timing belt FORD MONDEO 1993 Service Repair Manual

0•10
MExamine the handbrake mechanism,
checking for frayed or broken cables,
excessive corrosion, or wear or insecurity of
the linkage. Check that the mechanism works
on each relevant wheel, and releases fully,
without binding.
MIt is not possible to test brake efficiency
without special equipment, but a road test
can be carried out later to check that the
vehicle pulls up in a straight line.
Fuel and exhaust systems
MInspect the fuel tank (including the filler
cap), fuel pipes, hoses and unions. All
components must be secure and free from
leaks.
MExamine the exhaust system over its entire
length, checking for any damaged, broken or
missing mountings, security of the retaining
clamps and rust or corrosion.
Wheels and tyres
MExamine the sidewalls and tread area of
each tyre in turn. Check for cuts, tears, lumps,
bulges, separation of the tread, and exposure
of the ply or cord due to wear or damage.
Check that the tyre bead is correctly seated
on the wheel rim, that the valve is sound andproperly seated, and that the wheel is not
distorted or damaged.
MCheck that the tyres are of the correct size
for the vehicle, that they are of the same size
and type on each axle, and that the pressures
are correct.
MCheck the tyre tread depth. The legal
minimum at the time of writing is 1.6 mm over
at least three-quarters of the tread width.
Abnormal tread wear may indicate incorrect
front wheel alignment.
Body corrosion
MCheck the condition of the entire vehicle
structure for signs of corrosion in load-
bearing areas. (These include chassis box
sections, side sills, cross-members, pillars,
and all suspension, steering, braking system
and seat belt mountings and anchorages.)
Any corrosion which has seriously reduced
the thickness of a load-bearing area is likely to
cause the vehicle to fail. In this case
professional repairs are likely to be needed.
MDamage or corrosion which causes sharp
or otherwise dangerous edges to be exposed
will also cause the vehicle to fail.
Petrol models
MHave the engine at normal operating
temperature, and make sure that it is in good
tune (ignition system in good order, air filter
element clean, etc).
MBefore any measurements are carried out,
raise the engine speed to around 2500 rpm,
and hold it at this speed for 20 seconds. Allow
the engine speed to return to idle, and watchfor smoke emissions from the exhaust
tailpipe. If the idle speed is obviously much
too high, or if dense blue or clearly-visible
black smoke comes from the tailpipe for more
than 5 seconds, the vehicle will fail. As a rule
of thumb, blue smoke signifies oil being burnt
(engine wear) while black smoke signifies
unburnt fuel (dirty air cleaner element, or other
carburettor or fuel system fault).
MAn exhaust gas analyser capable of
measuring carbon monoxide (CO) and
hydrocarbons (HC) is now needed. If such an
instrument cannot be hired or borrowed, a
local garage may agree to perform the check
for a small fee.
CO emissions (mixture)
MAt the time or writing, the maximum CO
level at idle is 3.5% for vehicles first used after
August 1986 and 4.5% for older vehicles.
From January 1996 a much tighter limit
(around 0.5%) applies to catalyst-equipped
vehicles first used from August 1992. If the
CO level cannot be reduced far enough to
pass the test (and the fuel and ignition
systems are otherwise in good condition) then
the carburettor is badly worn, or there is some
problem in the fuel injection system or
catalytic converter (as applicable).
HC emissionsMWith the CO emissions within limits, HC
emissions must be no more than 1200 ppm
(parts per million). If the vehicle fails this test
at idle, it can be re-tested at around 2000
rpm; if the HC level is then 1200 ppm or less,
this counts as a pass.
MExcessive HC emissions can be caused by
oil being burnt, but they are more likely to be
due to unburnt fuel.
Diesel models
MThe only emission test applicable to Diesel
engines is the measuring of exhaust smoke
density. The test involves accelerating the
engine several times to its maximum
unloaded speed.
Note: It is of the utmost importance that the
engine timing belt is in good condition before
the test is carried out.
M
Excessive smoke can be caused by a dirty
air cleaner element. Otherwise, professional
advice may be needed to find the cause.
