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Section 17 (Engine - 2.0L SPI): Assembly: Engine

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL SPECIFICATIONS

G04034751
 Crankshaft Rear Seal Pilot
303-329 (T88P-6701-B2)
G04034752
 Crankshaft Rear Seal Replacer
303-328 (T88P-6701-B1)
G04034753
 Oil Pump Seal Replacer
303-164 (T81P-6700-A)
G04034754
 Strap Wrench
303-D055 (D85L-6000-A) or equivalent
MATERIAL SPECIFICATIONS

Item Specification
Engine oil WSS-M2C153-H
Silicone gasket and sealant F6AZ-19562-AA 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 aluminium 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 .
    Fig 1: Installing Main Bearings
    G04034755Courtesy of FORD MOTOR CO.
  1. Install the main bearings.
    1. Upper crankshaft main bearing.
    2. Crankshaft thrust main bearing.
  2. Install the crankshaft.
    Fig 2: Installing Crankshaft
    G04034756Courtesy 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 3: Installing Lower Crankshaft Main Bearings And Five Main Bearing Caps
    G04034757Courtesy 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 4: Installing Piston And Connecting Rod Assemblies
    G04034758Courtesy of FORD MOTOR CO.
  5. Install the four crankshaft rod caps.
    Fig 5: Installing Four Connecting Rod Caps
    G04034759Courtesy 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 Crankshaft Rear Oil Seal
    G04034760Courtesy 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
    G04034761Courtesy of FORD MOTOR CO.
  8. Install the oil pump.
    • Use a new gasket.
    Fig 8: Installing Oil Pump
    G04034762Courtesy of FORD MOTOR CO.
  9. Using the special tool, install a new oil pump seal.
    Fig 9: Installing Oil Pump Seal
    G04034763Courtesy of FORD MOTOR CO.
  10. Install the oil baffle.
    Fig 10: Installing Oil Baffle
    G04034764Courtesy 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
    G04034765Courtesy 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: Installing Oil Pan
    G04034766Courtesy 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 bloc! using a straight edge.
    Fig 13: Tightening Oil Pan Bolts In Sequence
    G04034767Courtesy of FORD MOTOR CO.
  14. Install the oil pan. Tighten the bolts in the sequence shown.
    • The stud bolt locations are one and five.
    15. CAUTION: Always use new cylinder head bolts.
    NOTE: Lubricate the cylinder head bolts with engine oil prior to installation.
    Fig 14: Tightening Cylinder Head Bolts In Sequence
    G04034768Courtesy of FORD MOTOR CO.
  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.
    16. NOTE: Inspect the valve cover gasket. Install a new gasket if it is cracked, torn, distorted or damaged.
    Fig 15: Installing Valve Cover
    G04034769Courtesy of FORD MOTOR CO.
  16. Install the valve cover.
  17. Install the timing belt guide and the crankshaft sprocket.
    Fig 16: Installing Timing Belt Guide And Crankshaft Sprocket
    G04034770Courtesy of FORD MOTOR CO.
  18. Install the water pump.
    • Use a new gasket.
    Fig 17: Installing Water Pump
    G04034771Courtesy of FORD MOTOR CO.
  19. Install the timing belt tensioner.
    Fig 18: Installing Timing Belt Tensioner
    G04034772Courtesy of FORD MOTOR CO.
  20. Line up the timing marks of the crankshaft.
    Fig 19: Lining Up Timing Marks Of Crankshaft
    G04034773Courtesy of FORD MOTOR CO.
  21. Line up the timing marks of the camshaft.
    Fig 20: Lining Up Timing Marks Of Camshaft
    G04034774Courtesy of FORD MOTOR CO.
    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.
    Fig 21: Installing Timing Belt
    G04034775Courtesy of FORD MOTOR CO.
  22. Install the timing belt.
    1. Position the timing belt.
    2. Remove the holding tool.
    3. Release the tensioner.
  23. Rotate the crankshaft two turns and recheck the timing marks.
  24. Install the upper timing belt cover.
    Fig 22: Installing Upper Timing Belt Cover
    G04034776Courtesy of FORD MOTOR CO.
