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Section 1327 (Engine - 2.3L): Assembly: Engine

WARNING: This page is about a different car, the 2004 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL SPECIFICATIONS

G04035738
 Installer, Crankshaft Rear Main Oil Seal
303-328 (T88P-6701-B1)
G04035739
 Engine Stand
014-0232 or equivalent
G04035740
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04035741
 Timing Peg, Crankshaft
303-507
G04035742
 Alignment Plate, Camshaft
303-465 (T94P-6256-CH)
G04035743
 Holding Fixture, Drive Pinion Flange
205-126 (T78P-4851-A)
G04035744
 Adapter for 205-126
(205-072-02)
G04035745
 Aligner, Clutch Disc
308-006 (T71P-7137-H)
G04035746
 Heavy Duty Floor Crane
014-00071 or equivalent
G04035747
 Locking Tool, Flywheel
303-103 (T74P-8375-A)
MATERIAL SPECIFICATIONS

Item Specification
Metal Surface Cleaner
F4AZ-19A536-RA or equivalent		 WSE-M5B392-A
Silicone Gasket and Sealant
F7AZ-19554-EA or equivalent		 WSE-M4G323-A4
Super Premium SAE 5W-20 Motor Oil
XO-5W20-QSP or equivalent		 WSS-M2C153-H
Silicone Brake Caliper Grease and Dielectric Compound
D7AZ-19A331-A		 ESE-M1C171-A
Motorcraft Premium Gold Coolant
VC-7-A		 WSS-M97B51-A1
High-Temperature 4x4 Front Axle and Wheel Bearing Grease
E8TZ-19590-A		 ESA-M1C198-A
CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.
CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe damage can occur.

All vehicles 

    WARNING: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
  1. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC).
  2. Remove the engine plug bolt.
    Fig 1: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    3. NOTE: Only turn the engine in the normal direction of rotation.
    NOTE: Installing the special tool in this step will prevent the engine from being rotated in the clockwise direction. However, the engine can still be rotated in the counterclockwise direction.
    Fig 2: Installing Special Tool
    G04035749Courtesy of FORD MOTOR CO.
  3. Install the special tool.
    4. NOTE: Clean the gasket surface with metal surface cleaner.
    Fig 3: Tightening Oil Pump Bolts In Sequence
    G04035750Courtesy of FORD MOTOR CO.
  4. Install a new gasket and the oil pump assembly. Tighten the bolts in the sequence shown in two stages.
    • Stage 1: Tighten the bolts to 10 Nm (89 lb-in).
    • Stage 2: Tight the bolts to 23 Nm (17 lb-ft).
  5. Install a new oil pump pickup tube gasket and the pickup tube.
    Fig 4: Installing Oil Pump Pickup Tube Gasket And Pickup Tube
    G04035751Courtesy of FORD MOTOR CO.
  6. Using the special tool, install the crankshaft rear main oil seal.
    Fig 5: Installing Crankshaft Rear Main Oil Seal
    G04035752Courtesy of FORD MOTOR CO.
  7. Tighten the crankshaft rear main oil seal bolts in the sequence shown.
    Fig 6: Tightening Crankshaft Rear Main Oil Seal Bolts In Sequence
    G04035753Courtesy of FORD MOTOR CO.
    8. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
    NOTE: Clean the mating surface with metal surface cleaner.
    NOTE: If the oil pan is not secured within four minutes of sealant application the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 7: Tightening Oil Pan Bolts In Sequence
    G04035754Courtesy of FORD MOTOR CO.
  8. Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Tighten the oil pan bolts in the sequence shown.
  9. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
    Fig 8: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
    10. NOTE: Clean the gasket surface with metal surface cleaner.
    Fig 9: Identifying Silicone Gasket And Sealant Location
    G03897827Courtesy of FORD MOTOR CO.
  10. Apply silicone gasket and sealant to the locations shown.
  11. Install a new cylinder head gasket.
  12. Clean the cylinder head surface with metal surface cleaner.
    13. NOTE: The cylinder head must be secured within four minutes of silicone gasket application. If the cylinder head is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
    NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
    NOTE: Lubricate the cylinder head bolts with clean engine oil.
