - Remove and Install (both)

Mondeo 1993 (01/1993-07/1996)
(21 284 0)
 Print

Removal and Installation

Special Tools

15‐030 AUniversal flange

holding wrench

21‐140Engine support bar

21‐140‐01Adaptor

21‐140‐02Adaptor

21‐140‐03Adaptor

21‐162Timing tool, camshaft

alignment

Remove
1. Preparatory measures.
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
NOTE:
Disconnect the battery ground lead.

• Slacken the right‐hand front wheel nuts.

• Cut cable ties when necessary and renew them when
assembling.
2. Remove the intake pipe.
1. Disconnect the mass air flow (MAF) multiplug.
2. Disconnect the intake air temperature sensor (IAT
sensor) multiplug.
3. Remove one bolt and two nuts.
4. Release the retaining clips.

3. Disconnect the throttle cable.

1. Pull off the throttle cable retaining clip.
2. Unhook the throttle cable and move it to the rear.

4. Disconnect the multiplug, the ground cable and the

high‐pressure pipe.
1. Disconnect the multiplug from the power steering
pressure (PSP) switch.
2. Detach the ground lead from the engine lifting eye.
3. Detach the power steering high‐pressure pipe.

5. Detach the lower wheel arch trim panel.

• Remove the front wheels.
1. Undo the upper wheel arch trim panel.
2. Detach the lower wheel arch trim panel.

6. Remove the lower radiator shroud.

7. Undo the bolts on the coolant pump pulley.

8. Remove the drive belt.

1. Slacken the drive belt.
2. Take off the drive belt.
• Remove the coolant pump pulley.

9. Check the position of the subframe.

   It should be possible to insert the special tools free
of tension in the subframe and body locating bores. If
not, align the subframe (refer to Operation Number 21
133 0).

10. Remove the left‐hand engine roll restrictor.

1. Remove the centre bolt.
2. Detach the engine roll restrictor from the subframe
and take it out.

11. Fit the gauge in place of the left‐hand engine roll

restrictor.
NOTE:
If the gauge cannot be fitted free of tension,
then the engine needs to be re‐aligned with
the transmission as described in Operation
No. 12 133 0.
1. Attach the gauge to the subframe.
2. Screw in the centre bolt.
• Lower the vehicle.
12. Fit the engine support bar.
   Attach the engine support bar to the engine lifting
eyes and lift the engine slightly.

13. Detach the left‐hand engine mounting bracket.

14. Open the coolant expansion tank.

• Remove the bolts.
• Lay the coolant expansion tank to one side.

15. Detach the left‐hand engine mounting.

16. Remove the middle and upper timing belt covers.

1. Detach the drive belt idler pulley.
2. Remove the upper timing belt cover.
3. Remove the middle timing belt cover.
 17. Remove the cylinder head cover.
• Disconnect the HT leads from the spark plugs.
1. Remove the cylinder head cover (ten bolts).
2. Remove the spark plugs.

18. Align the camshafts.

   Place the aligning tool on the camshafts.

19. Remove the timing belt.

1. Release the belt tensioner pulley.
2. Back off the belt tensioner pulley using an Allen
key.
• Secure the belt tensioner pulley.
• Remove the timing belt.

20. Remove the camshaft pulleys.

21. Remove the camshafts.

• Slacken the bearing cap bolts in pairs in the
indicated sequence half a turn at a time.
• Repeat this until the bearing caps are completely
released.
• Remove the bearing caps, camshafts and radial oil
seals.

Install
22. Fit the camshafts.
• Apply sealer to the mating face of the bearing cap
with the cylinder head at the timing belt end.
NOTE:
The camshafts are marked. The inlet
camshaft has an additional cam for the
camshaft position sensor (CMP sensor) at the
end of the shaft.
• Fit the camshafts.

23. Fit the camshaft bearing caps.

NOTE:
The numbering starts on the exhaust side
with ”0" and faces outwards.
   Fit the bearing caps.

24. Tighten the camshaft bearing caps in two stages.

• Screw in the retaining 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 retaining bolts in pairs in the indicated
sequence.

25. Fit the camshaft radial oil seals.

• Draw in the new radial oil seals using the special
tool, a washer and an M10 x 70 bolt.
NOTE:
The pulleys must be able to turn freely on the
camshafts.
• Fit the camshaft pulleys.

26. Align the camshafts.

   Place the aligning tool on the camshafts.
27. Turn the crankshaft to the TDC position.
   For greater accuracy, extend the mark on the sump
with a small strip of metal (25 mm wide) or similar.

28. Pre‐tension the timing belt tensioner and tighten it.

   Tension the pulley against the spring by turning it
clockwise with an Allen key and secure it.

29. Fit the timing belt.

• Check that the crankshaft is at TDC.
1. Fit the timing belt in an anticlockwise direction,
starting at the crankshaft pulley.
2. Release the belt tensioner pulley.

30. Secure the camshaft pulleys.

NOTE:
The crankshaft must remain in the TDC
position.
• Secure the camshaft pulleys.
• Remove the Special Tool 21‐162.
• Turn the crankshaft two revolutions in a clockwise
direction to the TDC position.
31. Secure the timing belt tensioner.
• Secure the belt tensioner pulley.
• Check that the crankshaft and camshafts are at TDC.
• If there is a tiny error:
• Align the camshaft using flange‐holding wrench 15‐
030 A so that aligning tool 21‐162 can be inserted. The
crankshaft must remain in the TDC position.

32. Adjusting tool 21‐162 cannot be inserted.

• Undo the camshaft pulley on the affected camshaft,
using a flange‐holding wrench to stop it from turning.
• Rotate the camshaft until the aligning tool can be
inserted.
NOTE:
The crankshaft must remain in the TDC
position.
• Secure the camshaft pulley.

33. Fit the cylinder head cover.

• Coat the spark plug threads with ”Never‐Seez".
1. Screw in the spark plugs and tighten them.
2. Fit the cylinder head cover with a new gasket.
• Connect the HT leads to the spark plugs.

34. Fit the middle and the upper timing belt covers.
1. Fit the middle timing belt cover.
2. Fit the upper timing belt cover.
3. Fit the drive belt idler pulley.

35. Attach the front engine mounting.

 CAUTION:
Do not turn or distort the engine mounting.

36. Attach the front engine mounting bracket.

1. Tighten new nuts on the engine.
• Detach the engine support bar.
2. Tighten a new nut on the engine mounting.

37. Fit the coolant expansion tank.

   Raise the vehicle.

38. Fit the coolant pump pulley.

   The bolts cannot be tightened until the drive belt is
in place.

39. Lay the drive belt in place and tension it.

   The diagram shows the routing with and without an
air conditioning compressor.

40. Tighten the coolant pump pulley bolts.

41. Remove the gauge.
1. Unscrew the centre bolt.
2. Detach the gauge from the subframe.

CAUTION:
Do not tilt the engine roll restrictor.

42. Fit the left‐hand engine roll restrictor.

1. Attach the engine roll restrictor to the subframe.
2. Fit the centre bolt.

43. Fit the radiator undershield.

44. Fit the lower wheel arch trim panel.

1. Fit the lower wheel arch trim panel.
2. Fit the upper wheel arch trim panel.
45. Attach the front wheel.

46. Connect the multiplug, ground cable and high‐

pressure pipe.
1. Connect the PSP switch multiplug.
2. Connect the ground lead to the engine lifting eye.
3. Connect the power steering high‐pressure pipe.
 47. Fit the throttle cable.
1. Attach the throttle cable.
2. Fit the throttle cable retaining clip.

48. Install the intake pipe.

1. Secure the retaining clips.
2. Tighten the bolt and the two nuts.
3. Connect the IAT sensor multiplug.
4. Connect the MAF multiplug.

49. Secure the right‐hand front wheel.

50. Finishing operations.
• Connect the battery negative lead.
• Enter the radio keycode.
• Reprogramme the preset radio stations.
• Reset the clock.
• Carry out a road test to enable the powertrain
control module (PCM) to gather data.

Seal - Camshafts – Renew (One) (21 288

Mondeo 1993 (01/1993-07/1996)
0)
 Print

Removal and Installation

Special Tools

15‐030 AUniversal flange‐

holding wrench

15‐097Subframe locating pins

21‐009 BCamshaft radial oil

seal installer

21‐140Engine support bar

 21‐140‐01Adaptor

21‐140‐02Adaptor

21‐140‐03Adaptor

21‐143Camshaft radial seal

remover

21‐162Timing tool, camshaft

alignment

21‐172Installation gauge for

engine/transmission assembly

Remove
1. Preparatory measures.
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
CAUTION:
Disconnect the battery ground lead.

