Engine -- 2.0L Spi: Component Locations Ford Focus I рестайлинг

Special Tool(s)

SPECIAL TOOL SPECIFICATIONS Remover/Installer, Hose Clamp 412-108 (T96P-18539-A)

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1. Release the fuel pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-207778) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791)
3. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
4. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-207748) .
5. Detach the intake manifold bracket. Loosen the nuts and remove the bolts.
6. Lower the vehicle.
7. Remove the air cleaner housing. Disconnect the mass air flow (MAF) sensor electrical connector. Disconnect the air cleaner outlet hose. Remove the air cleaner housing from the rubber bushing.
8. Disconnect the accelerator cable. Unhook the cable. Remove the plastic clip and position the accelerator cable to one side.
9. Disconnect the speed control cable. Unhook the cable. Remove the plastic clip and position the speed control cable to one side.
10. Disconnect the positive crankcase ventilation hoses.
11. Disconnect the vacuum hoses. EVAP solenoid valve. Brake booster. Delta pressure feedback electronic (DPFE) system sensor. Exhaust gas recirculation (EGR) valve.
12. Disconnect the EGR valve. Discard the gasket.
13. Disconnect the coolant hoses from the intake manifold.
14. Remove the vacuum hose assembly.
15. Disconnect the throttle position (TP) sensor and the idle air control (IAC) valve.
16. Remove the bolt and bracket from the oil level indicator tube.
17. Remove the intake manifold upper support bracket.
18. Disconnect the fuel injector electrical connectors.
19. Disconnect the electrical connectors. Intake manifold runner control (IMRC). Camshaft position (CMP) sensor. Ignition Coil.
20. Disconnect the fuel lines from the fuel rail. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-207778) .
21. Remove the intake manifold retainers and position the manifold to the rear of the engine compartment (shown with engine removed).
22. Remove the IMRC manifolds (shown with engine removed). Remove the two studs first. Discard the gaskets.
23. Remove the intake manifold from the engine compartment.

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1. Position the intake manifold to the rear of the engine compartment (shown with engine removed).
2. Install the IMRC manifolds and the two studs (shown with engine removed). Tighten the studs in two stages. Stage 1: 10 Nm. Stage 2: 90 degrees.
3. Install the intake manifold and retainers (shown with engine removed). Tighten the nuts and bolts in two stages Stage 1: 10 Nm. Stage 2: 90 degrees.
4. Connect the fuel lines to the fuel rail. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-207778) .
5. Connect the electrical connectors. Ignition coil. CMP sensor. IMRC.
6. Connect the fuel injector electrical connectors.
7. Install the intake manifold upper support bracket.
8. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
9. Attach the intake manifold bracket. Install the bolts and tighten the nuts.
10. Lower the vehicle.
11. Install the bracket and bolt to the oil level indicator tube.
12. Connect the TP sensor and the IAC valve.
13. Connect the coolant hoses to the intake manifold. Remove the clamps.
14. Install the vacuum hose assembly.
15. Connect the EGR valve. Install a new gasket.
16. Connect the vacuum hoses. EVAP solenoid valve. Brake booster. DPFE system sensor. EGR valve.
17. Connect the positive crankcase ventilation hoses. Make sure the twist-lock positive crankcase ventilation valve is secure.
18. Connect the speed control cable. Connect the cable. Position the speed control cable and install the plastic clip.
19. Connect the accelerator cable. Connect the cable. Position the accelerator cable and install the plastic clip.
20. Install the air cleaner housing. Connect the MAF sensor electrical connector. Connect the air cleaner outlet hose. Install the air cleaner housing into the rubber bushing.
21. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-207748) .
22. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .

SPECIAL TOOL SPECIFICATIONS Oil Pump Seal Replacer 303-164 (T81P-6700-A) Seal Remover 303-409 (T92C-6700-CH) Lifting Bracket, Engine 303-050 (T70P-6000) Support Bar, Engine 303-290A Adaptor for 303-290A 303-290-01 Adaptor for 303-290A 303-290-03A Adaptor for 303-290A 303-290-02

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SPECIAL TOOL SPECIFICATIONS Valve Spring Compressor 303-163 (T81P-6513-A)

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SPECIAL TOOL SPECIFICATIONS Lifting Bracket, Engine 303-050 (T70P-6000) Support Bar, Engine 303-290A Adapter for 303-290A 303-290-03A Adapter for 303-290A 303-290-03A Adapter for 303-290A 303-290-02

