Ford Mondeo (petrol engines). Manual — part 77
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 available at time of writing
Torque wrench settings
Nm
lbf ft
Cylinder head cover bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1.5
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
5
Camshaft toothed pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
50
Camshaft bearing cap bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
7
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
14
Cylinder head bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
18
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
33
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Angle-tighten a further 105°
Timing belt cover fasteners:
Upper-to-middle (outer) cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . .
4
3
Cover-to-cylinder head or block bolts . . . . . . . . . . . . . . . . . . . . . . . .
7
5
Cover studs-to-cylinder head or block . . . . . . . . . . . . . . . . . . . . . . . .
9 to 11
6.5 to 8
Timing belt tensioner bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
28
Timing belt tensioner backplate locating peg . . . . . . . . . . . . . . . . . . . . .
8 to 11
6 to 8
Timing belt tensioner spring retaining pin . . . . . . . . . . . . . . . . . . . . . . . .
10
7
Timing belt guide pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 to 40
26 to 30
Water pump pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
7
Water pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
See Chapter 3
Auxiliary drivebelt idler pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
35
Inlet manifold nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
13
Alternator mounting bracket-to-cylinder block bolts . . . . . . . . . . . . . . .
47
35
Cylinder head support plates:
Front plate Torx screws - to power steering pump/air conditioning
compressor mounting bracket and cylinder head . . . . . . . . . . . . . . .
47
35
Rear plate/engine lifting eye - to alternator mounting bracket
and cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
35
Front engine lifting eye bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
12
Inlet and exhaust manifold studs-to-cylinder head . . . . . . . . . . . . . . . .
10 maximum
7 maximum
Exhaust manifold heat shield bolts:
Shield-to-cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
5
Shield/dipstick tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
7
Shield/coolant pipe-to-manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
17
Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
12
Air conditioning refrigerant pipe-to-exhaust manifold bolts . . . . . . . . . .
10
7
Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108 to 115
80 to 85
Oil pump-to-cylinder block bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
7
Oil pick-up pipe-to-pump screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
7
Oil baffle/pump pick-up pipe nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
14
Oil filter adaptor-to-pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 to 25
13 to 18
Oil pressure warning light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
20
Oil level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
20
Sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 to 22
15 to 16
Coolant pipe-to-sump bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
7
Flywheel/driveplate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110 to 112
81 to 83
Crankshaft left-hand oil seal carrier bolts . . . . . . . . . . . . . . . . . . . . . . . .
22
16
Transmission-to-engine bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
30
Engine/transmission front mounting:
Mounting bracket-to-transmission . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not available
Mounting-to-subframe bolts/nuts - stage 1 . . . . . . . . . . . . . . . . . . . .
10
7
Mounting-to-subframe bolts/nuts - stage 2 . . . . . . . . . . . . . . . . . . . .
48
35
Mounting centre bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120
89
Engine/manual transmission rear mounting:
Mounting bracket-to-transmission 12 mm fasteners . . . . . . . . . . . . .
78 to 84
58 to 62
Mounting bracket-to-transmission 10 mm fasteners . . . . . . . . . . . . .
48
35
Mounting-to-subframe bolts and nut - stage 1 . . . . . . . . . . . . . . . . . .
10
7
Mounting-to-subframe bolts and nut - stage 2 . . . . . . . . . . . . . . . . . .
48
35
Mounting centre bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120
89
2A•2 In-car engine repair procedures
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 left-hand mounting:
Bracket-to-transmission nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
61
Mounting centre bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not available
Mounting-to-body bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not available
Engine/transmission right-hand mounting:
Bracket-to-engine and mounting nuts . . . . . . . . . . . . . . . . . . . . . . . .
83 to 90
61 to 66
Mounting-to-body bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
62
Note: Refer to Part B of this Chapter for remaining torque wrench settings.
In-car engine repair procedures 2A•3
2A
How to use this Chapter
This Part of Chapter 2 is devoted to repair
procedures possible while the engine is still
installed in the vehicle, and includes only the
Specifications relevant to those procedures.
Since these procedures are based on the
assumption that the engine is installed in the
vehicle, if the engine has been removed from
the vehicle and mounted on a stand, some of
the preliminary dismantling steps outlined will
not apply.
Information concerning engine/transmission
removal and refitting, and engine overhaul, can
be found in Part B of this Chapter, which also
includes the Specifications relevant to those
procedures.
General description - engine
The engine, also known by Ford’s internal
code name “Zetec” (formerly “Zeta”), is of
four-cylinder, in-line type, mounted
transversely at the front of the vehicle, with
the (clutch and) transmission on its left-hand
end (see illustrations).
Apart from the plastic timing belt covers and
the cast-iron cylinder block/crankcase, all
major engine castings are of aluminium alloy.
