Ford Mondeo (petrol engines). Manual - part 79

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.

4 Unscrew the pulley bolt and remove the
pulley (see illustrations).
5 Refitting 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

1 Unscrew the cover’s two mounting bolts
and withdraw it (see illustration).
2 Refitting is the reverse of the removal
procedure; ensure the cover edges engage
correctly with each other, and note the torque
wrench setting specified for the bolts.

Middle cover

3 Unscrew the six nuts securing the
engine/transmission right-hand mounting
bracket, then withdraw the bracket.
4 Slacken the water pump pulley bolts.
5 Remove the timing belt upper cover (see
paragraph 1 above).
6 Remove the auxiliary drivebelt (see Chap-
ter 1).
7 Unbolt and remove the water pump pulley
(see illustration).
8 Unscrew the middle cover fasteners (one
bolt at the front, one at the lower rear, one
stud at the top rear) and withdraw the cover
(see illustration).
9 Refitting is the reverse of the removal
procedure. Ensure the cover edges engage
correctly with each other, and note the torque
wrench settings specified for the various
fasteners. When reassembling the engine/
transmission right-hand mounting, renew the
self-locking nuts, and do not allow the
mounting to twist as the middle two of the
bracket’s six nuts are tightened.

Lower cover

10 Remove the crankshaft pulley (see
Section 8).
11 Unscrew the cover’s three securing bolts
and withdraw it (see illustration).
12 Refitting is the reverse of the removal
procedure; ensure the cover edges engage
correctly with each other, and note the torque
wrench settings specified for the various
fasteners.

Inner shield

13 Remove the timing belt, its tensioner
components and the camshaft toothed
pulleys (see Sections 10 and 11).
14 The shield is secured to the cylinder head
by two bolts at the top, and by two studs

lower down; unscrew these and withdraw the
shield (see illustration).
15 Refitting is the reverse of the removal
procedure; note the torque wrench settings
specified for the various fasteners.

Note: To carry out this operation, a new
timing belt (where applicable), a new cylinder
head cover gasket, and some special tools
(see text) will be required. If the timing belt is
being removed for the first time since the
vehicle left the factory, a tensioner spring and
retaining pin must be obtained for fitting on
reassembly.

10 Timing belt - removal, 

refitting and adjustment

9 Timing belt covers - 

removal and refitting

2A•10 In-car engine repair procedures

8.4A  Unscrew pulley bolt to release

crankshaft pulley

8.4B  Ensure pulley is located on

crankshaft Woodruff key on reassembly

9.1  Remove bolts (arrowed) to release

timing belt upper cover

9.8  Remove fasteners (arrowed) to release

timing belt middle cover

9.7  Slacken water pump pulley bolts and

remove pulley

9.11  Removing timing belt lower cover -

bolt locations arrowed

9.14  Timing belt inner shield fasteners

(arrowed)

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

5 Remove the cylinder head cover (see
Section 5).
6 Remove the spark plugs, covering their
holes with clean rag, to prevent dirt or other
foreign bodies from dropping in (see Chap-
ter 1).
7 Remove the auxiliary drivebelt (see Chap-
ter 1).
8 Rotate the crankshaft clockwise until the
second pair of notches in the pulley rim align
with the edge of the sump mark, so that Nos
1 and 4 cylinders are at TDC (see Section 4).

9 Unbolt and remove the water pump pulley
and the auxiliary drivebelt idler pulley.
10 Obtain Ford service tool 21-162, or
fabricate a substitute from a strip of metal 
5 mm thick (while the strip’s thickness is
critical, its length and width are not, but
should be approximately 180 to 230 mm by
20 to 30 mm). Check that Nos 1 and 4
cylinders are at Top Dead Centre (TDC) - No 1
on the compression stroke - by resting this
tool on the cylinder head mating surface, and
sliding it into the slot in the left-hand end of
both camshafts (see illustration). The tool
should slip snugly into both slots while resting
on the cylinder head mating surface; if one
camshaft is only slightly out of alignment, it is
permissible to use an open-ended spanner to
rotate the camshaft gently and carefully until
the tool will fit.
11 If both camshaft slots (they are machined
significantly off-centre) are below the level of
the cylinder head mating surface, rotate the
crankshaft through one full turn clockwise
and fit the tool again; it should now fit as
described in the previous paragraph.
12 With the camshaft aligning tool remaining
in place, remove the crankshaft pulley. Do not
use the locked camshafts to prevent the
crankshaft from rotating - use only the locking
methods described in Section 8.
13 Remove the timing belt lower and middle
covers (see Section 9).
14 With the camshaft aligning tool still in
place, slacken the tensioner bolt, and use an
Allen key inserted into its centre to rotate the
tensioner clockwise as far as possible away
from the belt; retighten the bolt to secure the
tensioner clear of the timing belt (see
illustration).
15 If the timing belt is to be re-used, use
white paint or similar to mark its direction of
rotation, and note from the manufacturer’s
markings which way round it is fitted.
Withdraw the belt (see illustration). Do not
rotate the crankshaft until the timing belt is
refitted.
16 If the belt is being removed for reasons
other than routine renewal, check it carefully
for any signs of uneven wear, splitting, cracks
(especially at the roots of the belt teeth) or

In-car engine repair procedures  2A•11

2A

10.10  Fit camshaft aligning tool to ensure

engine is locked with Nos 1 and 4 cylinders

at TDC

10.14  Slacken tensioner bolt, and use

Allen key to rotate tensioner away from

timing belt . . .