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SPECIAL TOOL SPECIFICATIONS Wrench, Pulley, Camshaft 303-098 (T74P-6256-B) Installer, Oil Seal, Timing Cover 303-160 (T81P-6292-A) Remover, Oil Seal 303-409 (T92C-6700-CH)

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SPECIAL TOOL SPECIFICATIONS Remover/Installer, Hose Clamp 412-108 (T96P-18539-A)

SPECIAL TOOL SPECIFICATIONS Remover/Installer, hose clamp 412-108 (T96P-18539-A)

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SPECIAL TOOL SPECIFICATIONS Installer, Crankshaft front, oil seal 303-164 (T81P-6700-A) Bracket, Engine lifting 303-050 (T70P-6000) Support Bar, Engine 303-290A Adaptor for 303-290A 303-290-01 Adaptor for 303-290A 303-290-03A Adaptor for 303-290A 303-290-02

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1. Remove the timing belt. For additional information, refer to «TIMING BELT»(ref-234425-S31821205612006060900000) .
2. Using the special tools, support the engine.
3. Remove the jack.
4. Remove the crankshaft timing belt pulley.
5. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-234425-S21910376102006060900000) .
6. Remove the crankshaft position (CKP) sensor.
7. Remove the two bolts and the oil pump screen cover and tube. Discard the gasket.
8. Remove the oil pump. Discard the gasket.
9. Remove the oil pump seal.

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1. Install the oil pump. Position the oil pump.
2. Using the special tool, install the oil pump seal.
3. Install the crankshaft position (CKP) sensor.
4. Install the two bolts and the oil pump screen cover and tube.
5. Install the oil pan. For additional information, refer to «OIL PAN»(ref-234425-S21910376102006060900000) .
6. Install the crankshaft timing belt pulley.
7. Position the jack.
8. Remove the special tools.
9. Install the timing belt. For additional information, refer to «TIMING BELT»(ref-234425-S31821205612006060900000) .

SPECIAL TOOL SPECIFICATIONS Seal Remover 303-409 (T92C-6700-CH) Crankshaft Rear Seal Replacer 303-328 (T88P-6701-B1) Crankshaft Rear Seal Replacer 303-329 (T88P-6701-B2) Locking Tool, Flywheel 303-103 (T74P-6375-A)

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SPECIAL TOOL SPECIFICATIONS Slide Hammer 100-001 (T50T-100-A) Remover, Halfshaft 205-241 (T86P-3514-A) Spreader Bar 303-D089 (D93P-6001-A3) Remover/Installer, Cooling Hose Clamp 412-108 (T96P-18539-A)

SPECIAL TOOL SPECIFICATIONS Flange Holding Wrench, Universal 205-072 (15-03A) Remover/Installer, hose clamp 412-108 (T96P-18539-A) Lifting Bracket, Engine 303-050 (T70P-6000)

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SPECIAL TOOL SPECIFICATIONS Camshaft Seal Replacer 303-160 (T81P-6292-A) Valve Spring Compressor 303-163 (T81P-6513-A) Seal Remover 303-409 (T92C-6700-CH) Remover and Holding Tool 303-098

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SPECIAL TOOL SPECIFICATIONS Pin Locator 303-D058 (D86P-6135-A) or equivalent Piston Pin Remover/Replacer 303-025 (T68P-6135-A1) Piston Pin Remover/Replacer 303-062 (T71P-6135-P1) Piston Pin Remover/Replacer 303-158 (T81P-6135-A2)

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1. Remove the connecting rod bearings from the connecting rod and the rod cap.
2. Remove the piston rings using a suitable piston ring expander.
3. Mark the pistons to ensure assembly with the same connecting rod and installation in the same cylinder from which they were removed.
4. Place (1) sleeve in (2) base and position (3) pin locator into the center hole of sleeve.
5. Position the piston pin over the pin locator.
6. Place driver into the bore of the piston pin and press the pin out of the connecting rod.

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1. Place (1) sleeve in (2) and position (3) pin locator into the center hole of sleeve.
2. Position the piston to be assembled onto the locator.
3. Press the pin into the piston and the connecting rod with driver.
4. Install the piston rings using a suitable expander. The compression ring is to be installed with the grooved side facing down.
5. Install a connecting rod bearing in the connecting rod and the rod cap.
6. Check the connecting rod to crankshaft clearance. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .

