Duratec 8V 1.6L Engine Assembly (Power unit / Engine Duratec 8V 1.6 l / Ford Focus 1 1998-2004)

Special tool

	Universal Flange Holding Wrench 205-072 (15-030A)
	Engine lift bracket 303-122 (21-068A)
	Socket wrench for cylinder head bolts 303-392 (21-167)
	Booth 303-435 (21-187)
	Support bracket for 303-435 303-435-06 (21-031B)
	Support plate for 303-435-06 303-435-11 (21-146C)

General equipment:

Piston ring compressor
Steel ruler
Fixing clamps

Name	Specification
Motor oil	WSS-M2C912-A1
Sealant	WSEM-4G323-A
Sealant	WSK-M2G349-A4

1. Install the crankshaft main bearing shells.

NOTE: Bearing cap numbering starts from the front of the engine, which is also where the arrows point.

Install the crankshaft.

Apply clean engine oil to the main journals and bearing shells.
Make sure piston #1 is at top dead center (TDC).

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

Install the crankshaft thrust washers.

NOTE: Connecting rod numbers start from the front of the engine. The arrow on the piston crown points toward the front of the engine.

Using a suitable piston ring compressor, install the pistons.

Apply clean motor oil to the pistons and cylinder liners.
Distribute the piston ring joints evenly around the circumference. This also applies to the oil scraper ring elements.
Using a hammer handle, insert pistons No.1 and No.4 into the cylinders. The crankpin should be at bottom dead center (BDC).
Make sure the bearing shells are clean and dry and install them into the appropriate connecting rods and bearing caps.
Turn the crankshaft 180 degrees and install pistons No.2 and 3.

CAUTION: Install new connecting rod mounting bolts.

NOTE: Connecting rods and connecting rod bearing caps have the same numbering.

Install the bearing caps.

Apply clean motor oil to the bearing shells and journals.
Tighten the bearing cap bolts in two stages.
Stage 1: 4 Nm
Stage 2: 90 degrees

6. Install the oil pan deflector.

7. Install the timing chain guide, timing chain tensioner arm and crankshaft sprocket.

NOTE: The mark on the crankshaft sprocket and the single colored link on the timing chain must be aligned opposite each other.

Install the timing chain.

CAUTION: Install the oil pump only with the crankshaft pulley.

CAUTION: When installing a new oil pump, do not remove the crankshaft pulley or clamp before installation.

NOTE: Install a new oil pump gasket.

NOTE: The new oil pump is supplied complete with the crankshaft front oil seal and crankshaft pulley.

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

Install the oil pump assembly.

10. Using the special tool, tighten the crankshaft pulley bolt. Remove the assembly clamp.

11.

NOTE: The oil pump sealing flange must be located within ±0.20 mm of the lower sealing flanges of the cylinder block.

Using a suitable ruler, align the oil pump and cylinder block sealing flanges.

12.

NOTE: Install new sealed bolts in positions 1 and 3.

Tighten the oil pump mounting bolts. Tighten the bolts in the sequence shown.

13.

NOTE: Make sure the O-ring is installed correctly.

Install the oil pickup tube.

14.

CAUTION: Do not remove the mounting sleeve before installation.

NOTE: Install a new crankshaft rear oil seal retainer.

NOTE: The new rear oil seal retainer is supplied assembled on the mounting sleeve.

NOTE: Do not touch the dust collection tab and sealing tab.

NOTE: The sealing lip must not be coated with oil.

NOTE: Make sure the locating pins are installed correctly.

Install the crankshaft rear seal retainer.

15.

CAUTION: Install the oil pan gasket within five minutes of applying the sealant.

Apply sealant to the joints of the cylinder block.

16.

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

Using a suitable ruler, align the oil pan with the cylinder block.

Maximum "retreat" of the oil pan: 0.25 mm.
Maximum oil pan protrusion: 0.10 mm.

17. Tighten the oil pan mounting bolts in the sequence shown (Stage 1).

18. Tighten the oil pan mounting bolts in the sequence shown (Stage 2).

19. Install the adapter plate.

20. Install the flywheel.

21. Install the water pump.

22. Install the water pump pulley.

23.

NOTE: Install a new cylinder head gasket.

NOTE: Install new cylinder head bolts.

NOTE: Route the timing chain through the cylinder head and tie it to the cylinder head.

Using a special tool, install the cylinder head.

Tighten the cylinder head bolts in the sequence shown in four stages.
Stage 1: Tighten bolts 1 through 10 to 40 Nm.
Step 2: Tighten the front two bolts (M8) to 15 Nm.
Step 3: Tighten the front two bolts (M8) 45 degrees.
Step 4: Turn bolts 1 through 10 120 degrees.

24.

NOTE: The camshaft sprocket timing mark must be at the 12 o'clock position.

NOTE: The camshaft sprocket timing mark and the marked timing chain links must be aligned with each other.

Place the timing chain on the camshaft sprocket. The timing mark on the camshaft sprocket should be at the 12 o'clock position when cylinder #1 is at TDC.