Engine assembly (Power unit / Diesel engine 1.8 l / Ford Focus 1 1998-2004)

Special tool

	Universal Flange Holding Wrench 205-072 (15-030A)
	Bolt Tightening Angle Gauge 303-174 (21-540)
	Crankshaft Top Dead Center Pin 303-193 (21-104)
	Camshaft Seal Installer 303-199A (21-110A)
	Camshaft Alignment Plate 303-376 (21-162B)
	Flywheel Locking Tool 303-393 (21-168)
	Clamp removal/installation tool 303-397 (24-003)
	Booth 303-435 (21-187)
	Support bracket for 303-435 303-435-06 (21031B)
	Oil Pump Alignment Tool 303-652 (21-230)
	Clutch slave disc alignment tool 308-204 (16-067)
	Crankshaft Position Sensor Bracket Alignment Pin 310-057 (23-049)

General equipment:

Micrometer
Set of feeler gauges
Internal micrometer
Piston ring compressor
Dial indicator stand
Dial indicator
Plastigage Bearing Radial Clearance Gauge

Name	Specification
Sealant	WSE-M4G323-A4
Sealant	WSK-M2G348-A5
Motor oil 5W-30	WSS-M2C912-A1

All cars

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and with very small clearances. Therefore, it is especially important to maintain absolute cleanliness when working with these components. Always plug any open ports or lines.

1. Apply clean engine oil to the main journals, bearing shells and thrust washers.

2.

CAUTION: Install the upper and lower main bearing shells in the correct order.

Install the main bearing shells into the cylinder block and into the main bearing caps.

3. Install the crankshaft into the cylinder block.

4.

NOTE: The grooves in the thrust washers must face outward.

Install the crankshaft thrust washers into the third main bearing so that the oil grooves face outward.

5.

NOTE: Install the main bearing caps with the arrows facing forward. The caps are marked 1, 2, 3, 4, and 5, starting from the front and working toward the rear of the engine.

Install the crankshaft.

Tighten the bolts in the sequence shown in three stages.

Step 1: Tighten bolts 1 through 10 to 45 Nm.

Step 2: Tighten bolts 1 through 10 to 70 Nm.

Step 3: Turn bolts 1 through 10 60 degrees.

6. Apply clean engine oil to the working surfaces of the cylinders.

7.

NOTE: Install the pistons so that the arrows point toward the front of the engine.

NOTE: The joints of the piston rings and oil scraper ring elements must be evenly spaced around the circumference.

Using a suitable piston ring compressor, install the pistons. Install clean, dry connecting rod bearing shells into the connecting rods.

CAUTION: Connecting rod bearing cap bolts should only be used twice.

NOTE: Mark bolt heads with a punch to indicate reuse.

NOTE: The big end bearing cap markings must face toward the front of the engine.

Install the connecting rod bearing caps.

Tighten the bolts in three stages.
Step 1: Tighten the bolts finger tight.
Stage 2: 25 Nm
Stage 3: 65 Nm
After installation, apply engine oil to the journals.

NOTE: Install a new rear timing chain case gasket.

Install the rear timing chain housing.

10.

NOTE: Install a new ladder frame gasket.

Install the ladder frame (14 bolts).

Align the ladder frame flush with the cylinder block.
Tighten the bolts in the sequence shown.

Cars with air conditioning system

11. Install the air conditioning (A/C) compressor support bracket.

All cars

12.

Note: Install a new O-ring for the oil pump intake pipe.

Install the oil pump pickup tube.

13.

Note: Install new O - rings.

Install the oil pump connecting pipe.

14.

NOTE: Do not damage mating surfaces.

NOTE: There must be no sealant or oil residue on the mating surfaces or in the blind holes.

Clean the mating surfaces of the oil pan and ladder frame.

15.

CAUTION: Make sure that no sealant gets into the blind holes of the ladder frame. Failure to follow this instruction may result in engine damage.

NOTE: Install the oil pan within ten minutes after applying the sealant.

NOTE: Once the oil pan contacts the ladder frame, do not remove it.

Install the oil pan.

Apply a 2.5mm bead of sealant to the ladder frame (in a dashed line).
Tighten the bolts and nuts in the sequence shown.