    Fig 10: Tightening Cylinder Head Bolts In Sequence
    G04035757Courtesy of FORD MOTOR CO.
  13. Install the cylinder head and the new bolts. Tighten the bolts in the sequence shown in five stages.
    • Stage 1: Tighten the bolts to 5 Nm (44 lb-in).
    • Stage 2: Tighten the bolts to 15 Nm (11 lb-ft).
    • Stage 3: Tighten the bolts to 45 Nm (33 lb-ft).
    • Stage 4: Tighten the bolts an additional 90 degrees (1/4 turn).
    • Stage 5: Tighten the bolts an additional 90 degrees (1/4 turn).
    14. CAUTION: Install the camshafts with the alignment slots in the camshaft lined up so the camshaft alignment plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as marked in the disassembly procedure. Rotating the camshafts, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.
    NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
    Fig 11: Tightening Camshaft Bearing Cap Bolts In Sequence
    G04035758Courtesy of FORD MOTOR CO.
  14. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in three stages.
    • Stage 1: Tighten the camshaft bearing caps one turn at a time until tight.
    • Stage 2: Tighten the bolts to 7 Nm (62 lb-in).
    • Stage 3: Tighten the bolts to 16 Nm (12 lb-ft).
    15. NOTE: Install a crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
    Fig 12: Installing Crankshaft Sprocket, Crankshaft Sprocket Diamond Washers, Oil Pump Chain And Oil Pump Sprocket
    G04035759Courtesy of FORD MOTOR CO.
  15. Install the crankshaft sprocket, crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.
    • The crankshaft sprocket flange must be facing away from the engine block.
    16. NOTE: The oil pump chain sprocket must be held in place.
    Fig 13: Installing Oil Pump Sprocket Bolt
    G04035760Courtesy of FORD MOTOR CO.
  16. Install the oil pump sprocket bolt.
  17. Install the oil pump chain guide and the shoulder bolt.
    Fig 14: Installing Oil Pump Chain Guide And Shoulder Bolt
    G04035761Courtesy of FORD MOTOR CO.
  18. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
    Fig 15: Installing Oil Pump Chain Tensioner
    G04035762Courtesy of FORD MOTOR CO.
    19. NOTE: Sprockets must turn freely on the camshafts.
    Fig 16: Installing Camshaft Sprockets And Bolts
    G04035763Courtesy of FORD MOTOR CO.
  19. Install the camshaft sprockets and the bolts. Do not tighten the sprocket bolts at this time.
    20. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
    Fig 17: Compressing Timing Chain Tensioner Plunger
    G04035764Courtesy of FORD MOTOR CO.
  20. Using the edge of a vise, compress the timing chain tensioner plunger.
  21. Using a small pick, push back and hold the ratchet mechanism.
    Fig 18: Pushing Back And Holding Ratchet Mechanism
    G04035765Courtesy of FORD MOTOR CO.
  22. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 19: Pushing Ratchet Arm Back Into Tensioner Housing
    G04035766Courtesy of FORD MOTOR CO.
  23. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
    Fig 20: Installing Paper Clip Into Hole In Tensioner Housing
    G04035767Courtesy of FORD MOTOR CO.
  24. Install the timing chain.
    Fig 21: Installing Timing Chain
    G04035768Courtesy of FORD MOTOR CO.
  25. Install the timing chain guides.
    Fig 22: Installing Timing Chain Guides
    G04035769Courtesy of FORD MOTOR CO.
  26. Install the timing chain tensioner. Remove the paper clip to apply tension to the timing chain.
    Fig 23: Installing Timing Chain Tensioner
    G04035770Courtesy of FORD MOTOR CO.
    27. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    Fig 24: Identifying Special Tool In Slots Of Both Camshafts
    G03972934Courtesy of FORD MOTOR CO.
  27. Install the special tool in the timing slots on the rear of both camshafts. Timing slots are offset from the centerline of the camshaft.
