Engine - 2.0L Zetec: Other Ford Focus I рестайлинг

Valve Train

The exhaust valve springs are marked blue while the inlet valve springs are marked red. The valve clearance can be adjusted by exchanging the valve tappets. Precision is required when adjusting the valve clearance in order to avoid repeated removal and reinstallation of the camshafts.

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Mechanical Bucket Tappet

The level of wear is so minimal that initial checking and adjustment of the valve clearance is not necessary until 150,000 km (90,000 miles).

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1. A new timing belt must be installed after 150,000 km (90,000 miles) or after 10 years.
2. A new timing belt must always be installed after repair work in which it was removed.

Timing Belt Tensioner

An automatic timing belt tensioner ensures that the belt has the correct tension. When a new belt is fitted, the tensioner is moved into the base setting (arrowhead (3) and marker (2) are in line). This base setting is taken up by one of the cams (4). Another (spring-loaded) cam ensures that the belt is kept at the correct tension when the engine is running. The belt tensioner moves up to 30 degrees from its center position in each direction.

Note. Do not re-tighten the belt since there is a risk of exceeding the permitted working range in one of the directions. The belt tensioner base setting only applies in the case of new timing belts. Re-tightening of the belt can cause it to rip or flutter.

It is no longer possible to check the base setting once the adjustment tools and pin have been removed (the spring forces of the valve train are exerted on the belt and change the position of the belt tensioner).

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Intake Manifold

The new Zetec-E engines are fitted with an intake manifold made of glass fibre reinforced plastic. The ducts in the intake manifold are arranged to ensure that the intake distance is the same for each cylinder.

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Crankshaft

The crankshaft is housed in five bearings and has a counterweight for each cylinder. The central main bearing has two thrust half shells which axially guide the crankshaft and set the end float.

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Connecting (ISC) Rod Bearings

The connecting rods are numbered one to four starting at the timing belt end. It is practically impossible to mix up the connecting rod bearing caps and connecting rods since the connecting rod bearing caps are broken away from the connecting rod during production. The fracture profile of a connecting rod bearing cap therefore only fits one of the connecting rods.

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The crankcase reinforcements are designed to damp engine vibrations. This leads to a further reduction in interior noise levels. The crankcase reinforcements are sealed against the cylinder block by means of a flat carrier gasket.

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The crankcase reinforcement spacers are needed to even out any excessive gap between the transmission and the crankcase reinforcements.

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The unit is closed off at the bottom by a drawn sheet metal oil pan which is directly fixed to the crankcase reinforcements. A 3 mm wide bead of sealer ensures that the unit is leakproof.

Powertrain Control Module (PCM)

The PCM controls the Zetec-E engine. To enable it to do this, the PCM requires comprehensive information regarding the current operating state of the engine. The PCM obtains this information by means of numerous sensors.

1. The PCM controls: the fully electronic (EI) ignition system the sequential electronic fuel injection (SEFI) the air-conditioning system in conjunction with the cooling system.

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

Material

MATERIAL ITEM SPECIFICATIONS

MATERIAL ITEM SPECIFICATIONS

Scheme 274

1. Remove the timing belt. For additional information, refer to «TIMING BELT»(ref-234423-S39362823462006060900000) .
2. Detach the crankshaft timing belt. Remove the crankshaft pulley hub. Remove the timing belt thrust washer.
3. Using the special tool remove the crankshaft front oil seal.

MATERIAL ITEM SPECIFICATIONS

Scheme 275

1. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-234423-S09383935172006060900000) . Remove the valve tappets and place them in order to one side.
2. Unscrew the spark plug on cylinder No. 1 and connect the compressed air supply.
3. Using the special tools and apply compressed air to the cylinder. Using the special tools, compress the valve springs and remove the valve collets using some grease and a small screwdriver. Remove the valve spring retainers and the valve springs.
4. Remove the valve springs.
5. Using special tools, remove the valve stem seals.

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1. Valve stem seal installation sleeve.
2. Using the special tool, install the valve stem oil seals.
3. Using the special tools, install the valve springs. Insert the valve springs and the valve spring retainers. Compress the valve springs and install the valve collets using some grease and a small screwdriver.
4. Disconnect the compressed air supply and screw in the spark plug.
5. Repeat appropriate steps for all the other cylinders.
6. Coat the valve tappets with engine oil and insert them.
7. Install the camshafts. For additional information, refer to «CAMSHAFTS»(ref-234423-S09383935172006060900000) .

