Engine -- 2.0L Spi: Other Ford Focus I рестайлинг

General

The 2.0L SPI (Split Port Induction) engines significant features are

1. Idle Stability
2. Engine Performance
3. Fuel Economy

The 2.0L SPI Engines new features are

1. Multi-layer steel cylinder head gasket
2. Single-layer steel IMRC gasket to cylinder head
3. New aluminum intake manifold with water heated PCV fitting
4. New aluminum engine mount
5. New aluminum valve cover with integrated PCV
6. New aluminum FEAD bracket
7. New electric IMRC actuator
8. New 50 mm throttle body
9. 60 mm mass air flow sensor
10. Reduced load valve springs
11. Reduced weight valve spring retainer

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For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

Material

MATERIAL SPECIFICATIONS

Scheme 721

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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. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
5. Remove the crankshaft timing belt pulley.
6. Using the special tool, remove and discard the crankshaft front oil seal.

Scheme 723

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Scheme 725

1. Using the special tool, install a new crankshaft oil seal. Lubricate the crankshaft and crankshaft oil seal lip with engine oil.
2. Install the crankshaft timing belt pulley.
3. Lower the vehicle.
4. Place the jack under the oil pan and raise slowly until the special tool 303-290 is free from strain.
5. Remove the special tools.
6. Install the timing belt. For additional information, refer to «TIMING BELT»(ref-234425-S31821205612006060900000) .

SPECIAL TOOL SPECIFICATIONS

Scheme 726

Scheme 727

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
2. Disconnect the ignition wires from the spark plugs. Remove the two ignition wire separators from the valve cover.
3. Remove the spark plugs.
4. Remove the valve cover.
5. Remove the rocker arms.
6. Install an adaptor and apply 965 kPa of air pressure to hold the valve shut.
7. Using the special tool to compress the valve spring and remove the valve spring retainer key and the valve spring.

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Scheme 731

1. Use the special tool to compress the valve spring and install the valve spring retainer.
2. Install the rocker arms.
3. Remove the adaptor.
4. Install the valve cover.
5. Install the spark plugs (shown with engine removed). Apply lubricant to the spark plug thread.
6. Push on the spark plug connector until it engages.
7. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .

Scheme 732

1. Remove the valve springs. For additional information, refer to «VALVE SPRINGS»(ref-234425-S05434063012006060900000) .
2. Remove and discard the valve stem seal.

Scheme 733

1. Install the valve stem seal.
2. Install the valve springs. For additional information, refer to «VALVE SPRINGS»(ref-234425-S05434063012006060900000) .

MATERIAL SPECIFICATIONS

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1. Remove the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
2. Remove the battery tray and detach the ground cable. Unclip and disconnect the electrical connector. Unclip the wiring harness. Remove the bolts. Detach the positive and negative cables.
3. Remove the air cleaner housing. Disconnect the mass air flow (MAF) sensor electrical connector. Detach the air cleaner outlet pipe. Remove the air cleaner housing from the rubber bushing.
4. Remove the air cleaner intake pipe.
5. Remove the electrical ignition (El) coil. Disconnect the electrical connector. Remove the bolts and position the El coil.
6. Disconnect the fresh air and positive crankcase ventilation hoses.
7. Remove the valve cover.
8. Remove the rocker arms.
9. Remove the valve tappets. Remove the valve tappet guide plate retainers. Remove the valve tappet guide plates. Remove the valve tappets.
10. Remove the timing belt. For additional information, refer to «TIMING BELT»(ref-234425-S31821205612006060900000) .
11. Remove the camshaft oil seal. For additional information, refer to «CAMSHAFT SEAL»(ref-234425-S39635056112006060900000) .
12. Using the special tools, support the engine.
13. Remove the engine rear mounting.
14. Detach the air cleaner housing bracket and position it to one side.
15. Remove the camshaft thrust plate.
16. Remove and discard the blanking plug from the rear of the cylinder head.
17. Remove the camshaft from the rear of the cylinder head.

