Fuel injection 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 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 (21-031B)
	Oil Pump Alignment Tool 303-652 (21-230)
	Crankshaft Alignment Tool 303-710 (21-257)
	Clutch slave disc alignment tool 308-204 (16-067)

General equipment:

Micrometer
Set of feeler gauges
Internal micrometer
Piston ring compressor
Dial indicator stand
Dial indicator
Radial clearance gauge for plain bearings "Plastigage"
Engine Vacuum Cleaner

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

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.

CAUTION: Do not disassemble fuel injectors or clean their nozzles, even using ultrasonic cleaning.

CAUTION: To prevent foreign material from entering the fuel injection system components, always clean them before performing any repairs to such components.

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

2. 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.

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.

Using a special tool, install the connecting rod bearing caps.

Tighten the bolts in three stages.
Step 1: Tighten the bolts finger tight.
Stage 2: 60 degrees
Stage 3: 20 degrees
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.

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

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: 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.

15. Tighten the crankshaft rear oil seal retainer bolts.

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

17. Using the special tool, install the crankshaft position (CKP) sensor support bracket.

18.

CAUTION: There must be no sealant residue in the blind holes of the ladder frame. Failure to follow this instruction may result in engine damage.

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.

19.

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 silicone sealant and caulk to the ladder frame (intermittently).
Tighten the bolts and nuts in the sequence shown.

20.

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

Install the drain plug.

21.

NOTE: Install new flywheel bolts.

NOTE: Do not fully tighten the flywheel bolts at this stage.

Install the dual flywheel.

22. Using the special tool, lock the dual flywheel in the required position.

23.

NOTE: Install new flywheel bolts.

NOTE: Do not fully tighten the flywheel bolts at this stage.

Using special tools, install the dual flywheel.

Tighten the bolts in two stages in the sequence shown.
Stage 1: 35 Nm
Stage 2: 45 degrees

24. Remove the special tools.

25. Inspect the dual mass flywheel. Refer to Section 303-00 for additional information.

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

27.

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 a special tool, install the clutch slave and pressure plates.

28.

NOTE: Install a new crankshaft position (CKP) sensor.

NOTE: The CKP sensor must be in contact with the flywheel.

Install the CKP sensor.

29. Install the fuel pump bracket.

30. Install the coolant distribution pipe.

31. Using the special tool, connect the upper coolant hose to the coolant distribution pipe.

32.

NOTE: Install a new fuel pump gasket.

Install the fuel pump.

33. Install the fuel pump bracket.

34. Install the chain, sprockets and timing guides.

35. Install the fuel pump sprocket.

36. Install the timing chain tensioner.

37.

NOTE: Install a new timing chain housing cover gasket.

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

38. Install the accessory drive belt pulley.

39.

NOTE: Install a new crankshaft pulley bolt.

Using a special tool, install the crankshaft pulley.

Tighten the bolt, working in two stages.
Stage 1: 110 Nm
Stage 2: 255 Nm

40.

NOTE: Install a new water pump gasket.

Install the water pump.

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

42. Install the front engine mount bracket.

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".

NOTE: Install a new cylinder head gasket.

Install the cylinder head gasket.

44.

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.

45. Install the oil catch can.

46. Install the rear timing belt cover.

47.

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

Install the high pressure fuel pump oil seal retainer.

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

49. Install the fuel pump pulley.

50.

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

Install the camshaft pulley mounting bolt.

51. Install the special tool.

52. Install the special tool. Remove the plug from the cylinder block.

53.

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

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

54.

CAUTION: Do not allow the engine to turn when installing the special tool.

CAUTION: Before installing the special tool, make sure the engine is at top dead center.

CAUTION: Make sure the special tool is installed correctly.

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

55.

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

Check the timing belt.

56. Check the timing belt tensioner.

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

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

58.

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

Install the timing belt tensioner.

59.

CAUTION: Never install a used timing belt.

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

NOTE: Install a new timing belt.

Install the timing belt.

60.

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.

61.

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.

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

1.Install the special tool.
2. Tighten the bolt.

63. Remove the special tool.

64. Raise and support the vehicle. Refer to Section 100-02 for additional information.

65. Remove the special tool.

66. Remove the special tool.

67.

NOTE: The engine should only be turned in the normal direction of crankshaft rotation.

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

Turn the engine over six revolutions.

68. Install the special tool.

69.

NOTE: The engine should only be turned in the normal direction of crankshaft rotation.

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

70.

CAUTION: Do not allow the engine to turn when installing the special tool.

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

CAUTION: Make sure the special tool is installed correctly.

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

71. Lower the car.

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.

74.

NOTE: If necessary, install a new cylinder head cover gasket.

Install the cylinder head cover.

75. Install the timing belt cover.

76. Install the fuel rail support bracket.

77.

NOTE: Do not tighten the fuel rail mounting bolts at this stage.

Install the fuel manifold.

78.

NOTE: Install new high pressure fuel supply lines.

Lubricate the high pressure fuel supply line connection threads with clean ISO 4113 grease supplied in the high pressure fuel supply line replacement parts kit.

79.

CAUTION: Do not allow the mating ends of the high pressure fuel supply line nipple joint to collide, as this may cause damage to the fuel line and foreign material to enter the fuel injection system.

CAUTION: Remove the plugs from the high-pressure fuel supply line, fuel injector and fuel rail as late as possible. Failure to do so may result in dirt entering the fuel injection system.

NOTE: To facilitate identification of the high pressure fuel supply lines, the connections on the fuel injector side are engraved with the cylinder number.

