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Section 298 (Engine-2.0L SPI): Assembly: Engine: Material

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Material Specification Index - Engine (Assembly)
G01615389Courtesy of FORD MOTOR CO.
    CAUTION: Do not use abrasive grinding discs to remove the gasket material; use only plastic manual scrapers. Do not scratch or gouge aluminum sealing surfaces.
    NOTE: All bearing surfaces must be lubricated before assembly or installation.
    NOTE: The crankshaft main bearings are precision selective fit. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  1. Install the main bearings.
    1. Upper crankshaft main bearing.
    2. Crankshaft thrust main bearing.
      Fig 2: Installing Main Bearings
      G01615390Courtesy of FORD MOTOR CO.
  2. Install the crankshaft.
    Fig 3: Installing Crankshaft
    G01615391Courtesy of FORD MOTOR CO.
    3. NOTE: The crankshaft main bearings are numbered 1 to 5 with No. 1 at the front of the engine. Make sure the arrow faces the front of the engine.
    NOTE: Apply axial load to the rear of the crankshaft simultaneously to tightening of the bolts. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
    Fig 4: Installing Lower Crankshaft Main Bearings And Bearing Caps
    G01615392Courtesy of FORD MOTOR CO.
  3. Install the five lower crankshaft main bearings and the five main bearing caps.
  4. Install the piston and connection rod assemblies.
    Fig 5: Installing Piston And Connection Rod Assemblies
    G01615393Courtesy of FORD MOTOR CO.
  5. Install the four crankshaft rod caps.
    Fig 6: Installing Four Crankshaft Rod Caps
    G01615394Courtesy of FORD MOTOR CO.
    6. NOTE: Coat the rear oil seal area and the crankshaft rear oil seal lip with engine oil.
    NOTE: Make sure the crankshaft rear oil seal is on correctly and that the edges are not rolled over.
    Fig 7: Installing New Crankshaft Rear Oil Seal
    G01615395Courtesy of FORD MOTOR CO.
  6. Using the special tools, install a new crankshaft rear oil seal.
  7. Install the crankshaft rear seal retainer.
    • Use a new gasket.
      Fig 8: Installing Crankshaft Rear Seal Retainer
      G01615396Courtesy of FORD MOTOR CO.
  8. Install the oil pump.
    • Use a new gasket.
      Fig 9: Installing Oil Pump
      G01615397Courtesy of FORD MOTOR CO.
  9. Using the special tool, install a new oil pump seal.
    Fig 10: Installing New Oil Pump Seal
    G01615398Courtesy of FORD MOTOR CO.
  10. Install the oil baffle.
    Fig 11: Installing Oil Baffle
    G01615399Courtesy of FORD MOTOR CO.
  11. Install the oil pump screen cover and tube.
    • Use a new gasket.
      Fig 12: Installing Oil Pump Screen Cover And Tube
      G01615400Courtesy of FORD MOTOR CO.
  12. Clean and inspect the mounting faces of both the oil pan and the cylinder block. To remove all traces of previous sealant, use solvent to clean the cylinder block and oil pan. Both surfaces must be flat, clean and dry.
    13. NOTE: Install the oil pan within ten minutes after the sealant is applied.
    Fig 13: Applying Silicone Gasket And Sealant At Oil Pan To Cylinder Block Joints
    G01615401Courtesy of FORD MOTOR CO.
  13. Apply silicone gasket and sealant F6AZ-19562-AA or equivalent Ford specification WSE-M4G323-A6 approximately 3 mm (0.125 In) wide at the oil pan to cylinder block joints and the crankshaft rear oil seal retainer to cylinder block joints.
    14. NOTE: Make sure the press fit tabs are fully engaged in the oil pan gasket channel when installing the oil pan gasket and oil pan.
    NOTE: The rear edge of the oil pan must be aligned with the rear face of the cylinder block using a straight edge.
  14. Install the oil pan. Tighten the bolts in the sequence shown.
    • The stud bolt locations are one and five.