16.

NOTE: Inspect the oil pan drain plug seal for damage. Install a new drain plug and seal if necessary.

Install the drain plug.

17.

NOTE: The new crankshaft rear oil seal retainer is supplied with a locating sleeve that must be removed during installation.

NOTE: Do not fully tighten the crankshaft rear oil seal retainer bolts at this stage.

Install the crankshaft rear oil seal retainer.

18. Tighten the crankshaft rear oil seal retainer bolts.

19. Remove the crankshaft rear oil seal retainer mounting sleeve.

20.

NOTE: Do not fully tighten the crankshaft position (CKP) sensor support bracket bolts at this stage.

Install the CKP sensor support bracket.

21.

NOTE: Install new flywheel bolts.

Using a special tool, install the flywheel.

Tighten the bolts in the sequence shown in three stages.
Stage 1: 18 Nm
Stage 2: 45 degrees
Stage 3: 45 degrees

22. Remove the special tool.

23. Using the special tool, center the clutch slave disc on the pressure plate.

24.

CAUTION: Tighten the clutch pressure plate mounting bolts finger tight and then to the specified torque, two turns at a time, working in the sequence shown.

Using the special tool, install the clutch slave and pressure plates. Remove the special tool.

25. Using the special tool, install the CKP sensor mounting bracket.

26. Install the coolant distribution pipe.

27. Using the special tool, connect the upper coolant hose to the coolant distribution line.

28.

NOTE: Install a new high pressure fuel pump gasket.

Install the high pressure fuel pump.

29. Install the high pressure fuel pump bracket.

30. Install the chain, sprockets and timing guides.

31.

NOTE: Do not tighten the high pressure fuel pump sprocket bolts at this stage.

Install the high pressure fuel pump sprocket.

32. Install the timing chain tensioner.

33. Using the special tool, install the timing chain housing cover.

34. Install the accessory drive belt pulley.

35. Using the special tool, install the crankshaft pulley.

Tighten the bolt, working in two stages.
Stage 1: 90 Nm
Stage 2: 90 degrees

36. Install the special tool. Remove the cylinder block plug.

37.

NOTE: The crankshaft must be turned in the normal direction of rotation.

Turn the crankshaft to the top dead center (TDC) position. Slowly turn the crankshaft until it stops.

38.

NOTE: Using a 6 mm drill bit, set the high pressure fuel pump to the top dead center position of the crankshaft.

Install the high pressure fuel pump sprocket.

39. Remove the special tool.

40.

NOTE: The crankshaft must be turned in the normal direction of rotation.

NOTE: Using a suitable marker, mark the crankshaft pulley to indicate top dead center.

Turn the crankshaft 90 degrees.

41.

NOTE: Install a new water pump gasket.

Install the water pump.

42. Using the special tool, install the water pump pulley.

43.

CAUTION: The thickness of the new cylinder head gasket must match the thickness of the "old" one (marked with holes/teeth).

NOTE: Marked "TOP/OBEN".

Install a new cylinder head gasket.

44.

NOTE: The turbocharger oil return hose must be connected with the cylinder head installed.

Install the cylinder head.

45.

CAUTION: Install new cylinder head bolts.

Install the cylinder head mounting bolts.

Using the special tool, tighten the bolts in four stages in the sequence shown.
Stage 1: Tighten bolts 1 through 10 to 20 Nm.
Step 2: Tighten bolts 1 through 10 to 54 Nm.
Step 3: Turn bolts 1 through 10 90 degrees.
Stage 4: Short bolts: 70 degrees, long bolts: 90 degrees.

46. Install the oil catch can.

47. Install the rear timing belt cover.

48.

NOTE: Install a new high pressure fuel pump oil seal retainer.

Install the high pressure fuel pump oil seal retainer.

49. Using sealant, seal the high-pressure fuel pump pulley to the fuel pump sprocket. Apply sealant to the outer edge of the high-pressure fuel pump pulley bolt holes.

50. Install the high pressure fuel pump pulley.

51.

NOTE: Do not fully tighten the camshaft pulley bolt at this stage.