MATERIAL ITEM SPECIFICATIONS

Scheme 278

1. Using the special tools, compress the valve springs. Compress the valve springs and remove the valve collets using some grease and a small screwdriver. Remove the valve spring retainers and the valve springs.
2. Remove the valve springs.
3. Using the special tools, remove the valve stem seals.
4. Remove the valves and place them in order to one side.

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1. Regrind the valves.
2. Thoroughly clean off any traces of sealer and grinding paste from all components.
3. Coat the valve stems with engine oil and insert them in the valve guides.
4. Valve stem seal installation sleeve.
5. Using the special tool, install new valve stem oil seals.
6. Using the special tools, install the valve springs. Insert the valve springs and the valve spring retainers. Compress the valve springs and install the valve collets using some grease and a small screwdriver.

MATERIAL ITEM SPECIFICATIONS

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1. Remove the intake pipe.
2. Detach the accelerator cable and the speed control cable (if equipped).
3. Remove the timing belt. For additional information, refer to «TIMING BELT»(ref-234423-S39362823462006060900000) .
4. Remove the camshaft timing pulleys. Prevent turning using the special tool.
5. Unscrew the bolts of the camshaft bearing caps evenly in several stages two turns at a time. Remove the oil seals. Remove the camshafts.

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1. Apply sealant to camshaft bearing cap numbers 0 and 5 in the areas shown.
2. Turn the crankshaft to approximately 60 degrees before TDC on cylinder number 1.
3. Lubricate the camshaft and camshaft bearing caps with engine oil.
4. Tighten the bolts of the camshaft bearing caps. Stage 1:10 Nm Stage 2: 19 Nm
5. Check the valve clearance and adjust if necessary. For additional information, refer to «VALVE CLEARANCE»(ref-234426-S16741537422006060900000) .
6. Install the camshaft oil seals. Lubricate the camshaft and oil seal lip with engine oil. Using the special tool install a new oil seal. NOTE: Do not tighten the bolts. The camshaft timing pulleys must be able to turn freely on the camshafts. Install the camshaft timing pulleys.
7. Install the timing belt. For additional information, refer to «TIMING BELT»(ref-234423-S39362823462006060900000) .
8. Lower the vehicle.
9. Attach the accelerator cable and the speed control cable (if equipped).
10. Install the intake pipe.
11. Standard finishing operations Connect the battery ground cable. Check fluid levels and correct if necessary. Check the routing of vacuum hoses and cables and secure them with cable ties. Check fluid levels again and correct if necessary.

ITEM MATERIAL SPECIFICATION

Scheme 287

1. Remove the timing belt. For additional information, refer to «TIMING BELT»(ref-234423-S39362823462006060900000) .
2. Remove the camshaft pulleys. Remove the bolts.
3. Remove camshaft bearing caps numbers 0 and 5. Remove the camshaft oil seals.

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1. Thinly coat camshaft bearing caps numbers 0 and 5 with gasket maker.
2. Install a new exhaust camshaft oil seal.
3. Install camshaft bearing caps numbers 0 and 5.
4. Using the special tool, press in the intake and exhaust camshaft oil seals.
5. Slide the timing belt pulleys onto the camshafts and screw in the timing belt pulley bolts.
6. Install a new timing belt. For additional information, refer to «TIMING BELT»(ref-234423-S39362823462006060900000) .

MATERIAL ITEM SPECIFICATIONS

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1. General Instructions. The positions of the engine mounting and the engine roll restrictor are described looking from the transmission towards the engine. If necessary, use Special Tool 412-108 to remove coolant and ventilation hoses. Owing to special model variants, some steps do not apply to all vehicles. These are clearly marked in the text. If necessary, cut the cable tie and install new on installation.
2. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
3. Detach the drive belt cover.
4. Remove the drive belt. Loosen the bolts on the coolant pump pulley. Slacken the drive belt by turning clockwise and remove it. Detach the coolant pump belt pulley. Detach the multi-groove belt idler pulley.
5. Detach the crankshaft pulley/vibration damper.
6. Detach the lower timing belt cover.
7. Lower the vehicle.
8. Detach the coolant expansion tank and lay it to one side.
9. Remove the PAS reservoir and lay it to one side.
10. Position the jack with the wooden block under the oil pan and raise so that the front engine mounting is free from load.
11. Remove the front engine mounting.
12. Detach the timing belt upper cover. Leave the timing belt cover in its installed position.
13. Detach the timing belt center cover/front engine mounting bracket. Remove the timing belt upper cover.
14. Remove the cylinder head cover. Pull off the spark plug connectors. Detach the PCV hose. Remove ten bolts.
15. Remove the spark plugs.
16. Turn the engine to TDC on cylinder No. 1.
17. Detension the timing belt. Unscrew the bolt four turns. Position the tensioner so the locating tab is at approximately the 4 o'clock position. Line up the hex key slot in the tensioner adjusting washer with the pointer that is located behind the pulley.
18. Remove and discard the timing belt.
19. Slacken the camshaft timing pulleys. Prevent from turning using the special tool.

