Engine - Svt: Other Ford Focus I рестайлинг

ENGINE DATA

ENGINE DATA

Cylinder Block

Part modified to include piston spray jets.

Cylinder Head

Inlet Port - High flow design with new manifold break-out.

Exhaust Port - Standard port but with secondary air feed to the back of the exhaust valve.

Water Jacket - Revised flow around ports.

Oil feed arrangement for variable valve timing installation.

Incorporation of VCT (variable camshaft timing) solenoid in front camshaft bearing cap.

Inlet Valves

33.5 mm diameter with revised spacing to maintain bridge material and longer length for new port.

Exhaust Valves

Standard diameter but longer to commonize tappet with the inlet side.

Inlet Camshaft

Increased lift and duration with variable timing.

Trigger wheel fitted to indicate cam position.

Exhaust Camshaft

Increased lift and duration.

Tappet

Series of sizes commencing with unique graded part to suit new length valve and revised cam profile.

Valve Springs

Inlet and Exhaust unique parts to suit new valve lengths and revised cam profiles.

Front Engine Mount

Mounting studs moved to clear VCT pulley.

Alternator Bracket

Modified to accommodate revised engine mount.

Intake Manifold

Made up of two assemblies replacing the single piece manifold with fixed length tracts.

1. Plenum Assembly
2. Housing Assembly-Manifold-Injectors
3. Variable-length intake runner design.

The unit is in the short runner position with the engine off and then switches to the long runner position when the engine starts. The runners then switch to short runner position above 6000 rpm.

Throttle Body

Modified 63 mm diameter part.

Injectors

Increased flow items specified as 224.8 g/min at 2.7 bar (normal fuel rail pressure)

Fuel Rail

Redesigned part with integral damper and no fuel return connection. The fuel inlet to the rail has been repositioned requiring a new fuel feed hose assembly.

Oil Cooler

Modine type.

Variable Cam Timing System

Solenoid Assembly

Variable Timing Unit Assembly

Exhaust System

Tuned 4-2-1 system with the catalyst located under the oil pan.

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

Material

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 933

1. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-234426-S00221357122006060900000) . 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.

Scheme 934

Scheme 935

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-234426-S00221357122006060900000) .

MATERIAL SPECIFICATIONS

Scheme 936

1. Remove the cylinder head.
2. Remove the valve. Compress the valve spring. Remove the valve collets.
3. Remove the valve springs.
4. Remove the valve stem oil seal. Insert the special tool. Turn the special tool clockwise and pull it out.
5. Repeat the removal steps for the remaining valves.

Scheme 937

1. Regrind the valves with grinding paste.
2. Thoroughly clean all components to remove any traces of abrasive.
3. Coat valve shaft with lubricant and insert valve.
4. Install the valve stem seal. Cover the groove in the valve stems with the valve stem seal fitting sleeve. Slide the valve stem seal onto the valve stem and remove the fitting sleeve.
5. Install the valve spring. Insert the valve spring and valve spring retainers. Compress the valve spring. Insert the collets.
6. Repeat the installation steps for the remaining valves.
7. Install the cylinder head.

