Engine assembly (Power unit / Engine Duratec ST 2.0 l / Ford Focus 1 1998-2004)

Special tool

	Crankshaft Rear Oil Seal Installer 303-291 (21-141)
	Template for setting the distribution of moments, Alignment of the camshaft 303-376 (21-162V)
	Pin for setting the distribution of moments, TDC of the crankshaft 303-574 (21-163)
	Tool for installing oil seal of timing cover 303-039 (21-009B)
	Flywheel Locking Tool 303-254 (21-135)

General equipment: Steel ruler.

Name	Specification
Sealant	WSK-M4G320-A
Sealant	WSK-M2G348-A5
Sealant	WSS-M4G323-A7
Motor oil	WSS-M2C912-A1
Silicone grease	A960-M1C171-AA

NOTE: Install a new crankshaft rear oil seal retainer gasket.

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

Install the rear oil seal retainer.

2. Install the crankshaft position sensor (CSP) and mounting bracket.

CAUTION: The oil seal must be fully inserted into the special tool.

Insert the new crankshaft rear oil seal into the special tool.

To ensure proper installation, clamp the special tool in a vice and insert the oil seal using the handle of a hammer during installation.
1.Incorrect installation
2. Correct installation

NOTE: Install a new crankshaft rear oil seal.

Using the special tool and two old flywheel bolts, install the crankshaft rear oil seal.

5. Adjust the position of the crankshaft rear oil seal holder so that the sealing surface of the oil seal holder is located 0.3 mm - 0.8 mm below the cylinder block, and tighten the mounting bolts.

6. Remove the special tool.

NOTE: Install a new oil pump gasket.

NOTE: Do not fully tighten the oil pump mounting bolts at this stage.

Install the oil pump.

8. Adjust the position of the oil pump on both sides so that the mating surface is located at a distance of 0.3 mm - 0.8 mm above the lower edge of the cylinder block.

9. Tighten the oil pump mounting bolts.

10.

NOTE: The lower crankcase fastener must be tightened to the specified torque within 10 minutes of applying the sealant.

NOTE: If the allowable protrusion or clearance dimensions are exceeded, install shims as described below.

Check the position of the lower section of the crankcase.

Using a steel ruler, adjust the position of the lower crankcase section so that the cylinder block and the lower crankcase section are flush, or do not exceed a protrusion of 0.10 mm or a gap of 0.25 mm.
Apply sealant to the joints between the cylinder block and the oil pump holder.
Install the lower crankcase section with a new gasket and tighten the bolts finger tight.

11. If necessary, install the lower crankcase adjusting shims.

if there is a gap of 0.26 - 0.50 mm, install a 0.25 mm adjusting shim.
if there is a gap of 0.51 - 0.75 mm, install a 0.50 mm adjusting shim.

12.

NOTE: Install a new oil pump pickup tube gasket.

Install the lower crankcase section.

1. Tighten the bolts and check the alignment as described in the previous paragraph. Correct it if necessary.
2. Install the oil pump intake pipe.

13.

CAUTION: If sealant gets into blind holes, it may damage the lower section of the crankcase.

Install ten M6 x 20mm studs into the blind holes as shown.

14.

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

Apply a 3mm thick bead of sealant to the mating surface of the oil pan.

15.

NOTE: Once the lower crankcase section has made contact with the housing, the oil pan must not be removed.

Install the oil pan.

Remove the pins.
Install and tighten the bolts in the sequence shown, working in two stages.
Stage 1: 6 Nm
2nd stage: 10 Nm

16.

NOTE: Install new flywheel mounting bolts.

NOTE: Remove any remaining thread locking compound from the threaded holes.

Using a special tool, install the flywheel.

17. Install the clutch slave plate and pressure plate. For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.

18.

NOTE: Install a new cylinder head gasket.

NOTE: Install the cylinder head bolts without oil.

NOTE: Tighten the cylinder head bolts in three stages, working in the sequence shown.

Install the cylinder head.

1st stage: 20 Nm
2nd stage: 40 Nm
Stage 1: 90 degrees

19. Lubricate the valve lifters with engine oil and install them in the correct order.

20. Rotate the crankshaft to approximately 60 degrees BTDC.

21. Set the camshafts so that none of the cam lobes are in the full lift position.

22. Apply engine oil to the camshafts and camshaft bearing caps and install them in place.

23.

NOTE: Working in stages, tighten the camshaft bearing cap bolts evenly in the sequence shown, tightening the bolts 1/2 turn at a time.

Install the camshafts. Tighten the bolts in the sequence shown.

24.

NOTE: Install a new oil feed flange oil seal.

Apply sealant to the marked areas on the oil supply flange.

