Ford Mondeo 4 Owners Manual

1With the vehicle parked on firm level
ground, open the bonnet and disconnect the
battery negative (earth) lead - see Chapter 5,
Section 1 (see illustration).
2Unbolt the power steering high-pressure
pipe from the cylinder head rear support
plate/engine lifting eye, and from the front
support plate/pump bracket.
3Unscrew the six nuts securing the
engine/transmission right-hand mounting
bracket, then withdraw the bracket.
4Slacken the water pump pulley bolts.5Remove the cylinder head cover (see
Section...

contamination with oil or coolant. Renew the
belt if there is the slightest doubt about its
condition. As a safety measure, the belt must
be renewed as a matter of course at the
intervals given in Chapter 1; if its history is
unknown, the belt should be renewed
irrespective of its apparent condition
whenever the engine is overhauled. Similarly,
check the tensioner spring (where fitted),
renewing it if there is any doubt about its
condition. Check also the toothed pulleys for
signs of wear or damage, and...

the camshaft aligning tool will slip into place;
take care not to disturb the relationship of the
pulley to the timing belt. Without disturbing
the pulley’s new position on the camshaft,
tighten the pulley bolt to its specified torque
wrench setting (see illustration). Remove the
camshaft aligning tool, rotate the crankshaft
through two further turns clockwise and refit
the tool to check that it now fits as it should.
26When the timing belt has been settled at
its correct tension, and the camshaft...

related components, to remove all traces of
oil. Fit a new belt on reassembly.
2If the timing belt is still clean, slip it off the
toothed pulley, taking care not to twist it too
sharply; use the fingers only to handle the
belt. Do notrotate the crankshaft until the
timing belt is refitted. Cover the belt, and
secure it so that it is clear of the working area
and cannot slip off the remaining toothed
pulley.
3Unfasten the pulley bolt and withdraw the
pulley (see Section 11).
4Unbolt the camshaft...

wear (scoring, pitting etc) and for ovality, and
renew if necessary.
8Measure the outside diameter of each
tappet (see illustration)- take measurements
at the top and bottom of each tappet, then a
second set at right-angles to the first; if any
measurement is significantly different from
the others, the tappet is tapered or oval (as
applicable) and must be renewed. If the
necessary equipment is available, measure
the inside diameter of the corresponding
cylinder head bore. Compare the
measurements...

away from the gauge, and note the gauge
reading. If the endfloat measured is found to
be at or beyond the specified service limit, fit
a new camshaft and repeat the check; if the
clearance is still excessive, the cylinder head
must be renewed.
Refitting
17On reassembly, liberally oil the cylinder
head hydraulic tappet bores and the tappets
(see illustration). Note that if new tappets are
being fitted, they must be charged with clean
engine oil before installation. Carefully refit the
tappets to the...

23If using Ford’s recommended procedure,
fit new oil seals to the camshafts as
described in paragraph 5 of Section 12.
24Using the marks and notes made on
dismantling to ensure that each is refitted to
its original camshaft, refit the toothed pulleys
to the camshafts, tightening the retaining
bolts loosely (see illustration). Slip the timing
belt back onto the pulleys (refer to para-
graph 21 of Section 10) and tighten the bolts
securely - use the forked holding tool
described in paragraph 18 of Section...

14Unscrew the two nuts to disconnect the
exhaust system front downpipe from the
manifold (Chapter 4); disconnect the oxygen
sensor wiring, so that it is not strained by the
weight of the exhaust system.
15Remove the auxiliary drivebelt (see
Chapter 1).
16Support the weight of the
engine/transmission using a trolley jack, with
a wooden spacer to prevent damage to the
sump.
17Unscrew the six nuts securing the
engine/transmission right-hand mounting
bracket, then withdraw the bracket. Unbolt
the auxiliary...

then an ordinary socket extension bar and an
angle gauge, to tighten the cylinder head
bolts in the stages given in the Specifications
Section of this Chapter (see illustrations).
Note:Once tightened correctly, following this
procedure, the cylinder head bolts do not
require check-tightening, and must notbe re-
torqued.
33Refit the hydraulic tappets (if removed),
the camshafts, their oil seals and pulleys (see
Sections 10, 11, 12 and 13, as appropriate).
Temporarily refit the crankshaft pulley, and...

additional lifting eyes where required (see
illustration). Remove completely the
engine/transmission front mounting, unscrew
the rear mounting’s centre bolt, and unbolt
the left-hand mounting from the body.
Unscrew the six nuts securing the right-hand
mounting bracket, and withdraw the bracket.
13Being careful to watch the wiring, coolant
hoses, fluid cooler pipes or gearchange
linkage and transmission support rods (where
appropriate), and the radiator electric cooling
fan, to ensure that nothing is...