4Checks carried out on
YOUR VEHICLE’S EXHAUST
EMISSION SYSTEM
MOT Test Checks
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Chapter 1 Routine maintenance and servicing
Air conditioning system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . 7
Automatic transmission linkage lubrication . . . . . . . . . . . . . . . . . . . 18
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery check, maintenance and charging . . . . . . . . . . . . . . . . . . . . 9
Brake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Clutch pedal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 28
Door and bonnet check and lubrication . . . . . . . . . . . . . . . . . . . . . . 24
Driveshaft rubber gaiter and CV joint check . . . . . . . . . . . . . . . . . . . 20
Electrical system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine compartment wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine oil and filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fluid level checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Idle speed and mixture check and adjustment . . . . . . See Chapter 4Ignition timing check . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Manual transmission oil level check . . . . . . . . . . . . . . . . . . . . . . . . . 16
Positive Crankcase Ventilation (PCV) system check
and filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Power steering fluid level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Roadwheel nut tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . See end of Chapter
Steering, suspension and roadwheel check . . . . . . . . . . . . . . . . . . . 19
Timing belt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Tyre and tyre pressure checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Underbody and fuel/brake line check . . . . . . . . . . . . . . . . . . . . . . . . 22
Underbonnet check for fluid leaks and hose condition . . . . . . . . . . 12
Ventilation system pollen filter renewal . . . . . . . . . . . . . . . . . . . . . . . 27
Windscreen/tailgate washer system and wiper blade check . . . . . . 6
1•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,suitable
for competent DIY
mechanicDifficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty Contents
1
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Ford Mondeo maintenance schedule
1•3
1
Maintenance schedule
The manufacturer’s recommended maintenance schedule for these
vehicles is as described below - note that the schedule starts from the
vehicle’s date of registration. These are the minimum maintenance
intervals recommended by the factory for Mondeos driven daily, but
subjected only to “normal” use. If you wish to keep your vehicle in
peak condition at all times, you may wish to perform some of these
procedures even more often. Because frequent maintenance
enhances the efficiency, performance and resale value of your vehicle,
we encourage you to do so. If your usage is not “normal”, shorter
intervals are also recommended - the most important examples of
these are noted in the schedule. These shorter intervals apply
particularly if you drive in dusty areas, tow a caravan or trailer, sit with
the engine idling or drive at low speeds for extended periods (ie, in
heavy traffic), or drive for short distances (less than four miles) in
below-freezing temperatures.
When your vehicle is new, it should be serviced by a Ford dealer
service department to protect the factory warranty. In many cases, the
initial maintenance check is done at no cost to the owner. Note that
this first free service (carried out by the selling dealer 1500 miles or 3
months after delivery), although an important check for a new vehicle,
is not part of the regular maintenance schedule, and is therefore not
mentioned here.
Weekly checks
m mCheck the engine oil level, and top-up if necessary
(Section 3)
m mCheck the brake fluid level, and top-up if necessary
(Section 3). If repeated topping-up is required, check the
system for leaks or damage at the earliest possible
opportunity (Sections 12 and 22)
m mCheck the windscreen/tailgate washer fluid level, and top-
up if necessary (Section 3)
m mCheck the tyre pressures, including the spare (Section 4)
m mVisually check the tyres for excessive tread wear, or
damage (Section 4)
m mCheck the operation of all (exterior and interior) lights and
the horn, wipers and windscreen/tailgate washer system
(Sections 6 and 8). Renew any blown bulbs (Chapter 12),
and clean the lenses of all exterior lights
Monthly checks
m mCheck the coolant level, and top-up if necessary (Sec-
tion 3)
m mCheck the battery electrolyte level, where applicable
(Section 3)
m mCheck the power steering fluid level, and top-up if
necessary (Section 5)
m mVisually check all reservoirs, hoses and pipes for leakage
(Section 12)
m mCheck the operation of the air conditioning system
(Section 14)
m mCheck the operation of the handbrake (Section 23)
m mCheck the aim of the windscreen/tailgate/headlight
washer jets, correcting them if required (Section 6)
m mCheck the condition of the wiper blades, renewing them if
worn or no longer effective - note that the manufacturer
recommends renewing the blades as a safety precaution,
irrespective of their apparent condition, at least once a
year (Section 6)
Every 10 000 miles or 12 months,
whichever occurs first
Note:If the vehicle is used regularly for very short (less than
10 miles), stop/go journeys, the oil and filter should be renewed
between services (ie, every 5000 miles/6 months).