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1. Turn the camshafts to ignition position on cylinder No. 1 and insert the special tool into the camshafts.
2. Rotate the crankshaft to TDC on cylinder No. 1.
3. Remove the blanking plug, completely screw in the special tool and auto-align the crankshaft to TDC.
4. Position a new timing belt in place. Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension.
5. Pre tension the timing belt. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover. Position the hex key slot in the tensioner adjusting washer to the 4 o'clock position. Tighten the attaching bolt enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 6 mm hex key.
6. Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment).
7. While holding the adjusting washer in position, tighten the bolt.
8. Tighten the bolts of the camshaft timing pulleys.
9. Unscrew and remove Special Tool 303-574.
10. Remove Special Tool 303-465 from the camshafts.
11. Check the valve timing by inserting the special tool. Correct it if necessary. Screw in Special Tool 303-574 and make sure that the crankshaft is touching it. Insert Special Tool 303-465 into the camshafts; if necessary loosen the timing pulleys and correct the camshaft alignment. Detach the special tools.
12. Screw in and tighten the blanking plug.
13. Install the cylinder head cover and spark plugs. Tighten the bolts in two stages. Stage 1: 2 Nm Stage 2: 7 Nm Attach the PCV hose. Coat the spark plug thread with Never Seeze, screw in the spark plugs and push in the spark plug connector until it engages.
14. Attach the timing belt center cover/front engine mounting bracket.
15. Attach the timing belt upper cover.
16. Install the front engine mounting.
17. Connect the PAS reservoir.
18. Install the coolant expansion tank.
19. Pull the jack out towards the front of the vehicle.
20. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
21. Attach the lower timing belt cover.
22. Attach the crankshaft pulley/vibration damper.
23. Install the drive belt. Attach the multi-groove belt idler pulley. NOTE: Screw in the bolts only until it starts to take up, do not tighten them. Attach the coolant pump pulley. Install the drive belt by turning clockwise and tension it. Tighten the bolts on the coolant pump pulley.
24. Attach the drive belt cover.
25. Lower the vehicle.
26. Standard finishing operations: Connect the battery negative cable. Check fluid levels and correct if necessary. Check the routing of vacuum hoses and cables and secure them with cable ties.

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1. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
2. Detach the catalyst bracket and disconnect the plugs for the heated oxygen sensor (H02S).
3. Lower the vehicle.
4. Detach the heat shield.
5. Remove the air cleaner housing. Pull out the plug of the mass air flow (MAF) sensor. Detach the positive crankcase ventilation (PCV) hose. Detach the intake hose. Remove the air cleaner housing from the rubber bushings.
6. Remove and discard the exhaust gas recirculation (EGR) tube.
7. Detach the exhaust manifold from the catalyst.
8. Detach the exhaust manifold from the cylinder head.

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1. Attach the exhaust manifold to the cylinder head using the alignment spacers with the two outside bolts and a new manifold gasket.
2. Loosen the bracket for the catalytic converter so that it can move freely.
3. Position the catalytic converter on the exhaust manifold using new hardware.
4. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
5. Using a nut and bolt, temporarily secure the catalytic converter to the bracket at the rear.
6. Tighten the catalytic converter to the exhaust manifold.
7. Attach the catalytic converter. Tighten the bolts on the catalytic converter bracket. Install a new EGR-pipe. Attach the heat shield.
8. Attach the bracket for the catalytic converter. Tighten the bolts. Remove the temporary bolt from the rear catalytic converter bracket.
9. Lower the vehicle.
10. Attach the air filter housing. Press the air filter housing into the rubber bushings. Push on the mass air flow (MAF) sensor multiplug. Attach the PCV hose. Attach the intake hose.