  25. Install the timing belt cover.
    Fig 23: Installing Timing Belt Cover
    G04034777Courtesy of FORD MOTOR CO.
    26. NOTE: Using the special tool, hold the crankshaft pulley.
    Fig 24: Installing Crankshaft Pulley
    G04034778Courtesy of FORD MOTOR CO.
  26. Install the crankshaft pulley.
    • Install the bolt.
  27. Install the crankshaft position (CKP) sensor.
    Fig 25: Installing Crankshaft Position Sensor
    G04034779Courtesy of FORD MOTOR CO.
  28. Install the spark plugs.
    29. NOTE: Inspect the water outlet connection gasket. Install a new gasket if it is cracked, torn, or damaged.
    Fig 26: Installing Water Outlet Connection
    G04034780Courtesy of FORD MOTOR CO.
  29. Install the water outlet connection.
    30. NOTE: Tighten the bolts evenly.
    Fig 27: Installing Exhaust Manifold
    G04034781Courtesy of FORD MOTOR CO.
  30. Install the exhaust manifold.
    • Use a new gasket.
  31. Install the accessory drive bracket.
    Fig 28: Installing Accessory Drive Bracket
    G04034782Courtesy of FORD MOTOR CO.
  32. Install the generator (if necessary).
    Fig 29: Installing Generator
    G04034783Courtesy of FORD MOTOR CO.
    33. NOTE: Wrap the threads with Teflon® tape.
    Fig 30: Installing Oil Pressure Sender Unit
    G04034784Courtesy of FORD MOTOR CO.
  33. Install the oil pressure sender unit.
  34. Install the knock sensor.
    Fig 31: Installing Knock Sensor
    G04034785Courtesy of FORD MOTOR CO.
  35. Install the oil filter.
    Fig 32: Installing Oil Filter
    G04034786Courtesy of FORD MOTOR CO.
  36. Install the coil bracket, coil and spark plug wires.
    Fig 33: Installing Coil Bracket, Coil And Spark Plug Wires
    G04034787Courtesy of FORD MOTOR CO.
  37. Connect the spark plug wires.
    Fig 34: Connecting Spark Plug Wires
    G04034788Courtesy 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 35: Installing Gasket And Intake Manifold
    G04034789Courtesy of FORD MOTOR CO.
  39. Install the intake manifold bracket.
    Fig 36: Installing Intake Manifold Bracket
    G04034790Courtesy of FORD MOTOR CO.
  40. Position the fuel charging wire harness.
    Fig 37: Positioning Fuel Charging Wire Harness
    G04034791Courtesy of FORD MOTOR CO.
  41. Connect the electrical connectors.
    • Camshaft position (CMP) sensor
    • IMRC
    • Ignition coil
    • Capacitor
    • Water temperature sender unit
    Fig 38: Connecting Electrical Connectors
    G04034792Courtesy of FORD MOTOR CO.
  42. Connect the fuel pressure sensor electrical connectors.
    Fig 39: Connecting Fuel Pressure Sensor Electrical Connectors
    G04034793Courtesy of FORD MOTOR CO.
  43. Connect the oil pressure sender unit and the knock sensor electrical connectors.
    Fig 40: Connecting Oil Pressure Sender Unit And Knock Sensor Electrical Connectors
    G04034794Courtesy of FORD MOTOR CO.
  44. Connect the idle air control valve and the throttle position sensor.
    Fig 41: Connecting Idle Air Control Valve And Throttle Position Sensor
    G04034795Courtesy of FORD MOTOR CO.
  45. Connect the fuel injectors electrical connectors.
    Fig 42: Connecting Fuel Injectors Electrical Connectors
    G04034796Courtesy of FORD MOTOR CO.
  46. Connect the crankshaft position sensor electrical connector.
    Fig 43: Connecting Crankshaft Position Sensor Electrical Connector
    G04034797Courtesy of FORD MOTOR CO.
  47. Install the oil indicator tube.
    Fig 44: Installing Oil Indicator Tube
    G04034798Courtesy of FORD MOTOR CO.
  48. Connect the EGR tube to the exhaust manifold.
    • Use a new gasket.
    Fig 45: Connecting EGR Tube To Exhaust Manifold
    G04034799Courtesy of FORD MOTOR CO.
  49. Install the EGR tube to the EGR valve.
    Fig 46: Installing EGR Tube To EGR Valve
    G04034800Courtesy 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 47: Installing Flywheel
    G04034801Courtesy 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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