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Section 288 (Engine-2.3L): Assembly: Engine: Assembly

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.

    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 damper bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC).
  2. Remove the plug bolt.
    Fig 1: Removing Plug Bolt
    G01611631Courtesy of FORD MOTOR CO.
    3. NOTE: After the No. 1 piston is set in the TDC position and the Timing Peg is installed, the Timing Peg will stop the engine from turning in a clockwise direction.
    Fig 2: Installing Special Tool (303-507)
    G01611632Courtesy of FORD MOTOR CO.
  3. Install the special tool.
    4. NOTE: Clean the gasket surface with metal surface cleaner.
  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).
      Fig 3: Identifying Oil Pump Assembly Bolts Tightening Sequence
      G01611633Courtesy of FORD MOTOR CO.
  5. Install a new oil pump pickup tube gasket and the pickup tube.
    Fig 4: Installing Oil Pump Pickup Tube Gasket And Pickup Tube Bolts
    G01611634Courtesy of FORD MOTOR CO.
  6. Using the special tool, install the crankshaft rear main oil seal.
    Fig 5: Installing Crankshaft Rear Main Oil Seal
    G01611635Courtesy of FORD MOTOR CO.
  7. Tighten the crankshaft rear main oil seal bolts in the sequence shown.
    Fig 6: Crankshaft Rear Main Oil Seal Bolts Tightening Sequence
    G01611636Courtesy 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: Oil Pan Bolts Tightening Sequence
    G01611637Courtesy 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: Installing Cylinder Head Alignment Dowels
    G01611638Courtesy of FORD MOTOR CO.
    10. NOTE: Clean the gasket surface with metal surface cleaner.
    Fig 9: Identifying Silicone Gasket And Sealant To Locations
    G01611639Courtesy 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.
  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).
      Fig 10: Cylinder Head Bolts Tightening Sequence
      G01611640Courtesy of FORD MOTOR CO.
    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.
  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).
      Fig 11: Camshaft Bearing Caps Bolts Tightening Sequence
      G01611641Courtesy of FORD MOTOR CO.
  15. Install the oil pump chain and sprockets.
    • The crankshaft sprocket flange must be facing away from the engine block.
      Fig 12: Identifying Crankshaft Sprocket Flange
      G01611642Courtesy of FORD MOTOR CO.
    16. NOTE: The oil pump chain sprocket must be held in place.
    Fig 13: Tightening Oil Pump Sprocket Bolt
    G01611643Courtesy of FORD MOTOR CO.
  16. Tighten 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
    G01611644Courtesy 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
    G01611645Courtesy of FORD MOTOR CO.
    19. NOTE: Sprockets must turn freely on the camshafts.
    Fig 16: Installing Camshaft Sprockets
    G01611646Courtesy 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
    G01611647Courtesy 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 Ratchet Mechanism
    G01611648Courtesy 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
    G01611649Courtesy 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 To Hold Ratchet Assembly
    G01611650Courtesy of FORD MOTOR CO.
  24. Install the timing chain.
    Fig 21: Installing Timing Chain
    G01611651Courtesy of FORD MOTOR CO.
  25. Install the timing chain guides.
    Fig 22: Installing Timing Chain Guides
    G01611652Courtesy 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
    G01611653Courtesy 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.
    Fig 24: Installing Special Tool (303-465)
    G01611654Courtesy of FORD MOTOR CO.
    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
    G01611655Courtesy 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: Applying Bead Of Silicone Gasket And Sealant To Front Cover
    G01611656Courtesy of FORD MOTOR CO.
  31. Apply silicone gasket and sealant to the locations shown.
    Fig 27: Identifying Apply Silicone Gasket And Sealant Locations
    G01611657Courtesy 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.
  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).
      Fig 28: Front Cover Bolts Tightening Sequence
      G01611658Courtesy of FORD MOTOR CO.
    33. NOTE: Do not reuse the crankshaft damper bolt.
    NOTE: Apply clean engine oil on seal area before installing.