MATERIAL SPECIFICATIONS

General Equipment

GENERAL EQUIPMENT SPECIFICATIONS

MATERIAL SPECIFICATIONS

GENERAL EQUIPMENT SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 938

Scheme 939

Scheme 940

Scheme 941

Scheme 942

Scheme 943

Scheme 944

Scheme 945

Scheme 946

Scheme 947

Scheme 948

Scheme 949

Scheme 950

Scheme 951

Scheme 952

Scheme 953

Scheme 954

Scheme 955

Scheme 956

1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-207778) .
2. Disconnect the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
3. Release the coolant system pressure.
4. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
5. Drain the coolant from the radiator. Allow the coolant to drain into a suitable container. Install the radiator drain plug after draining the coolant.
6. Disconnect the oil pressure switch electrical connector.
7. Remove the intake manifold lower retaining bolt.
8. Disconnect the knock sensor electrical connector and separate it from the intake manifold.
9. Disconnect the catalyst monitor sensor electrical connector and separate it from the bracket.
10. Lower the vehicle.
11. Detach the brake booster pipe from the intake manifold. Release the quick release coupling and detach the brake booster pipe.
12. Remove the air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-207759) .
13. Remove the splash shield.
14. Disconnect the vehicle speed control cable. Disconnect the inner cable from the throttle body. Detach the vehicle sped control cable from the throttle body.
15. Detach the accelerator cable from the throttle body.
16. Detach the intake manifold runner control (IMRC) actuator cable from the IMRC lever (intake manifold assembly shown removed for clarity). Rotate the IMRC lever. Remove the IMRC actuator cable.
17. Disconnect the vacuum hoses from the intake manifold.
18. Disconnect the fuel injector wiring harness.
19. Disconnect the camshaft position (CMP) sensor electrical connector.
20. Detach the fuel lines. Detach the ground cable from the engine lifting eye.
21. Remove the exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD»(ref-234426-S27472261802006060900000) .
22. Detach the thermostat housing.
23. Detach the power steering pipe bracket from the cylinder head.
24. Disconnect the wiring harness from the electronic ignition (El) coil and from the engine coolant temperature (ECT) sensor.
25. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-234426-S00221357122006060900000) .
26. Detach the power steering pump bracket from the cylinder head and cylinder block.
27. Detach the generator. Loosen the bolt. Remove the bolt.
28. Remove the upper bolt from the generator bracket.
29. Remove the valve tappets.
30. Remove the cylinder head bolts.
31. Remove the cylinder head.

Scheme 957

Scheme 958

Scheme 959

Scheme 960

Scheme 961

Scheme 962

Scheme 963

Scheme 964

Scheme 965

Scheme 966

Scheme 967

Scheme 968

Scheme 969

Scheme 970

Scheme 971

Scheme 972

Scheme 973

Scheme 974

Scheme 975

1. Using a spatula, remove the gasket residue. Thoroughly clean the threaded holes of the cylinder head bolts.
2. Check the cylinder head distortion. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
3. Make up two locating studs as shown.
4. Install the cylinder head gasket. Position the cylinder head gasket. Insert the fabricated locating studs. Check that the locating studs are seated correctly.
5. Install the cylinder head.
6. Tighten the cylinder head bolts in three stages in the sequence indicated. Stage 1: 20 Nm Stage 2: 40 Nm Stage 3: 90 degrees.
7. Install the valve tappets in order.
8. Install the generator bracket bolt.
9. Attach the generator.
10. Attach the power steering pump bracket to the cylinder head and cylinder block.
11. Install the camshafts. For additional information, refer to «CAMSHAFTS»(ref-234426-S00221357122006060900000) .
12. Check the valve clearance and, if necessary, adjust.
13. Connect the wiring harness to the electric ignition (El) coil and to the engine coolant temperature (ECT) sensor.
14. Attach the power steering pipe bracket to the cylinder head.
15. Install the intake manifold lower retaining bolt.
16. Connect the catalyst monitor sensor electrical connector and attach it to the bracket.
17. Connect the knock sensor electrical connector.
18. Install the exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD»(ref-234426-S27472261802006060900000) .
19. Attach the thermostat housing.
20. Attach the fuel lines. Attach the ground cable to the engine lifting bracket.
21. Connect the camshaft position (CMP) sensor connector.
22. Connect the fuel injector wiring harness.
23. Attach the accelerator cable and the speed control cable (if equipped) to the throttle body.
24. Connect the vehicle speed control cable. Attach the vehicle speed control cable to the throttle body. Connect the inner cable from the throttle body.
25. Install the splash shield.
26. Attach the intake manifold runner control (IMRC) actuator cable to the IMRC lever (intake manifold assembly shown removed for clarity). Rotate the IMRC lever. Install the IMRC actuator cable.
27. Attach the vacuum hoses to the intake manifold.
28. Install the air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-207759) .
29. Attach the brake booster pipe to the intake manifold.
30. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
31. Connect the oil pressure switch electrical connector.
32. Drain and fill the engine with clean engine oil.
33. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
34. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-207748) .

GENERAL EQUIPMENT SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 976

1. Remove the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
2. Drain the engine. Allow the oil to drain into a suitable container.
3. Install the oil drain plug (engine shown remove for clarity).
4. Remove the oil pan retaining bolts (engine shown removed for clarity).
5. Using a suitable spatula, remove the oil pan (engine shown removed for clarity).

Scheme 977

1. Clean the mating faces of the oil pan and the lower crankcase.
2. Clean all traces of oil residue and oil sludge from the oil pan.
3. Install ten M6 x 20 mm studs into the blind holes shown (engine shown removed for clarity).
4. Apply a 3 mm diameter bead of sealant to the mating face of the oil pan.
5. Attach the oil pan to the lower crankcase housing. Remove the studs.
6. Install the oil pan retaining bolts. Tighten the oil pan retaining bolts in the sequence shown in two stages. Stage 1: 6 Nm Stage 2: 10 Nm
7. Install the oil pan drain plug.
8. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
9. Fill the engine with engine oil.