    28. NOTE: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshafts in place.
    Fig 25: Tightening Camshaft Sprocket Bolts
    G04035772Courtesy of FORD MOTOR CO.
  28. Tighten the camshaft sprocket bolts.
  29. Clean the front cover gasket surface with metal surface cleaner.
  30. Apply a 2.5 mm bead of silicone gasket and sealant to the front cover.
    Fig 26: Locating Silicone Gasket
    G03897744Courtesy of FORD MOTOR CO.
  31. Apply silicone gasket and sealant to the locations shown.
    Fig 27: Applying Silicone Gasket And Sealant
    G04035774Courtesy of FORD MOTOR CO.
    32. NOTE: The front cover must be secured within four minutes of silicone gasket application. If the front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
    Fig 28: Tightening Front Cover Bolts In Sequence
    G04035775Courtesy of FORD MOTOR CO.
  32. Install the front cover. Tighten the bolts in the sequence shown in three stages.
    • Stage 1: Tighten the 8 mm bolts to 10 Nm (89 lb-in).
    • Stage 2: Tighten the 10 mm bolts to 25 Nm (18 lb-ft).
    • Stage 3: Tighten the 13 mm bolts to 48 Nm (35 lb-ft).
    33. CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe damage can occur.
    NOTE: Do not reuse the crankshaft pulley bolt.
    NOTE: Apply clean engine oil on seal area before installing.
    Fig 29: Installing Crankshaft Pulley
    G04035776Courtesy of FORD MOTOR CO.
  33. Install the crankshaft pulley and hand-tighten the bolt.
    34. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
    NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
    Fig 30: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
    G03950429Courtesy of FORD MOTOR CO.
  34. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
    • Rotate the pulley as necessary to align the bolt holes.
    35. CAUTION: Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover.
    Fig 31: Tightening Pulley Bolt In Two Stages
    G04035778Courtesy of FORD MOTOR CO.
  35. Using the special tools to hold the crankshaft pulley in place, tighten the pulley bolt in two stages:
    • Stage 1: Tighten to 100 Nm (74 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
  36. Remove the special tools.
    Fig 32: Removing Special Tools
    G04035779Courtesy of FORD MOTOR CO.
  37. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 33: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
    G03950429Courtesy of FORD MOTOR CO.
  38. Remove the special tool.
    Fig 34: Removing Special Tool
    G04035781Courtesy of FORD MOTOR CO.
  39. Remove the special tool.
    Fig 35: Identifying Special Tool In Slots Of Both Camshafts
    G03972934Courtesy of FORD MOTOR CO.
    40. NOTE: Only turn the engine in the normal direction of rotation.
  40. Turn the engine two complete revolutions.
    41. NOTE: Only turn the engine in the normal direction of rotation.
  41. Turn the engine until the No. 1 piston is at top dead center (TDC).
  42. Install the special tool.
    Fig 36: Installing Special Tool
    G04035783Courtesy of FORD MOTOR CO.
    43. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
    Fig 37: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
    G03950429Courtesy of FORD MOTOR CO.
  43. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
    • If it is not possible to install the bolt, correct the engine timing.
  44. Using the special tool, check the position of the camshafts.
    • If it is not possible to install the special tool, correct the engine timing.
    Fig 38: Identifying Special Tool In Slots Of Both Camshafts
    G03972934Courtesy of FORD MOTOR CO.
  45. Remove the special tool.
    Fig 39: Identifying Special Tool In Slots Of Both Camshafts
    G03972934Courtesy of FORD MOTOR CO.
    46. NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.
    Fig 40: Locating CKP Sensor
    G03898012Courtesy of FORD MOTOR CO.
  46. Install a new CKP sensor.
    • Do not tighten the bolts at this time.
    47. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.
    Fig 41: Adjusting CKP Sensor
    G04035788Courtesy of FORD MOTOR CO.
  47. Adjust the CKP sensor with the alignment tool and tighten the bolts.
  48. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 42: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
    G03950429Courtesy of FORD MOTOR CO.
  49. Remove the special tool.
    Fig 43: Removing Special Tool
    G04035790Courtesy of FORD MOTOR CO.
