Engine- 2.3L: Removal & Installation Ford Focus I рестайлинг

Removal

Scheme 1189

Scheme 1190

1. Remove the accessory drive belt.
2. Remove the valve cover. For additional information, refer to «VALVE COVER»(ref-234427-S11704634312006060900000) .
3. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
4. Install the special tool in the slots on the rear of both camshafts.
5. Remove the plug bolt.
6. Install the special tool.
7. Install the special tools.
8. Remove the crankshaft pulley. Remove the crankshaft pulley bolt. Remove the special tools. Remove the crankshaft pulley.

Scheme 1191

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1. Install the crankshaft pulley and hand-tighten the bolt.
2. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover. Rotate the pulley as necessary to align the bolt holes.
3. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in two stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn).
4. Remove the special tools.
5. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
6. Remove the special tool.
7. Remove the special tool.
8. Turn the engine two complete revolutions.
9. Turn the crankshaft until the No. 1 piston is at top dead center (TDC).
10. Install the special tool.
11. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, correct the engine timing.
12. Using the special tool, check the position of the camshafts. If it is not possible to install the special tool, correct the engine timing.
13. Remove the special tool.
14. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
15. Remove the special tool.
16. Install the plug bolt.
17. Install the valve cover. For additional information, refer to «VALVE COVER»(ref-234427-S11704634312006060900000) .
18. Install the accessory drive belt.

1. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-234427-S12493837862006060900000) .
2. Using the special tool, remove the crankshaft front oil seal.

Scheme 1198

1. Remove the thru-bolt from the special tool. NOTE: Lubricate the oil seal with clean engine oil. Using the special tool, install the crankshaft front oil seal.
2. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-234427-S12493837862006060900000) .

Scheme 1199

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
2. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-234427-S12493837862006060900000) .
3. Release the wiring harness. Remove the nuts retaining the wiring harness. Release the wiring harness from the front cover studs and position aside.
4. Disconnect the CKP sensor electrical connector.
5. Remove the accessory belt tensioner. Remove the bolts. Remove the tensioner.
6. Disconnect the power steering pressure (PSP) switch electrical connector.
7. Remove the nut and detach the PSP tube bracket.
8. Using the special tool, remove the power steering pump pulley.
9. Disconnect the PSP tube. Remove and discard the O-ring seal.
10. Remove the four bolts and position the power steering pump aside.
11. Remove the coolant pump pulley.
12. Remove the RH motor mount. For additional information, refer to «ENGINE MOUNT - RH»(ref-234427-S33977000012006060900000) .
13. Remove the accessory drive belt idler pulley.
14. Remove the retainers and the engine front cover.

Scheme 1209

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1. Clean and inspect the mounting surfaces of the engine and the front cover.
2. Apply a 2.5-mm bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5-mm bead of silicone gasket and sealant to the front cover.
3. Install the front cover. Tighten the bolts in the sequence shown, to the following specifications: Tighten the 8-mm bolts to 10 Nm (89 lb-in). Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
4. Position the power steering pump and install the four retaining bolts.
5. Using the special tool, install a new O-ring on the PSP tube fitting.
6. Connect the power steering PSP tube fitting.
7. Using the special tool, install the power steering pump pulley.
8. Attach the PSP tube bracket and install the nut.
9. Connect the PSP switch electrical connector.
10. Install the coolant pump pulley.
11. Install the accessory drive belt idler pulley.
12. Install the accessory drive belt tensioner. Position the tensioner. Install the tensioner belts.
13. Install the RH motor mount. For additional information, refer to «ENGINE MOUNT - RH»(ref-234427-S33977000012006060900000) .
14. Connect the CKP sensor electrical connector and the wiring harness pin-type retainers.
15. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-234427-S12493837862006060900000) .
16. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
17. Fill and purge the power steering fluid. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-207742) .

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Scheme 1221

1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-234427-S41996954992006060900000) .
2. Remove the timing chain tensioner. Compress the timing chain tensioner and insert a paper clip into the hole. Remove the bolts and timing chain tensioner.
3. Remove the RH timing chain guide.
4. Remove the timing chain.
5. Remove the bolts and the LH timing chain guide.
6. If necessary, remove the bolts and the camshaft sprockets. Use the flats on the camshaft to prevent camshaft rotation.

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1. Remove the special tool.
2. If the camshaft sprockets were not removed, use the flats on the camshafts to prevent camshaft rotation and loosen the sprocket bolts.
3. If removed, install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
4. Install the LH timing chain guide and bolts.
5. Install the timing chain.
6. Install the RH timing chain guide.
7. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
8. Install the special tool.
9. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
10. Install the front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-234427-S41996954992006060900000) .

1. Remove the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-234427-S28466906932006060900000) .
2. Using the special tools, 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.

Installation

1. 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. Disconnect and remove the air supply.
2. Install the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-234427-S28466906932006060900000) .

Scheme 1225

1. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-234427-S36316281482006060900000) . 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, 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. Using the special tools, remove the valve stem seals.

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Scheme 1227

1. Install the 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 the appropriate steps for all the other cylinders.
6. Coat the valve tappets with clean engine oil and insert them.
7. Tighten the spark plugs.
8. Install the camshafts. For additional information, refer to «CAMSHAFTS»(ref-234427-S36316281482006060900000) .

Note. Valve tappets are select fit and the valve clearance must be checked before removing the tappets. For additional information, refer to VALVE CLEARANCE CHECK . If the valve clearance has already been checked, proceed with removal.

Scheme 1228

1. Remove the timing chain. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-234427-S28866566972006060900000) .
2. Remove the special tool.
3. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
4. Loosen the camshaft bearing bolts in the sequence shown, one turn at a time. Repeat until all the tension is released. Remove the camshaft bearing caps. Remove the camshafts.
5. Remove the valve tappets.
6. Inspect the valve tappets. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .

Scheme 1229

1. Install the valve tappets.
2. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in three stages. Stage 1: Tighten the camshaft bearing cap bolts, one turn at a time, until the cam is fully seated. Stage 2: Tighten the bolts to 7 Nm (62 lb-in). Stage 3: Tighten the bolts to 16 Nm (12 lb-ft).
3. Install the special tool.
4. Install the timing chain. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-234427-S28866566972006060900000) .
5. Confirm each valve's clearance at base circle with the lobe pointed away from the tappet.

1. Check valve clearance. For additional information, refer to «VALVE CLEARANCE CHECK»(ref-234427-S19781877962006060900000) .
2. Remove the timing chain and sprockets. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-234427-S28866566972006060900000) .
3. Remove the special tool.
4. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
5. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time. Repeat the first step until all tension is released from the camshaft bearing caps. Remove the camshaft bearing caps. Remove the camshafts.

1. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in three stages. Stage 1: Tighten the camshaft bearing bolt caps one turn at a time until tight. Stage 2: Tighten the bolts to 7 Nm (62 lb-in). Stage 3: Tighten the bolts to 16 Nm (12 lb-ft).
2. Install the camshaft drive gears and hand-tighten the bolts.
3. Install the timing chain and sprockets. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-234427-S28866566972006060900000) .

Note. Engine balancing is not required. Balance weights should not be installed on the new flywheel.

Note. Special bolts are used for installation. Do not use standard bolts.

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1. Inspect the pilot bearing. Install a new pilot bearing as necessary.
2. Install the flywheel.
3. Install the special tool.
4. Tighten the bolts in the sequence shown in three stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (50 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
5. Install the clutch assembly. For additional information, refer to «CLUTCH - MTX75 TRANSAXLE»(ref-207767) .
6. Install the transmission. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION - MTX75»(ref-207772) .