GENERAL EQUIPMENT SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 978

Scheme 979

Scheme 980

Scheme 981

Scheme 982

Scheme 983

Scheme 984

Scheme 985

1. Remove the crankshaft front seal. For additional information, refer to «CRANKSHAFT FRONT SEAL»(ref-234426-S24771419922006060900000) .
2. Install the engine front mount.
3. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
4. Detach the air conditioning (A/C) compressor from the bracket and secure it on the radiator crossmember.
5. Remove the A/C compressor bracket (engine shown removed for clarity).
6. Remove the intermediate shaft center bearing bracket.
7. Remove the catalytic converter bracket (engine shown removed for clarity).
8. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-234426-S19968245452006060900000) .
9. Remove the lower crankcase-to-transmission bolts.
10. Remove the lower crankcase (engine shown removed for clarity). Remove the oil pick-up tube. Remove the lower crankcase retaining bolts. Discard the gasket.
11. Remove the accessory drive belt tensioner.
12. Remove the oil pump (engine shown removed for clarity). Discard the gasket.

Scheme 986

Scheme 987

Scheme 988

Scheme 989

Scheme 990

Scheme 991

Scheme 992

Scheme 993

Scheme 994

Scheme 995

1. Install the oil pump (engine shown removed for clarity).
2. Align the oil pump on both sides so that the mating face is 0.3 mm - 0.8 mm above the lower edge of the cylinder block.
3. Tighten the oil pump retaining bolts (engine shown removed for clarity).
4. Using the special tool and the crankshaft pulley retaining bolt, install the crankshaft front seal. Coat the oil seal lip and crankshaft running surface with engine oil.
5. Install the accessory drive belt tensioner.
6. Apply a 4 mm bead of sealer to the areas as shown.
7. Install the lower crankcase (engine shown removed for clarity).
8. Tighten the lower crankcase to transaxle retaining bolts.
9. Tighten the lower crankcase-to-cylinder block retaining bolts (engine shown removed for clarity).
10. Install the oil pump pickup tube.
11. Install the oil pan. For additional information, refer to «OIL PAN»(ref-234426-S19968245452006060900000) .
12. Install the intermediate shaft center bearing bracket.
13. Install the catalytic converter bracket (engine shown removed for clarity).
14. Install the air conditioning (A/C) compressor bracket (engine shown removed for clarity).
15. Attach the A/C compressor to the bracket.
16. Lower the vehicle.
17. Position the hydraulic jack with the wooden block under the oil pan and raise so that the engine front mount is free from load.
18. Remove the engine front mount.
19. Install the timing belt. For additional information, refer to «TIMING BELT»(ref-234426-S01870671512006060900000) .

MATERIAL SPECIFICATIONS

Scheme 996

Scheme 997

1. Detach the clutch. Lock the flywheel using Special Tool 303-254. Slacken the clutch pressure plate bolts evenly. Detach the clutch pressure plate and the clutch disc.
2. Detach the flywheel. Remove Special Tool 303-254.
3. Remove the oil seal.

Scheme 998

Scheme 999

Scheme 1000

1. Insert a new crankshaft rear oil seal into the special tool. To ensure correct installation, place the special tool on a vice and press in the oil seal using a hammer handle. Incorrect installation Correct installation
2. Draw in the oil seal. Push in the oil seal using the special tool and two flywheel; bolts.
3. Attach the flywheel.
4. Lubricate the clutch disc engagement splines evenly all over with high-temperature grease.
5. Center the clutch disc on the clutch pressure plate.
6. Attach the clutch. Fit the clutch pressure plate with centered clutch disc. Working diagonally, tighten the bolts in several stages one turn at a time. Check the centering and correct if necessary.
7. Detach the special tools.