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1. Install the camshaft through the rear of the cylinder head.
2. Install the camshaft thrust plate.
3. Install a new camshaft oil seal. For additional information, refer to «CAMSHAFT SEAL»(ref-234425-S39635056112006060900000) .
4. Install a new blanking plug with sealer.
5. Attach the air cleaner housing bracket.
6. Install the engine rear mounting.
7. Lower the engine.
8. Remove the special tools.
9. Install the timing belt. For additional information, refer to «TIMING BELT»(ref-234425-S31821205612006060900000) .
10. Install the valve tappets into the cylinder head bores with the oil feed holes (1) in the valve tappets facing away from the oil feed holes (2) in the cylinder head bores.
11. Install the valve tappet guide plates (1) and valve tappet guide retainers (2).
12. Install the rocker arms.
13. Install the valve cover.
14. Connect the fresh air and positive crankcase ventilation hoses. Make sure that the positive crankcase ventilation hose is secured.
15. Install the El coil. Connect the electrical connector. Install the bolts.
16. Install the air cleaner intake pipe.
17. Install the air cleaner housing. Connect the MAF electrical connector. Attach the air cleaner intake pipe. Push the air cleaner housing into the rubber bushing.
18. Install the battery tray. Install the positive and negative cables. Tighten the bolts. Clip on the wiring harness. Connect and attach the electrical connector.
19. Install the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .

MATERIAL SPECIFICATIONS

Scheme 759

Scheme 760

1. Remove the timing belt. For additional information, refer to «TIMING BELT»(ref-234425-S31821205612006060900000) .
2. Using the special tool, remove the camshaft timing belt pulley.
3. Using the special tool, remove the camshaft oil seal.

Scheme 761

Scheme 762

1. Using the special tool, install a new oil seal. Lubricate the oil seal lip and the camshaft running face with engine oil. Insert the oil seal in the special tool and draw it in with the timing belt pulley bolt.
2. Using the special tool, install the camshaft timing belt pulley.
3. Install the timing belt. For additional information, refer to «TIMING BELT»(ref-234425-S31821205612006060900000) .

MATERIAL SPECIFICATIONS

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1. Remove the accessory drive belt.
2. Detach the coolant expansion tank. Remove the bolt and position the expansion tank to one side.
3. Detach the power steering reservoir and position to one side.
4. Remove the right-hand front wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-234422) .
5. Remove the crankshaft pulley/vibration damper.
6. Lower the vehicle.
7. Disconnect the ignition wires from the spark plugs. Remove the two ignition wire separators from the valve cover.
8. Remove the spark plugs (shown with engine removed).
9. Place a jack with a wooden block under the oil pan and raise slowly until the front engine mounting is free from strain.
10. Remove the engine front mounting.
11. Remove the timing belt cover.
12. Remove the engine front mounting bracket (shown with engine removed).
13. Align the timing marks.
14. Remove the timing belt. Use an 8 mm Allen wrench and turn counter clockwise 1/4 turn. Insert a 3 mm (1/8 inch) drill bit to lock the timing belt tensioner in place. Remove the timing belt.

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Scheme 780

1. Check the alignment of the timing mark on the crankshaft timing belt pulley.
2. Check the alignment of the timing mark on the camshaft timing belt pulley.
3. Install the timing belt. Install the timing belt over the pulleys in a counter clockwise direction starting at the crankshaft. Keep the belt span from the crankshaft to the camshaft tight while installing the timing belt over the camshaft. Remove the 3 mm (1/8 inch) drill bit to release the timing belt tensioner.
4. Turn the crankshaft at least two turns in clockwise direction to TDC position for cylinder one.
5. Check the alignment of the timing marks. If the alignment is not correct repeat the previous steps.
6. Install the engine front mounting bracket (shown with engine removed).
7. Install the timing belt cover (shown with engine removed).
8. Install the engine front mounting.
9. Remove the jack.
10. Install the spark plugs (shown with engine removed).
11. Push on the spark plug connector until it engages.
12. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
13. Install the crankshaft pulley/vibration damper. Position the drive belt on the crankshaft pulley.
14. Install the right-hand front wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-234422) .
15. Install the power steering reservoir.
16. Install the coolant expansion tank.
17. Install the accessory drive belt.