25. Install the oil supply flange.

26. Install the exhaust camshaft oil seal.

Lubricate the camshaft and the sealing lip of the oil seal with engine oil.
Install new oil seals using a special tool, washer and M10x70 bolt.

27. Turn the crankshaft to the top dead center position for cylinder No.1.

28.

NOTE: Cylinders #1 and #4 are at top dead center with the woodruff key facing the piston.

Remove the plug and use a special tool to align the crankshaft position at top dead center.

29. Turn the camshafts to the ignition point on cylinder No.1 and insert the special tool into the camshafts.

30.

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

Install the camshaft pulleys.

31. Install the new water pump gasket by bending the tabs.

1. Install the gasket in place.
2. Fix the gasket by bending the tabs.

32.

CAUTION: Do not bend the timing belt (do not bend the timing belt more than 35 mm in diameter).

CAUTION: Do not turn the crankshaft, make sure it is still positioned against the timing pin.

NOTE: When installing the timing belt, do not allow the protrusion on the timing belt tensioner to enter the sheet metal cover.

Position the new timing belt.

1. Install the crankshaft pulley together with the thrust washer onto the crankshaft.
2.Install the water pump.
3. Install the upper idler pulley.
4.Starting at the crankshaft timing belt pulley and working in a counterclockwise direction, position the timing belt, keeping the belt taut.
5. Secure the timing belt tensioner and tighten the bolt five turns.

33.

CAUTION: Incorrect timing belt tension will result in incorrect valve actuation timing.

Pre-tighten the timing belt.

1. Turn the tensioner installation tab counterclockwise and insert the installation tab into the slot in the rear timing cover.
2. Position the hex keyway in the tensioner adjusting washer at the 4 o'clock position.
3. Using a 6mm Allen key, tighten the bolt just enough to seat the tensioner firmly on the rear timing cover, but still allow the tensioner adjusting washer to rotate.

34.

CAUTION: Tighten the timing chain by turning it counterclockwise.

Using the Allen key, turn the adjusting washer counterclockwise until the notch in the arrow is centered over the reference line on the setting tab (the arrow moves clockwise as you adjust).

35. While holding the adjusting washer in position, tighten the bolt.

36.

NOTE: Hold the camshafts with an open-end hex wrench to prevent them from turning.

Tighten the camshaft pulley mounting bolts.

37.

NOTE: Hold the camshaft with an open-end hex wrench to prevent it from turning.

Install the intake camshaft pulley plug.

38. Remove the special tool.

39. Remove the special tool.

40.

NOTE: Rotate the engine two revolutions in the direction of normal crankshaft rotation.

Check the valve timing by installing special tools and adjust the alignment if necessary.

Screw in special tool 303-574 and make sure that the crankshaft rests on the special tool.
Insert special tool 303-376 into the camshafts. If necessary, release the timing pulleys and correct the camshaft alignment.
Remove special tools.

41. Install the plug.

42. Install the valve cover.

43.

CAUTION: Use a blunt object (plastic tie) to apply silicone grease to avoid damaging the spark plug electrical connectors.

CAUTION: Press down on the spark plug electrical connectors while keeping them in line with the spark plugs.

NOTE: Apply silicone grease to the inside surface of the spark plug electrical connectors to a depth of 5 - 10 mm.

Connect the spark plug electrical connectors. Press the spark plug electrical connectors until they click into place.

44.

NOTE: Check the installation of the gasket on the top cover and adjust the gasket position if necessary.

Install the timing belt covers and pulleys.

1. Bottom cover
2. Crankshaft pulley
3.Top cover
4.Front engine support bracket.
5. Intermediate pulley of the drive belt
6.Water pump pulley

45. Connect the positive crankcase ventilation hose. Use a new seal.

1. Three bolts
2.One bolt

46. Connect the auxiliary elements located on the outlet side.

1.Air conditioning compressor bracket.
2.Power steering pump bracket.
3. Bracket for connecting the power steering pump to the cylinder block.

47. Install the oil cooler.

48. Secure the engine to the engine lifting eyes on the hoist and remove it from the assembly stand. Lower the engine onto the assembly stand and leave it secured to the hoist.

49.

NOTE: Coat the oil filter seal with engine oil.

Connect the auxiliary elements located on the inlet side.

1. Oil pressure relay
2. Knock sensor (KS)
3.Install a new oil filter.
4. Generator bracket, fixed to the cylinder block
5. Generator bracket, fixed to the cylinder head

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

51. Install the generator.

1. Tighten the bolt.
2. Tighten the bolt.
3.Connect the positive wire.

52. Connect the electrical connectors of the oil pressure switch and the KS sensor.

Engine assembly

Special tool

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