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FORD Mondeo (36) 1.8 TD TCi RFN

1996 - 2000

Timing belt: removal/installation

Warnings and recommendations
Unless otherwise advised by the manufacturer, the following procedures are recommended:

Always fit a new timing belt after removal

Coolant pump renewal is recommended after timing belt removal

Check the tensioner and idler pulleys; renew if necessary

Never turn the engine in the direction opposite to that of normal operation

Check the belt(s) for cracks, fraying, wear and oil contamination

Note: The engine must be cold before timing belt adjustment

Note: Avoid bending, torsion or traction

General
Before disconnecting the battery cable, check the audio system security code

Removal
Disconnect the battery

Remove the front right wheel

Remove the engine lower covers

Drain the cooling system

Support the engine

Remove the front engine support

Vehicles with air conditioning:

Remove the air-conditioning belt

All vehicles:

Remove the alternator belt

Remove the timing belt lower cover

Remove theB.V.
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Disconnect the cooling hose from the expansion tank

Disconnect the fuel return line

Disconnect the EGR hose

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FORD Mondeo (36) 1.8 TD TCi RFN

1996 - 2000

Timing belt: removal/installation

Disconnect
Warningstheandcooling system hoses
recommendations
Unless otherwise
Disconnect the starter
advised
motor
by the
wiring
manufacturer, the following procedures are recommended:

Attach the engine to the engine support bar

Remove the power steering pump drive belt

Remove the power steering pump but do not disconnect the lines

Remove the power steering tensioner pulley

Remove the engine support bracket

Remove the expansion tank

Remove the lower front engine support

Remove the crankshaft pulley

Disconnect the heater hose from the coolant pump

Remove the timing belt upper cover

Remove the crankcase breathers

Always fit a new timing belt after removal
Remove the valve cover
Coolant pump renewal is recommended after timing belt removal
Turn the crankshaft to TDC for cylinder 1 1
Check the tensioner and idler pulleys; renew if necessary
Lock the injection pump gearwheel with a locking pin Ø 6 mm
Never turn the engine in the direction opposite to that of normal operation
Use a special tool to lock the crankshaft 2, 21-104
Check the belt(s) for cracks, fraying, wear and oil contamination
Fit the camshaft locking tool 21-162B
Note: The engine must be cold before timing belt adjustment
Loosen the injection pump tensioner
Note: Avoid bending, torsion or traction
Remove the injection pump drive belt
General
Lock the camshaft gearwheel 15-030A
Before disconnecting the battery cable, check the audio system security code
Remove the idler pulley 4
Removal
Remove the timing belt
Disconnect the battery
Remove the tensioner 5
Remove the front right wheel
Remove the camshaft gearwheel
Remove the engine lower covers
Installation
Drain the cooling system
Fit the timing belt onto the crankshaft gearwheel
Support the engine
Refit the timing belt tensioner 5
Remove the front engine support
Refit the timing belt idler pulley 4B
Vehicles with air conditioning:
Fit the timing belt onto the tensioner pulley and camshaft gearwheel
Remove the air-conditioning belt
Fit the camshaft gearwheel
All vehicles:
Lock the camshaft gearwheel
Remove the alternator belt
Tighten the bolt 4A, 10 Nm
Remove the timing belt lower cover
Remove all the locking tools
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Turn the crankshaft clockwise 6x

Fit all the locking tools

Loosen the bolt 6

Loosen the camshaft gearwheel 7

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FORD Mondeo (36) 1.8 TD TCi RFN

1996 - 2000

Timing belt: removal/installation

Use the special
Warnings andtool to lock the camshaft
recommendations 15-030A

Align
Unlessthe
otherwise
tensioneradvised
needleby
with
thethe
manufacturer,
mark on the the
timing
following
belt rear
procedures
cover are recommended:

Tighten the bolt 4A : 45 Nm

Tighten the camshaft gearwheel 35 Nm

Remove all the locking tools

Turn the crankshaft clockwise 4x

Fit all the locking tools

Check the tensioner marks

Measure the distance: ± 3 mm

Further refitting is in the reverse order of removal

Torque settings
Front engine support: 120 Nm, 50 Nm

Lower engine support: 85 Nm

Always fit a new timing belt after removal
Engine support to engine bracket: 85 Nm
Coolant pump renewal is recommended after timing belt removal
Power steering pump: 25 Nm
Check the tensioner and idler pulleys; renew if necessary
Power steering tensioner pulley: 25 Nm
Never turn the engine in the direction opposite to that of normal operation
Crankshaft pulley: 25 Nm
Check the belt(s) for cracks, fraying, wear and oil contamination
Special
Note: Thetools
engine must be cold before timing belt adjustment
Camshaft locking tool: 21-162B
Note: Avoid bending, torsion or traction
Crankshaft locking tool: 21-104
General
Camshaft gearwheel: 15-030A
Before disconnecting the battery cable, check the audio system security code

Removal ©HaynesPro B.V. ©HaynesPro B.V.

Disconnect the battery

Remove the front right wheel

Remove the engine lower covers

Drain the cooling system

Support the engine

Remove the front engine support

Vehicles with air conditioning:

Remove the air-conditioning belt

All vehicles:

Remove the alternator belt

Remove the timing belt lower cover

©HaynesPro B.V. Powered by Haynes Pro 2016