MATERIAL ITEM SPECIFICATIONS

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1. General remarks. The positions of the engine mounting and the engine roll restrictor are described looking from the transmission towards the engine. If necessary, use Special Tool 412-108 to remove coolant and ventilation hoses. Owing to special model variants, some steps do not apply to all vehicles. These are clearly marked in the text.
2. Release the fuel pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-207778-S01731693742005120100000) .
3. If necessary, separate cable ties and install on installation.
4. Open the coolant reservoir.
5. Raise the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
6. Drain the coolant from the radiator. Install the radiator drain plug after draining the coolant.
7. Detach the brake booster pipe from the intake manifold. Release the quick release coupling and pull out the brake booster pipe.
8. Disconnect the oil pressure switch connector.
9. Lower the vehicle.
10. Remove the air cleaner housing. Pull out the plug of the mass air flow (MAF) sensor. Detach the PCV hose. Detach the intake hose. Remove the air cleaner housing from the rubber bushings.
11. Detach the accelerator cable and the speed control cable (if equipped). Unhook the cable. Pull off the plastic clip and lay the accelerator cable to one side.
12. Detach the EGR valve and EGR pipe bracket.
13. Pull off the vacuum hoses.
14. Disconnect the fuel injector wiring.
15. Disconnect the camshaft position (CMP) sensor.
16. Detach the fuel lines. Detach the ground cable.
17. Detach the heat shield.
18. Detach the thermostat housing.
19. Detach the catalytic converter from the exhaust manifold.
20. Detach the power steering pipe bracket and the oil level indicator tube.
21. Detach the bracket from the power steering pump. Remove the lower studs. Remove the upper bolts.
22. Detach the generator. Loosen the bolt. Remove the bolt.
23. Unscrew the upper bolt from the generator bracket.
24. Remove the timing belt. For additional information, refer to «TIMING BELT»(ref-234423-S39362823462006060900000) .
25. Unscrew the bolts of the camshaft bearing caps evenly in several stages two turns at a time. Remove the oil seals. Remove the camshafts. Remove the tappets and keep them in order.
26. Remove the cylinder head bolts.
27. Remove the cylinder head.

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1. General remarks. If necessary, use Special Tool 412-108 to install coolant and ventilation hoses.
2. Preparatory operations CAUTION: Do not damage the cylinder liner surfaces. Remove carbon deposits from the top edge of the cylinder. Remove gasket residue with seal remover and a spatula. Thoroughly clean the threaded holes of the cylinder head bolts.
3. Check the cylinder head deformation. For additional information, refer to «CYLINDER HEAD DISTORTION»(ref-207747-S32672569452005120100000) .
4. Make up two locating studs as shown.
5. Install a new cylinder head cover gasket on the cylinder block. Position a new cylinder head gasket. Insert the fabricated locating studs. Check that the locating studs are seated correctly.
6. Install the cylinder head. Position the cylinder head on the cylinder block.
7. Tighten the cylinder head bolts in three stages in the sequence indicated. Stage 1: 20 Nm Stage 2: 40 Nm Stage 3: 90 degrees. Apply engine oil to the tappets and insert them.
8. Apply sealant to camshaft bearing cap numbers 0 and 5 in the areas shown.
9. Turn the crankshaft to approximately 60 degrees before TDC on cylinder number 1.
10. Lay the camshaft in place so that none of the cams is at full lift. Lubricate the camshaft and camshaft bearing caps with engine oil.
11. Tighten the bolts of the camshaft bearing caps. Stage 1: 10 Nm Stage 2: 19 Nm
12. Check the valve clearance and adjust if necessary. For additional information, refer to «VALVE CLEARANCE»(ref-234426-S16741537422006060900000) .
13. Install the camshaft oil seals. Lubricate the camshaft and oil seal lip with engine oil. Using the special tool install a new oil seal. NOTE: Do not tighten the bolts. The camshaft timing pulleys must be able to turn freely on the camshafts. Attach the timing belt pulleys.
14. Install the timing belt. For additional information, refer to «TIMING BELT»(ref-234423-S39362823462006060900000) .
15. Lower the vehicle.
16. Attach the power steering pump bracket. Screw in the upper bolts. Insert the lower studs. Tighten the bolts and nuts.
17. Install the upper bolt to the generator bracket.
18. Attach the generator.
19. Attach the oil level indicator tube and the power steering pipe bracket.
20. Attach the catalytic converter to the exhaust manifold.
21. Attach the thermostat housing with new gasket.
22. Attach the heat shield.
23. Attach the fuel lines.
24. Connect the camshaft position (CMP) sensor.
25. Connect the fuel injector wiring.
26. Attach the EGR valve with a new gasket and EGR pipe bracket.
27. Attach the accelerator cable and the speed control cable (if equipped).
28. Push on the vacuum hoses.
29. Attach the air filter housing. Press the air filter housing into the rubber bushings. Push on the mass air flow (MAF) sensor multiplug. Attach the PCV hose. Attach the intake hose.
30. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
31. Push on the oil pressure switch electrical connector.
32. Attach the brake booster pipe and the PCV hose to the intake manifold.
33. Standard finishing operations Connect the battery negative cable. Top off the coolant. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-207748-S36034059462005120100000) . Close the coolant expansion tank. Check fluid levels and correct if necessary. Check the routing of vacuum hoses and cables and secure them with cable ties. Check fluid levels again and correct if necessary. NOTE: The engine oil temperature must be at least 80°C. Change the engine oil and the oil filter. For additional information, refer to «ENGINE OIL»(ref-234423-S11052439052006060900000) .