    Fig 29: Installing Crankshaft Pulley
    G01611659Courtesy 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 Standard Bolt Through Crankshaft Pulley And Thread Into Front Cover
    G01611660Courtesy 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 result in damage to the engine.
  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.
      Fig 31: Installing Crankshaft Pulley Bolts
      G01611661Courtesy of FORD MOTOR CO.
  36. Remove the special tools.
    Fig 32: Removing Special Tools (205-126)
    G01611662Courtesy of FORD MOTOR CO.
  37. Remove the M6 bolt.
  38. Remove the special tool.
    Fig 33: Removing Special Tool (303-507)
    G01611663Courtesy of FORD MOTOR CO.
  39. Remove the special tool from the camshafts.
    Fig 34: Removing Special Tool (303-465)
    G01611664Courtesy of FORD MOTOR CO.
  40. Install the side plug.
    Fig 35: Installing Side Plug
    G01611665Courtesy of FORD MOTOR CO.
  41. Clean the valve cover gasket surface with metal surface cleaner.
  42. Apply silicone gasket and sealant to the locations shown.
    Fig 36: Applying Silicone Gasket And Sealant To Locations
    G01611666Courtesy of FORD MOTOR CO.
    43. 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.
  43. Install the valve cover.
    • Tighten the bolts in the sequence shown.
      Fig 37: Valve Cover Bolts Tightening Sequence
      G01611667Courtesy of FORD MOTOR CO.
  44. Install the following:
    • Camshaft position (CMP) sensor.
    • Cylinder head temperature (CHT) sensor.
    • Spark plugs.
      Fig 38: Installing CMP Sensor, CHT Sensor And Spark Plugs
      G01611668Courtesy of FORD MOTOR CO.
    45. NOTE: Apply dielectric compound to the inside of the coil boots.
  45. Install the ignition coils.
    • Tighten the bolts to 10 Nm (89 lb-in).
    46. 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 39: Installing Coolant Pump
    G01611669Courtesy of FORD MOTOR CO.
  46. Install the coolant pump.
  47. Install the coolant pump pulley.
    Fig 40: Installing Coolant Pump Pulley
    G01611670Courtesy of FORD MOTOR CO.
  48. Install the fuel injection supply manifold and the ground strap.
    Fig 41: Installing Fuel Injection Supply Manifold And Ground Strap
    G01611671Courtesy of FORD MOTOR CO.
    49. NOTE: The knock sensor (KS) must not touch the engine vent cover.
    Fig 42: Installing Engine Vent Cover And KS
    G01611672Courtesy of FORD MOTOR CO.
  49. Install the engine vent cover and the KS.
    50. NOTE: Clean the thermostat housing gasket surface with metal surface cleaner.
    Fig 43: Installing Thermostat Housing
    G01611673Courtesy of FORD MOTOR CO.
  50. Install a new gasket and the thermostat housing.
  51. Install the bypass hose and the clamp.
    Fig 44: Installing Bypass Hose And Clamp
    G01611674Courtesy of FORD MOTOR CO.
  52. Connect the ignition coil and the CHT sensor electrical connectors.
    Fig 45: Connecting Ignition Coil And CHT Sensor Electrical Connectors
    G01611675Courtesy of FORD MOTOR CO.
  53. Reposition the CHT sensor boot.
    Fig 46: Repositioning CHT Sensor Boot
    G01611676Courtesy of FORD MOTOR CO.
  54. Connect the fuel injector connector and the wiring harness pin-type retainers.
    55. Fig 47: Connecting Fuel Injector Connector And Wiring Harness Pin-Type Retainers
    G01611677Courtesy of FORD MOTOR CO.
  55. Install the intake manifold assembly.
    56. Fig 48: Installing Intake Manifold Assembly
    G01611678Courtesy of FORD MOTOR CO.
  56. Secure the pin-type retainers to the intake manifold.
    57. Fig 49: Securing Pin-Type Retainers To Intake Manifold
    G01611679Courtesy of FORD MOTOR CO.
