Car engine overhaul Ford Mondeo 1 and 2
Technical requirements of 4-cylinder engine
Cylinder head Maximum gasket warpage 0.10 mm Valve guide hole 6.060...6.091 mm Valve seat angle 90° Valve seat width 1.4...1.7 mm Valves - general information Intake...
Cylinder head Maximum gasket warpage 0.10 mm Valve guide hole 6.060...6.091 mm Valve seat angle 90° Valve seat width 1.4...1.7 mm Valves - general information Intake...
Technical requirements of 6-cylinder engine
Cylinder head Diameter of the hole for the hydraulic compensator 16.018...16.057 mm Working clearance of hydraulic compensator 0.018...0.069 mm Hydraulic compensator...
Cylinder head Diameter of the hole for the hydraulic compensator 16.018...16.057 mm Working clearance of hydraulic compensator 0.018...0.069 mm Hydraulic compensator...
Using the information in this chapter
This chapter provides information on engine/transmission removal and installation, as well as repairs that require the powertrain to be removed from the vehicle and...
This chapter provides information on engine/transmission removal and installation, as well as repairs that require the powertrain to be removed from the vehicle and...
General information about engine repair
There are many factors to consider when deciding whether to carry out a major overhaul. High mileage is not a prerequisite for repairs, and low mileage is not a reason...
There are many factors to consider when deciding whether to carry out a major overhaul. High mileage is not a prerequisite for repairs, and low mileage is not a reason...
Methods of removing the power unit and precautions
If you have decided that your engine needs a major overhaul, follow the preparatory procedures. The convenience of the place where the work is carried out is very...
If you have decided that your engine needs a major overhaul, follow the preparatory procedures. The convenience of the place where the work is carried out is very...
Removal and installation of the power unit (4-cylinder)
Warning: Gasoline is highly flammable. Use extreme caution when working around the fuel system. Work in a well-ventilated area - open all windows and doors to create an...
Warning: Gasoline is highly flammable. Use extreme caution when working around the fuel system. Work in a well-ventilated area - open all windows and doors to create an...
Removal and installation of the power unit (6-cylinder)
See Warnings and Notes paragraph 4 . Duratec engines Removal Note: Ford service centers use a special device to align the power unit with the subframe. Before removing...
See Warnings and Notes paragraph 4 . Duratec engines Removal Note: Ford service centers use a special device to align the power unit with the subframe. Before removing...
Engine disassembly sequence
1. Engine disassembly and repair work will be significantly simplified if the engine is installed on a special mobile stand. Before installing the engine on such a...
1. Engine disassembly and repair work will be significantly simplified if the engine is installed on a special mobile stand. Before installing the engine on such a...
Disassembling the cylinder head
Note: A new or reconditioned cylinder head can be purchased from manufacturers or repair specialists. Please note that special tools are required for disassembly and...
Note: A new or reconditioned cylinder head can be purchased from manufacturers or repair specialists. Please note that special tools are required for disassembly and...
Cylinder head inspection and valve mechanism
1. A thorough cleaning of the cylinder head and valve parts followed by a detailed inspection are the basis for determining the work required to repair the valves. Note:...
1. A thorough cleaning of the cylinder head and valve parts followed by a detailed inspection are the basis for determining the work required to repair the valves. Note:...
Cylinder head assembly
1. Regardless of whether the cylinder head has been repaired or not, before starting assembly, you need to check it and make sure that it is clean. It should not contain...
1. Regardless of whether the cylinder head has been repaired or not, before starting assembly, you need to check it and make sure that it is clean. It should not contain...
Removing connecting rod and piston groups
Note: Before starting a repair, you need to make sure that you can obtain spare parts ( see par. 1 of this chapter ). If you do not have any of the spare parts, contact...
Note: Before starting a repair, you need to make sure that you can obtain spare parts ( see par. 1 of this chapter ). If you do not have any of the spare parts, contact...
Removing the crankshaft
Warning: Please pay attention to the warning and note regarding the V-engine in paragraphs 1 and 3 . Note: The crankshaft can only be removed after the power unit has...
Warning: Please pay attention to the warning and note regarding the V-engine in paragraphs 1 and 3 . Note: The crankshaft can only be removed after the power unit has...
Cleaning and inspection of the cylinder block/crankcase
Cleaning 1. To perform a complete cleaning, remove the coolant pump, all external components, and all electrical switches and sensors. Unscrew the piston oil spray...
Cleaning 1. To perform a complete cleaning, remove the coolant pump, all external components, and all electrical switches and sensors. Unscrew the piston oil spray...
Inspection of connecting rod and piston groups
Note: Before starting a repair, you need to make sure that you can obtain spare parts ( see paragraph 1 of this chapter ). If you do not have any of the spare parts,...
Note: Before starting a repair, you need to make sure that you can obtain spare parts ( see paragraph 1 of this chapter ). If you do not have any of the spare parts,...