MATERIAL ITEM SPECIFICATIONS

Scheme 352

1. Remove the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
2. Drain the engine oil at the drain plug and remove the oil pan bolts (shown with engine removed).
3. Remove the oil pan (shown with engine removed). Separate the oil pan from the lower crankcase using a sharp spatula. Release the oil pan from the lower crankcase by tapping slightly against the tightened drain plug with a rubber hammer.

MATERIAL ITEM SPECIFICATIONS

General Equipment

GENERAL EQUIPMENT SPECIFICATIONS

MATERIAL ITEM SPECIFICATIONS

MATERIAL ITEM SPECIFICATIONS

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1. Remove the camshaft position sensor.
2. Remove the electronic ignition (EI) coil pack.
3. Remove the intake manifold.
4. Remove the exhaust manifold.
5. Remove the timing belt tensioner and idler pulley. Timing belt tensioner Idler pulley
6. Remove the timing belt inner cover.
7. Remove the bracket.
8. Remove the rear lifting eye.
9. Remove the front lifting eye.
10. Remove the cylinder head temperature (CHT) sensor.
11. Using the special tools, compress the valve spring and remove the valve spring retainer keys, the valve spring retainers, and the valve springs. Remove the special tools.
12. Inspect the valve spring, valve spring retainer and valve spring retainer key. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) . Install new parts as necessary.
13. Remove the valves.
14. Using the special tools, remove and discard the valve stem seals.
15. Inspect the valves. For additional information refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) . Install new parts as necessary.

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1. Install the valves.
2. Lubricate valve and guides with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H and using the special tool install the valve stem seals onto the cylinder head valve guides.
3. Place the valve spring in position over the valve and install the valve spring retainer.
4. Using the special tools, compress the valve spring and install the valve spring retainer keys. Remove the special tools.
5. Install the CHT sensor.
6. Install the front lifting eye.
7. Install the rear lifting eye.
8. Install the bracket.
9. Install the timing belt inner cover.
10. Install the timing belt tensioner and the idler pulley. Timing belt tensioner. Idler pulley
11. Install the exhaust manifold.
12. Install the intake manifold.
13. Install the electronic ignition (EI) coil pack.
14. Install the camshaft position sensor.