  57. Install the positive crankcase ventilation (PCV) hose.
    58. Fig 50: Installing Positive Crankcase Ventilation (PCV) Hose
    G01611680Courtesy of FORD MOTOR CO.
  58. Connect the crankshaft position (CKP) sensor electrical connector and the wiring harness pin-type retainers.
    Fig 51: Connecting Crankshaft Position (CKP) Sensor Electrical Connector And Wiring Harness Pin-Type Retainers
    G01611681Courtesy of FORD MOTOR CO.
  59. Connect the swirl control valve monitor electrical connector and the hose.
    Fig 52: Connecting Swirl Control Valve Monitor Electrical Connector And Hose
    G01611682Courtesy of FORD MOTOR CO.
  60. Connect the idle air control (IAC) motor electrical connector.
    Fig 53: Connecting Idle Air Control (IAC) Motor Electrical Connector
    G01611683Courtesy of FORD MOTOR CO.
  61. Connect the throttle position (TP) sensor electrical connector.
    Fig 54: Connecting Throttle Position (TP) Sensor Electrical Connector
    G01611684Courtesy of FORD MOTOR CO.
  62. Install the exhaust gas recirculation (EGR) valve.
    1. Install the EGR valve and bolts.
    2. Connect the EGR valve electrical connector.
      Fig 55: Installing Exhaust Gas Recirculation (EGR) Valve
      G01611685Courtesy of FORD MOTOR CO.
  63. Install the block heater, if equipped.
    Fig 56: Installing Block Heater
    G01611686Courtesy of FORD MOTOR CO.
  64. Connect the knock sensor (KS) electrical connector.
    Fig 57: Connecting Knock Sensor (KS) Electrical Connector
    G01611687Courtesy of FORD MOTOR CO.
  65. Connect the heater hose to the thermostat housing.
    Fig 58: Connecting Heater Hose To Thermostat Housing
    G01611688Courtesy of FORD MOTOR CO.
  66. Connect the coolant hose to the EGR valve.
    Fig 59: Connecting Coolant Hose To EGR Valve
    G01611689Courtesy of FORD MOTOR CO.
  67. Install the generator.
    Fig 60: Installing Generator
    G01611690Courtesy of FORD MOTOR CO.
  68. Install the coolant bypass.
    1. Install the bolts.
    2. Install the hose.
      Fig 61: Installing Coolant Bypass Bolts
      G01611691Courtesy of FORD MOTOR CO.
  69. Install the oil level indicator tube.
    1. Install the oil level indicator tube.
    2. Install the bolts.
    3. Install the oil level indicator.
      Fig 62: Installing Oil Level Indicator Tube
      G01611692Courtesy of FORD MOTOR CO.
  70. Install the accessory drive belt.
    Fig 63: Installing Accessory Drive Belt
    G01611693Courtesy of FORD MOTOR CO.
  71. Using the heavy duty floor crane and the spreader bar, remove the engine from the stand.
  72. Install the flywheel or the flexplate and the bolts. 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 64: Flywheel Or Flexplate Bolts Tightening Sequence
      G01611694Courtesy of FORD MOTOR CO.

    73. Vehicles equipped with a manual transmission 

  73. Lubricate the transmission input shaft pilot bearing with front axle grease.
    Fig 65: Lubricating Transmission Input Shaft Pilot Bearing With Front Axle Grease
    G01611695Courtesy of FORD MOTOR CO.
  74. 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 66: Adjusting Clutch Pressure Plate
      G01611696Courtesy of FORD MOTOR CO.
  75. Using the special tool, position the clutch disc on the flywheel.
    Fig 67: Positioning Clutch Disc On Flywheel
    G01611697Courtesy of FORD MOTOR CO.
    76. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
  76. Position the clutch pressure plate and install the bolts. Tighten the bolts in a star pattern sequence.
    • Remove the Clutch Disc Aligner.
      Fig 68: Installing Clutch Pressure Plate
      G01611698Courtesy of FORD MOTOR CO.
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