• Slacken the right‐hand front wheel nuts.

• Cut cable ties when necessary and renew them when
assembling.
2. Remove the intake pipe.
1. Disconnect the mass air flow (MAF) multiplug.
2. Disconnect the intake air temperature sensor (IAT
sensor) multiplug.
3. Remove one bolt and two nuts.
4. Release the retaining clips.
3. Disconnect the throttle cable.
1. Pull off the throttle cable retaining clip.
2. Unhook the throttle cable and move it to the rear.

4. Disconnect the multiplug, the ground cable and the

high‐pressure pipe.
1. Disconnect the multiplug from the power steering
pressure (PSP) switch.
2. Detach the ground lead from the engine lifting eye.
3. Detach the power steering high‐pressure pipe.

5. Detach the lower wheel arch trim panel.

• Remove the front wheels.
1. Undo the upper wheel arch trim panel.
2. Detach the lower wheel arch trim panel.

6. Remove the lower radiator shroud.

7. Undo the bolts on the coolant pump pulley.

8. Remove the drive belt.
1. Slacken the drive belt.
2. Take off the drive belt.
• Remove the coolant pump pulley.

9. Check the position of the subframe.

   It should be possible to insert the special tools free
of stress in the subframe and body locating bores. If
not, align the subframe (refer to Operation Number 21
133 0).

10. Remove the left‐hand engine roll restrictor.

1. Remove the centre bolt.
2. Detach the engine roll restrictor from the subframe
and remove it.

11. Fit the gauge in place of the left‐hand engine roll

restrictor.
   If the gauge cannot be fitted free of tension, then
the engine needs to be re‐aligned with the
transmission as described in Operation No. 12 133 0.
1. Attach the gauge to the subframe.
2. Screw in the centre bolt.
• Lower the vehicle.

12. Fit the engine support bar.

   Attach the engine support bar to the engine lifting
eyes and tension it.
13. Detach the front engine mounting bracket

14. Undo the coolant expansion tank.

• Remove the bolts.
• Lay the coolant expansion tank to one side.

15. Detach the front engine mounting.

16. Remove the middle and upper timing belt covers.

1. Detach the drive belt idler pulley.
2. Remove the upper timing belt cover.
3. Remove the middle timing belt cover.

17. Remove the cylinder head cover.

• Disconnect the HT leads from the spark plugs.
1. Remove the cylinder head cover (ten bolts).
2. Remove the spark plugs.
 18. Align the camshafts.
   Place the aligning tool on the camshafts.

19. Remove the timing belt.

1. Release the belt tensioner pulley.
2. Back off the belt tensioner pulley using an Allen
key.
• Secure the belt tensioner pulley.
• Remove the timing belt.

20. Remove the camshaft pulleys.

21. Remove the camshaft seal.

   Remove the front camshaft bearing cap.

Install
22. Fit the front camshaft bearing cap.
   Apply sealer to the cylinder head mating face.
23. Fit the camshaft radial oil seals.
• Draw in the new radial oil seals using the special
tool, a washer and an M10 x 70 bolt.
NOTE:
The pulleys must be able to turn freely on the
camshafts.
• Fit the camshaft pulleys.

24. Align the camshafts.

   Fit the special tool.

25. Turn the crankshaft to the TDC position.

   For greater accuracy, extend the mark on the sump
with a small strip of metal (25 mm wide) or similar.

26. Pre‐tension the timing belt tensioner and tighten it.

   Tension the pulley against the spring by turning it
clockwise with an Allen key and secure it.
27. Fit the timing belt.
• Check that the crankshaft is at TDC.
1. Fit the timing belt in an anticlockwise direction,
starting at the crankshaft pulley.
2. Release the belt tensioner pulley.

28. Secure the camshaft pulleys.

NOTE:
The crankshaft must remain in the TDC
position.
• Secure the camshaft pulleys.
• Remove the Special Tool 21‐162.
• Turn the crankshaft two revolutions in a clockwise
direction to the TDC position.

29. Secure the timing belt tensioner.

• Secure the belt tensioner pulley.
• Check that the crankshaft and camshafts are at TDC.
• If there is a tiny error:
• Align the camshaft with a flange‐holding wrench so
that aligning tool 21‐162 can be inserted. The
crankshaft must remain in the TDC position.

30. Aligning tool 21‐162 cannot be inserted.

• Undo the camshaft pulley on the affected camshaft,
using a flange‐holding wrench to stop it from turning.
• Rotate the camshaft until the aligning tool can be
inserted.
NOTE:
The crankshaft must remain in the TDC
position.
• Secure the camshaft pulley.
31. Fit the cylinder head cover.
• Coat the spark plug threads with 'Never Seez'.
1. Screw in the spark plugs and tighten them.
2. Fit the cylinder head cover with a new gasket.
• Connect the HT leads to the spark plugs.

32. Fit the middle and the upper timing belt covers.
1. Fit the middle timing belt cover.
2. Fit the upper timing belt cover.
3. Fit the drive belt idler pulley.

33. Attach the front engine mounting.

CAUTION:
Do not distort or turn the engine mounting.

34. Attach the front engine mounting bracket.

1. Tighten new nuts on the engine.
• Detach the engine support bar.
2. Tighten a new nut on the engine mounting.

35. Fit the coolant expansion tank.

   Raise the vehicle.
36. Fit the coolant pump pulley.
   The bolts cannot be tightened until the drive belt is
in place.

37. Lay the drive belt in place and tension it.

   The diagram shows the routing with and without an
air conditioning compressor.

38. Tighten the coolant pump pulley bolts.

39. Remove the gauge.

1. Unscrew the centre bolt.
2. Detach the gauge from the subframe.

40. Fit the left‐hand engine roll restrictor.

CAUTION:
Do not tilt the engine roll restrictor.

1. Attach the engine roll restrictor to the subframe.

2. Fit the centre bolt.
41. Fit the radiator undershield.

42. Fit the lower wheel arch trim panel.

1. Fit the lower wheel arch trim panel.
2. Fit the upper wheel arch trim panel.
43. Attach the front wheel.

44. Connect the multiplug, ground cable and high‐

pressure pipe.
1. Connect the PSP switch multiplug.
2. Connect the ground lead to the engine lifting eye.
3. Connect the power steering high‐pressure pipe.

45. Fit the throttle cable.

1. Attach the throttle cable.
2. Fit the throttle cable retaining clip.

46. Install the intake pipe.

1. Secure the retaining clips.
2. Tighten the bolt and the two nuts.
3. Connect the IAT sensor multiplug.
4. Connect the MAF multiplug.
 47. Secure the right‐hand front wheel.
48. Finishing operations.
• Connect the battery ground lead.
• Enter the radio keycode.
• Reprogramme the preset radio stations.
• Reset the clock.
• Carry out a road test to enable the powertrain
control module (PCM) to gather data.

General Specifications Mondeo 1993 (01/1993-07/1996)