10.15  . . . then withdraw timing belt

10.1  Timing belt and cover details

1  Timing belt upper cover
2  Inlet camshaft toothed pulley
3  Exhaust camshaft toothed pulley
4  Timing belt
5  Timing belt tensioner
6  Crankshaft toothed pulley
7  Timing belt middle cover
8  Timing belt lower cover
9  Crankshaft pulley
10  Water pump pulley

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 ensure that the
tensioner and guide pulleys rotate smoothly
on their bearings; renew any worn or
damaged components. If signs of oil or
coolant contamination are found, trace the
source of the leak and rectify it, then wash
down the engine timing belt area and related
components, to remove all traces of oil or
coolant.
17 On reassembly, temporarily refit the
crankshaft pulley, to check that the pulley
notches and sump rib are aligned as
described in paragraph 8 above, then ensure
that both camshafts are aligned at TDC by
the special tool (paragraph 10). If the engine
is being reassembled after major dismantling,
both camshaft toothed pulleys should be free
to rotate on their respective camshafts; if the
timing belt alone is being renewed, both
pulleys should still be securely fastened.
18 A holding tool will be required to prevent
the camshaft toothed pulleys from rotating
while their bolts are slackened and
retightened; either obtain Ford service tool

15-030A, or fabricate a substitute as follows.
Find two lengths of steel strip, one
approximately 600 mm long and the other
about 200 mm, and three bolts with nuts and
washers; one nut and bolt forming the pivot of
a forked tool, with the remaining nuts and
bolts at the tips of the “forks”, to engage with
the pulley spokes as shown in the
accompanying illustrations. Note: Do not use
the camshaft aligning tool (whether genuine
Ford or not) to prevent rotation while the
camshaft toothed pulley bolts are slackened
or tightened; the risk of damage to the
camshaft concerned and to the cylinder head
is far too great. Use only a forked holding tool
applied directly to the pulleys, as described.
19 If it is being fitted for the first time, screw
the timing belt tensioner spring retaining pin
into the cylinder head, tightening it to the
specified torque wrench setting. Unbolt the
tensioner, hook the spring on to the pin and
the tensioner backplate, then refit the
tensioner, engaging its backplate on the
locating peg (see illustrations).
20 In all cases, slacken the tensioner bolt (if
necessary), and use an Allen key inserted into
its centre to rotate the tensioner clockwise as
far as possible against spring tension, then
retighten the bolt to secure the tensioner (see
illustration).
21 Fit the timing belt; if the original is being
refitted, ensure that the marks and notes
made on removal are followed, so that the
belt is refitted the same way round, and to run
in the same direction. Starting at the

crankshaft toothed pulley, work anti-
clockwise around the camshaft toothed
pulleys and tensioner, finishing off at the rear
guide pulley. The front run, between the
crankshaft and the exhaust camshaft toothed
pulleys, must be kept taut, without altering
the position either of the crankshaft or of the
camshaft(s) - if necessary, the position of the
camshaft toothed pulleys can be altered by
rotating each on its camshaft (which remains
fixed by the aligning tool). Where the pulley is
still fastened, use the holding tool described
in paragraph 18 above to prevent the pulley
from rotating while its retaining bolt is
slackened - the pulley can then be rotated on
the camshaft until the belt will slip into place;
retighten the pulley bolt.
22 When the belt is in place, slacken the
tensioner bolt gently until the spring pulls the
tensioner against the belt; the tensioner
should be retained correctly against the
timing belt inner shield and cylinder head, but
must be just free to respond to changes in
belt tension (see illustration).
23 Tighten both camshaft toothed pulley
bolts (or check that they are tight, as
applicable) and remove the camshaft aligning
tool. Temporarily refit the crankshaft pulley,
and rotate the crankshaft through two full
turns clockwise to settle and tension the
timing belt, returning the crankshaft (pulley
notches) to the position described in
paragraph 8 above. Refit the camshaft
aligning tool; it should slip into place as
described in paragraph 10. If all is well,
proceed to paragraph 26 below.
24 If one camshaft is only just out of line, fit
the forked holding tool to its toothed pulley,
adjust its position as required, and check that
any slack created has been taken up by the
tensioner; rotate the crankshaft through two
further turns clockwise, and refit the camshaft
aligning tool to check that it now fits as it
should. If all is well, proceed to paragraph 26
below.
25 If either camshaft is significantly out of
line, use the holding tool described in
paragraph 18 above to prevent its pulley from
rotating while its retaining bolt is slackened -
the camshaft can then be rotated (gently and
carefully, using an open-ended spanner) until

2A•12 In-car engine repair procedures

10.19A  Fitting tensioner spring retaining

pin

10.19B  Hook spring onto tensioner and

refit as shown - engage tensioner

backplate on locating peg (arrowed) . . .

