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Section 2 (Engine - 2.0L SPI): Assembly: Engine: Material

WARNING: This page is about a different variant/trim than selected.
MATERIAL SPECIFICATION

Engine oil WSS-M2C153-H
Silicone gasket and sealant F6AZ-19562-AA or equivalent Ford specification WSE-M4G323-A6
    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 article .
  1. Install the main bearings.
    1. Upper crankshaft main bearing.
    2. Crankshaft thrust main bearing.
      Fig 1: Installing Upper Crankshaft Main Bearing And Crankshaft Thrust Main Bearing
      G03432435Courtesy of FORD MOTOR CO.
  2. Install the crankshaft.
    Fig 2: Installing Crankshaft
    G03432436Courtesy 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 article .
    Fig 3: Installing Lower Crankshaft Main Bearings And Main Bearing Caps With Torque Specifications With Torque Specifications
    G03432437Courtesy 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 4: Installing Piston And Connecting Rod Assemblies
    G03432438Courtesy of FORD MOTOR CO.
  5. Install the four crankshaft rod caps.
    Fig 5: Installing Crankshaft Rod Caps With Torque Specifications With Torque Specifications
    G03432439Courtesy 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 6: Installing New Crankshaft Rear Oil Seal
    G03432440Courtesy 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 7: Installing Crankshaft Rear Seal Retainer With Torque Specifications
      G03432441Courtesy of FORD MOTOR CO.
  8. Install the oil pump.
    • Use a new gasket.
      Fig 8: Installing Oil Pump With Torque Specifications
      G03432442Courtesy of FORD MOTOR CO.
  9. Using the special tool, install a new oil pump seal.
    Fig 9: Installing New Oil Pump Seal
    G03432443Courtesy of FORD MOTOR CO.
  10. Install the oil baffle.
    Fig 10: Installing Oil Baffle With Torque Specifications
    G03432444Courtesy of FORD MOTOR CO.
  11. Install the oil pump screen cover and tube.
    • Use a new gasket.
      Fig 11: Installing Oil Pump Screen Cover And Tube With Torque Specifications
      G03432445Courtesy 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 12: Applying Silicone Gasket And Sealant F6AZ-19562-AA At Oil Pan To Cylinder Block Joints With Torque Specifications
    G03432446Courtesy 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 13: Tightening Sequence Of Oil Pan Bolts With Torque Specifications
      G03432447Courtesy of FORD MOTOR CO.
      • CAUTION: Always use new cylinder head bolts.
      NOTE: Lubricate the cylinder head bolts with engine oil prior to installation.
    • 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 N.m.
      2. Back the bolts off one-half turn.
      3. Tighten all the bolts in the sequence shown to 50 N.m.
      4. Rotate all the bolts in a single sequence an additional 180 degrees, in two steps of 90 degrees each.
        Fig 14: Identifying Tightening Sequence Of Cylinder Head Bolts
        G03432448Courtesy of FORD MOTOR CO.
      • NOTE: Inspect the valve cover gasket. Install a new gasket if it is cracked, torn, distorted or damaged.
      Fig 15: Installing Valve Cover With Torque Specifications
      G03432449Courtesy of FORD MOTOR CO.
    • Install the valve cover.
    • Install the timing belt guide and the crankshaft sprocket.
      Fig 16: Installing Timing Belt Guide And Crankshaft Sprocket
      G03432450Courtesy of FORD MOTOR CO.
    • Install the water pump.
      • Use a new gasket.
        Fig 17: Installing Water Pump With Torque Specifications
        G03432451Courtesy of FORD MOTOR CO.
    • Install the timing belt tensioner.
      Fig 18: Installing Timing Belt Tensioner With Torque Specifications
      G03432452Courtesy of FORD MOTOR CO.
    • Line up the timing marks of the crankshaft.
      Fig 19: Aligning Timing Marks Of Crankshaft
      G03432453Courtesy of FORD MOTOR CO.
    • Line up the timing marks of the camshaft.
      Fig 20: Aligning Timing Marks Of Camshaft
      G03432454Courtesy of FORD MOTOR CO.
      • 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.
    • Install the timing belt.
      1. Position the timing belt.
      2. Remove the holding tool.
      3. Release the tensioner.
        Fig 21: Installing Timing Belt
        G03432455Courtesy of FORD MOTOR CO.
    • Rotate the crankshaft two turns and recheck the timing marks.
    • Install the upper timing belt cover.
      Fig 22: Installing Upper Timing Belt Cover With Torque Specifications
      G03432456Courtesy of FORD MOTOR CO.
    • Install the timing belt cover.
      Fig 23: Installing Timing Belt Cover With Torque Specifications
      G03432457Courtesy of FORD MOTOR CO.
      • NOTE: Using the special tool, hold the crankshaft pulley.
    • Install the crankshaft pulley.
      • Install the bolt.