 Print

Specifications
Engine Data
1,8 TCI Diesel Engine
Engine management EDC
Emission standard 93 EEC/87 US
Fuel Diesel
Engine code without catalytic converter RFM
Engine code with catalytic converter RFN
Injection sequence 1‐3‐4‐2
Bore mm 82,5
Stroke mm 82,0
Cubic capacity (effective) cm3 1753
Compression ratio 21,5 : 1
Compression pressure at starter motor
bar 28 - 34
speed
Engine power output (EEC) kW 65
Engine power output (EEC) at rev/min 4500
kW
Power output (DIN) 65 (88)
(PS)
Power output at rev/min 4500
Torque (DIN) Nm 178
Torque (DIN) at rev/min 2000
Idle speed rev/min 800 - 900
Maximum engine speed – continuous rev/min 4800
Maximum engine speed – intermittent rev/min 5150 - 5250
Dimensions
Cylinder block 1,8 TCI Diesel Engine
Number of main bearings 5
Cylinder bore dia., class A mm 82,500 - 82,515
Cylinder bore dia., class B mm 82,515 - 82,530
Cylinder bore dia., class C mm 82,660 - 82,675
Cylinder bore dia., class D mm 82,675 - 82,690
Cylinder bore dia., class E mm 83,000 - 83,015
Cylinder bore dia., class F mm 83,500 - 83,515
Big‐end bearing radial clearances mm 0,015 - 0,062
Main bearing parent bore dia. mm 57,683 - 57,696
Dimensions
Crankshaft 1,8 TCI Diesel Engine
Main bearing journal dia., standard mm 53,970 - 53,990
Main bearing journal dia., 1st undersize
mm 53,720 - 53,740
0,25
Main bearing journal dia., 2nd undersize
mm 53,470 - 53,490
0,50
Big‐end bearing journal dia., standard mm 48,970 - 48,990
Big‐end bearing journal dia., 1st undersize
mm 48,720 - 48,740
0,25
Big‐end bearing journal dia., 2nd undersize
mm 48,470 - 48,490
0,50
Big‐end bearing clearances mm 0,016 - 0,074
Crankshaft end float mm 0,14 - 0,37
Connecting rod axial movement relative to
mm 0,125 - 0,325
crank web
Max. frictional torque, without big ends and
Nm 10
pistons.
Dimensions
Connecting Rod 1,8 TCl Diesel Engine
Bore dia., big end mm 52,000 - 52,020
Bore dia., small end mm 26,012 - 26,020
Distance between connecting rod small and
mm 129,880 - 129,940
big ends, class A
Distance between connecting rod small and
mm 129,941 - 130,000
big ends, class B
Distance between connecting rod small and
mm 130,001 - 130,060
big ends, class C
Distance between connecting rod small and
mm 130,052 - 130,120
big ends, class D
Main bearing radial clearances mm 0,016 - 0,074
Dimensions
Pistons 1,8 TCI Diesel Engine
Piston dia. (measured at right angles to
mm 82,461 - 82,479
piston pin bore), class A
Piston dia. (measured at right angles to
mm 82,476 - 82,494
piston pin bore), class B
Piston dia. (measured at right angles to
mm 82,621 - 82,639
piston pin bore), class C
Piston dia. (measured at right angles to
mm 82,636 - 82,654
piston pin bore), class D
Piston dia. (measured at right angles to
mm 82,961 - 82,979
piston pin bore), class E
Piston dia. (measured at right angles to
mm 83,461 - 83,479
piston pin bore), class F
Piston clearance in bore (initial installation),
mm 0,021 - 0,054
classes A - F
Piston protrusion at TDC mm 0,500 - 0,840
Piston ring gap (fitted), upper compression
mm 0,350 - 0,500
ring
Piston ring gap (fitted), lower compression
mm 0,350 - 0,500
ring
Piston ring gap (fitted), oil control ring mm 0,250 - 0,580
Piston ring clearance in piston groove,
mm 0,090 - 0,122
upper compression ring
Piston ring clearance in piston groove,
mm 0,070 - 0,102
lower compression ring
Piston ring clearance in piston groove, oil
mm 0,050 - 0,082
control ring
The piston ring gaps must be spaced
evenly around the circumference of the
Ring gap positions piston. This also applies to the oil
control rings. Stagger the ring gaps at
120° to one another.
Dimensions
Piston pins 1,8 TCI Diesel Engine
Piston pin dia. mm 25,996 - 26,000
Floating fit in both piston and
Piston pin type
connecting rod
Piston pin retention Circlip
Dimensions
Cylinder head 1,8 TCI Diesel Engine
Camshaft bearing dia., standard mm 30,500 - 30,525
Camshaft bearing dia., oversize mm 30,575 - 30,600
Valve tappet bore dia., standard mm 35,000 - 35,030
Valve tappet bore dia., oversize mm 35,500 - 35,530
Valve guide bore dia., standard mm 8,000 - 8,025
Valve guide bore dia., 1st oversize mm 8,263 - 8,288
Valve guide bore dia., 2nd oversize mm 8,463 - 8,488
Thickness of cylinder head gasket mm (number of tooth marks)
Thickness of cylinder head gasket with
mm 1,36 (two tooth marks)
piston protrusion of 0,500 - 0,680 mm
Thickness of cylinder head gasket with
mm 1,42 (three tooth marks)
piston protrusion of 0,681 - 0,740 mm
Thickness of cylinder head gasket with
mm 1,52 (four tooth marks)
piston protrusion of 0,741 - 0,840 mm
Max. permissible unevenness over entire
mm 0,08
head mating face
Do not skim cylinder head mating face.
Dimensions
Camshaft 1,8 TCI Diesel Engine
Valve timings, inlet valve opens before TDC °C/S 6
Valve timings, inlet valve closes after BDC °C/S 32
Valve timings, exhaust valve opens before
°C/S 57
BDC
Valve timings, exhaust valve closes after
°C/S 7
TDC
Cam lift, inlet mm 9,0
Cam lift, exhaust mm 10,0
End float mm 0,100 - 0,240
Bearing journal dia. mm 27,960 - 27,980
Bearing clearances mm 0,016 - 0,075
Valve clearances (cold), inlet mm 0,35 ±0,05
Valve clearances (cold), exhaust mm 0,50 ±0,05
Shim thicknesses mm 3,00 to 4,75
Shim thicknesses, in steps of mm 0,05
Engine Oil
Ambient Temperature Specification
–15 to over + 40° C Ford Super Engine Oil SAE 15W40 CCMC PD2
–10 to over + 40° C Ford Super Engine Oil SAE 20W50 CCMC PD2
Ford XR+ High‐
–20 to over + 40°C Performance High‐ SAE 10W40 CCMC PD2
Lubricity Engine Oil
Ford Formula S Synthetic
-30 to over +40°C SAE 5W50 CCMC PD2
Engine Oil
Engine lubrication
Description
Oil pressure (minimum, oil temperature approx. 80 5C), at
bar 0,75
idle speed
Oil pressure (minimum, oil temperature approx. 80 5C), at
bar 1,50
2000 rev/min
Pressure relief valve opens at bar 2,0 - 4,0
Oil pump, max. clearance between inner/outer rotors mm 0,174
Lubricants, Adhesives and Sealers
Description Ford Specification
Transmission fluid (MTX‐75) ESD‐M2C168‐A
Coolant ESD‐M97B49‐A
Power steering hydraulic fluid ESPM‐2C‐166‐H
Sealer for camshaft bearing cap No.1; sump/cylinder block SPM‐4G‐9112‐F/G
SM‐4G‐4644‐AA/AB:
only coat the first
three threads. Wipe
Sealer for blanking plugs, oil pressure switch, oil passages off any surplus
sealer as it can
destroy the sump
gasket.
Capacities
Description Litres
Engine oil, initial fill incl. filter 5,0
Engine oil, incl. change of filter 4,5
Engine oil, excl. change of filter 4,1
Coolant, incl. manual transmission 9,3
Transmission fluid (MTX 75)
Drive Belt Tension
Description mm
Alternator (new) 1-2
Alternator (used) 1-3
Power steering pump (new) 1-2
Power steering pump (used) 1-3
Air conditioning compressor (new) 1-3
Air conditioning pump (used) 2-4
Tightening Torques
General Nm lbf.ft
Centre bearing of right‐hand front axle driveshaft 27 20
Air conditioning compressor 25 18
Idler pulley - air conditioning drive belt 13 10
Subframe to body 83 61
Left‐hand engine mounting 83 61
Bracket of right‐hand engine mounting to engine 83 61
Bracket to engine mounting 83 61
Bracket of rear engine roll restrictor 84 62
Front and rear engine roll restrictors to subframe 48 35
Centre bolt of front and rear engine roll restrictors 120 88
Steering gear to subframe 130 96
Gearshift linkage to body 44 32
Shift rod to transmission 23 17
Shift rod stabiliser to engine roll restrictor 55 41
Stabiliser bar link rod to suspension strut 47 35
Castellated nut on track rod end 26 19
Lower suspension arm ball joint to spindle carrier 83 61
Condenser to radiator 7 5
Radiator bracket to subframe 10 7
Air conditioning dehydrator to subframe 7 5
Drive belt tensioner to timing cover 23 17
Power steering pump clamp bolt 24 18
Power steering pump pivot bolt 24 18
Power steering pump belt cover 10 7
Flange bolt securing earth lead to engine/transmission 40 30
Accelerator cable upper bracket to lower bracket 16 12
Vacuum line to vacuum pump 16 12
Hose/wiring loom bracket to lifting eye 23 17
Intercooler to bracket 18 13
Shift rod clamp bolt 16 12
Front exhaust pipe to turbocharger 40 30
Catalytic converter to rear exhaust pipe 40 30
Radiator coolant drain plug 23 17
Wheel nuts 85 63
Alternator to bracket M8 24 18
Alternator to bracket M10 50 37
Tensioning pulley bracket to alternator bracket 24 18
Clamping bolt of alternator tensioning pulley 24 18
Tightening Torques
Cylinder Head Nm lbf.ft
Glow plug wiring 2 1
Glow plugs 28 21
Fuel filter to bracket 23 17
Cylinder head bolts, stage 1 10 7
Cylinder head bolts, stage 2 100 74
Cylinder head bolts, wait 3 mins.
Cylinder head bolts, stage 3 ‐180° ‐180°
Cylinder head bolts, stage 3 70 52
Cylinder head bolts, stage 3 120° 120°
Vacuum pump to cylinder head 22 16
Vacuum line bracket to cylinder head 22 16
Timing belt idler pulley to cylinder head 45 33
Camshaft timing pulley with flange to camshaft 30 22
Bolt - timing belt tensioner - camshaft 9 7
Camshaft timing pulley to camshaft flange 9 7
Camshaft oil baffle 20 15
Cylinder head cover 5 4
Camshaft bearing caps 23 17
Crankshaft vibration damper to flange 35 26
Torques
Cylinder block Nm lbf.ft
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°
Flywheel, stage 1 18 13
Flywheel, stage 2 45° 45°
Flywheel, stage 3 45° 45°
Clutch pressure plate to flywheel 30 22
Crankshaft rear radial oil seal carrier 20 15
Front plate to cylinder block 24 18
CKP sensor bracket 21 15
Auxiliary shaft thrust plate 9 7
Auxiliary shaft radial oil seal carrier 23 17
Engine mounting bracket/power steering pump bracket to cylinder
47 35
block
Retaining bolt - rear timing belt cover to cylinder block 24 18
Auxiliary shaft timing pulley 45 33
Crankshaft pulley/vibration damper, stage 1 150 111
Crankshaft pulley/vibration damper, stage 2 ‐90° ‐90°
Crankshaft pulley/vibration damper, stage 3 120 88
Crankshaft pulley/vibration damper, stage 4 60° 60°
Clamping bolt - timing belt tensioner - camshaft 50 37
Blanking plug for hole for TDC pin 24 18
Timing belt cover 8 6
Alternator bracket to cylinder block 42 31
Turbocharger/cylinder block bracket to turbocharger 23 17
Turbocharger/cylinder block bracket to cylinder block 47 35
Front axle driveshaft bracket to cylinder block 48 35
Tightening Torques
Oil circuit Nm lbf.ft
Oil pressure switch to cylinder head 20 15
Sump drain plug 25 18
Cylinder block oilway blanking plugs 22 16
Sump 11 8
Oil intake pipe bracket to cylinder block 22 16
Hose clamp, turbocharger oil return hose 5 4
Oil dipstick tube 10 7
Oil pump to cylinder block 23 17
Oil feed line to turbocharger 18 13
Turbocharger oil feed line bracket to cylinder block 48 35
Torques
Coolant circuit Nm lbf.ft
Coolant pump 23 17
Thermostat housing to cylinder head 20 15
Coolant pump/thermostat housing coolant hose 3 2
Vacuum line bracket to thermostat housing 9 7
Coolant pipe to cylinder block 25 18
Torques
Fuel system Nm lbf.ft
Fuel‐injection pump to front plate 24 18
Injectors 70 52
Fuel‐injection pump/cylinder block bracket 23 17
Fuel regulating thermostat to thermostat housing 23 17
Fuel filter bracket to cylinder head/lifting eye 23 17
Fuel injection line to injector/fuel injection pump 25 18
Fuel‐injection pump timing pulley to flange 23 17
Fuel‐injection pump timing belt tensioner to cylinder block 45 33
Fuel‐injection pump belt pulley 25 18

