Ford Mondeo 4 Owners Manual

and right-hand mountings. Do not yet
release the hoist; the weight of the
engine/transmission unit must not be
taken by the mountings until all are
correctly aligned.
(d) Fitting the Ford service tool in place of the
front mounting, tighten the
engine/transmission mounting fasteners
to their specified torque wrench settings,
and in the sequence described in Part B
of this Chapter, Section 4, paragraphs 49
and 50.
(e) Refill the cooling system (see Chapter 1).
(f) Refill the engine with oil, remembering...

the gasket, move the pump into the correct
position, and tighten its bolts to the specified
torque wrench setting.
14Check that the pump is correctly located;
if necessary, unbolt it again, and repeat the
full procedure to ensure that the pump is
correctly aligned.
15Fit a new crankshaft right-hand oil seal
(see Section 20).
16Using grease to stick the gasket in place
on the pump, refit the pick-up/strainer pipe,
tightening its screws and nut to their specified
torque wrench settings (see illustration)....

3Clean the seal housing and crankshaft,
polishing off any burrs or raised edges, which
may have caused the seal to fail in the first
place.
4Refit the oil pump (see Section 16). Grease
the lips and periphery of the new seal, to ease
installation.
5To fit a new seal, Ford recommend the use
of their service tool 21-093A, with the
crankshaft pulley bolt, to draw the seal into
place; an alternative can be arranged using a
socket of suitable size, with a washer to
match the crankshaft pulley bolt (see...

Removal
1Remove the transmission (see the relevant
Part of Chapter 7). Now is a good time to
check components such as oil seals and
renew them if necessary.
2Where appropriate, remove the clutch
(Chapter 8). Now is a good time to check or
renew the clutch components and pilot
bearing.
3Use a centre-punch or paint to make
alignment marks on the flywheel/driveplate
and crankshaft, to ensure correct alignment
during refitting.
4Prevent the flywheel/driveplate from
turning by locking the ring gear teeth, or...

resonator to the air mass meter and plenum
chamber hoses, then swing the resonator up
clear of the thermostat housing (see Chapter
4). Unbolt the pulse-air filter housing from the
mounting bracket, then unfasten thebolts/nuts securing the mounting to the
subframe, unscrew the centre bolt and
withdraw the mounting; note the location of
the wiring connector bracket. The mounting’s
bracket can be unbolted from the
transmission if required (see illustration).
9On refitting, ensure that the mounting-to-...

the nuts are self-locking, and must therefore
be renewed whenever they are disturbed.
Unscrew the centre bolt to dismantle the
mounting, if necessary to renew components.
15On refitting, renew the self-locking nuts,
and do not allow the mounting to twist as the
nuts are tightened (see illustration). Tighten
all fasteners to the specified torque wrench
settings.Rear mounting
16Where the vehicle is fitted with automatic
transmission, a separate damper may be
fitted beneath the subframe, which must be...

Chapter 2  Part B: Engine removal 
and general engine overhaul procedures
Compression test - description and interpretation  . . . See Chapter 2A
Crankshaft - inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Crankshaft - refitting and main bearing running 
clearance check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankshaft - removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cylinder...

Pistons and piston rings
Piston diameter - 1.6 litre engine:
Class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.975 to 75.985 mm
Class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.985 to 75.995 mm
Class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.995 to 76.005 mm
Piston diameter - 1.8 litre engine:
Class 1 . . . . . . . . . . . . ....

How to use this Chapter
This Part of Chapter 2 is devoted to
engine/transmission removal and refitting, to
those repair procedures requiring the removal
of the engine/transmission from the vehicle,
and to the overhaul of engine components. It
includes only the Specifications relevant to
those procedures. Refer to Part A for
additional Specifications, if required.
General information
The information ranges from advice
concerning preparation for an overhaul and
the purchase of replacement parts, to...

safely and with relative ease, and which may
have to be hired or borrowed, includes (in
addition to the engine hoist) a heavy-duty trolley
jack, a strong pair of axle stands, some wooden
blocks, and an engine dolly (a low, wheeled
platform capable of taking the weight of the
engine/transmission, so that it can be moved
easily when on the ground). A complete set of
spanners and sockets (as described in the front
of this manual) will obviously be needed,
together with plenty of rags and cleaning
solvent...