        Fig 24: Installing Crankshaft Pulley With Torque Specifications
        G03432458Courtesy of FORD MOTOR CO.
    • Install the crankshaft position (CKP) sensor.
      Fig 25: Installing Crankshaft Position (CKP) Sensor With Torque Specifications
      G03432459Courtesy of FORD MOTOR CO.
    • Install the spark plugs.
      • NOTE: Inspect the water outlet connection gasket. Install a new gasket if it is cracked, torn, or damaged.
      Fig 26: Installing Water Outlet Connection With Torque Specifications
      G03432460Courtesy of FORD MOTOR CO.
    • Install the water outlet connection.
      • NOTE: Tighten the bolts evenly.
    • Install the exhaust manifold.
      • Use a new gasket.
        Fig 27: Installing Exhaust Manifold With Torque Specifications
        G03432461Courtesy of FORD MOTOR CO.
    • Install the accessory drive bracket.
      Fig 28: Installing Accessory Drive Bracket With Torque Specifications
      G03432462Courtesy of FORD MOTOR CO.
    • Install the generator (if necessary).
      Fig 29: Installing Generator With Torque Specifications
      G03432463Courtesy of FORD MOTOR CO.
      • NOTE: Wrap the threads with Teflon tape.
      Fig 30: Installing Oil Pressure Sender Unit With Torque Specifications
      G03432464Courtesy of FORD MOTOR CO.
    • Install the oil pressure sender unit.
    • Install the knock sensor.
      Fig 31: Installing Knock Sensor
      G03432465Courtesy of FORD MOTOR CO.
    • Install the oil filter.
      Fig 32: Installing Oil Filter
      G03432466Courtesy of FORD MOTOR CO.
    • Install the coil bracket, coil and spark plug wires.
      Fig 33: Installing Coil Bracket, Coil And Spark Plug Wires With Torque Specifications
      G03432467Courtesy of FORD MOTOR CO.
    • Connect the spark plug wires.
      Fig 34: Connecting Spark Plug Wires
      G03432468Courtesy of FORD MOTOR CO.
    • Install a new gasket and the intake manifold.
      • Tighten the nuts and bolts to 10 N.m and 90 degrees.
        Fig 35: Installing New Gasket And Intake Manifold
        G03432469Courtesy of FORD MOTOR CO.
    • Install the intake manifold bracket.
      Fig 36: Installing Intake Manifold Bracket With Torque Specifications
      G03432470Courtesy of FORD MOTOR CO.
    • Position the fuel charging wire harness.
      Fig 37: Installing Fuel Charging Wire Harness
      G03432471Courtesy of FORD MOTOR CO.
    • Connect the electrical connectors.
      • Camshaft position (CMP) sensor
      • IMRC
      • Ignition coil
      • Capacitor
      • Water temperature sender unit
        Fig 38: Connecting Electrical Connectors
        G03432472Courtesy of FORD MOTOR CO.
    • Connect the fuel pressure sensor electrical connectors.
      Fig 39: Connecting Fuel Pressure Sensor Electrical Connectors
      G03432473Courtesy of FORD MOTOR CO.
    • Connect the oil pressure sender unit and the knock sensor electrical connectors.
      Fig 40: Connecting Oil Pressure Sender Unit And Knock Sensor Electrical Connectors
      G03432474Courtesy of FORD MOTOR CO.
    • Connect the idle air control valve and the throttle position sensor.
      Fig 41: Connecting Idle Air Control Valve And Throttle Position Sensor
      G03432475Courtesy of FORD MOTOR CO.
    • Connect the fuel injectors electrical connectors.
      Fig 42: Connecting Fuel Injectors Electrical Connectors
      G03432476Courtesy of FORD MOTOR CO.
    • Connect the crankshaft position sensor electrical connector.
      Fig 43: Connecting Crankshaft Position Sensor Electrical Connector
      G03432477Courtesy of FORD MOTOR CO.
    • Install the oil indicator tube.
      Fig 44: Installing Oil Indicator Tube
      G03432478Courtesy of FORD MOTOR CO.
    • Connect the EGR tube to the exhaust manifold.
      • Use a new gasket.
        Fig 45: Connecting EGR Tube To Exhaust Manifold With Torque Specifications
        G03432479Courtesy of FORD MOTOR CO.
    • Install the EGR tube to the EGR valve.
      Fig 46: Installing EGR Tube To EGR Valve With Torque Specifications
      G03432480Courtesy of FORD MOTOR CO.
    • Remove the engine from the stand.
    • Install the flywheel.
      • Tighten the bolts fingertight.
      • Install the special tool.
      • Tighten the bolts.
      Fig 47: Installing Flywheel With Torque Specifications
      G03432481Courtesy of FORD MOTOR CO.
  15. Install the clutch (if equipped). For additional information, refer to CLUTCHES article .
  16. Install and connect:
    • Fresh air and positive crankcase ventilation hoses
    • Coolant hoses and tubes
    • Vacuum hoses
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