SPECIAL TOOL SPECIFICATIONS Crankshaft Rear Seal Pilot 303-329 (T88P-6701-B2) Crankshaft Rear Seal Replacer 303-328 (T88P-6701-B1) Oil Pump Seal Replacer 303-164 (T81P-6700-A) Strap Wrench 303-D055 (D85L-6000-A) or equivalent

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MATERIAL SPECIFICATIONS

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1. Install the main bearings. Upper crankshaft main bearing. Crankshaft thrust main bearing.
2. Install the crankshaft.
3. Install the five lower crankshaft main bearings and the five main bearing caps.
4. Install the piston and connecting rod assemblies.
5. Install the four crankshaft rod caps.
6. Using the special tools, install a new crankshaft rear oil seal.
7. Install the crankshaft rear seal retainer. Use a new gasket.
8. Install the oil pump. Use a new gasket.
9. Using the special tool, install a new oil pump seal.
10. Install the oil baffle.
11. Install the oil pump screen cover and tube. Use a new gasket.
12. Clean and inspect the mounting faces of both the oil pan and the cylinder block. To remove all traces of previous sealant, use solvent to clean the cylinder block and oil pan. Both surfaces must be flat, clean and dry.
13. Apply silicone gasket and sealant F6AZ-19562-AA or equivalent Ford specification WSE-M4G323-A6 approximately 3 mm (0.125 In) wide at the oil pan to cylinder block joints and the crankshaft rear oil seal retainer to cylinder block joints.
14. Install the oil pan. Tighten the bolts in the sequence shown. The stud bolt locations are one and five.
15. Install a new gasket and tighten the cylinder head bolts in the following sequence. Tighten all the bolts in a single sequence to 50 Nm. Back the bolts off one-half turn. Tighten all the bolts in the sequence shown to 50 Nm. Rotate all the bolts in a single sequence an additional 180 degrees, in two steps of 90 degrees each.
16. Install the valve cover.
17. Install the timing belt guide and the crankshaft sprocket.
18. Install the water pump. Use a new gasket.
19. Install the timing belt tensioner.
20. Line up the timing marks of the crankshaft.
21. Line up the timing marks of the camshaft.
22. Install the timing belt. Position the timing belt. Remove the holding tool. Release the tensioner.
23. Rotate the crankshaft two turns and recheck the timing marks.
24. Install the upper timing belt cover.
25. Install the timing belt cover.
26. Install the crankshaft pulley. Install the bolt.
27. Install the crankshaft position (CKP) sensor.
28. Install the spark plugs.
29. Install the water outlet connection.
30. Install the exhaust manifold. Use a new gasket.
31. Install the accessory drive bracket.
32. Install the generator (if necessary).
33. Install the oil pressure sender unit.
34. Install the knock sensor.
35. Install the oil filter.
36. Install the coil bracket, coil and spark plug wires.
37. Connect the spark plug wires.
38. Install a new gasket and the intake manifold. Tighten the nuts and bolts to 10 Nm and 90 degrees.
39. Install the intake manifold bracket.
40. Position the fuel charging wire harness.
41. Connect the electrical connectors. Camshaft position (CMP) sensor IMRC Ignition coil Capacitor Water temperature sender unit
42. Connect the fuel pressure sensor electrical connectors.
43. Connect the oil pressure sender unit and the knock sensor electrical connectors.
44. Connect the idle air control valve and the throttle position sensor.
45. Connect the fuel injectors electrical connectors.
46. Connect the crankshaft position sensor electrical connector.
47. Install the oil indicator tube.
48. Connect the EGR tube to the exhaust manifold. Use a new gasket.
49. Install the EGR tube to the EGR valve.
50. Remove the engine from the stand.
51. Install the flywheel. Tighten the bolts fingertight. Install the special tool. Tighten the bolts.
52. Install the clutch (if equipped). For additional information, refer to «CLUTCH - IB5 TRANSAXLE»(ref-207766) , «CLUTCH - MTX75 TRANSAXLE»(ref-207767) or «CLUTCH - MT285 TRANSAXLE»(ref-207768) .
53. Install and connect: Fresh air and positive crankcase ventilation hoses Coolant hoses and tubes Vacuum hoses

SPECIAL TOOL SPECIFICATIONS Spreader Bar 303-D089 (D93P-6001-A3) Remover/Installer, Cooling Hose Clamp 412-108 (T96P-18539-A)

SPECIAL TOOL SPECIFICATIONS Flange Holding Wrench, Universal 205-072 (15-03A) Lifting Bracket, Engine 303-050 (T70P-6000) Remover/Installer, Hose Clamp 412-108 (T96P-18539-A)

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