Inspection of the crankshaft
1. Wash the crankshaft and dry it with compressed air. Warning: When working with compressed air, wear eye protection. Clean the shaft oil passages with a pipe cleaner...
1. Wash the crankshaft and dry it with compressed air. Warning: When working with compressed air, wear eye protection. Clean the shaft oil passages with a pipe cleaner...
Inspection of main and connecting rod bearings
1. Even if the main and connecting rod bearing liners are replaced during engine repair, the worn out liners must be saved for careful analysis, which will provide...
1. Even if the main and connecting rod bearing liners are replaced during engine repair, the worn out liners must be saved for careful analysis, which will provide...
Engine assembly sequence
1. Before starting assembly, make sure you have all the necessary parts, components and tools. Read the full description of the entire sequence of works in order to...
1. Before starting assembly, make sure you have all the necessary parts, components and tools. Read the full description of the entire sequence of works in order to...
Installing piston rings
1. Before installing the piston rings, check the gap in the lock as follows. Lay out the connecting rod-piston groups and new piston rings so that, from the time the gap...
1. Before installing the piston rings, check the gap in the lock as follows. Lay out the connecting rod-piston groups and new piston rings so that, from the time the gap...
Installation and control of crankshaft main bearing clearance
1. The general assembly of the engine begins with the installation of the crankshaft. It is assumed that the cylinder block/crankcase and crankshaft have been cleaned,...
1. The general assembly of the engine begins with the installation of the crankshaft. It is assumed that the cylinder block/crankcase and crankshaft have been cleaned,...
Installation and control of connecting rod bearing clearance
1. Before installing the connecting rod and piston assemblies, it is necessary to thoroughly clean the cylinders, check the presence of the lead-in chamfers on each...
1. Before installing the connecting rod and piston assemblies, it is necessary to thoroughly clean the cylinders, check the presence of the lead-in chamfers on each...
First launch after repair
1. After installing the engine in the vehicle, recheck the oil and coolant levels. Check again that all necessary parts and components are installed and securely...
1. After installing the engine in the vehicle, recheck the oil and coolant levels. Check again that all necessary parts and components are installed and securely...
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Mondeo 4
Mondeo 3
Mondeo 2
Mondeo 1 and 2
Mondeo 1
- General information
- User guide
- Power unit
- Engine repair
- Lubrication system
- Cooling system
- Exhaust system
- Supply system
- Fuel vapor recovery
- Transmission
- Clutch
- Car gearbox
- Wheel drives
- Chassis
- Front suspension
- Rear suspension
- Steering
- Brake system
- Body
- Exterior
- Interior
- Doors, locks and windows
- Heating and ventilation
- Security systems
- Electrical equipment
- Electrical appliances
- Headlights and lighting
- Battery and alternator
Mondeo 3
- General information
- Introduction to the guide
- Workplace equipment
- Car care
- Help with malfunctions
- Power unit
- Engine repair
- Lubrication system
- Cooling system
- Fuel injection system
- Ignition system
- Fuel system
- Transmission
- Chassis
- Chassis
- Brake system
- Body
- Interior
- Exterior
- Electrical equipment
- Light and appliances
- Battery and alternator
- Schematic diagrams
Mondeo 2
- General information
- User guide
- Maintenance and care
- Wheels and rims
- Power unit
- V16 engine
- Duratec VE
- Lubrication system
- Cooling system
- Power systems
- Ignition system
- Exhaust system
- Transmission
- Clutch
- Mechanical gearbox
- Automatic gearbox
- Wheel drives
- Chassis
- Front suspension
- Rear suspension (sedan)
- Rear suspension
- Steering
- Brake system
- Brake service
- Electrical equipment
- Battery and alternator
- Light and appliances
Mondeo 1 and 2
- General information
- User guide
- Vehicle data
- Repair on the road
- Weekly checks
- Periodic maintenance
- Troubleshooting
- Engine
- 4 cylinder engines
- 6 cylinder engines
- Removal and repair
- Cooling system
- Fuel/exhaust systems
- Emission management
- Starting and charging systems
- Ignition system
- Transmission
- Clutch
- Mechanical gearbox
- Automatic gearbox
- Drive shafts
- Chassis
- Brake system
- Suspension
- Steering
- Body
- Exterior
- Interior
- Electrical equipment
Mondeo 1
- General information
- Car care
- Maintenance
- Troubleshooting
- Power unit
- Engine repair
- Cooling and lubrication system
- Ignition system
- Fuel/exhaust systems
- Fuel injection (gasoline)
- Fuel injection (diesel)
- Transmission
- Clutch and drive shafts
- Car gearbox
- Chassis
- Suspension
- Steering
- Brake system
- Wheels and tires
- Body
- Exterior
- Interior
- Doors, locks and windows
- Heating system
- Electrical equipment
- Equipment and devices
- Power devices
- Lighting and signaling
- Windshield wipers and washers
- Electrical circuits