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)

Scheme 1001

Scheme 1002

MATERIAL SPECIFICATIONS

All vehicles

Scheme 1003

Scheme 1004

Scheme 1005

Scheme 1006

Scheme 1007

Scheme 1008

Scheme 1009

Scheme 1010

Scheme 1011

Scheme 1012

Scheme 1013

Scheme 1014

Scheme 1015

Scheme 1016

Scheme 1017

Scheme 1018

Scheme 1019

Scheme 1020

Scheme 1021

Scheme 1022

Scheme 1023

Scheme 1024

Scheme 1025

Scheme 1026

Scheme 1027

Scheme 1028

Scheme 1029

Scheme 1030

Scheme 1031

Scheme 1032

Scheme 1033

Scheme 1034

Scheme 1035

Scheme 1036

Scheme 1037

Scheme 1038

Scheme 1039

Scheme 1040

Scheme 1041

Scheme 1042

1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-207778) .
2. Release the coolant system pressure.
3. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
4. Remove the air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-207759) .
5. Detach the ground cable from the inner fender.
6. Remove the air cleaner intake tube and resonator.
7. Remove the air conditioning (A/C) compressor and secure it to the radiator crossmember.
8. Drain the coolant (shown from below). Allow the coolant to drain into a suitable container. Install the drain plug after draining.
9. Drain the engine. Allow the oil to drain into a suitable container.
10. Install the oil drain plug (engine shown remove for clarity).
11. Partially lower the vehicle.
12. Loosen the strut and spring assembly upper mount retaining nuts by five turns on both sides.
13. Remove the splash shield.
14. Detach the accelerator cable and the speed control cable (if equipped) from the throttle body.
15. Detach the intake manifold runner control (IMRC) actuator cable from the IMRC lever (intake manifold assembly shown removed for clarity). Rotate the IMRC lever. Detach the IMRC actuator cable from the intake manifold.
16. Remove the ignition coil pack cover.
17. Disconnect the ignition coil pack electrical connector. Disconnect the radio capacitor.
18. Disconnect the block heater harness (if equipped).
19. Disconnect the starter field wire electrical connector.
20. Disconnect the fuel injector wiring harness.
21. Disconnect the ground cable from the engine lifting eye.
22. Disconnect the generator electrical connector.
23. Detach the hydraulic line from the clutch slave cylinder. Remove the clip. Remove the clutch line and secure it to one side using cable ties.
24. Disconnect the wiring harness electrical connector.
25. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
26. Disconnect the vehicle speed sensor (VSS) electrical connector.
27. Disconnect the reversing lamp switch electrical connector.
28. Partially lower the vehicle.
29. Disconnect the vacuum hoses from the intake manifold.
30. Detach the brake booster pipe from the intake manifold. Release the quick release coupling and detach the brake booster pipe.
31. Detach the fuel lines. Detach the ground cable.
32. Detach the coolant hoses.
33. Disconnect the oil cooler hose.
34. Remove the power steering pump upper bolts.
35. Detach the gearshift cables from the transaxle. Detach the gearshift cable and the selector cable from the selector levers. Detach the retaining bracket from the transaxle.
36. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
37. Remove the power steering pump lower retaining bolts and disconnect the radiator lower coolant hose from the water pump housing.
38. Disconnect the power steering pressure (PSP) switch electrical connector.
39. Disconnect the crankshaft position (CKP) sensor connector.
40. Detach the coolant hose from the oil cooler.
41. Lower the vehicle.
42. Detach the coolant expansion tank and position it to one side.
43. Drain the power assisted steering (PAS) reservoir.
44. Detach the PAS reservoir and position it to one side.
45. Detach the power steering line bracket from the cylinder head.
46. Remove the power steering pump bracket.
47. Remove the crossmember.
48. Remove the catalytic converter support bracket. Remove the catalyst monitor sensor.
49. Detach the catalytic converter from the exhaust manifold. Discard the gasket and nuts. Remove the heated oxygen (HO2S) sensor.
50. Remove the flexible exhaust pipe.
51. Detach the RH halfshaft and the intermediate shaft from the transaxle and secure it to one side. Allow the oil to drain into a suitable container. Discard the center bearing cap and locknuts.
52. Using the special tools, detach the LH halfshaft from the transaxle and secure it to one side. Allow the oil to drain into a suitable container. Discard the snap ring.
53. Position the assembly table with suitable wooden blocks under the engine and transmission assembly.
54. Carefully lower the vehicle until the engine and transmission assembly is positioned on the assembly stand.
55. Secure the engine and transmission assembly to the assembly stand table with a retaining strap.
56. Remove the engine rear mount.
57. Remove the engine front mount.
58. Carefully raise the vehicle. Pull forward the assembly stand.
59. Using the special tools, secure the engine and transmission assembly on an engine hoist.
60. Remove the transaxle upper retaining bolts.
61. Disconnect the starter motor electrical connectors.
62. Remove the starter motor. Detach the ground cable from the transaxle.
63. Remove the transaxle RH retaining bolts.
64. Remove the transaxle LH retaining bolts.
65. Separate the engine from the transaxle.