m mCheck the electrical system (Section 8)
m mCheck the battery (Section 9)
m mCheck the seat belts (Section 10)
m mCheck the auxiliary drivebelt (Section 11)
m mCheck for fluid leaks and hose condition (Section 12)
m mCheck the condition of all wiring (Section 13)
m mCheck all air conditioning components (Section 14)
m mChange the engine oil and filter (Section 15)
m mCheck the manual transmission oil level (Section 16)
m mCheck the adjustment of the clutch pedal (Section 17)
m mLubricate the automatic transmission linkage (Section 18)
m mCheck the steering, suspension and wheels (Section 19)
m mCheck the driveshaft gaiters and CV joints (Section 20)
m mCheck the exhaust system (Section 21)
m mCheck the underbody, and all fuel/brake lines (Section 22)
m mCheck the brake system (Section 23)
m mCheck and lubricate the doors and bonnet (Section 24)
m mCheck the security of all roadwheel nuts (Section 25)
m mRoad test (Section 26). Check the level of the automatic
transmission fluid with the engine still hot, after the road
test (Section 7)
Every 20 000 miles or 2 years,
whichever occurs first
Carry out all operations listed above, plus the following:
m mRenew the ventilation system pollen filter (Section 27)
m mRenew the coolant (Sections 2 and 28)
Every 30 000 miles or 3 years,
whichever occurs first
Carry out all operations listed above, plus the following:
m mRenew the air filter element (Section 29). Note that this
task must be carried out at more frequent intervals if the
vehicle is used in dusty or polluted conditions
m mCheck the Positive Crankcase Ventilation (PCV) system,
and clean the filter (Section 30)
m mRenew the spark plugs (Section 31)
Every 60 000 miles
Carry out all operations listed above, plus the following:
m
mRenew the timing belt (Section 32)
m mRenew the fuel filter (Section 33)
Every 3 years
(regardless of mileage)
m mRenew the brake fluid (Section 34)
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To prevent the possibility of mixing up spark
plug (HT) leads, it is a good idea to try to work
on one spark plug at a time.
4If the marks on the original-equipment
spark plug (HT) leads cannot be seen, mark
the leads 1 to 4, to correspond to the cylinder
the lead serves (No 1 cylinder is at the timing
belt end of the engine). Pull the leads from the
plugs by gripping the rubber boot sealing thecylinder head cover opening, not the lead,
otherwise the lead connection may be
fractured.
5It is advisable to soak up any water in the
spark plug recesses with a rag, and to remove
any dirt from them using a clean brush,
vacuum cleaner or compressed air before
removing the plugs, to prevent any dirt or
water from dropping into the cylinders. Warning: Wear eye protection
when using compressed air!
6Unscrew the spark plugs, ensuring that the
socket is kept in alignment with each plug - if
the socket is forcibly moved to either side, the
porcelain top of the plug may be broken off. If
any undue difficulty is encountered when
unscrewing any of the spark plugs, carefully
1•24Every 30 000 miles
Specifications
Engine
Direction of crankshaft rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise (seen from right-hand side of vehicle)
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C148
Cooling system
Coolant protection at 40% antifreeze/water mixture ratio:
Slush point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -25°C (-13°F)
Solidifying point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -30°C (-22°F)
Coolant specific gravity at 40% antifreeze/water mixture ratio and
15°C/59°F - with no other additives in coolant . . . . . . . . . . . . . . . . . . . . 1.061
Fuel system
Idle speed - nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 830 ± 50 rpm*
Air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U618
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L218
* Note: Given for reference only - not adjustable.
Ignition system
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2 (No 1 cylinder at timing belt end of engine)
Spark plugs:*
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RE7YCC
Electrode gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm
Spark plug (HT) leads:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion type not available
Maximum resistance per lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 000 ohms
* Information on spark plug types and electrode gaps is as recommended by Champion Spark Plug. Where alternative types are used, refer to
their manufacturer’s recommendations
Braking system
Note: No minimum lining thicknesses are given by Ford - the following is given as a general recommendation. If the pad wear warning light
comes on before the front brake pad linings reach the minimum thickness, the pads should nevertheless be renewed immediately.
Minimum front or rear brake pad lining thickness . . . . . . . . . . . . . . . . . 1.5 mm
Minimum rear brake shoe lining thickness . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm
Suspension and steering
Tyre pressures (cold):Front Rear
Normally laden* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 bars (31 psi) 2.1 bars (31 psi)
Fully laden* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 bars (35 psi) 2.8 bars (41 psi)
Note: Normally laden means up to 3 persons. For sustained high speeds above 100 mph (160 km/h), increased pressures are necessary.
Consult the driver’s handbook supplied with the vehicle.