Install the camshaft pulley mounting bolt.

52. Install the special tool.

53. Install the special tool.

54.

NOTE: The crankshaft must be turned in the normal direction of rotation.

Turn the crankshaft to the top dead center (TDC) position. Slowly turn the crankshaft until it stops.

55.

CAUTION: Do not turn the crankshaft while installing the special tool.

CAUTION: Before locking the special tool, make sure the crankshaft is at top dead center.

CAUTION: Make sure the special tool is installed correctly.

Using a special tool, lock the crankshaft in the required position.

56.

NOTE: Use only the latest timing belts. They are identified by the laser etched Ford logo.

Check the timing belt.

Engines with mechanical timing belt tensioner

57. Install the new automatic timing belt tensioner.

All cars

58. Check the timing belt tensioner.

1.Make sure the tensioner pointer turns freely clockwise.
2. The arrow shows the rotation of the tensioner counterclockwise.

59. Turn the timing belt tensioner adjustment lever clockwise to the 3 o'clock position.

60.

NOTE: Do not fully tighten the timing belt tensioner mounting bolt at this stage.

Install the timing belt tensioner.

61.

CAUTION: Never install a used timing belt.

CAUTION: Install the timing belt so that the arrows point in the direction of crankshaft rotation.

NOTE: Install a new timing belt.

Install the timing belt.

62.

NOTE: The camshaft pulley must be able to rotate freely on the camshaft taper.

Tighten the camshaft pulley bolt finger tight and then loosen it half a turn.

63.

NOTE: Using a socket wrench, maintain the timing belt tension until the timing belt tensioner bolt is tightened.

Tighten the timing belt.

1. Turn the timing belt tensioner adjusting lever counterclockwise to slightly tighten the timing belt.
2. The pointer should be located between the edges of the window.
3. Tighten the timing belt tensioner mounting bolt.

64. Using the special tool, tighten the camshaft pulley mounting bolt.

65. Remove the special tool.

66. Remove the special tool.

67. Remove the special tool.

68.

NOTE: The crankshaft must be turned in the normal direction of rotation.

Turn the crankshaft six revolutions.

69. Install the special tool.

70.

NOTE: The crankshaft must be turned in the normal direction of rotation.

Turn the crankshaft to the top dead center position. Slowly turn the crankshaft until it stops.

71.

CAUTION: Do not turn the crankshaft while installing the special tool.

CAUTION: Before locking the special tool, make sure the crankshaft is at top dead center.

CAUTION: Make sure the special tool is installed correctly.

Using a special tool, lock the crankshaft in the required position.

72.

CAUTION: If the pointer is not visible in the timing belt tensioner window, the timing belt tensioning procedure must be repeated.

Check if the timing belt tensioner pointer is in the window.

73.

CAUTION: If the special tool cannot be installed, the timing belt tensioning procedure must be repeated.

Install the special tool. If the special tool cannot be installed, the procedure should be repeated.

Cars with charge air cooler.

74. Install the front engine mount bracket.

75. Install the timing belt cover.

Cars without charge air cooler

76. Install the front engine mount bracket.

77. Install the lower timing belt cover.

All cars

78.

NOTE: Install a new valve cover gasket if necessary.

Install the valve cover.

1. Apply engine oil to the valve cover gasket before installing it.

79. Install the generator bracket.

80.

NOTE: Install a new oil cooler gasket.

Install the oil cooler.

81.

NOTE: Install a new oil filter.

Install the oil filter.

82.

Note: Install new O-rings for the turbocharger oil supply line.

Install the turbocharger oil supply line.

83.

Note: Install a new O-ring for the turbocharger oil supply line.

Connect the oil supply line to the turbocharger.

84. Install the generator and drive shaft.

85.

NOTE: Install new high pressure fuel supply lines.

Install high pressure fuel supply lines.

86.

NOTE: Connect the oil separator to the engine lifting eye. Tighten the engine lifting eye and then tighten the oil separator.

NOTE: Install the clamp at a 45 degree angle to horizontal.

Install the crankcase ventilation oil separator.

87. Fill the engine with engine oil.

88. Remove the special tool.

Engine assembly

Special tool

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