SPECIAL TOOL SPECIFICATIONS Slide Hammer 205-047 (15-011) Mounting Bracket for 303-435 303-435-04 (21-064) Locking Tool, Flywheel 303-254 (21-135) Lifting Bracket, Engine 303-122 (21-068A) Mounting Plate for 303-435-04 303-435-12 (21-150A) Adapter for 205-047 303-633 (21-227) Socket, Cylinder Head Bolt 303-392 (21-167)

Scheme 1043

Scheme 1044

Scheme 1045

Scheme 1046

Scheme 1047

GENERAL EQUIPMENT SPECIFICATIONS

Scheme 1048

Scheme 1049

Scheme 1050

Scheme 1051

Scheme 1052

Scheme 1053

Scheme 1054

Scheme 1055

Scheme 1056

Scheme 1057

Scheme 1058

Scheme 1059

Scheme 1060

Scheme 1061

Scheme 1062

Scheme 1063

Scheme 1064

1. Disconnect the oil pressure switch and the knock sensor (KS) electrical connectors.
2. Remove the generator. Disconnect the positive cable. Remove the bolt. Remove the bolt.
3. Remove the ancillary components on the intake side. Generator mounting bracket. Oil filter. Knock sensor (KS). Oil pressure switch.
4. Remove the oil cooler.
5. Install the mounting plate to the engine.
6. Install the mounting bracket to the mounting plate.
7. Attach the engine to the assembly stand and remove the engine lifting bracket.
8. Remove the ancillary components on the exhaust side. Power steering pump bracket. Air conditioning compressor bracket.
9. Disconnect the positive crankcase ventilation.
10. Remove the clutch assembly. For additional information, refer to «CLUTCH - IB5 TRANSAXLE»(ref-207766) , «CLUTCH - MTX75 TRANSAXLE»(ref-207767) or «CLUTCH - MT285 TRANSAXLE»(ref-207768) .
11. Using the special tool, lock the flywheel in position.
12. Remove the timing belt cover. Water pump belt pulley. Drive belt idler pulley. Engine front mount bracket. Upper timing belt cover. Remove the damper from the crankshaft pulley. Lower timing belt cover.
13. Disconnect the spark plug electrical connectors.
14. Remove the valve cover.
15. Remove the timing belt drive and the water pump. Slacken the timing belt tensioner by twisting it counter-clockwise and remove it. Remove the timing belt. Remove the idler pulley. Remove the water pump. Remove the crankshaft timing pulley and the thrust washer.
16. Remove the intake camshaft pulley blanking plug.
17. Remove the camshaft pulleys.
18. Remove the oil feed flange. Discard the camshaft oil seals. Discard the oil feed flange oil seal.
19. Remove the camshafts. Remove the valve tappets and position them in order, to one side.
20. Remove the cylinder head.
21. Using the special tool, remove the flywheel. Discard the bolts.
22. Remove the special tool.
23. Remove the drain plug and the oil pan retaining bolts. Allow the oil to drain into a suitable container.
24. Using the special tool, remove the oil pan.
25. Remove the oil intake pipe and the lower crankcase. Oil intake pipe bolts. Lower crankcase bolts.
26. Remove the oil pump.
27. Remove the crankshaft rear oil seal carrier, crankshaft position (CKP) sensor and CKP bracket.

MATERIAL SPECIFICATIONS

Scheme 1065

Scheme 1066

Scheme 1067

Scheme 1068

Scheme 1069

Scheme 1070

Scheme 1071

Scheme 1072

Scheme 1073

Scheme 1074

Scheme 1075

Scheme 1076

Scheme 1077

Scheme 1078

Scheme 1079

Scheme 1080

Scheme 1081

1. Disconnect the throttle position (TP) sensor electrical connector (air cleaner shown removed for clarity).
2. Disconnect the camshaft position (CMP) sensor electrical connector.
3. Disconnect the idle air control (IAC) valve electrical connector (air cleaner shown removed for clarity).
4. Remove the CMP sensor.
5. Remove the electronic ignition (EI) coil pack.
6. Disconnect the vacuum line from the fuel pressure sensor.
7. Disconnect the vacuum line from the fuel pulse damper.
8. Remove the fuel injection supply manifold.
9. Separate the two sections of the intake manifold.
10. Remove the bracket.
11. Remove the intake manifold inner section locknut and bolts (intake manifold shown removed for clarity). Discard the locknut.
12. Remove the intake manifold inner section.
13. Remove the timing belt tensioner and idler pulley.
14. Remove the inner timing belt cover.
15. Remove the rear lifting eye.
16. Remove the front lifting eye.
17. 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.
18. Inspect the valve spring, valve spring retainer and valve spring retainer key. Install new parts as necessary.
19. Remove the valves.
20. Using the special tools, remove and discard the valve stem seals.
21. Inspect the valves. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) . Install new parts as necessary.