Engine – Dismantle and Reassemble (21

Mondeo 1993 (01/1993-07/1996)
134 8)
 Print

Removal and Installation

Special Tools

15‐030 AUniversal flange‐

holding wrench

16‐067Clutch disc locator

21‐011 FRadial oil installer

21‐031 BMounting bracket

21‐104Crankshaft TDC setting

pin

21‐148ARadial oil seal locator

and installer

21‐164Cylinder head bolt

wrench
 21‐200Puller, crankshaft
timing pulley

21‐217Aligning tool,
crankshaft rear oil seal

21‐540Angle gauge

23‐019Timing pin for

camshaft timing pulley

23‐03427 mm socket for

injectors

Proprietary Tools
Description
Dial indicator
Magnetic base for dial indicator
Piston ring compressor
New 6 mm drill bit
Two‐legged puller
Internal puller
Micrometer, 25 - 50 mm
Micrometer, 50 - 75 mm
Internal gauge
Workshop Equipment
Description
Assembly stand
Materials
Description
Obtainable through:
Replacement Services
Limited, 30 Euston
Plastigage
Street, Freemans
Industrial Estate,
Leicester, LE2 7ST.
Dismantle
1. Remove the coolant pipe to the oil cooler.
1. Detach the coolant pipe from the oil cooler.
2. Remove the bracket (two bolts).
2. Remove the complete oil pump.
1. Remove the oil feed line from the turbocharger.
2. Unscrew the bolt of the oil feed line.
3. Remove the oil pump (four bolts).

3. Detach the turbocharger bracket.

4. Remove the front axle driveshaft bracket.

5. Attach the engine to an assembly stand.

• Attach the mounting bracket.
• Attach the engine to an assembly stand.
• Drain off the engine oil.

6. Detach the alternator and the drive belt tensioner

pulley.
1. Unscrew the tensioning pulley clamp bolt.
2. Slacken the drive belt by undoing the adjusting
bolt and take it off.
3. Remove the tensioning pulley.
4. Remove the alternator (three bolts).
7. Remove the alternator bracket.

8. Remove the fuel‐injection pump pulley.

1. Disconnect the coolant hose.
2. Remove the pulley.

9. Remove the timing/drive belt covers (five

bolts/three clips).

10. Remove the camshaft timing belt.

• Release the timing belt tensioner clamp bolt and
slacken the timing belt.
• Tighten the timing belt tensioner clamp bolt.
• Remove the timing belt.

11. Remove the fuel‐injection pump drive belt.

• Release the timing belt tensioner clamp bolt and
slacken the timing belt.
• Tighten the timing belt tensioner clamp bolt.
• Remove the timing belt.
 WARNING:
The tensioner is under spring pressure.

12. Remove the fuel‐injection pump belt tensioner

and pulley.
1. Remove the tensioner.
2. Remove the pulley.

WARNING:
The tensioner is under spring pressure.

13. Detach the camshaft timing belt tensioner and

timing pulley.
1. Remove the tensioner.
NOTE:
Remove the pulley using a proprietary two‐
legged puller.
2. Remove the pulley.

14. Remove the crankshaft vibration damper.

   Immobilise the crankshaft by means of the flywheel
ring gear.

15. Remove the rear belt covers.

1. Detach the timing pulley.
2. Remove the rear cover bolt.
   Remove the covers.

16. Detach the fuel injection lines at the injectors.

• Disconnect the leak‐off hoses.
• Disconnect the fuel injection lines (four union nuts).
17. Remove the fuel lines and the fuel heater.
1. Disconnect the fuel lines from the fuel filter (two
quick‐release couplings).
2. Detach the fuel heater from the bracket (two clips).
   Press the locking pins of the clips through and prise
out the clips.

18. Remove the fuel filter with the bracket.

1. Remove the nuts from the bracket.
2. Remove the vacuum line bolt.
   Remove the fuel filter with the bracket.
3. Disconnect the vacuum line from the turbocharger.

19. Remove the fuel‐injection pump bracket.

1. Remove the bracket (two bolts/three nuts).
2. Unscrew the fuel regulating thermostat from the
thermostat housing.
3. Remove the vacuum line bracket (one bolt).
4. Disconnect the vacuum hose from the fuel injection
pump.

20. Remove the fuel injection pump.

21. Detach the engine mounting bracket/power

steering pump bracket and the coolant pump hose.
1. Bracket to lifting eye (two bolts).
2. Bracket to cylinder block (four bolts).
3. Disconnect the coolant hose.
22. Detach the positive crankcase ventilation (PCV)
hoses.
1. To the cylinder block.
2. To the turbocharger.
   Detach the oil dipstick tube (one bolt) and withdraw
it.

23. Remove the vacuum pump.

1. Remove the bolts securing the vacuum pump and
the bracket for the glow plug wiring.
2. Remove the vacuum pump oil return hose.