The crankshaft runs in five main bearings,
the centre main bearing’s upper half
incorporating thrustwashers to control
crankshaft endfloat. The connecting rods
rotate on horizontally-split bearing shells at
their big-ends. The pistons are attached to the
connecting rods by gudgeon pins which are an
interference fit in the connecting rod small-end
eyes. The aluminium alloy pistons are fitted
with three piston rings: two compression rings
and an oil control ring. After manufacture, the
cylinder bores and piston skirts are measured
and classified into three grades, which must be
carefully matched together, to ensure the
correct piston/cylinder clearance; no oversizes
are available to permit reboring.
The inlet and exhaust valves are each
closed by coil springs; they operate in guides
which are shrink-fitted into the cylinder head,
as are the valve seat inserts.
Both camshafts are driven by the same
toothed timing belt, each operating eight
valves via self-adjusting hydraulic tappets,
thus eliminating the need for routine checking
and adjustment of the valve clearances. Each
camshaft rotates in five bearings that are line-
bored directly in the cylinder head and the
(bolted-on) bearing caps; this means that the
bearing caps are not available separately
from the cylinder head, and must not be
interchanged with caps from another engine.
The water pump is bolted to the right-hand
1 General information
1.3A Longitudinal cross-section through engine - inset showing timing belt details
1 Inlet camshaft
2 Exhaust camshaft
3 Oil galleries
4 Exhaust port
5 Oil strainer and pick-up pipe
6 Oil baffle
7 Crankshaft
8 Piston-cooling oil jet (where
fitted)
9 Inlet valve
10 Inlet port
11 Fuel injector
12 Inlet camshaft toothed
pulley
13 Timing belt
14 Exhaust camshaft toothed
pulley
15 Timing belt (front) guide
pulley
16 Crankshaft toothed pulley
- behind
17 Crankshaft pulley
18 Oil cooler (where fitted)
19 Timing belt (rear) guide
pulley
20 Timing belt tensioner
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 specified.
General description - lubrication
system
Lubrication is by means of an eccentric-
rotor trochoidal pump, which is mounted on
the crankshaft right-hand end, and draws oil
through a strainer located in the sump. The
pump forces oil through an externally-
mounted full-flow cartridge-type filter - on
some versions of the engine, an oil cooler is
fitted to the oil filter mounting, so that clean
oil entering the engine’s galleries is cooled by
the main engine cooling system. From the
filter, the oil is pumped into a main gallery in
the cylinder block/crankcase, from where it is
distributed to the crankshaft (main bearings)
and cylinder head (see illustration).
The big-end bearings are supplied with oil
via internal drillings in the crankshaft. On
some versions of the engine, each piston
crown is cooled by a spray of oil directed at
its underside by a jet. These jets are fed by
passages off the crankshaft oil supply
galleries, with spring-loaded valves to ensure
that the jets open only when there is sufficient
pressure to guarantee a good oil supply to
the rest of the engine components; where the
jets are not fitted, separate blanking plugs are
provided, so that the passages are sealed,
but can be cleaned at overhaul (see
illustration).
2A•4 In-car engine repair procedures
1.3B Lateral cross-section through engine
1 Exhaust valve
2 Piston
3 Oil baffle
4 Oil strainer and pick-up
pipe
5 Spark plug
6 Fuel injector
7 Piston-cooling oil jets
(where fitted)
1.10 Engine lubrication system - inset showing longitudinal cross-section
1 Main oil gallery
2 From oil filter
3 Oil pump
4 Cylinder head oil-retaining valve
5 Cylinder head oil gallery
6 Cylinder head oil supply
7 Oil return
8 Piston-cooling oil spray (where fitted)
9 Oil filter - oil cooler not shown here
1.11 Piston-cooling oil jet details
1 Oil jets (when fitted)
2 Oil flow - only when valve opens at set
pressure
3 Oil spray
4 Blanking plug (when fitted)
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 crankshaft and camshaft
bearings and the hydraulic tappets receive a
pressurised supply, the camshaft lobes and
valves are lubricated by splash, as are all
other engine components.
Valve clearances - general
It is necessary for a clearance to exist
between the tip of each valve stem and the
valve operating mechanism, to allow for the
expansion of the various components as the
engine reaches normal operating
temperature.
On most older engine designs, this meant
that the valve clearances (also known as
“tappet” clearances) had to be checked and
adjusted regularly. If the clearances were
allowed to be too slack, the engine would be
very noisy, its power output would suffer, and
its fuel consumption would increase. If the
clearances were allowed to be too tight, the
engine’s power output would be reduced,
and the valves and their seats could be
severely damaged.
The engines covered in this manual,
however, employ hydraulic tappets which use
the lubricating system’s oil pressure
automatically to take up the clearance
between each camshaft lobe and its
respective valve stem. Therefore, there is no
need for regular checking and adjustment of
the valve clearances, but it is essential that
only good-quality oil of the recommended
viscosity and specification is used in the
engine, and that this oil is always changed at
the recommended intervals. If this advice is
not followed, the oilways and tappets may
become clogged with particles of dirt, or
deposits of burnt (inferior) engine oil, so that
the system cannot work properly; ultimately,
one or more of the tappets may fail, and
expensive repairs may be required.
