Engine assembly (Focus 1)

Special tool

	Universal Flange Holding Wrench 205-072 (15030A)
	Protractor 303-174 (21540)
	Flywheel Locking Tool 303-204 (21168)
	Camshaft Alignment Tool 303-376 (21-162B)
	Socket wrench for cylinder head bolts 303-392 (21167)
	Crankshaft Oil Seal Installation Tool 303-395 (21171)
	Assembly stands 303-435 (21187)
	Support bracket for 303-435 303-435-06 (21031B)
	Support plate for 303-435-06 303-435-14 (21212)
	Spark Plug Wrench 303-499 (21202)
	Crankshaft Top Dead Center Pin 303-507 (21210)
	Spark Plug Pliers 303-622 (21226)
	Clutch slave disc alignment tool 308-204 (16067)

General equipment:

Studs, M8x20
Steel ruler
Repair zone crane

Name	Specification
Motor oil	WSS-M2C912-A1
Sealant for camshaft bearing caps	WSK-M2G348-A2
Sealant for joints of sealing surfaces of cylinder block, rear oil seal of crankshaft, oil pan	WSE-M4G323-A4
Oil Pressure Switch Thread Sealant	WDK-M2G349-A7
Lubrication (spark plug threads - Never Seeze)	ESE-M1244-A
Silicone grease	ESE-M1C171-AA

Assembly

All cars

1.

CAUTION: Crank mechanism components, pistons and cylinder liners cannot be replaced individually. For additional information, refer to the Description and Function chapter in this section.

Preparatory operations:

Before installation, apply engine oil to the threads and mating surfaces of all bolts and washers.
All mating surfaces and reusable components should be thoroughly cleaned and inspected for damage.

2. Secure the cylinder block with the crank mechanism (incomplete block) on the assembly stand. Use special tools 303-435-14 and 303-435-06.

3.

NOTE: Adjust the fit of the oil seal housing.

Attach the new rear oil seal housing with the seal and install the crankshaft position sensor (CKP) support.

4. Install the CKP sensor.

Cars with manual transmission.

5.

NOTE: Observe the tightening sequence and position of the flywheel dowel pin.

Install the flywheel.

Attach the flywheel, lock it from turning with a special tool and tighten the nuts, working in two stages according to the prescribed tightening sequence.
Stage 1: 30 Nm
Stage 2 using special tool 303-174: 80 degrees

Stage 2 using special tool 303-174: 80 degrees

Remove the engine speed limiter center bolt (right front axle shaft).

NOTE: Observe the tightening sequence and position of the drive disc dowel pin.

Install the drive disk.

Install the drive disc, lock it with the special tool and tighten it, working in two stages in the specified tightening sequence.
Stage 1: 30 Nm
Stage 2 using special tool 303-174: 80 degrees

All cars

7.

NOTE: Align the oil pump drive shaft with the crankshaft.

Connect the oil pump and oil inlet pipe together with a new gasket.

NOTE: Lubricate the oil seal lip and crankshaft journal with engine oil.

Install the front crankshaft oil seal. Use the special tool.

Cars manufactured up to 11.1999.

NOTE: Apply sealant 10 mm beyond the joints of the mating surfaces.

Apply sealant to the cylinder block mating surface and the crankshaft rear oil seal housing mating surface.

10. Check the position of the oil pan.

Install the oil pan with a new gasket and hand tighten the bolts.
Using a steel straightedge, align the oil pan so that the cylinder block is flush with the flywheel side of the oil pan.

Using a steel straightedge, align the oil pan so that the cylinder block is flush with the flywheel…

Cars manufactured since 12.1999.

11.

CAUTION: Use studs. If sealant gets into blind holes, the engine crankcase may be damaged.

Install five studs (M8x20) into the indicated blind holes.

12.

NOTE: The oil pan must be connected within ten minutes after applying the sealant.

Apply a 3mm wide bead of sealant to the oil pan flange.

13.

NOTE: Tightening sequence.

Tighten the oil pan bolts, working in two stages.

Stage 1: 10 Nm
Stage 2: 20 Nm
Turn out the pins.

Cars manufactured up to 11.1999.

14.

NOTE: Tightening sequence.

Tighten the oil pan bolts.

Cars with manual transmission

15. Install the clutch.

Center the clutch pressure plate on the driven disc. Use a special tool.
Tighten the six bolts evenly, working in a crisscross pattern.
Remove the special tool.

All cars

16.

CAUTION: The knock sensor (KS) wire must not touch the cylinder head or the crankcase ventilation hose (approximately 10/11 o'clock position).

Connect the crankcase ventilation hose and the knock sensor.

17.

CAUTION: Check thermostat and replace if necessary. Refer to Section 303-03 for additional information.

NOTE: The thermostat oil seal should only be replaced if necessary.

NOTE: Apply sealant to the oil pressure switch threads.

Connect the thermostat housing with a new gasket and the oil pressure switch.

1. Thermostat housing with new gasket
2. Oil pressure relay

18.

CAUTION: Do not damage the coolant pump impeller.

Install the coolant pump. Use a new gasket.

19.

NOTE: Tightening sequence.

NOTE: The cylinder head is installed on two guide bushings.

NOTE: Removed cylinder head bolts can be reused.

Install the cylinder head.

Make sure all mating surfaces are clean.
Install a new cylinder head gasket.
Align the cylinder head and tighten the bolts, working in three stages in the sequence shown.
Stage 1: 15 Nm
Stage 2: 30 Nm
Stage 3 using special tool 303-174: 90 degrees

Stage 3 using special tool 303-174: 90 degrees

20. Install the three lower intake manifold bolts and connect the oil level dipstick tube. Secure the knock sensor (KS) connector to the oil level dipstick tube.