24. Remove the thermostat housing.

25. Remove the injectors and the glow plugs.

1. Remove the injectors.
   Remove the heat shields.
2. Remove the glow plug wiring.
3. Remove the glow plugs.

26. Remove the cylinder head cover and the oil baffle.
• Remove the cylinder head cover (three bolts).
• Remove the gasket.
• Detach the oil baffle.
27. Remove the turbocharger oil return hose.

28. Remove
• Slacken and unscrew the cylinder head bolts in the
indicated sequence.
• Remove the cylinder head and lay it on wooden
blocks.
• Remove the gasket.

29. Remove the crankshaft position sensor (CKP

sensor) with its bracket.
30. Remove the clutch (six bolts).

31. Remove the flywheel (eight bolts).

NOTE:
From '96 MY onwards the oil seal is
integrated into the carrier.
32. Remove the crankshaft rear radial oil seal carrier.
   Drive out the oil seal on a flat surface.

NOTE:
Remove the sump downwards so that no oil
sludge or abraded particles get into the
engine.
33. Remove the sump (fourteen bolts).

34. Remove the auxiliary shaft pulley and radial oil

seal carrier.
1. Remove the auxiliary shaft pulley (one bolt).
2. Remove the auxiliary shaft radial oil seal carrier
(three bolts).
35. Remove the auxiliary shaft.
• Remove the thrust plate bolts.
• Withdraw the auxiliary shaft with the thrust plate.

36. Remove the coolant pump.

CAUTION:
Only insert the expanding part of the puller.

37. Pull off the crankshaft timing pulley.

1. Insert the puller.
2. Draw back the puller as far as its stop.

38. Pull off the crankshaft timing pulley (continued).

   Screw in the spindle and pull off the crankshaft
timing pulley.

39. Remove the front plate.

   Extract the radial oil seal.
 40. Detach the oil intake pipe and bracket.

CAUTION:
Do not touch the area near the piston rings.

41. Remove the pistons.

• Detach the big‐end bearing caps.
• Remove the ring of carbon around the upper edge of
the cylinder bores using a proprietary scraper.
NOTE:
Put the big‐end bearing shells and caps down
in order, do not mix them up.
   Extract the pistons with the connecting rods and
bearing shells.
42. Remove the crankshaft.
• Remove the main bearing caps.
• Remove the crankshaft.
• Remove the bearing shells and thrust half washes
and put them down in order for reuse.

Assemble
43. Preparations.
   Clean all the mating faces and reusable parts
thoroughly and check for damage.
44. Clean the piston cooling oil splash nozzles and the
oilways.

45. Measure the diameter of the main and big‐end

bearing journals using a proprietary precision gauge.
   Repeat each measurement at an angle of 90°.
   Different sizes of crankshaft are used in production.
The different crankshafts are not marked.
   If the measurements do not accord with the
specified figures in the Technical Data, the crankshaft
must be overhauled or replaced.
 NOTE:
The main bearing caps or lower crankcase
must be fitted without bearing shells and
tightened to the specified torque.
46. Measure the cylinder bore with an internal gauge.
   Carry out the measurement in different directions
and at different heights in order to discover any out‐of
roundness or conicity.

47. Preparations for measuring the bearing clearances.

NOTE:
Carry out the following steps precisely.

• Measure each bearing individually by means of a

length of Plastigage thread.
• This must always be done with just the bearing caps
of the bearing being measured in place and torqued
down to specification.
• The bearing shells and journals must be free of oil
and dirt.
• The measuring point should be close to the
respective dead centre position.
48. Measure the crankshaft main bearing clearances.
• Place the appropriate bearing shells in the cylinder
block dry.
• Place the crankshaft in the cylinder block dry.
• Lay a length of Plastigage thread on the bearing
journal across the bearing.

49. Measure the crankshaft main bearing clearances

(continued).
NOTE:
The bearing cap numbering starts at the
timing belt end to which the arrows also
point.
• Fit each bearing cap with its associated bearing shell
and secure it.
• Remove the bearing cap.
50. Compare the length of Plastigage thread with the
Plastigage scale.
• The reading corresponds to the bearing clearance.
• If necessary, the bearing shells must be changed and
the bearing journals overhauled.

51. Fit the crankshaft.

• Lubricate the main bearing journals, bearing shells
and thrust half washers with engine oil.
• Insert the thrust half washers in main bearing No. 3
with the lubricating groove towards the outside.
NOTE:
The bearing cap numbering starts at the
timing belt end to which the arrows also
point.
• Fit the crankshaft main bearing caps with their
associated bearing shells.
• Tighten the bolts.
52. Check the crankshaft end float.
• Set up the dial indicator.
• Measure the end float by lifting the crankshaft by
means of a screwdriver.
• If necessary rectify the end float by fitting new thrust
half washers to main bearing No. 3.

NOTE:
Piston classification in case a piston needs to
be renewed.
53. Measure the piston with a micrometer.
   Carry out the measurement at the same height as
the piston pin bore, but at an angle of 90° to it.

54. Piston classification.

1. Cylinder bore classification.
2. Piston diameter classification.
3. The weight classes are marked with ”+" and ”-".
 CAUTION:
Do not mix up the piston rings. Refit the
piston rings in exactly the same position.
55. Measure the piston ring gaps.
   The figures given in the General Specifications apply
to a gauge ring used in production. These values may
be exceeded by 0,15 mm when measured in the
cylinder.

NOTE:
The piston ring should protrude from the
groove. Measure the clearance behind the
wear ridge.
56. Measure the piston ring clearances.

57. Fit the pistons.

• Lubricate the pistons and cylinder bores with engine
oil.
• Distribute the piston ring gaps uniformly around the
circumference – this also applies to the elements of
the oil control ring.
NOTE:
The numbering on the connecting rod starts
at the timing belt end. The arrow on the
piston crown points towards the timing belt
end.
• Compress the piston rings using a proprietary piston
ring compressor.
• Press the pistons into the cylinder with 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.
58. Measure the big‐end bearing clearances and fit
the bearing caps.
• Measure the big‐end bearing clearance as described
in sub‐operations 45 to 48.
• Lubricate the bearing shells and bearing journals
with engine oil.
NOTE:
The numbers on the connecting rods and
big‐end bearing caps must correspond.
   Fit the appropriate big‐end bearing shells and
bearings caps and tighten to specification.
59. Fit the oil intake pipe and bracket.
NOTE:
Make sure that the O‐ring is seated
correctly.
1. Insert the oil intake pipe with a new O‐ring.
2. Fit the bracket.

60. Fit the front plate.

   Fit the front plate with a new gasket and new
oilways seals.
1. Centre the front plate using the special tool.
NOTE:
The mating face of the front plate must be
flush with the lower edge of the cylinder
block (tolerance ± 0,1 mm).
2. Secure the front plate (four bolts).

61. Fit the front plate radial oil seal.

   Draw in the radial oil seal using the special tool and
the vibration damper bolt.

62. Fit the crankshaft timing belt pulley.

NOTE:
Make sure that the O‐ring in the timing belt
pulley is in satisfactory condition.
• Lubricate the O‐ring and the end of the crankshaft
with engine oil.
• Carefully slide the pulley on as far as the shoulder.
• The locating pin in the end of the crankshaft and the
bore in the pulley must line up.

63. Apply sealer at the cylinder block mating face

joints.
   The sump bolts must be tightened within 20 minutes
of applying the sealer.
 64. Fit the sump.
   Fit the sump with a new gasket and screw in the
bolts finger tight (x14).

Only for PTFE seals

CAUTION:
The oil seal lip and the crankshaft mating
face must be free of oil.
CAUTION:
The support ring automatically falls out
when the oil seal carrier is fitted. Do not
remove it beforehand.
65. Fit a new crankshaft rear oil seal carrier.
• Move a new crankshaft rear oil seal carrier with
integrated oil seal together with the bolts into
installation position.
• Screw in the bolts finger tight.
• Insert the special tool and centre the oil seal carrier
on the crankshaft.
Only for PTFE seals
66. Tighten the bolts on the crankshaft rear oil seal
carrier, working diagonally.
   Remove the special tool.

67. Fit the crankshaft rear radial oil seal carrier.

NOTE:
The oil seal carrier is centred by means of
locating lugs in the oil seal carrier recess.
• Locate the new oil seal carrier with its gasket in
place with the retaining bolts.
• Tighten the seven bolts, working diagonally.

68. Tighten the fourteen sump bolts.

69. Draw the crankshaft rear radial oil seal into the
carrier.
   Draw in the radial oil seal as far as the shoulder
using the special tool and two flywheel bolts.

NOTE:
Use new bolts.