      Fig 14: Identifying Oil Pan Bolts Tightening Sequence
      G01615402Courtesy of FORD MOTOR CO.
    15. CAUTION: Always use new cylinder head bolts.
    NOTE: Lubricate the cylinder head bolts with engine oil prior to installation.
  15. Install a new gasket and tighten the cylinder head bolts in the following sequence.
    1. Tighten all the bolts in a single sequence to 50 Nm.
    2. Back the bolts off one-half turn.
    3. Tighten all the bolts in the sequence shown to 50 Nm.
    4. Rotate all the bolts in a single sequence an additional 180 degrees, in two steps of 90 degrees each.
      Fig 15: Identifying Cylinder Head Bolts Tightening Sequence
      G01615403Courtesy of FORD MOTOR CO.
    16. NOTE: Inspect the valve cover gasket. Install a new gasket if it is cracked, torn, distorted or damaged.
    Fig 16: Installing Valve Cover
    G01615404Courtesy of FORD MOTOR CO.
  16. Install the valve cover.
  17. Install the timing belt guide and the crankshaft sprocket.
    Fig 17: Installing Timing Belt Guide And Crankshaft Sprocket
    G01615405Courtesy of FORD MOTOR CO.
  18. Install the water pump.
    • Use a new gasket.
      Fig 18: Installing Water Pump
      G01615406Courtesy of FORD MOTOR CO.
  19. Install the timing belt tensioner.
    Fig 19: Installing Timing Belt Tensioner
    G01615407Courtesy of FORD MOTOR CO.
  20. Line up the timing marks of the crankshaft.
    Fig 20: Lining Up Timing Marks Of Crankshaft
    G01615408Courtesy of FORD MOTOR CO.
  21. Line up the timing marks of the camshaft.
    22. NOTE: Install the timing belt over the sprockets in a counterclockwise direction starting at the crankshaft. Keep the belt span from the crankshaft to the camshaft tight while installing the timing belt over the camshaft.
  22. Install the timing belt.
    1. Position the timing belt.
    2. Remove the holding tool.
    3. Release the tensioner.
      Fig 21: Installing Timing Belt
      G01615409Courtesy of FORD MOTOR CO.
  23. Rotate the crankshaft two turns and recheck the timing marks.
    Fig 22: Rechecking Timing Marks
    G01615410Courtesy of FORD MOTOR CO.
  24. Install the upper timing belt cover.
    Fig 23: Installing Upper Timing Belt Cover
    G01615411Courtesy of FORD MOTOR CO.
  25. Install the timing belt cover.
    Fig 24: Installing Timing Belt Cover
    G01615412Courtesy of FORD MOTOR CO.
    26. NOTE: Using the special tool, hold the crankshaft pulley.
  26. Install the crankshaft pulley.
    • Install the bolt.
      Fig 25: Installing Crankshaft Pulley
      G01615413Courtesy of FORD MOTOR CO.
  27. Install the crankshaft position (CKP) sensor.
    Fig 26: Installing Crankshaft Position Sensor
    G01615414Courtesy of FORD MOTOR CO.
  28. Install the spark plugs. For additional information, refer to REMOVAL & INSTALLATION .
    29. NOTE: Inspect the water outlet connection gasket. Install a new gasket if it is cracked, torn, or damaged.
    Fig 27: Installing Water Outlet Connection
    G01615415Courtesy of FORD MOTOR CO.
  29. Install the water outlet connection.
    30. NOTE: Tighten the bolts evenly.
  30. Install the exhaust manifold.
    • Use a new gasket.
      Fig 28: Installing Exhaust Manifold
      G01615416Courtesy of FORD MOTOR CO.
  31. Install the accessory drive bracket.
    Fig 29: Installing Accessory Drive Bracket
    G01615417Courtesy of FORD MOTOR CO.