General Equipment

SPECIAL TOOL SPECIFICATIONS

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Scheme 785

1. Remove the air cleaner housing. Disconnect electrical connector of the mass air flow (MAF) sensor. Detach the intake hose. Remove the air cleaner housing from the rubber bushing.
2. Disconnect the heated oxygen sensor (HO2S) electrical connector.
3. Remove the heat shield. Remove the nuts and the power steering high pressure tube. Remove the nuts and the heat shield.
4. Remove the exhaust gas recirculation (EGR) tube.
5. Loosen the EGR tube fitting approximately three turns.
6. Remove the catalytic converter (TWC). For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
7. Lower the vehicle.
8. Remove the nuts, the exhaust manifold and the gasket. Discard the gasket.

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Scheme 790

1. Install the exhaust manifold and a new gasket.
2. Raise the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
3. Install the TWC. For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
4. Install the EGR-tube and install the nuts.
5. Tighten the EGR-Tube nut.
6. Install the heat shield. Position the heat shield and install the nuts. Install the power steering pressure tube and install the nuts.
7. Connect the heated oxygen sensor (HO2S) electrical connector.
8. Install the air cleaner housing (ACL) Connect the MAF electrical connector. Attach the intake hose.
9. Connect the battery ground lead.

GENERAL EQUIPMENT SPECIFICATIONS

MATERIAL SPECIFICATIONS

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1. Remove the air cleaner housing. Disconnect the mass air flow (MAF) electrical connector. Detach the intake hose. Remove the air cleaner housing from the rubber bushing.
2. Remove the battery tray and detach the ground cable. Detach and separate the connector. Detach the wiring harness. Unscrew the bolts. Detach the positive and negative cables.
3. Detach the accelerator cable. Unhook the cable. Pull off the plastic clip and lay the accelerator cable to one side.
4. Remove the speed control cable. Unhook the cable. Pull off the plastic clip and lay the speed control cable to one side.
5. Disconnect the both powertrain control module (PCM) connectors.
6. Disconnect the heated oxygen sensor (HO2S) electrical connector.
7. Detach the vacuum hoses. EVAP Brake servo Delta Pressure Feedback Electronic System Sensor (DPFE) Exhaust gas recirculation (EGR) valve
8. Remove the nut and the oil level indicator tube.
9. Drain the coolant (shown from below).
10. Remove the coolant hoses from the thermostat housing.
11. Remove the coolant hose.
12. Drain off the fuel. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-207778) . Detach the fuel hose.
13. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
14. Disconnect the knock sensor (KS) and the oil pressure switch electrical connectors (shown from below). Oil pressure switch Knock sensor
15. Detach the intake manifold bracket. Loosen the nuts and remove the bolts.
16. Disconnect and remove the catalyst monitor sensor electrical connector.
17. Lower the vehicle.
18. Remove the heat shield. Power steering pipe Heat shield
19. Remove the catalytic converter from the exhaust manifold.
20. Remove the timing belt. For additional information, refer to «TIMING BELT»(ref-234425-S31821205612006060900000) .
21. Disconnect the crankshaft position sensor (CKP) electrical connector.
22. Disconnect the PCV and the fresh air hoses.
23. Remove the valve cover.
24. Loosen the cylinder head bolts in the indicated sequence.
25. Remove the cylinder head. Discard the gasket.

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1. Clean all gasket material from the mating surfaces on the cylinder head and cylinder block. Clean out the bolt holes in the cylinder block. Inspect the cylinder head for distortion. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
2. Install a new head gasket on the cylinder block.
3. Install the cylinder head assembly and tighten the cylinder head bolts in the following sequence. Tighten all bolts in a single sequence to 50 Nm. Back the bolts off 1/2 turn. Tighten the bolts in sequence shown to 50 Nm. Rotate all the bolts in a single sequence an additional 180 degrees in two steps of 90 degrees each.
4. Install the valve cover.
5. Connect the fresh air and PCV hoses. Make sure that the twist-on PCV is secure.
6. Connect the crankshaft position sensor (CKP) electrical connector.
7. Install and tension the timing belt. For additional information, refer to «TIMING BELT»(ref-234425-S31821205612006060900000) .
8. Install the catalytic converter to the exhaust manifold.
9. Install the heat shield. Heat shield Power steering tube
10. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
11. Connect the knock sensor (KS) and the oil pressure switch electrical connector.
12. Connect the CMS sensor electrical connector.
13. Install the intake manifold bracket (shown with engine removed). Install the bolts and tighten the nuts.
14. Lower the vehicle.
15. Install the fuel hose.
16. Install the coolant hose.
17. Install the coolant hoses to the thermostat housing.
18. Install the oil level indicator tube.
19. Install the vacuum hose.
20. Install the vacuum hoses. EVAP Brake servo Delta Pressure Feedback Electronic System Sensor (DPFE) EGR-valve
21. Connect the HO2S electrical connector.
22. Connect both PCM connectors.
23. Install the speed control cable. Install the cable. Install the plastic clip.
24. Install the accelerator cable. Install the cable. Install the plastic clip.
25. Install the air cleaner housing. Connect the MAF electrical connector. Attach the intake hose. Install the air cleaner housing to the rubber bushing.
26. Change the engine oil (and the oil filter).
27. Fill the cooling system. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
28. Connect the battery ground cable.
29. Install the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
30. Start the engine and check for leaks.