70. Fit the flywheel (eight bolts).

71. Centre the clutch disc on the clutch pressure plate.

72. Fit the clutch.

1. Fit the clutch pressure plate in position with the
centred clutch disc.
2. Tighten the six bolts uniformly, working diagonally.
3. Remove the special tool.

73. Fit the CKP sensor with its bush.

   If the sensor malfunctions, the air gap between the
flywheel and the sensor should be increased by using a
spacer.
 74. Fit the coolant pump.
• Position the coolant pump with a new gasket and
the spring holder of the timing belt tensioner pulley.
• Tighten the four bolts.

75. Fit the auxiliary shaft with the thrust plate.

• Lubricate the auxiliary shaft, the bearing bush in the
cylinder block and the thrust plate with engine oil.
• Fit the auxiliary shaft with the thrust plate.
NOTE:
The lubricating grooves on the thrust plate
must point outwards.
   Tighten the thrust plate bolts.

76. Fit the auxiliary shaft radial oil seal carrier.

• Lubricate the end of the auxiliary shaft with engine
oil.
• Slide the new oil seal carrier with the integral oil seal
and plastic fitting bush onto the end of the auxiliary
shaft.
• Tighten the oil seal carrier bolts.
• Remove the plastic fitting bush after fitment and
check that the seal is seated correctly.

77. Measure the Piston Protrusion.

• Measure the piston protrusion of each cylinder at
TDC.
• Measure the distance between the piston crown and
the cylinder block.
NOTE:
Carry out two measurements for each
cylinder at a distance of 5 mm from the edge
of the piston.
   The largest measurement determines the choice of
cylinder head gasket (see General Specifications).
78. Align the Crankshaft and Camshaft.
• Turn the crankshaft to bring cylinder to TDC.
• Turn the camshaft until the groove in the camshaft
eccentric is parallel with the upper edge of the cylinder
head (with the larger semi‐circle at the top).
• The crankshaft and camshaft must not be turned any
more.
79. Fit the cylinder head gasket.
NOTE:
The gasket is marked ”TOP/OBEN".

1. Fit a new cylinder head gasket.

2. Check that the locating bushes are seated
correctly.
3. Check that the thickness marking corresponds to
the measurement in sub‐operation 70.

NOTE:
The turbocharger oil return hose must be
connected when the cylinder head is fitted.
80. Fit the cylinder head.

81. Pre‐tighten the cylinder head bolts.

• Screw in new un‐oiled cylinder head bolts.
• Tighten the cylinder head bolts in two stages in the
specified sequence.
82. Tighten the cylinder head bolts.
CAUTION:
For stage 3, first slacken the cylinder head
bolt then tighten it to the specified torque
and angle before moving onto the next bolt.
NOTE:
The cylinder head bolts must not be re‐
torqued.
   Wait three minutes then tighten the cylinder head
bolts to Stage 3 in the specified sequence.

83. Fit the injectors and the glow plugs.

1. Fit the glow plugs.
2. Fit the glow plug wiring (four nuts).
NOTE:
Make sure that the heat shields are fitted
correctly.
3. Fit the injectors with new heat shields.

84. Fit the thermostat housing with a new gasket.

85. Connect the coolant hose to the coolant pump
and fit the engine mounting/power steering pump
bracket.
1. Connect the coolant hose.
2. Bracket to cylinder block (four bolts).
3. Bracket to lifting eye (two bolts).

86. Fit the vacuum pump.

1. Connect the oil return hose.
   Fit the vacuum pump with a new O‐ring, the glow
plug wiring bracket and bolts.
NOTE:
Fit the lower bolt first.

2. Tighten the bolts evenly.

87. Fit the fuel injection pump.

88. Fit the fuel‐injection pump bracket.

1. Fit the bracket (two bolts/three nuts).
2. Fit the fuel regulating thermostat.
3. Fit the vacuum line bracket (one bolt).
   Connect the vacuum hose to the fuel injection
pump.

89. Fit the fuel filter with its bracket.

   Locate the fuel filter and bracket in position.
1. Fit the bracket.
2. Screw in the vacuum line bolt.
3. Connect the vacuum line to the turbocharger.
90. Fit the fuel heater and the fuel lines.
1. Fit the fuel heater to the bracket (two clips).
2. Fit the fuel lines to the fuel filter (two quick‐release
couplings).

91. Connect the fuel injection lines to the injectors.

• Connect the fuel‐injection lines (four union nuts).
• Connect the leak‐off hoses.

92. Fit the rear belt covers.

   Locate the covers in position.
1. Fit the pulley (one bolt)
2. Fit the rear cover bolt.

93. Fit the pulleys and the camshaft timing belt

tensioner.
1. Fit the camshaft pulley (one bolt).
NOTE:
The locating pin on the auxiliary shaft and
the hole in the pulley must line up.
2. Fit the auxiliary shaft pulley (one bolt).
3. Fit the timing belt tensioner (two bolts).
4. Compress the tensioner spring and secure it with
the clamp bolt.

94. Fit the fuel‐injection pump pulley (three bolts).

   Centre the bolts in the slots; do not tighten the
bolts.
95. Fit the fuel‐injection pump belt tensioner.
   Compress the tensioner spring and secure it with the
clamp bolt.

96. Fit the crankshaft vibration damper.

• Immobilise the crankshaft by means of the flywheel
ring gear.
• Fit the vibration damper, the lug and the notch must
line up.
• Insert the vibration damper bolt dry and tighten it to
the specified torque.

97. Align the camshaft pulley.

1. Align the camshaft pulley with the special tool
through the opening in the pulley and into the hole in
the cylinder head.
2. Slacken the bolts securing the pulley to the pulley
flange.

98. Align the fuel‐injection pump pulley and bring the

crankshaft to TDC.
1. Align the fuel‐injection pump pulley with the shank
of a new 6 mm drill bit through the opening in the
pulley and into the hole in the pump housing.
   Unscrew the blanking plug from the opening in the
cylinder block for setting TDC.
2. Screw the special tool into the cylinder block.
NOTE:
The special tool must be screwed in as far as
the stop; the crankshaft must be resting
against the special tool.
   Turn the crankshaft to TDC.
99. Fit the fuel‐injection pump drive belt.
NOTE:
The direction in which the belt runs is
marked.
   Fit a new belt as shown, with the slack side towards
the belt tensioner.
NOTE:
Make sure that the drive belt is sitting
correctly.
   Slacken the bolt of the belt tensioner and allow the
tensioner to snap against the belt.
1. Tighten the belt tensioner clamp bolt.
2. Tighten the bolts of the camshaft pulley.
 NOTE:
The bolts must not be at the ends of the
slots.
100. Fit the camshaft timing belt.
NOTE:
The direction in which the belt runs is
marked.
   Fit a new timing belt with the slack side towards the
timing belt tensioner.
NOTE:
Make sure that the drive belt is sitting
correctly.
   Release the belt tensioner clamp bolt and allow the
tensioner to snap against the belt.
1. Tighten the belt tensioner clamp bolt.
NOTE:
The bolts must not be at the ends of the
slots.
2. Tighten the bolts of the camshaft pulley.
   Remove Special Tools 21‐104 and 23‐019 and the 6
mm drill bit.
101. Preparations for adjusting the tension of the
belts.
• Turn the crankshaft two revolutions in the normal
direction of rotation until the slot in the fuel injection
pump pulley is at 12 o'clock.
• Turn the slot back in the opposite direction to 11
o'clock.
1. Screw in the special tool.
   Carefully turn the crankshaft in the normal direction
of rotation until it comes up against the special tool.
2. The special tool must go through the opening in the
camshaft pulley and into the hole in the cylinder head.
3. The 6 mm drill bit must go through the slot in the
fuel‐injection pump pulley and into the hole in the
pump housing.
 CAUTION:
Re‐tensioning of a used timing belt is not
permitted.
102. Tension the fuel‐injection pump drive belt.
NOTE:
Only slacken the bolts of the pulleys half a
turn each.
• Slacken the bolts of the camshaft pulley.
• Slacken the bolts of the fuel‐injection pump pulley.
1. Slacken the bolt of the fuel‐injection pump belt
tensioner a quarter of a turn so that the belt tensioner
presses against the drive belt.
2. Tighten the bolt of the fuel‐injection pump belt
tensioner.
3. Tighten the bolts of the fuel‐injection pump pulley.
NOTE:
The crankshaft must remain in the TDC
position.

CAUTION:
Re‐tensioning of a used timing belt is not
permitted.
103. Tension the camshaft timing belt.
NOTE:
Do not withdraw the 6 mm drill bit.