MATERIAL ITEM SPECIFICATIONS

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1. Preparatory operations.
2. Remove the carbon deposits at the upper edge of the cylinder.
3. Using a scraper and sealant remover, clean all re-usable parts and check them for damage.
4. Thoroughly clean all threaded bores.
5. Available sizes of main bearing shell. NOTE: The main bearing shells are color coded. Size A: 2.145-2.152 mm (green) Size B: 2.142-2.147 mm (brown) Size C: 2.135-2.142 mm (brown) Size D: 2.130-2.137 mm (brown)
6. Measure the radial clearance of the crankshaft. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) . Select a bearing shell in accordance with the previous step to determine bearing clearance of 0.020-0.040 mm
7. Measure the axial clearance of the crankshaft. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
8. Measure the radial clearance of the camshaft. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
9. Measure the axial clearance of the camshaft. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
10. Measure the crankshaft. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
11. Measure the camshaft. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
12. Measure the cylinder bore. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
13. Measure the pistons. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
14. Measure the piston ring gaps. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
15. Measure the axial play of the piston rings. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
16. Check the cylinder head distortion. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
17. Install the crankshaft. Lay the main bearing shells clean and free of oil into the cylinder block and into the bearing caps. Coat the inner side of the bearing shells with engine oil. Lay the crankshaft in place. NOTE: Do not tighten the main bearing cap bolts yet. Attach the main bearing caps.
18. Install the pistons. Coat the pistons and cylinder liners with engine oil. Distribute the piston ring gaps and the elements of the oil scraper ring evenly around the circumference (120 degrees). Compress the piston rings using a piston ring compressor. Press pistons 1 and 4 with the handle of a hammer into the cylinders. The connecting rod bearing journals for cylinders 1 and 4 must be at BDC. Lay the corresponding bearing shells clean and free of oil into the connecting rod and the connecting rod bearing cap. Coat the inner side of the bearing shells with engine oil. NOTE: Use new connecting rod bearing cap bolts. NOTE: Do not tighten the connecting rod bearing cap bolts yet. Attach the bearing caps. Rotate the crankshaft through 180 degrees and insert pistons 2 and 3. Lay the corresponding bearing shells clean and free of oil into the connecting rod and the connecting rod bearing cap. Coat the inner side of the bearing shells with engine oil.
19. Tighten down the main bearings and connecting rod bearings. Tighten the main bearing bolts in two stages. Stage 1: 25 Nm Stage 2: 60 degrees Tighten the connecting rod bearing bolts in two stages. Stage 1: 35 Nm Stage 2: 90 degrees
20. Install the rear oil seal carrier and the crankshaft position (CKP) sensor with its bracket. Position a new oil seal carrier with a new seal in installation position and tighten the bolts finger tight. Align the oil seal carrier so that the mating face of the oil seal carrier is between 0.3 and 0.8 mm below the cylinder block. Tighten the bolts. Install the CKP sensor bracket.
21. Using special tool, draw in the oil seal.
22. Align the oil pump. Position the oil pump with a new gasket and tighten the bolts finger tight. Align the oil pump on both sides so that the sealing surfaces are 0.3-0.8 mm below the cylinder block.
23. Install the oil pump with a new crankshaft front oil seal. Check the alignment as described in the previous step, and correct if necessary. Tighten the bolts in two stages: Stage 1: 6 Nm. Stage 2: 45 degrees.
24. Apply a 4 mm (0.15 in) bead of sealer to the areas as shown. Coat the joins between the cylinder block and the oil pump/oil seal carrier with sealant. Position the lower crankcase with a new gasket and tighten the bolts finger tight. NOTE: If the permissible amounts for protrusions and/or gaps are exceeded, fit spacer shims as described in the next step. Align the lower crankcase using a steel straight edge so that the cylinder block and the lower crankcase are level, or at least do not exceed the following tolerances: MTX 75 manual transaxle: 0.10 mm protrusion to 0.25 mm gap. FN automatic transaxle: 0.00 mm to 0.25 mm gap.
25. Align the lower crankcase.
26. Install lower crankcase spacer washers as necessary. With a gap of 0.26-0.50 mm, fit 0.25 mm spacer washers. With a gap of 0.51-0.75 mm, fit 0.50 mm spacer washers.
27. Attach the lower crankcase and the oil intake pipe using a new gasket. Tighten the bolts and check the alignment as described in the previous step, correct as necessary. Oil intake pipe bolts
28. Install 10 studs, M6 x 20, in the shown dead end bores.
29. Clean off any residues of oil or oil sludge from the oil pan.
30. Apply a 3 mm bead of sealant to the oil pan flange.
31. Attach the oil pan and tighten the bolts in two stages. Stage 1: 6 Nm Stage 2: 10 Nm
32. Install the flywheel. Attach the special tool and tighten the bolts.
