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Engine - 2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-TDCi(100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW,Emission Requirements: Stage IV - Timing Belt

Mondeo 2007.5 (02/2007-)

Print

Removal and Installation

Special Tool(s)

General Equipment

Removal

303-1059Alignment Peg, Crankshaft

303-393Locking Tool, Flywheel

303-393-01Adapter for 303-393

303-396-01Adapter for 303-396

303-735Alignment Peg, Camshaft

Trolley jack

1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

2. Remove the following items:1. Refer to: Accessory Drive Belt (303-05F Accessory Drive - 2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L

Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW/2.0L Duratorq-TDCi(118kW/160PS) - DW, Removal and Installation).

2. Refer to: Starter Motor (303-06F Starting System - 2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-

TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW, Removal and Installation).

3.

4. General Equipment: Trolley jack

5.

6.

7. CAUTION: Make sure that the crankshaft is not rotated while the special tool is installed.Install the Special Tool(s): 303-1059

8. Install the Special Tool(s): 303-735

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Installation

9. Install the Special Tool(s): 303-393, 303-393-01

10. CAUTION: Take extra care when handling the crankshaft position (CKP) sensor ring.

11.

1.

1. NOTE: Make sure that a new component is installed.2. Torque: 56 Nm

2. 1. NOTE: Make sure that a new component is installed.2. NOTE: Make sure that a new component is installed.

3. NOTE: Only tighten the bolt finger tight at this stage.

4. CAUTION: Take extra care when handling the crankshaft position (CKP) sensor ring.

3.1. Allen key, 6mm3. Torque: 21 Nm

4. Torque: 50 Nm

5. Remove the Special Tool(s): 303-396-01, 303-1059

6. Remove the Special Tool(s): 303-735

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7. CAUTION: Only rotate the crankshaft clockwise.

Rotate the crankshaft 4 revolutions.

8. Install the Special Tool(s): 303-1059

9. Install the Special Tool(s): 303-393, 303-393-01

10. NOTE: The special tool can only be installed if the valve timing is correct.Install the Special Tool(s): 303-735

11.

12. Remove the Special Tool(s): 303-735

13. Torque: 7 Nm

14.1. Torque: 10 Nm

2. NOTE: Only tighten the bolts finger tight at this stage.3. Torque: 133 Nm

15. Lower and remove the Trolley jack.

General Equipment: Trolley jack

16. Torque: 90 Nm

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17.

1. Torque: 7 Nm2. NOTE: Make sure that a new component is installed.Torque:

70 Nm60

Stage 1:Stage 2:

18. Remove the special tools.

Special Tool(s): 303-1059, 303-393, 303-393-01

19. Install the following items:1. Refer to: Accessory Drive Belt (303-05F Accessory Drive - 2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L

Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW/2.0L Duratorq-TDCi(118kW/160PS) - DW, Removal and Installation).

2. Refer to: Starter Motor (303-06F Starting System - 2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW, Removal and Installation).

20. Connect the battery.

Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

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