Wiper blades
Windscreen:
Driver’s side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion X 5303 (and SP 01 spoiler)
Passenger’s side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion X 5103
Tailgate:
Hatchback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion X 5103
Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion type not available
Torque wrench settingsNm lbf ft
Auxiliary drivebelt cover fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 10 4 to 7
Auxiliary drivebelt automatic tensioner Torx screws . . . . . . . . . . . . . . . . 23 17
Engine oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Manual transmission filler/level plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26
Radiator undershield screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11
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check the cylinder head threads and tapered
sealing surfaces for signs of wear, excessive
corrosion or damage; if any of these
conditions is found, seek the advice of a Ford
dealer as to the best method of repair.
7As each plug is removed, examine it as
follows - this will give a good indication of the
condition of the engine. If the insulator nose of
the spark plug is clean and white, with no
deposits, this is indicative of a weak mixture.
8If the tip and insulator nose are covered
with hard black-looking deposits, then this is
indicative that the mixture is too rich. Should
the plug be black and oily, then it is likely that
the engine is fairly worn, as well as the mixture
being too rich.
9If the insulator nose is covered with light tan
to greyish-brown deposits, then the mixture is
correct, and it is likely that the engine is in
good condition.
10If you are renewing the spark plugs,
purchase the new plugs, then check each of
them first for faults such as cracked insulators
or damaged threads. Note also that,
whenever the spark plugs are renewed as a
routine service operation, the spark plug (HT)
leads should be checked as described below.
11The spark plug electrode gap is of
considerable importance as, if it is too large or
too small, the size of the spark and its
efficiency will be seriously impaired. The gap
should be set to the value given in the
Specifications Section of this Chapter. New
plugs will not necessarily be set to the correct
gap, so they should always be checked
before fitting.
12Special spark plug electrode gap
adjusting tools are available from most motor
accessory shops (see illustration).
13To set the electrode gap, measure the
gap with a feeler gauge, and then bend open,
or closed, the outer plug electrode until the
correct gap is achieved (see illustration). The
centre electrode should never be bent, as this
may crack the insulation and cause plug
failure, if nothing worse. If the outer electrode
is not exactly over the centre electrode, bend
it gently to align them.14Before fitting the spark plugs, check that
the threaded connector
sleeves at the top of the plugs are tight, and
that the plug exterior surfaces and threads are
clean. Brown staining on the porcelain,
immediately above the metal body, is quite
normal, and does not necessarily indicate a
leak between the body and insulator.
15On installing the spark plugs, first check
that the cylinder head thread and sealing
surface are as clean as possible; use a clean
rag wrapped around a paintbrush to wipe
clean the sealing surface. Apply a smear of
copper-based grease or anti-seize compound
to the threads of each plug, and screw them
in by hand where possible. Take extra care to
enter the plug threads correctly, as the
cylinder head is of aluminium alloy - it’s often
difficult to insert spark plugs into their holes
without cross-threading them.
16When each spark plug is started correctly
on its threads, screw it down until it just seats
lightly, then tighten it to the specified torquewrench setting (see illustration). If a torque
wrench is not available - and this is one case
where the use of a torque wrench is strongly
recommended - tighten each spark plug
through no more than1/16 of a turn. Do not
exceed the specified torque setting, and
NEVERovertighten these spark plugs - their
tapered seats mean they are almost
impossible to remove if abused.
17Reconnect the spark plug (HT) leads in
their correct order, using a twisting motion on
the boot until it is firmly seated on the end of
the spark plug and on the cylinder head cover.
Spark plug (HT) lead check
18The spark plug (HT) leads should be
checked whenever the plugs themselves are
renewed. Start by making a visual check of
the leads while the engine is running. In a
darkened garage (make sure there is
ventilation) start the engine and observe each
lead. Be careful not to come into contact with
any moving engine parts. If there is a break in
the lead, you will see arcing or a small spark
at the damaged area.
19The spark plug (HT) leads should be
inspected one at a time, to prevent mixing up
the firing order, which is essential for proper
engine operation. Each original lead should be
numbered to identify its cylinder. If the
number is illegible, a piece of tape can be
marked with the correct number, and
wrapped around the lead (the leads should be
numbered 1 to 4, with No 1 lead nearest the
timing belt end of the engine). The lead can
then be disconnected.