33. Evenly coat the splines of the clutch disc with high-temperature grease.
34. Install the clutch. Position the clutch pressure plate with the centered clutch disc. Working diagonally in several stages, tighten the bolts one turn at a time. Check the centering and correct as necessary. Detach the special tool.
35. Make two guide studs as shown.
36. Lay a new cylinder head gasket on the cylinder block. Lay a new cylinder head gasket in place. Screw in the guide studs made in the previous step. Check that the alignment dowels are correctly seated.
37. Put the cylinder head in place. Hook the cylinder head into the workshop hoist by the engine lifting eyes and move it into position.
38. Attach the cylinder head. Stage 1: 20 Nm Stage 2: 40 Nm Stage 3: 90 degrees
39. Lubricate the valve tappets with engine oil and fit them in the correct order.
40. Apply a thin coat of gasket maker to the marked areas on camshaft bearing caps 0 and 5.
41. Turn the crankshaft to approximately 60 degrees BTDC.
42. Coat the camshafts and camshaft bearing caps with engine oil and insert them.
43. Tighten the camshaft bearing caps. Stage 1: 10 Nm Stage 2: 19 Nm
44. Check the valve clearance and adjust if necessary. For additional information, refer to «VALVE CLEARANCE»(ref-234426-S16741537422006060900000) .
45. Install the camshaft oil seals. Lubricate the camshaft and the seal lip of the oil seal with engine oil. Draw in the new oil seals using the special tool, a washer and an M10 x 70 bolt.
46. Turn the crankshaft to TDC on cylinder number 1.
47. Remove the blanking plug and align the crankshaft at TDC using the special tool.
48. Turn the camshafts to ignition point on cylinder number 1 and insert the special tool into the camshafts.
49. Slide the timing pulleys onto the camshafts and screw in the bolts.
50. Install a new gasket into the water pump. Lay the gasket in place. Secure the gasket by bending over the tabs.
51. Position a new timing belt in place. Slide the crankshaft timing pulley with a thrust washer onto the crankshaft. Attach the water pump. Attach the upper idler pulley. Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension. Attach the timing belt tensioner and screw in the bolt five turns.
52. Pre tension the timing belt. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover. Position the hex key slot in the tensioner adjusting washer to the 4 o'clock position. Tighten the attaching bold enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 6mm hex key.
53. Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment).
54. While holding the adjusting washer in position, tighten the bolt.
55. Tighten the bolts on the timing pulleys.
56. Unscrew and remove Special Tool 303-574.
57. Take Special Tool 303-465 off the camshafts.
58. Check the valve timing by inserting the special tools and correct the alignment as necessary. Screw in Special Tool 303-574 and make sure that the crankshaft is resting against the special tool. Insert Special Tool 303-465 into the camshafts. If necessary loosen the timing pulleys and correct the camshaft alignment. Detach the special tools.
59. Install the blanking plug.
60. Install the cylinder head cover and the spark plugs. Screw in the spark plugs. Tighten the cylinder head cover bolts in two stages. Stage 1: 2 Nm Stage 2: 7 Nm Push on the spark plug connectors until they click in place.
61. Attach the timing belt covers and the belt pulleys. Lower timing belt cover Crankshaft pulley/vibration damper Upper timing belt cover Center timing belt cover/front engine mounting bracket Drive belt idler pulley Water pump belt pulley
62. Connect the positive crankcase ventilation using a new seal. Three bolts One bolt
63. Attach the ancillary components on the exhaust side. Bracket for air conditioning compressor. Bracket for power steering pump to cylinder head. Bracket for power steering pump to cylinder block.
64. Hook the engine by the engine lifting eyes onto the workshop hoist and detach it from the assembly stand. Put the engine down onto the assembly stand and leave it hooked onto the workshop hoist.
65. Attach the ancillary components on the intake side. Oil pressure switch KS Attach a new oil filter. Generator bracket to cylinder block Generator bracket to cylinder head
66. Attach the intake manifold. Screw in five bolts and fit two nuts.
67. Attach the exhaust manifold to the cylinder head using the alignment spacers with the two outside bolts and a new manifold gasket.
68. Loosen the bracket for the catalytic converter so that it can move freely.
69. Position the catalytic converter on the exhaust manifold using new hardware.
70. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
71. Using a nut and bolt, temporarily secure the catalytic converter to the bracket at the rear.
72. Tighten the catalytic converter to the exhaust manifold.
73. Attach the catalytic converter. Tighten the bolts on the catalytic converter bracket. Install a new EGR-pipe. Attach the heat shield.
74. Attach the bracket for the catalytic converter. Tighten the bolts. Remove the temporary bolt from the rear catalytic converter bracket.
75. Attach the generator. Screw in and tighten the bolt. Tighten the bolt. Connect the positive cable.
76. Connect the multiplug to the oil pressure switch and the KS.

GENERAL EQUIPMENT SPECIFICATIONS

MATERIAL ITEM SPECIFICATIONS

GENERAL EQUIPMENT SPECIFICATIONS

MATERIAL ITEM SPECIFICATIONS