  50. Install the engine plug bolt.
    Fig 44: Installing Engine Plug Bolt
    G04035791Courtesy of FORD MOTOR CO.
  51. Clean the valve cover gasket surface with metal surface cleaner.
  52. Apply silicone gasket and sealant to the locations shown.
    Fig 45: Applying Silicone Gasket And Sealant
    G04035792Courtesy of FORD MOTOR CO.
    53. NOTE: The valve cover must be secured within four minutes of silicone gasket application. If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
    Fig 46: Tightening Valve Cover Bolts In Sequence
    G04035793Courtesy of FORD MOTOR CO.
  53. Install the valve cover.
    • Tighten the bolts in the sequence shown.
  54. Install the following:
    • Camshaft position (CMP) sensor.
    • Cylinder head temperature (CHT) sensor.
    • Spark plugs.
    Fig 47: Installing CHT Sensor, CMP Sensor & Spark Plugs
    G04035794Courtesy of FORD MOTOR CO.
    55. NOTE: Apply dielectric compound to the inside of the coil boots.
  55. Install the ignition coils.
    • Tighten the bolts to 10 Nm (89 lb-in).
    56. NOTE: Clean the coolant pump gasket surface with metal surface cleaner.
    NOTE: Lubricate the coolant pump O-ring seal with MERPOL® prior to assembly.
    Fig 48: Installing Coolant Pump
    G04035795Courtesy of FORD MOTOR CO.
  56. Install the coolant pump.
  57. Install the coolant pump pulley.
    Fig 49: Installing Coolant Pump Pulley
    G04035796Courtesy of FORD MOTOR CO.
  58. Install the fuel injection supply manifold and the ground strap.
    Fig 50: Installing Fuel Injection Supply Manifold And Ground Strap
    G04035797Courtesy of FORD MOTOR CO.
    59. NOTE: The knock sensor (KS) must not touch the engine vent cover.
    Fig 51: Installing Engine Vent Cover And KS
    G04035798Courtesy of FORD MOTOR CO.
  59. Install the engine vent cover and the KS.
    60. NOTE: Clean the thermostat housing gasket surface with metal surface cleaner.
    Fig 52: Installing Gasket And Thermostat Housing
    G04035799Courtesy of FORD MOTOR CO.
  60. Install a new gasket and the thermostat housing.
  61. Install the bypass hose and the clamp.
    Fig 53: Installing Bypass Hose And Clamp
    G04035800Courtesy of FORD MOTOR CO.
  62. Connect the ignition coil and the CHT sensor electrical connectors.
    Fig 54: Connecting Ignition Coil And CHT Sensor Electrical Connectors
    G04035801Courtesy of FORD MOTOR CO.
  63. Reposition the CHT sensor boot.
    Fig 55: Positioning CHT Sensor Boot
    G04035802Courtesy of FORD MOTOR CO.
  64. Connect the fuel injector connector and the wiring harness pin-type retainers.
    Fig 56: Connecting Fuel Injector Connector And Wiring Harness Pin-Type Retainers
    G04035803Courtesy of FORD MOTOR CO.
  65. Install the intake manifold assembly.
    Fig 57: Installing Intake Manifold Assembly
    G04035804Courtesy of FORD MOTOR CO.
  66. Secure the pin-type retainers to the intake manifold.
    Fig 58: Securing Pin-Type Retainers To Intake Manifold
    G04035805Courtesy of FORD MOTOR CO.
  67. Install the positive crankcase ventilation (PCV) hose.
    Fig 59: Installing Positive Crankcase Ventilation Hose
    G04035806Courtesy of FORD MOTOR CO.
  68. Connect the CKP sensor electrical connector and the wiring harness pin-type retainers.
    Fig 60: Connecting CKP Sensor Electrical Connector And Wiring Harness Pin-Type Retainers
    G04035807Courtesy of FORD MOTOR CO.
  69. Connect the CMP sensor electrical connector.
    Fig 61: Connecting CMP Sensor Electrical Connector
    G04035808Courtesy of FORD MOTOR CO.