On starting the engine from cold, there will
be a slight delay while full oil pressure builds
up in all parts of the engine, especially in the
tappets; the valve components, therefore,
may well “rattle” for about 10 seconds or so,
and then quieten. This is a normal state of
affairs, and is nothing to worry about,
provided that all tappets quieten quickly and
stay quiet.
After the vehicle has been standing for
several days, the valve components may
“rattle” for longer than usual, as nearly all the
oil will have drained away from the engine’s
top end components and bearing surfaces.
While this is only to be expected, care must
be taken not to damage the engine under
these circumstances - avoid high speed
running until all the tappets are refilled with oil
and operating normally. With the vehicle
stationary, hold the engine at no more than a
fast idle speed (maximum 2000 to 2500 rpm)
for 10 to 15 seconds, or until the noise
ceases. Do not run the engine at more than
3000 rpm until the tappets are fully recharged
with oil and the noise has ceased.
If the valve components are thought to be
noisy, or if a light rattle persists from the top
end after the engine has warmed up to
normal operating temperature, take the
vehicle to a Ford dealer for expert advice.
Depending on the mileage covered and the
usage to which each vehicle has been put,
some vehicles may be noisier than others;
only a good mechanic experienced in these
engines can tell if the noise level is typical for
the vehicle’s mileage, or if a genuine fault
exists. If any tappet’s operation is faulty, it
must be renewed (Section 13).
The following major repair operations can
be accomplished without removing the
engine from the vehicle. However, owners
should note that any operation involving the
removal of the sump requires careful
forethought, depending on the level of skill
and the tools and facilities available; refer to
the relevant text for details.
(a) Compression pressure - testing.
(b) Cylinder head cover - removal and
refitting.
(c) Timing belt covers - removal and refitting.
(d) Timing belt - renewal.
(e) Timing belt tensioner and toothed pulleys
- removal and refitting.
(f)
Camshaft oil seals - renewal.
(g) Camshafts and hydraulic tappets -
removal and refitting.
(h) Cylinder head - removal, overhaul and
refitting.
(i)
Cylinder head and pistons -
decarbonising.
(j)
Sump - removal and refitting.
(k) Crankshaft oil seals - renewal.
(l)
Oil pump - removal and refitting.
(m) Piston/connecting rod assemblies -
removal and refitting (but see note below).
(n) Flywheel/driveplate - removal and
refitting.
(o) Engine/transmission mountings - removal
and refitting.
Clean the engine compartment and the
exterior of the engine with some type of
degreaser before any work is done. It will
make the job easier, and will help to keep dirt
out of the internal areas of the engine.
Depending on the components involved, it
may be helpful to remove the bonnet, to
improve access to the engine as repairs are
performed (refer to Chapter 11 if necessary).
Cover the wings to prevent damage to the
paint; special covers are available, but an old
bedspread or blanket will also work.
If vacuum, exhaust, oil or coolant leaks
develop, indicating a need for component/
gasket or seal replacement, the repairs can
generally be made with the engine in the
vehicle. The intake and exhaust manifold
gaskets, sump gasket, crankshaft oil seals
and cylinder head gasket are all accessible
with the engine in place.
Exterior components such as the intake
and exhaust manifolds, the sump, the oil
pump, the water pump, the starter motor, the
alternator and the fuel system components
can be removed for repair with the engine in
place.
Since the cylinder head can be removed
without lifting out the engine, camshaft and
valve component servicing can also be
accomplished with the engine in the vehicle,
as can renewal of the timing belt and toothed
pulleys.
In extreme cases caused by a lack of
necessary equipment, repair or renewal of
piston rings, pistons, connecting rods and
big-end bearings is possible with the engine
in the vehicle. However, this practice is not
recommended, because of the cleaning and
preparation work that must be done to the
components involved, and because of the
amount of preliminary dismantling work
required - these operations are therefore
covered in Part B of this Chapter.
1 When engine performance is down, or if
misfiring occurs which cannot be attributed to
the ignition or fuel systems, a compression
test can provide diagnostic clues as to the
engine’s condition. If the test is performed
regularly, it can give warning of trouble before
any other symptoms become apparent.
2 The engine must be fully warmed-up to
normal operating temperature, the oil level
must be correct, the battery must be fully
charged, and the spark plugs must be
removed. The aid of an assistant will be
required also.
3 Disable the ignition system by unplugging
the ignition coil’s electrical connector, and
remove fuse 14 to disconnect the fuel pump.
4 Fit a compression tester to the No 1
cylinder spark plug hole - the type of tester
which screws into the plug thread is to be
preferred.
5 Have the assistant hold the throttle wide
open and crank the engine on the starter
motor; after one or two revolutions, the
compression pressure should build up to a
maximum figure, and then stabilise. Record
the highest reading obtained.
6 Repeat the test on the remaining cylinders,
recording the pressure developed in each.
7 At the time of writing, no compression
3 Compression test -
description and interpretation
2 Repair operations possible with
the engine in the vehicle
In-car engine repair procedures 2A•5
2A
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