Ford Mondeo 4 Owners Manual

Chapter 2  Part A: 
In-car engine repair procedures
Auxiliary drivebelt check and renewal  . . . . . . . . . . . . . See Chapter 1
Camshaft oil seals - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Camshafts and hydraulic tappets - removal, inspection 
and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compression test - description and interpretation  . . . . . . . . . . . . . . 3
Crankshaft oil seals - renewal  . . . . . . ....

Lubrication
Engine oil type/specification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Engine oil capacity  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Oil pressure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No information available at time of writing
Oil pump clearances  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No information...

Torque wrench settings (continued)Nm lbf ft
Engine/automatic transmission rear mounting:
Mounting bracket-to-transmission  . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 to 49 35 to 36
Mounting-to-subframe bolts - stage 1  . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Mounting-to-subframe bolts - stage 2  . . . . . . . . . . . . . . . . . . . . . . . . 48 35
Mounting centre bolt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 89
Engine/transmission...

end of the cylinder block, inboard of the
timing belt, and is driven with the power
steering pump and alternator by a flat
“polyvee”-type auxiliary drivebelt from the
crankshaft pulley.
When working on this engine, note that
Torx-type (both male and female heads) and
hexagon socket (Allen head) fasteners are
widely used; a good selection of bits, with the
necessary adaptors, will be required, so that
these can be unscrewed without damage
and, on reassembly, tightened to the torque
wrench settings...

The cylinder head is provided with two oil
galleries, one on the inlet side and one on the
exhaust, to ensure constant oil supply to the
camshaft bearings and hydraulic tappets. A
retaining valve (inserted into the cylinder
head’s top surface, in the middle, on the inlet
side) prevents these galleries from being
drained when the engine is switched off. The
valve incorporates a ventilation hole in its
upper end, to allow air bubbles to escape
from the system when the engine is restarted.
While the...

specifications were available from Ford, but a
typical reading would be in excess of 12 bars.
All cylinders should produce very similar
pressures; any difference greater than 10%
indicates the existence of a fault. Note that the
compression should build up quickly in a
healthy engine; low compression on the first
stroke, followed by gradually-increasing
pressure on successive strokes, indicates worn
piston rings. A low compression reading on the
first stroke, which does not build up during
successive...

throttle linkage as described in Chapter 4.
Where fitted, disconnect also the cruise
control actuator cable (see Chapter 12).
3Remove the timing belt upper cover (see
Section 9).
4Disconnect the crankcase breather hose
from the cylinder head cover union (see
illustration).
5Unplug the HT leads from the spark plugs
and withdraw them, unclipping the leads from
the cover.
6Working progressively, unscrew the
cylinder head cover retaining bolts, noting the
spacer sleeve and rubber seal at each, then
withdraw...

16Unscrew the bolts and nuts securing the
manifold to the cylinder head and withdraw it
(see illustration). Take care not to damage
vulnerable components such as the EGR pipe
and valve as the manifold assembly is
manoeuvred out of the engine compartment.
Refitting
17Refitting is the reverse of the removal
procedure, noting the following points:
(a) When using a scraper and solvent to
remove all traces of old gasket material
and sealant from the manifold and
cylinder head, be careful to ensure that
you do...

9Remove the nuts and detach the manifold
and gasket (see illustration). Take care not
to damage vulnerable components such as
the EGR pipe as the manifold assembly is
manoeuvred out of the engine compartment.
When removing the manifold with the engine
in the vehicle, additional clearance can be
obtained by unscrewing the studs from the
cylinder head; a female Torx-type socket will
be required (see illustration).
10Always fit a new gasket on reassembly, to
carefully-cleaned components (see below).
Do...

using the method outlined in (2) above.
(2) If the vehicle is fitted with automatic
transmission, see (2) above.
(c) If the engine/transmission has been
removed and separated, use the method
shown in illustration 21.11.
4Unscrew the pulley bolt and remove the
pulley (see illustrations).
5Refitting is the reverse of the removal
procedure; ensure that the pulley’s keyway is
aligned with the crankshaft’s locating key,
and tighten the pulley bolt to the specified
torque wrench setting.
Upper cover
1Unscrew...