1. Slacken the bolt of the camshaft belt tensioner a

quarter of a turn so that the belt tensioner presses
against the timing belt.
NOTE:
All the timing tools must be fitted correctly
and the crankshaft must be resting against
the timing pin.
2. Tighten the bolt of the camshaft belt tensioner.
3. Tighten the bolts of the camshaft pulley.
   Remove the special tools and the drill bit.
4. Fit the blanking plug.

104. Fit the pulley covers (five bolts/three clips).

105. Fit the fuel‐injection pump pulley.
1. Fit the fuel‐injection pump pulley (three bolts).
2. Connect the coolant hose.

106. Fit the alternator bracket.

107. Attach the alternator and the drive belt tensioner

pulley.
1. Fit the alternator (two bolts).
2. Fit the alternator (one bolt)
3. Fit the tensioning pulley (two bolts).
4. Screw in the tensioning pulley adjusting screw.

108. Lay the alternator drive belt in place and tension

it.
1. Lay the drive belt in place and tension it with the
tensioner pulley adjusting bolt.
2. Check the tension:
• 1 - 2 mm for a new drive belt
• 2 - 4 mm for a used drive belt
3. Secure the tensioning pulley.

109. Check the valve clearances and adjust as

necessary as described in Operation No. 21 213 0.
110. Fit the oil baffle (four nuts).
111. Fit the rocker cover with a new gasket.

112. Connect the PCV hoses.

1. To the cylinder block.
2. To the turbocharger.

113. Fit the oil dipstick tube with its bracket and a new
O‐ring.
114. Detach the engine from the assembly stand.

115. Fit the driveshaft bracket and oil pressure switch.

116. Fit the turbocharger bracket.

 117. Fit the complete oil pump.
NOTE:
Fill the oil pump with engine oil and lubricate
the gears.
1. Locate the oil pump in position with a new gasket
and new oil filter.
2. Tighten the four oil pump bolts.
3. Connect the oil feed line to the turbocharger.
4. Tighten the oil feed line bolt.

118. Fit the coolant pipe to the oil cooler.

1. Connect the coolant pipe to the oil cooler.
2. Tighten the two bracket bolts.

Cylinder Head – Remove and Install (21

Mondeo 1993 (01/1993-07/1996)
163 0)
 Print

Removal and Installation

Special Tools

21‐104Crankshaft TDC setting

pin

21‐140Engine support bar

15‐097ASubframe locating
pins

21‐068 AEngine lifting tackle

21‐140‐01Adaptor for 21‐140

21‐164Cylinder head bolt

wrench
 21‐172Installation gauge for
engine/transmission assembly

21‐540Angle gauge

23‐019Timing pin for

camshaft timing pulley

23‐03427 mm socket for

injectors

24‐003Remover and installer,

radiator hose clip

Proprietary Tools
New 6 mm drill bit
Two‐legged puller
Workshop Equipment
Workshop hoist
Materials
Description Finis Code
Lifting eye, Part No.
V86HF 17A084AA -
1635720
Drill out the lower hole
to dia. 11 mm
Remove
1. Disconnect the battery negative lead.
   Raise the vehicle.
2. Remove the engine undershield.

3. Drain off the coolant.

4. Check the position of the subframe.
   The special tools must engage in the sub‐frame and
body reference holes without force, otherwise align the
sub‐frame as described in Operation 21 133 0 in
Section 21‐01.

5. Remove the front engine roll restrictor.

1. Unscrew the centre bolt.
2. Detach the engine roll restrictor from the subframe
and remove it (two bolts).

6. Fit the special tool in place of the engine roll

restrictor.
   The special tool must engage without force,
otherwise align the engine/transmission assembly as
described in Operation 21 133 0 in Section 21‐01.
1. Attach the special tool to the sub‐frame.
2. Screw in the centre bolt.

7. Remove the vibration damper splash shield from the

wheel arch (three bolts).
   Lower the vehicle.

8. Detach the intercooler.

1. Undo the two screws on the left and right‐hand
sides.
2. Disconnect the hose from the inlet manifold.
9. Remove the intake system resonator.
   Release the hose clip and withdraw the resonator.

10. Remove the mass air flow sensor (MAF sensor).

1. Disconnect the plug.
NOTE:
There may be some resistance due to the
rubber ring.
2. Release the clips and the hose clip and remove the
MAF sensor.

11. Disconnect the plug from the thermostat housing.

1. Disconnect the temperature gauge sender unit
multiplug.
2. Disconnect the engine coolant temperature sensor
(ECT sensor) multiplug.
3. Disconnect the cooling fan motor switch (CFS)
multiplug.

12. Disconnect the coolant hoses from the thermostat

housing.
1. From radiator.
2. From expansion tank.
3. From coolant pump.

13. Release the clip securing the hoses/wiring loom

and lay the hoses/wiring loom to the side.
   Slide the rear part of the clip to the side.
14. Disconnect the fuel lines and release them from
the bracket.
1. Feed line to fuel‐injection pump.
2. Fuel line to fuel tank.

15. Detach the plug and wiring connections to the

cylinder head.
1. Plug of oil pressure switch.
2. Plug of fuel heater.
3. Power supply lead to glow plugs.

16. Disconnect the vacuum line and the oil return line
from the vacuum pump.

17. Detach the thermostat housing from the cylinder

head.
1. Detach the oil dipstick tube with the cable bracket.
2. Detach the thermostat housing and lay it to the side
(two bolts).

18. Detach the bracket on the engine lifting eye and

disconnect the fuel return line at the fuel injection
pump.
19. Disconnect the positive crankcase ventilation (PCV)
hoses from the cylinder head cover.
1. To the cylinder block.
2. To the turbocharger.

20. Disconnect the hoses from the cylinder head and

the exhaust gas recirculation valve (EGR valve).
1. Heater hose from cylinder head.
2. Vacuum hose from EGR valve.

21. Disconnect the hoses from the turbocharger.

1. Turbocharger oil feed hose
2. Turbocharger vacuum hose

22. Detach the cable bracket and coolant hose.

1. Cable bracket on alternator.
2. Coolant hose to expansion tank from cylinder head.

23. Attach the enlarged lifting eye (see Preparations)

with an alternator bolt.
 NOTE:
The support bar must be under load.

24. Fit the engine support bar.

25. Detach the belt cover from the power steering

pump.
1. Remove the two bolts.
2. Undo the power steering pump pivot bolt.

26. Detach the drive belt tensioner from the power

steering pump.
1. Undo the clamp bolt from the power steering
pump.
2. Slacken the drive belt by releasing the adjusting
bolt.
3. Detach the tensioner from the front cover.

27. Detach the power steering pump.

1. Take off the drive belt.
2. Remove the pivot bolt and lay the power steering
pump to one side.

28. Remove the right‐hand engine mounting bracket.

29. Remove the engine lifting eye bolts from the
bracket for the engine mounting/power steering pump.

30. Remove the fuel‐injection pump pulley.

• Disconnect the coolant hose at the coolant pump.
• Raise the vehicle.

31. Detach the exhaust pipe at the turbocharger.

32. Detach the turbocharger bracket and the

turbocharger oil return line.
NOTE:
Watch out for escaping oil.

1. Oil return line to cylinder block.

2. Turbocharger bracket

33. Remove the alternator drive belt.

1. Slacken the clamp bolt.
2. Slacken the drive belt with the adjusting bolt and
take it off.
34. Detach the lower timing belt cover (three bolts).
   Lower the vehicle.

35. Remove the upper timing belt cover.

   Release the three clips and the single bolt and lift
the cover off.

36. Turn the crankshaft to TDC.

• Turn the crankshaft in the normal direction of
rotation until the slot in the fuel‐injection pump pulley
is at 11 o'clock.
• Remove the blanking plug and screw the timing pin
into the cylinder block.
• Turn the crankshaft carefully until it comes up
against the timing pin.

37. Detach the camshaft timing belt.

• Slacken the clamping bolt of the timing belt
tensioner and relax the timing belt.
• Tighten the clamping bolt of the timing belt
tensioner.
• Remove the timing belt.

WARNING:
The timing belt tensioner is spring loaded.

38. Detach the camshaft timing belt tensioner and

timing pulley.
1. Detach the timing belt tensioner (two bolts).
2. Detach the timing pulley.
39. Detach the timing belt idler pulley.
   Bend back the rear timing belt cover.

40. Disconnect the fuel injection lines from the fuel

injection pump and the injectors.
   Disconnect the leak‐off hoses.