20Check inside the boot for corrosion, which
will look like a white crusty powder. Clean this
off as much as possible; if it is excessive, or if
cleaning leaves the metal connector too badly
corroded to be fit for further use, the lead
must be renewed. Push the lead and boot
back onto the end of the spark plug. The boot
should fit tightly onto the end of the plug - if it
doesn’t, remove the lead and use pliers
carefully to crimp the metal connector inside
the boot until the fit is snug.
21Using a clean rag, wipe the entire length of
1•25
1
Every 30 000 miles
31.12 Spark plug manufacturers
recommend using a wire-type gauge when
checking the gap - if the wire does not
slide between the electrodes with a slight
drag, adjustment is required31.13 To change the gap, bend the outer
electrode only, as indicated by the arrows,
and be very careful not to crack or chip the
porcelain insulator surrounding the centre
electrode31.16 Spark plugs have tapered seats - do
not overtighten them on refitting, or you
will not be able to get them out again
without risking damage to the plugs and
cylinder head
To avoid the possibility of cross-
threading a spark plug, fit a short piece
of rubber hose over the end of the
plug. The flexible hose acts as a
universal joint, to help align the plug
with the plug hole. Should the plug
begin to cross-thread, the hose will slip
on the spark plug, preventing thread
damage.
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1•26Every 60 000 miles
Every 60 000 miles
Refer to Chapter 2, Part A.
Warning: Petrol is extremely
flammable, so extra precautions
must be taken when working on
any part of the fuel system. Do not smoke,
or allow open flames or bare light bulbs,
near the work area. Also, do not work in a
garage if a gas appliance with a pilot light is
present. While performing any work on the
fuel system, wear safety glasses, and have
a suitable (Class B) fire extinguisher on
hand. If you spill any fuel on your skin, rinse
it off immediately with soap and water.
1The fuel filter is located at the front right-
hand corner of the fuel tank, just forward of
the vehicle’s right-hand rear jacking point. The
filter performs a vital role in keeping dirt and
other foreign matter out of the fuel system,
and so must be renewed at regular intervals,or whenever you have reason to suspect that
it may be clogged. It is always unpleasant
working under a vehicle - pressure-washing or
hosing clean the underbody in the filter’s
vicinity will make working conditions more
tolerable, and will reduce the risk of getting
dirt into the fuel system.
2Relieve any residual pressure in the system
by removing the fuel pump fuse (No 14) and
starting the engine; allow the engine to idle until
it dies. Turn the engine over once or twice on
the starter, to ensure that all pressure is
released, then switch off the ignition.
Warning: This procedure will
merely relieve the pressure
necessary for the engine to run -
remember that fuel will still be present in
the system components, and take
precautions before disconnecting them.
3Noting the comments made in Section 1 of
Chapter 5, disconnect the battery earth terminal.
4Jack up the rear right-hand side of the
vehicle, and support it securely on an axle stand.
5Using rag to soak up any spilt fuel, release
the fuel feed and outlet pipe unions from the
filter, by squeezing together the protruding
locking lugs on each union, and carefully
pulling the union off the filter stub (seeillustration). Where the unions are colour-
coded, the feed and outlet pipes cannot be
confused; where both unions are the same
colour, note carefully which pipe is connected
to which filter stub, and ensure that they are
correctly reconnected on refitting.
6Noting the arrows and/or other markings on
the filter showing the direction of fuel flow
(towards the engine), slacken the filter clamp
screw and withdraw the filter. Note that the
filter will still contain fuel; care should be
taken, to avoid spillage and to minimise the
risk of fire.
7On installation, slide the filter into its clamp
so that the arrow marked on it faces the
correct way, then slide each pipe union on to
its (correct) respective filter stub, and press it
down until the locking lugs click into their
groove (see illustrations). Tighten the clamp
screw carefully, until the filter is just prevented
from moving; do not overtighten the clamp
screw, or the filter casing may be crushed.
8Refit the fuel pump fuse and reconnect the
battery earth terminal, then switch the ignition
on and off five times, to pressurise the
system. Check for any sign of fuel leakage
around the filter unions before lowering the
vehicle to the ground and starting the engine.
33 Fuel filter renewal
32 Timing belt renewal
33.5 Squeeze together fuel filter pipe union
locking lugs, then pull pipes off filter stubs -
ensure pipes are correctly reconnected33.7A When installing the new filter,
ensure the arrow showing direction of fuel
flow points towards the engine . . .
Every 3 years
The procedure is similar to that for the
bleeding of the hydraulic system as described
in Chapter 9, except that the brake fluid
reservoir should be emptied by syphoning,and allowance should be made for the old
fluid to be removed from the circuit when
bleeding a section of the circuit.