21. Connect the PCV hose.

22.

NOTE: Install the valve lifters and shims in the correct sequence.

Install the valve lifters. If necessary, use suitable shims to adjust the valves.

23. Move the piston of cylinder No.1 to a position approximately 25 mm before top dead center. The flywheel should be in the position shown.

24.

NOTE: Identification numbers are located on the outside surface of the camshaft bearing caps.

Apply sealant to the indicated locations on the camshaft bearing cap No.1 and to the mating surface of the cylinder head.

25.

CAUTION: Install the camshafts so that neither cam lobe is in the full lift position.

NOTE: The exhaust camshaft has an additional cam for the camshaft position (CMP) sensor.

Install the camshafts. Apply engine oil to the camshafts and camshaft bearings before installation.

26.

NOTE: Identification of the camshaft bearing caps begins near the timing belt with the marking E1 on the exhaust side and I1 on the intake side.

NOTE: Tightening sequence.

Install the camshaft bearing caps and tighten the bolts, working in three stages.

Stage 1: Tighten each bolt one half turn until the camshaft bearing cap contacts the cylinder head.
Stage 2: 7 Nm
Stage 3: 45 degrees

27. Install a new camshaft oil seal. Lubricate the camshaft journals and the sealing lip of the oil seal using engine oil.

28. Install the inner timing belt cover.

29. Install the camshaft pulleys so that they can turn.

30. Turn the camshafts to the top dead center position for cylinder No.1. Turn the camshafts with a 21 mm open-end wrench until the special tool can be inserted.

30. Turn the camshafts to the top dead center position for cylinder No.1. Turn the camshafts with a…

31.

NOTE: If the special tool cannot be inserted, turn the crankshaft back approximately 20 degrees in a counterclockwise direction.

Turn the crankshaft to top dead center for cylinder #1.

Remove the plug from the alignment pin installation hole and screw in the special tool.
Carefully turn the crankshaft clockwise until it rests against the special tool.

Carefully turn the crankshaft clockwise until it rests against the special tool.

32. Install the pulley on the crankshaft.

33. Install the timing belt. Install the timing belt in place, starting at the crankshaft pulley and working counterclockwise.

34. Connect the lower timing belt cover.

34. Connect the lower timing belt cover.

35.

NOTE: For more information, refer to the Description and Operation chapter in this section.

Install the crankshaft pulley/damper. Use a new bolt.

1. Connect the special tool using two bolts (M10x40 and M10x45) and corresponding nuts.
2.Tighten the bolt, working in two stages.
Stage 1: 40 Nm
Stage 2 using special tool 303-174: 90 degrees

Stage 2 using special tool 303-174: 90 degrees

Timing Belt Tensioner with Eccentric

36. Install the timing belt tensioner.

37.

NOTE: Do not turn the eccentric when tightening. Hold it using a socket wrench.

Tighten the timing belt.

Using a 6mm Allen key, turn the eccentric counterclockwise until the arrow is aligned exactly with the middle of the square cutout.
Tighten the bolt.

Timing Belt Tensioner with Groove

38. Install the timing belt and tighten it.

Insert the bolts and hand tighten them.
Using a socket wrench, turn the tensioner so that the arrow is precisely aligned with the center of the rectangular hole.
Tighten the bolts.

All cars

39.

CAUTION: Do not tighten the camshaft pulley while holding the camshaft from turning with Special Tool 303-376.

NOTE: Do not rotate the crankshaft or camshafts.

Tighten the bolts on the camshaft pulleys.

40. Unscrew the special tool and remove the special tool 303-376.

41.

NOTE: If special tool 303-507 cannot be installed, turn the crankshaft approximately 20 degrees in a counterclockwise direction.

Check the valve timing.

Turn the crankshaft two revolutions clockwise and bring it to the top dead center position.
Screw in special tool 303-507.
Carefully turn the crankshaft clockwise until it rests against the special tool.
Use special tool 303-376 to check the top dead center position.
Remove special tools 303-376 and 303-507.

Remove special tools 303-376 and 303-507.

42.

NOTE: Only if special tool 303-376 cannot be inserted.

Adjust the valve timing.

Loosen the pulley on the problematic camshaft using special tool 205-072 to prevent it from turning.
Turn the camshaft by the hexagon using a 21 mm open-end wrench until special tool 303-507 can be inserted.
Tighten the pulley on the camshaft; the crankshaft must remain at top dead center.
Remove special tool 303-376 and unscrew special tool 303-507.
Check the valve timing again as described earlier.

Check the valve timing again as described earlier.

43. Screw the plug into the hole for the alignment pin.

44. Adjust the valve clearances. For more information, refer to the Valve Clearances chapter in this section.

45. Connect the engine mount bracket.

46. Apply grease to the spark plug threads and install them using a special tool.

47.

CAUTION: When installing a new cylinder head, check the cylinder head cover for damage and install a new cover if necessary.

CAUTION: To avoid damaging the spark plug connector seal, use a blunt object (such as a plastic zip tie) to apply silicone grease.

CAUTION: Connect the spark plug connector by applying a straight force to it.

NOTE: Coat the inside of the spark plug connector with silicone grease to a depth of (5-10) mm.

Install the cylinder head cover.

1. Tighten the cylinder head cover bolts in two stages. Stage 1: 3 Nm. Stage 2: 10 Nm.
2. Connect the plug connector of the cylinder head temperature sensor (CHT).
3. Connect the spark plug connector.
4. Install the high voltage wire clamp.