41. Remove the injectors.

   Remove the heat shields.

42. Remove the cylinder head cover.

   Remove the gasket.

43. Detach the oil baffle.

 44. Slacken the cylinder head bolts in the specified
sequence and remove them.

45. Attach the engine lifting tackle to the lifting eyes

and carefully lift the cylinder head out of the vehicle.
   Remove the cylinder head gasket.

Install
46. Preparations.
• Clean the mating faces thoroughly.
• Fit a new cylinder head gasket.
1. Check that the locating sleeves are located
correctly.
2. Thickness identification.

CAUTION:
Do not damage the rear timing belt cover.

NOTE:
The pistons must not be at TDC.

47. Carefully place the cylinder head on the cylinder

block with the aid of the lifting tackle.
48. Pre‐tighten the cylinder head bolts.
• Screw in new un‐oiled cylinder head bolts.
• Tighten the cylinder head bolts in the indicated
tightening sequence in two stages.

CAUTION:
For stage 3, first slacken the cylinder head
bolts then tighten them to the specified
torque and angle. Only then move on to the
next bolt.
NOTE:
The cylinder head bolts must not be re‐
torqued.
49. Tighten the cylinder head bolts.
   Wait three minutes and then tighten the cylinder
head bolts in the specified sequence to stage 3.
 NOTE:
Make sure the heat shields are fitted in the
correct position.
50. Fit the injectors with new heat shields.

51. Connect the fuel injection lines to the fuel injection

pump and the injectors (eight union nuts).
   Connect the leak‐off hoses.

52. Fit the timing belt idler pulley.

   Bend the rear timing belt cover over the camshaft
and fit the idler pulley.

53. Fit the camshaft timing belt tensioner and timing

pulley.
1. Camshaft timing belt cover
2. Camshaft timing belt tensioner
54. Align the camshaft pulley.
1. Align the camshaft pulley with the special tool
through the opening in the pulley and into the hole in
the cylinder head.
2. Slacken the bolts securing the pulley to the pulley
flange.

55. Check the setting of the fuel‐injection pump.

• Insert a new 6 mm drill bit in the timing pulley and
the fuel‐injection pump.
• If the drill bit cannot be inserted, the fuel‐injection
pump must be reset.

56. Fit the camshaft timing belt.

NOTE:
The direction in which the belt runs is
marked.
   Fit a new timing belt with the slack side towards the
timing belt tensioner.
NOTE:
Make sure that the drive belt is sitting
correctly.
   Release the belt tensioner clamp bolt and allow the
tensioner to snap against the belt.
1. Tighten the belt tensioner clamp bolt.
NOTE:
The bolts must not be at the ends of their
slots.
2. Tighten the bolts of the camshaft pulley.
   Remove Special Tools 21‐104 and 23‐019 and the 6
mm drill bit.
57. Preparations for adjusting the tension of the belts.
• Turn the crankshaft two revolutions in the normal
direction of rotation until the slot in the fuel injection
pump pulley is at 12 o'clock.
• Turn the slot back in the opposite direction to 11
o'clock.
1. Screw in the special tool.
   Carefully turn the crankshaft in the normal direction
of rotation until it comes up against the special tool.
2. The special tool must go through the opening in the
camshaft pulley and into the hole in the cylinder head.
3. The 6 mm drill bit must go through the slot in the
fuel‐injection pump pulley and into the hole in the
pump housing.

58. Tension the camshaft timing belt.

NOTE:
Do not withdraw the 6 mm drill bit.

1. Slacken the bolt of the camshaft belt tensioner a

quarter of a turn so that the belt tensioner presses
against the timing belt.
NOTE:
All the timing tools must be fitted correctly
and the crankshaft must be resting against
the timing pin.
2. Tighten the bolt of the camshaft belt tensioner.
3. Tighten the bolts of the camshaft pulley.
   Remove the special tools and the drill bit.
4. Fit the blanking plug.

59. Check the valve clearances and adjust if necessary

as described in Operation No. 21 213 0.
60. Fit the oil baffle.
61. Fit the cylinder head cover and gasket.

62. Fit the upper timing belt cover.

• Insert the cover from above and secure it with the
three clips and the single bolt.
• Raise the vehicle.

63. Fit the lower timing belt cover.

64. Lay the alternator drive belt in place and tension

it.
1. Lay the drive belt in place and tension it with the
adjusting bolt on the tensioner pulley.
2. Check the belt tension.
• 1 – 2 mm for new multi‐grooved belts
• 2 – 4 mm for used multi‐grooved belts
3. Secure the belt tensioner pulley.

65. Connect the exhaust pipe to the turbocharger.

66. Fit the turbocharger/cylinder block bracket and the
turbocharger oil return line.
1. Oil return line to cylinder block.
2. Bracket to turbocharger (two bolts).
3. Bracket to cylinder block.
   Raise the vehicle.

NOTE:
Fit the belt pulley and lower bolt at the same
time.
67. Fit the fuel‐injection pump pulley.
   Connect the coolant hose to the coolant pump.

68. Fit the lifting eye to the bracket for the engine
mounting/power steering pump.

NOTE:
Use new nuts.

69. Fit the right‐hand engine mounting bracket.

70. Fit the power steering pump.

1. Position the power steering pump and screw in the
pivot bolt.
2. Lay the drive belt in place.
71. Attach the drive belt tensioner to the power
steering pump.
1. Fit the tensioner to the front cover.
2. Tension the drive belt with the adjusting bolt.
3. Tighten the clamp bolt on the power steering
pump.

72. Fit the power steering pump belt cover.

1. Tighten the power steering pump pivot bolt.
2. Tighten the two bolts.

73. Remove the engine support bar.

   Detach the engine lifting eye from the alternator
bolt.

74. Fit the cable bracket and connect the coolant

hose.
1. Cable bracket on alternator.
2. Coolant hose from expansion tank to cylinder
head.

75. Connect the hoses to the turbocharger.

1. Turbocharger oil feed hose.
2. Turbocharger vacuum hose.
76. Connect the hoses to the cylinder head and the
EGR valve.
1. Heater hose to cylinder head.
2. Vacuum hose to EGR valve.

77. Connect the PCV hoses to the cylinder head cover.

1. To the cylinder block.
2. To the turbocharger.

78. Fit the bracket to the engine lifting eye and

connect the fuel return line to the fuel injection pump.

79. Fit the thermostat housing to the cylinder head.

1. Fit the thermostat housing with a new gasket (two
bolts).
2. Fit the oil dipstick tube and cable bracket.

80. Connect the vacuum line and the oil return line to
the vacuum pump.
 81. Connect the plugs and wiring.
1. Plug to oil pressure switch.
2. Plug to fuel heater.
3. Power supply lead to glow plugs.

82. Connect the fuel lines and secure them in the

bracket.
1. Feed line to fuel‐injection pump.
2. Fuel line to fuel tank.

83. Secure the hoses and the wiring loom with the
retaining clip.
   Attach the front part of the clip and slide on the rear
part from the side.

84. Connect the coolant hoses to the thermostat

housing.
1. From radiator.
2. From expansion tank.
3. From coolant pump.

85. Connect the plugs to the thermostat housing.

1. Temperature gauge sender unit multiplug
2. ECT sensor multiplug
3. CFS multiplug
86. Fit the MAF sensor.
   Lightly grease the rubber ring.
1. Fit the MAF sensor and secure the clips and the
hose clip.
2. Connect the multiplug.

87. Connect the intake system resonator.

88. Fit the intercooler.

1. Connect the hose to the inlet manifold.
2. Attach the intercooler and tighten the two bolts on
the left and right‐hand sides.
   Raise the vehicle.

89. Remove the special tool.

1. Unscrew the centre bolt.
2. Detach the special tool from the sub‐frame.

CAUTION:
Do not tilt the engine roll restrictor.

90. Attach the front engine roll restrictor.

1. Attach the engine roll restrictor to the sub‐frame
(two bolts).
2. Fit the centre bolt.
91. Attach the vibration damper splash shield to the
wheel arch.

92. Fit the engine undershield.

• Screw in the coolant drain plug.
• Lower the vehicle.

93. Standard finishing operations.

• Change the oil and the oil filter.
• Fill up with coolant.
• Check the fluid levels and rectify as necessary.
• Check the routing of the cables and hoses and secure
them with cable ties.
• Connect the battery negative lead.
• Enter the radio keycode.
• Reprogramme the preset radio stations.
• Adjust the clock.
• Carry out a road test to enable the PCM (EDC) to
gather data.