34 Brake fluid renewal
31.22 Measure the resistance of the spark
plug leads - if any exceeds the specified
maximum value, renew all the leads
the lead to remove built-up dirt and grease.
Once the lead is clean, check for burns, cracks
and other damage. Do not bend the lead
sharply, because the conductor might break.
22Disconnect the lead from the ignition coil
by pressing together the plastic retaining
catches and pulling the end fitting off the coil
terminal. Check for corrosion and for a tight
fit. If a meter with the correct measuring range
is available, measure the resistance of the
disconnected lead from its coil connector to
its spark plug connector (see illustration). If
the resistance recorded for any of the leads
exceeds the value specified, all the leadsshould be renewed as a set. Refit the lead to
the coil, noting that each coil terminal is
marked with its respective cylinder number,
so that there is no risk of mixing up the leads
and upsetting the firing order.
23Inspect the remaining plug leads, ensuring
that each is securely fastened both ends when
the check is complete. If any sign of arcing,
severe connector corrosion, burns, cracks or
other damage is noticed, obtain new spark
plug (HT) leads, renewing them as a set. If new
spark plug leads are to be fitted, remove and
refit them one at a time, to avoid mix-ups in
the firing order.
33.7B . . . secure pipe unions as described -
do not overtighten clamp screw (arrowed)
procarmanuals.com

Chapter 2 Part A:
In-car engine repair procedures
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . See Chapter 1
Camshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Camshafts and hydraulic tappets - removal, inspection
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compression test - description and interpretation . . . . . . . . . . . . . . 3
Crankshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Crankshaft pulley - removal and refitting . . . . . . . . . . . . . . . . . . . . . 8
Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 14
Cylinder head and valve components - cleaning and
inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 2B
Cylinder head cover - removal and refitting . . . . . . . . . . . . . . . . . . . 5
Engine oil and filter change . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Engine oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Engine overhaul - general information . . . . . . . . . . . . . See Chapter 2B
Engine/transmission - removal and refitting . . . . . . . . See Chapter 2B
Engine/transmission mountings - inspection and renewal . . . . . . . . 22
Exhaust manifold - removal, inspection and refitting . . . . . . . . . . . . 7Flywheel/driveplate - removal, inspection and refitting . . . . . . . . . . 21
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Inlet manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 6
Oil cooler - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oil level sensor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 18
Oil pressure warning light switch - removal and refitting . . . . . . . . . 19
Oil pump - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . 16
Repair operations possible with the engine in the vehicle . . . . . . . . 2
Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Timing belt - removal, refitting and adjustment . . . . . . . . . . . . . . . . 10
Timing belt covers - removal and refitting . . . . . . . . . . . . . . . . . . . . . 9
Timing belt tensioner and toothed pulleys - removal,
inspection and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Top Dead Centre (TDC) for No 1 piston - locating . . . . . . . . . . . . . . 4
Water pump - removal and refitting . . . . . . . . . . . . . . . See Chapter 3
General
Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder, in-line, double overhead camshafts
Engine code:
1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIF
1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RKA
2.0 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGA
Capacity:
1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1597 cc
1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1796 cc
2.0 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1988 cc
Bore:
1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.0 mm
1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.6 mm
2.0 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.8 mm
Stroke - all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.0 mm
Compression ratio:
1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3:1
1.8 and 2.0 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0:1
Compression pressure - at starter motor speed, engine fully warmed-up .Not available
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2 (No 1 cylinder at timing belt end)
Direction of crankshaft rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise (seen from right-hand side of vehicle)
Cylinder head
Hydraulic tappet bore inside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . 28.395 to 28.425 mm
Camshafts and hydraulic tappets
Camshaft bearing journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.960 to 25.980 mm
Camshaft bearing journal-to-cylinder head running clearance . . . . . . . . 0.020 to 0.070 mm
Camshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.080 to 0.220 mm
Hydraulic tappet diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.400 mm
2A•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,suitable
for competent DIY
mechanicDifficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
Specifications Contents2A
procarmanuals.com

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 settingsNm 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
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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
pulley15 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
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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 baffle4 Oil strainer and pick-up
pipe
5 Spark plug6 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 gallery6 Cylinder head oil supply
7 Oil return
8 Piston-cooling oil spray (where fitted)
9 Oil filter - oil cooler not shown here1.11 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)
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