MATERIAL SPECIFICATIONS

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Scheme 831

1. Remove the three-way catalytic converter (TWC). For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
2. Remove the bolts and the two brackets.
3. Remove the intake manifold bracket.
4. Remove the axleshaft bracket clamp.
5. Remove the axleshaft bracket.
6. Remove the coolant tube bolt.
7. Remove the oil pan drain plug and drain the engine oil. Install the drain plug.
8. Remove the oil pan. Discard the gasket.

Scheme 832

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Scheme 837

1. Clean and inspect the mounting faces of both the oil pan and the cylinder block. To remove all traces of previous sealer, use solvent to clean the cylinder block and oil pan. Both surfaces must be flat, clean and dry.
2. Apply silicone gasket and sealant approximately 3.0 mm wide at the oil pump to cylinder block joints and the crankshaft rear oil seal retainer to cylinder block joints.
3. Install the oil pan gasket in the oil pan.
4. Install the oil pan. Tighten the bolts in the indicated sequence.
5. Install the two brackets and the bolts.
6. Install the coolant tube bolt.
7. Install the axleshaft bracket.
8. Install the axleshaft bracket clamp.
9. Install the intake manifold bracket.
10. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
11. Fill the engine with engine oil
12. Start the engine and check for leaks.

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

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1. Remove the bolt and the camshaft position (CMP) sensor.
2. Disconnect the spark plug wires.
3. Remove the spark plugs.
4. Using the special tool remove the camshaft timing belt pulley.
5. Remove the intake manifold. Discard the gaskets.
6. Remove the exhaust manifold. Discard the gasket.
7. Remove the coolant outlet connection, thermostat and gasket.
8. Remove the ignition coil, ignition coil bracket and wires as one assembly.
9. Remove the rocker arms.
10. Remove the valve tappet(s). Remove the valve tappet guide plate retainers. Remove the valve tappet guide plates. Remove the valve tappets.
11. Remove the camshaft thrust plate.
12. Using the special tool, remove the camshaft front oil seal.
13. Remove the camshaft.
14. Using the special tool, compress the valve spring and remove the valve spring retainer key and the valve spring.
15. Slowly remove the special tool.
16. Remove the valves.
17. Remove and discard the valve stem seals.

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1. Install the valve seals.
2. Install the exhaust and intake valves.
3. Using special tool, compress the valve spring and install the valve spring retainer.
4. Install the camshaft.
5. Apply a thin film of clean engine oil to the lip of the camshaft front seal.
6. Using the special tool, install the camshaft front seal.
7. Install the camshaft thrust plate.
8. Install the valve tappets into the cylinder head bores with the oil feed holes (1) in the valve tappets facing away from the oil feed holes (2) in the cylinder head bores.
9. Install the valve tappet guide plates (1) and valve tappet guide retainers (2).
10. Install the rocker arms.
11. Install the coil bracket, coil and spark plug wires.
12. Install the coolant outlet connection.
13. Install the exhaust manifold. Use a new gasket.
14. Install a new gasket and the intake manifold. Tighten the nuts and bolts to 10 Nm and 90 degrees.
15. Using the special tool. Install the camshaft timing belt pulley.
16. Install the spark plugs (shown with engine removed).
17. Push on the spark plug connector until it engages.
18. Install the CMP sensor.

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS