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Engine - 2.0L SPI: Assembly: Engine

Fig 1: Identifying Special Tool(s) (1 Of 3)
G02206961Courtesy of FORD MOTOR CO.
Fig 2: Special Tool(s) (2 Of 3)
G02206962Courtesy of FORD MOTOR CO.
Fig 3: Special Tool(s) (3 Of 3)
G02206963Courtesy of FORD MOTOR CO.
Fig 4: Materials Specifications
G02206964Courtesy 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: During assembly, all bearing surfaces must be lubricated before assembly or installation.
NOTE: The crankshaft main bearings (6333) are precision selective fit. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION to check bearing clearances or to select fit a new crankshaft main bearing.
  1. Install the (A) upper crankshaft main bearings and the (B) crankshaft thrust main bearing (6337).
    Fig 5: Installing Upper Crankshaft Main Bearings And Crankshaft Thrust Main Bearing
    G02206965Courtesy of FORD MOTOR CO.
  2. Install the crankshaft.
    Fig 6: Installing Crankshaft
    G02206966Courtesy of FORD MOTOR CO.
    3. NOTE: The crankshaft main bearings are numbered 1 to 5 with No. 1 at the front of the engine (6007). 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 7: Installing Five Lower Crankshaft Main Bearings And Five Main Bearing Caps
    G02206967Courtesy of FORD MOTOR CO.
  3. Install the five lower crankshaft main bearings and the five main bearing caps.
  4. Install the piston and connecting rod assemblies.
    Fig 8: Installing Piston And Connecting Rod Assemblies
    G02206968Courtesy of FORD MOTOR CO.
  5. Install the four connecting rod caps.
    Fig 9: Installing Four Connecting Rod Caps
    G02206969Courtesy of FORD MOTOR CO.
    6. NOTE: Coat the rear oil seal area and the crankshaft rear oil seal lip with clean engine oil.
    NOTE: Make sure the crankshaft rear oil seal (6701) is on correctly and that the edges are not rolled over.
    Fig 10: Replacing Crankshaft Rear Oil Seal Using Special Tool
    G02206970Courtesy of FORD MOTOR CO.
  6. Use Crankshaft Rear Main Oil Seal Installers to replace the crankshaft rear oil seal.
  7. Install a new crankshaft rear oil seal retainer gasket (6344) and install the crankshaft rear seal retainer.
    Fig 11: Installing Crankshaft Rear Seal Retainer
    G02206971Courtesy of FORD MOTOR CO.
  8. Install the oil pump (6600).
    Fig 12: Installing Oil Pump
    G02206972Courtesy of FORD MOTOR CO.
  9. Use the Crankshaft Front Oil Seal Installer to install a new crankshaft front seal.
    Fig 13: Installing Crankshaft Front Seal Using Special Tool
    G02206973Courtesy of FORD MOTOR CO.
  10. Install the oil baffle.
    Fig 14: Installing Oil Baffle
    G02206974Courtesy of FORD MOTOR CO.
  11. Install the oil pump screen and cover assembly.
    Fig 15: Installing Oil Pump Screen And Cover Assembly
    G02206975Courtesy of FORD MOTOR CO.
  12. Clean and inspect the mounting faces of both the oil pan (6675) and the cylinder block (6010). To remove all traces of previous sealer, use solvent to clean the cylinder block and oil pump. Both surfaces must be flat, clean, and dry.
    13. NOTE: Install the oil pan within four minutes after the sealer is applied.
  13. Apply silicone gasket and sealant approximately 3.0 mm (0.125 in) wide at the oil pan to cylinder block joints and the crankshaft rear oil seal retainer (6335) 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.
  14. Install the oil pan gasket (6710) in the oil pan.
    15. NOTE: The rear edge of the oil pan must be aligned with the rear face of the cylinder block using a straight edge.
    Fig 16: Tightening Bolts In Sequence
    G02206976Courtesy of FORD MOTOR CO.
  15. Install the oil pan. Tighten the bolts in the sequence shown.
    16. CAUTION: Always use new cylinder head bolts.
    NOTE: Lubricate the cylinder head bolts with clean engine oil prior to installation.
  16. Install the cylinder head assembly and tighten the cylinder head bolts in the following sequence.
    1. Tighten all the bolts in a single sequence to 40-60 Nm (30-44 lb-ft).
    2. Back the bolts off 1/2 turn.
      Fig 17: Tightening Cylinder Head Bolts In Sequence
      G02206977Courtesy of FORD MOTOR CO.
    3. Tighten the bolts in the sequence shown to 40-60 Nm (30-44 lb-ft).
    4. Rotate all the bolts in a single sequence an additional 180 degrees in two steps of 90 degrees each.
  17. Install the valve cover gasket and valve cover (6582).
    Fig 18: Installing Valve Cover Gasket And Valve Cover
    G02206978Courtesy of FORD MOTOR CO.
  18. Install the engine mounting bracket.
    Fig 19: Installing Engine Mounting Bracket
    G02206979Courtesy of FORD MOTOR CO.
  19. Install the front engine accessory drive bracket.
    Fig 20: Installing Front Engine Accessory Drive Bracket
    G02206980Courtesy of FORD MOTOR CO.
  20. Install the power steering pump (3A674).
    Fig 21: Installing Power Steering Pump
    G02206981Courtesy of FORD MOTOR CO.
  21. Use the Strap Wrench and install the power steering pump pulley (3A733).
    Fig 22: Installing Power Steering Pump Pulley Using Special Tool
    G02206982Courtesy of FORD MOTOR CO.
  22. Install the timing belt guide and the crankshaft sprocket (6306).
    Fig 23: Installing Timing Belt Guide And Crankshaft Sprocket
    G02206983Courtesy of FORD MOTOR CO.
  23. Install the inner engine front cover.
    Fig 24: Installing Inner Engine Front Cover
    G02206984Courtesy of FORD MOTOR CO.
  24. Install the water pump (8501).
    Fig 25: Installing Water Pump
    G02206985Courtesy of FORD MOTOR CO.
  25. Install the camshaft sprocket (6256).
    Fig 26: Installing Camshaft Sprocket
    G02206986Courtesy of FORD MOTOR CO.
  26. Install the (A) bolt and the (B) timing belt tensioner.
    Fig 27: Installing Bolt And Timing Belt Tensioner
    G02206987Courtesy of FORD MOTOR CO.
    27. NOTE: Install the timing belt over the sprockets in a counterclockwise direction starting at the crankshaft (6303). Keep the belt span from the crankshaft to the camshaft (6250) tight while installing the timing belt over the camshaft.
    Fig 28: Installing Timing Belt
    G02206988Courtesy of FORD MOTOR CO.
  27. Install the (A) timing belt, remove the (B) holding tool, and release the (C) timing belt tensioner.
  28. Rotate crankshaft two times and recheck the timing marks.
  29. Install the outer engine front cover.
    Fig 29: Installing Outer Engine Front Cover
    G02206989Courtesy of FORD MOTOR CO.
  30. Install the crankshaft position sensor.
    Fig 30: Installing Crankshaft Position Sensor
    G02206990Courtesy of FORD MOTOR CO.
  31. Use Strap Wrench and install the crankshaft pulley.
    Fig 31: Installing Crankshaft Pulley Using Special Tool
    G02206991Courtesy of FORD MOTOR CO.
  32. Install the spark plugs.
  33. Install a new gasket and the water outlet connection.
    Fig 32: Installing Gasket And Water Outlet Connection
    G02206992Courtesy of FORD MOTOR CO.
  34. Install the ignition coil mounting bracket assembly.
    Fig 33: Installing Ignition Coil Mounting Bracket Assembly
    G02206993Courtesy of FORD MOTOR CO.
  35. Install the radio ignition interference capacitor and the ignition coil.
    Fig 34: Installing Radio Ignition Interference Capacitor And Ignition Coil
    G02206994Courtesy of FORD MOTOR CO.
    36. NOTE: Tighten the bolts evenly and sequentially.
    Fig 35: Installing Gasket And Exhaust Manifold
    G02206995Courtesy of FORD MOTOR CO.
  36. Install a new gasket and the exhaust manifold (9430).
  37. Install the generator (GEN) (10346).
    Fig 36: Installing Generator
    G02206996Courtesy of FORD MOTOR CO.
  38. Install the oil pressure switch.
    Fig 37: Installing Oil Pressure Switch
    G02206997Courtesy of FORD MOTOR CO.
  39. Install the knock sensor.
  40. Install the oil filter.
    Fig 38: Installing Oil Filter
    G02206998Courtesy of FORD MOTOR CO.
  41. Install the spark plug wires.
  42. Install the intake manifold runner control (IMRC) and the intake manifold (9424).
    Fig 39: Installing Intake Manifold Runner Control (IMRC) And Intake Manifold
    G02206999Courtesy of FORD MOTOR CO.
  43. Install the fuel charging wiring harness.
  44. Connect the following electrical connectors:
    • Water temperature indicator sender unit.
    • Ignition coil.
    • Intake manifold runner control.
    • Knock sensor.
    • Fuel pressure sensor.
    Fig 40: Connecting Electrical Connectors
    G02207000Courtesy of FORD MOTOR CO.
  45. Connect the (A) idle air control valve and the (B) throttle position sensor electrical connectors.
    Fig 41: Connecting Idle Air Control Valve And Throttle Position Sensor Electrical Connectors
    G02207001Courtesy of FORD MOTOR CO.
  46. Connect the four fuel injector electrical connectors.
    Fig 42: Connecting Four Fuel Injector Electrical Connectors
    G02207002Courtesy of FORD MOTOR CO.
  47. Connect the crankshaft position sensor electrical connector.
    Fig 43: Connecting Crankshaft Position Sensor Electrical Connector
    G02207003Courtesy of FORD MOTOR CO.
  48. Install the oil level indicator tube.
    Fig 44: Installing Oil Level Indicator Tube
    G02207004Courtesy of FORD MOTOR CO.
  49. Connect the EGR tube to the exhaust manifold.
    Fig 45: Connecting EGR Tube To Exhaust Manifold
    G02207005Courtesy of FORD MOTOR CO.
  50. Install a new gasket and install the EGR tube to the EGR valve.
    Fig 46: Installing EGR Tube To EGR Valve
    G02207006Courtesy of FORD MOTOR CO.
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