  70. Connect the swirl control valve monitor electrical connector and the hose.
    Fig 62: Connecting SWIRL Control Valve Monitor Electrical Connector And Hose
    G04035809Courtesy of FORD MOTOR CO.
  71. Connect the idle air control (IAC) motor electrical connector.
    Fig 63: Connecting Idle Air Control Motor Electrical Connector
    G04035810Courtesy of FORD MOTOR CO.
  72. Connect the throttle position (TP) sensor electrical connector.
    Fig 64: Connecting Throttle Position Sensor Electrical Connector
    G04035811Courtesy of FORD MOTOR CO.
  73. Install the exhaust gas recirculation (EGR) valve.
    1. Install the EGR valve and bolts.
    2. Connect the EGR valve electrical connector.
    Fig 65: Installing Exhaust Gas Recirculation Valve
    G04035812Courtesy of FORD MOTOR CO.
  74. Install the block heater, if equipped.
    Fig 66: Installing Block Heater
    G04035813Courtesy of FORD MOTOR CO.
  75. Connect the knock sensor (KS) electrical connector.
    Fig 67: Connecting Knock Sensor Electrical Connector
    G04035814Courtesy of FORD MOTOR CO.
  76. Connect the heater hose to the thermostat housing.
    Fig 68: Connecting Heater Hose To Thermostat Housing
    G04035815Courtesy of FORD MOTOR CO.
  77. Connect the coolant hose to the EGR valve.
    Fig 69: Connecting Coolant Hose To EGR Valve
    G04035816Courtesy of FORD MOTOR CO.
  78. Install the generator.
    Fig 70: Installing Generator
    G04035817Courtesy of FORD MOTOR CO.
  79. Install the coolant bypass.
    1. Install the bolts.
    2. Install the hose.
    Fig 71: Installing Coolant Bypass
    G04035818Courtesy of FORD MOTOR CO.
  80. Install the oil level indicator tube.
    1. Install the oil level indicator tube.
    2. Install the bolts.
    3. Install the oil level indicator.
    Fig 72: Installing Oil Level Indicator Tube
    G04035819Courtesy of FORD MOTOR CO.
  81. Install the accessory drive belt.
    Fig 73: Installing Accessory Drive Belt
    G04035820Courtesy of FORD MOTOR CO.
  82. Using the heavy duty floor crane and the spreader bar, remove the engine from the stand.
  83. Install the flywheel or the flexplate and the bolts.
  84. Install the special tool.
    Fig 74: Installing Flywheel Or Flexplate And Bolts
    G04035821Courtesy of FORD MOTOR CO.
  85. Tighten the bolts in the sequence shown in three stages.
    • Stage 1: Tighten the bolts to 50 Nm (37 lb-ft).
    • Stage 2: Tighten the bolts to 80 Nm (59 lb-ft).
    • Stage 3: Tighten the bolts to 112 Nm (83 lb-ft).
    Fig 75: Tightening Flywheel Or Flexplate Bolts In Sequence
    G04035822Courtesy of FORD MOTOR CO.

    86. Vehicles equipped with a manual transmission 

  86. Lubricate the transmission input shaft pilot bearing with front axle grease.
    Fig 76: Lubricating Transmission Input Shaft Pilot Bearing With Front Axle Grease
    G04035823Courtesy of FORD MOTOR CO.
  87. Adjust the clutch pressure plate.
    1. Using a suitable press, press downward on the fingers until the adjusting ring moves freely.
    2. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
    3. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
    Fig 77: Adjusting Clutch Pressure Plate
    G04035824Courtesy of FORD MOTOR CO.
  88. Using the special tool, position the clutch disc on the flywheel.
    Fig 78: Positioning Clutch Disc On Flywheel
    G04035825Courtesy of FORD MOTOR CO.
    89. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
    Fig 79: Tightening Clutch Pressure Plate Bolts
    G04035826Courtesy of FORD MOTOR CO.
  89. Position the clutch pressure plate and install the bolts. Tighten the bolts in a star pattern sequence.
    • Remove the Clutch Disc Aligner.
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