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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 Removal and Installation Special Tool(s) 303-1059 Alignment Peg, Crankshaft

Mondeo 2007.5 (02/2007-)

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303-393 Locking Tool, Flywheel

303-393-01 Adapter for 303-393

303-396-01 Adapter for 303-396

303-735 Alignment Peg, Camshaft

General Equipment Trolley jack

Removal
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 DuratorqTDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW, Removal and Installation). 3.

4. General Equipment: Trolley jack

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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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2012-02-23

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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.

Installation
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, 6mm 3. 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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2012-02-23

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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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2012-02-23

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17. 1. Torque: 7 Nm 2. NOTE: Make sure that a new component is installed. Torque: Stage 1: 70 Nm Stage 2: 60

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 DuratorqTDCi (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).

http://127.0.0.1:8888/wsm/js/procedure.do?psuid=&language=en&country=USA&pr...

2012-02-23