  32. Install the generator (if necessary).
    Fig 30: Installing Generator
    G01615418Courtesy of FORD MOTOR CO.
    33. NOTE: Wrap the threads with Teflon® tape.
    Fig 31: Installing Oil Pressure Sender Unit
    G01615419Courtesy of FORD MOTOR CO.
  33. Install the oil pressure sender unit.
  34. Install the knock sensor.
    Fig 32: Installing Knock Sensor
    G01615420Courtesy of FORD MOTOR CO.
  35. Install the oil filter.
    Fig 33: Installing Oil Filter
    G01615421Courtesy of FORD MOTOR CO.
  36. Install the coil bracket, coil and spark plug wires.
    Fig 34: Installing Coil Bracket, Coil And Spark Plug Wires
    G01615422Courtesy of FORD MOTOR CO.
  37. Connect the spark plug wires.
    Fig 35: Connecting Spark Plug Wires
    G01615423Courtesy of FORD MOTOR CO.
  38. Install a new gasket and the intake manifold.
    • Tighten the nuts and bolts to 10 Nm and 90 degrees.
      Fig 36: Installing New Gasket And Intake Manifold
      G01615424Courtesy of FORD MOTOR CO.
  39. Install the intake manifold bracket.
    Fig 37: Installing Intake Manifold Bracket
    G01615425Courtesy of FORD MOTOR CO.
  40. Position the fuel charging wire harness.
    Fig 38: Positioning Fuel Charging Wire Harness
    G01615426Courtesy of FORD MOTOR CO.
  41. Connect the electrical connectors.
    • Camshaft position (CMP) sensor
    • IMRC
    • Ignition coil
    • Capacitor
    • Water temperature sender unit
      Fig 39: Connecting Electrical Connectors
      G01615427Courtesy of FORD MOTOR CO.
  42. Connect the fuel pressure sensor electrical connectors.
    Fig 40: Connecting Fuel Pressure Sensor Electrical Connectors
    G01615428Courtesy of FORD MOTOR CO.
  43. Connect the oil pressure sender unit and the knock sensor electrical connectors.
    Fig 41: Connecting Oil Pressure Sender Unit And Knock Sensor Electrical Connectors
    G01615429Courtesy of FORD MOTOR CO.
  44. Connect the idle air control valve and the throttle position sensor.
    Fig 42: Connecting Idle Air Control Valve And Throttle Position Sensor
    G01615430Courtesy of FORD MOTOR CO.
  45. Connect the fuel injectors electrical connectors.
    Fig 43: Connecting Fuel Injectors Electrical Connectors
    G01615431Courtesy of FORD MOTOR CO.
  46. Connect the crankshaft position sensor electrical connector.
    Fig 44: Connecting Crankshaft Position Sensor Electrical Connector
    G01615432Courtesy of FORD MOTOR CO.
  47. Install the oil indicator tube.
    Fig 45: Installing Oil Indicator Tube
    G01615433Courtesy of FORD MOTOR CO.
  48. Connect the EGR tube to the exhaust manifold.
    • Use a new gasket.
      Fig 46: Connecting EGR Tube To Exhaust Manifold
      G01615434Courtesy of FORD MOTOR CO.
  49. Install the EGR tube to the EGR valve.
    Fig 47: Installing EGR Tube To EGR Valve
    G01615435Courtesy of FORD MOTOR CO.
  50. Remove the engine from the stand.
  51. Install the flywheel.
    • Tighten the bolts fingertight.
    • Install the special tool.
    • Tighten the bolts.
    Fig 48: Installing Flywheel
    G01615437Courtesy of FORD MOTOR CO.
  52. Install the clutch (if equipped). For additional information, refer to CLUTCH-IB5 TRANSAXLE , CLUTCH-MTX75 TRANSAXLE or CLUTCH-MT285 TRANSAXLE .
  53. Install and connect:
    • Fresh air and positive crankcase ventilation hoses
    • Coolant hoses and tubes
    • Vacuum hoses
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