10.20  . . . then use Allen key to position

tensioner so that timing belt can be refitted

10.22  Slacken tensioner bolt to give initial

belt tension

10.25  Using forked holding tool while

camshaft toothed pulley bolt is tightened

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.
26 When the timing belt has been settled at
its correct tension, and the camshaft aligning
tool fits correctly when the crankshaft pulley
notches are exactly aligned, tighten the
tensioner bolt to its specified torque wrench
setting (see illustration). Fitting the forked
holding tool to the spokes of each pulley in
turn, check that the pulley bolts are tightened
to their specified torque wrench setting.
Remove the camshaft aligning tool, rotate the
crankshaft through two further turns
clockwise, and refit the tool to make a final
check that it fits as it should.
27 The remainder of the reassembly
procedure is the reverse of removal, noting
the following points:
(a) Tighten all fasteners to the torque wrench

settings specified.

(b) When reassembling the

engine/transmission right-hand mounting,
renew the self-locking nuts, and do not
allow the mounting to twist as the middle
two of the bracket’s six nuts are
tightened.

Tensioner

Note: If the tensioner is being removed for the
first time since the vehicle left the factory, a
tensioner spring and retaining pin must be
obtained for fitting on reassembly.
1 While it is possible to reach the tensioner
once the timing belt upper and middle covers
only have been removed (see Section 9), the
whole procedure outlined below must be
followed, to ensure that the valve timing is
correctly reset once the belt’s tension has
been disturbed.
2 Release the tension from the timing belt as
described in Section 10, paragraphs 1 to 14.
3 Unscrew the tensioner bolt and withdraw
the tensioner, unhooking the spring, if fitted
(see illustration). Check the tensioner and
spring as described in paragraph 16 of
Section 10.
4 On reassembly, if it is being fitted for the
first time, screw the timing belt tensioner
spring retaining pin into the cylinder head,
tightening it to the specified torque wrench
setting. Hook the spring onto the pin and the
tensioner backplate, then refit the tensioner,
engaging its backplate on the locating peg.
5 Use an Allen key inserted into its centre to
rotate the tensioner clockwise as far as
possible against spring tension, then tighten
the bolt to secure the tensioner.
6 Reassemble, checking the camshaft
alignment (valve timing) and setting the timing
belt tension, as described in paragraphs 22 to
27 of Section 10.

Camshaft and crankshaft toothed
pulleys

7 While it may be possible to remove any of
these pulleys once their respective covers
have been removed, the complete timing belt
removal/refitting procedure (see Section 10)
must be followed, to ensure that the valve
timing is correctly reset once the belt’s
tension has been disturbed.

8 With the timing belt removed, the camshaft
toothed pulleys can be detached once their
retaining bolts have been unscrewed as
described in paragraphs 18 and 21 of Section
10. The crankshaft toothed pulley can be
pulled off the end of the crankshaft once the
crankshaft (grooved) pulley and the timing
belt have been removed. Note the “FRONT”
marking identifying the pulley’s outboard
face, and the thrustwasher behind it; note
which way round the thrustwasher is fitted
(see illustration). Note the pulley-locating
Woodruff key; if this is loose, it should be
removed for safe storage with the pulley.
9 Check the pulleys as described in
paragraph 16 of Section 10.
10 Refitting is the reverse of the removal
procedure.

Timing belt guide pulleys

11 Remove the timing belt covers (see
Section 9).
12 Unbolt and withdraw the pulley(s); check
their condition as described in paragraph 16
of Section 10.
13 Refitting is the reverse of the removal
procedure; tighten the pulley bolts to the
specified torque wrench setting (see
illustration).

Note: While it is possible to reach either oil
seal, once the respective toothed pulley has
been removed (see Section 11) to allow the
seal to be prised out, this procedure is not
recommended. Not only are the seals very
soft, making this difficult to do without risk of
damage to the seal housing, but it would be
very difficult to ensure that the valve timing
and the timing belt’s tension, once disturbed,
are correctly reset. Owners are advised to
follow the whole procedure outlined below.
1 Release the tension from the timing belt as
described in Section 10, paragraphs 1 to 14.
Note: If the timing belt is found to be
contaminated by oil, remove it completely as
described, then renew the oil seal (see below).
Wash down the engine timing belt area and all

12 Camshaft oil seals - renewal

11 Timing belt tensioner and

toothed pulleys - removal,
inspection and refitting

In-car engine repair procedures  2A•13

2A

11.3  Removing timing belt tensioner

11.8  Note “FRONT” marking on outside

face of crankshaft toothed pulley - note

which way round thrustwasher behind is

fitted

11.13  Tighten timing belt guide pulley

bolts to specified torque settings on

refitting

10.26  When setting is correct, tighten

tensioner bolt to specified torque wrench

setting