NOTE: Do not tighten the high pressure fuel supply line nipple connections at this stage.

NOTE: Apply pressure to the high pressure fuel supply line to keep the nipple in contact with the cone of the fuel rail when connecting the nipple.

Connect the high pressure fuel supply lines to the fuel injectors. Discard the plugs as they are no longer needed.

80.

CAUTION: Do not strike the sealing surfaces of the high-pressure fuel supply line nipple connections, as this may damage the fuel line ends and allow foreign material to enter the fuel injection system.

CAUTION: Remove the plugs from the high-pressure fuel supply line, fuel injector and fuel rail as late as possible. Failure to do so may result in dirt entering the fuel injection system.

NOTE: Do not tighten the high pressure fuel supply line nipple connections at this stage.

NOTE: Apply pressure to the high pressure fuel supply line to keep the nipple in contact with the cone of the fuel rail when connecting the nipple.

Connect the fuel supply lines of cylinders No.1 and 4 to the fuel manifold. Discard the plugs as they are no longer needed.

81.

NOTE: Ensure that the clamp is installed in the same position as it was before removal.

Install the clamp on the high pressure fuel supply line.

82.

NOTE: Install a new high pressure fuel supply line nipple.

Lubricate the high pressure fuel supply line connection threads with clean ISO 4113 grease supplied in the high pressure fuel supply line replacement parts kit.

83.

CAUTION: Do not strike the sealing surfaces of the high-pressure fuel supply line nipple connections, as this may damage the fuel line ends and allow foreign material to enter the fuel injection system.

CAUTION: Remove the plugs from the high-pressure fuel supply line, fuel injector and fuel rail as late as possible. Failure to do so may result in dirt entering the fuel injection system.

NOTE: Do not tighten the high pressure fuel supply line nipple connection at this stage.

NOTE: Apply pressure to the high pressure fuel supply line to keep the nipple in contact with the cone of the fuel pump and fuel rail when connecting the nipple connections.

Install the high pressure fuel supply line.

1.Connect the high pressure fuel supply line to the fuel rail.
2.Connect the high pressure fuel supply line to the fuel pump.
Discard the plugs as they are no longer needed.

84.

CAUTION: Do not allow the mating ends of the high pressure fuel supply line nipple joint to collide, as this may cause damage to the fuel line and foreign material to enter the fuel injection system.

CAUTION: Remove the plugs from the high-pressure fuel supply line, fuel injector and fuel rail as late as possible. Failure to do so may result in dirt entering the fuel injection system.

NOTE: To facilitate identification of the high pressure fuel supply lines, the connections on the fuel injector side are engraved with the cylinder number.

NOTE: Do not tighten the high pressure fuel supply line nipple connections at this stage.

NOTE: Apply pressure to the high pressure fuel supply line to keep the nipple in contact with the fuel injector cones when connecting the nipple fittings.

Connect the high pressure fuel supply lines to the fuel injectors.

85.

CAUTION: Do not strike the sealing surfaces of the high-pressure fuel supply line nipple connections, as this may damage the ends of the fuel lines and allow foreign material to enter the fuel injection system.

CAUTION: Remove the plugs from the high-pressure fuel supply line, fuel injector and fuel rail as late as possible. Failure to do so may result in dirt entering the fuel injection system.

NOTE: Do not tighten the high pressure fuel supply line nipple connections at this stage.

NOTE: Apply pressure to the high pressure fuel supply line to keep the nipple in contact with the fuel rail cone when connecting the nipple connections.

Connect the high-pressure fuel supply lines of cylinders No.2 and 3 to the fuel manifold. Discard the plugs as they are no longer needed.

86. Connect the fuel injector return line to the fuel injectors.

87.

NOTE: Do not tighten the high pressure fuel supply line clamps at this stage.

NOTE: The clamps should be installed in the same position from which they were removed.

Install the high pressure fuel supply line clamps.

88.

NOTE: Do not fully tighten the high pressure fuel supply line clamp retaining nut at this stage.

Install the high pressure fuel supply line clamp retaining nut.

89. Tighten the fuel manifold mounting bolts.

90.

CAUTION: The high pressure fuel line nipple tightening tool should be positioned on the top of the nipple joint as this is where most of the material is. Failure to follow this instruction may result in damage to the nipple joint.

Tighten the nipple connections of the fuel supply lines of cylinders No.1 and 4 on the fuel injectors.

91.

CAUTION: The high pressure fuel line nipple tightening tool should be positioned on the top of the nipple joint as this is where most of the material is. Failure to follow this instruction may result in damage to the nipple joint.

Tighten the nipple connections of the fuel supply lines of cylinders No.1 and No.4 on the fuel manifold.

92.

CAUTION: The high pressure fuel line nipple tightening tool should be positioned on the top of the nipple joint as this is where most of the material is. Failure to follow this instruction may result in damage to the nipple joint.

Tighten the nipple connections of the high-pressure fuel supply lines.

93.

CAUTION: The high pressure fuel line nipple tightening tool should be positioned on the top of the nipple joint as this is where most of the material is. Failure to follow this instruction may result in damage to the nipple joint.

Tighten the nipple connections of the fuel supply lines of cylinders No.2 and No.3 to the fuel injectors.

94.

CAUTION: The high pressure fuel line nipple tightening tool should be positioned on the top of the nipple joint as this is where most of the material is. Failure to follow this instruction may result in damage to the nipple joint.

Tighten the nipple connections of the fuel supply lines of cylinders No.2 and No.3 on the fuel manifold.