Scheme 1082

Scheme 1083

Scheme 1084

Scheme 1085

Scheme 1086

Scheme 1087

Scheme 1088

Scheme 1089

Scheme 1090

Scheme 1091

Scheme 1092

Scheme 1093

Scheme 1094

Scheme 1095

Scheme 1096

1. Install the valves.
2. Lubricate valve and guides with engine oil 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 front lifting eye.
6. Install the rear lifting eye.
7. Install the inner timing belt cover.
8. Install the timing belt tensioner and the idler pulley.
9. Install the intake manifold inner section.
10. Install the intake manifold inner section locknut and bolts (intake manifold shown removed for clarity).
11. Install the bracket.
12. Assemble the two sections of the intake manifold.
13. Install the fuel injection supply manifold.
14. Connect the vacuum line to the fuel pulse damper.
15. Connect the vacuum line to the fuel pressure sensor.
16. Install the electronic ignition (EI) coil pack.
17. Install the CMP sensor.
18. Connect the idle air control (IAC) valve electrical connector.
19. Connect the CMP sensor electrical connector.
20. Connect the throttle position (TP) sensor electrical connector.

SPECIAL TOOL SPECIFICATIONS Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1) Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Timing Peg, Crankshaft 303-574 (T97P-6000-A) Installer, Camshaft Oil Seal 303-160 (T81P-6292-A) Holding Tool, Flywheel 303-103 (T74P-6375-A) Aligner, Clutch Disc 308-020 (T74P-7137-K)

Scheme 1097

Scheme 1098

Scheme 1099

MATERIAL SPECIFICATIONS

Scheme 1100

Scheme 1101

Scheme 1102

Scheme 1103

Scheme 1104

Scheme 1105

Scheme 1106

Scheme 1107

Scheme 1108

Scheme 1109

Scheme 1110

Scheme 1111

Scheme 1112

Scheme 1113

Scheme 1114

Scheme 1115

Scheme 1116

Scheme 1117

Scheme 1118

Scheme 1119

Scheme 1120

Scheme 1121

Scheme 1122

Scheme 1123

Scheme 1124

Scheme 1125

Scheme 1126

Scheme 1127

Scheme 1128

Scheme 1129

Scheme 1130

Scheme 1131

Scheme 1132

Scheme 1133

Scheme 1134

Scheme 1135

Scheme 1136

Scheme 1137

Scheme 1138

Scheme 1139

1. Preparatory operations.
2. Remove the carbon deposits from 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. 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 a bearing clearance of between 0.020 - 0.040 mm.
7. Measure the crankshaft end play. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
8. Measure the camshaft radial clearance . For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
9. Measure the camshaft end play. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
10. Measure the crankshaft main journal diameter. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
11. Measure the camshaft bearing journal diameter. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
12. Measure the cylinder bore taper. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
13. Measure the piston diameter. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
14. Measure the piston ring end gaps. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
15. Measure the piston rings to groove clearance. 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. Position the crankshaft. Install the main bearing caps. Position the main bearing shells, clean and free of oil, into the cylinder block and the bearing caps. Coat the inner side of the bearing shells with engine oil.
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 suitable 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. Position 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 fully tighten the connecting rod bearing cap bolts at this stage. Install the bearing caps. Rotate the crankshaft through 180 degrees and insert pistons 2 and 3. Position 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 the main bearing and connecting rod bearing bolts. 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. Align the rear oil seal carrier so that the mating face of the oil seal carrier is not more than 0.2 mm below the cylinder block.
21. Tighten the crankshaft rear seal carrier retaining bolts. Tighten the bolts in two stages: Stage 1: 12 Nm. Stage 2: 42 degrees.
22. Install the crankshaft position (CKP) sensor bracket.
23. Using the special tool, install the crankshaft rear seal.
24. 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.
25. Install the oil pump with a new crankshaft front 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.
26. Apply a 4 mm bead of sealer to the areas as shown.
27. Align the lower crankcase. Position the lower crankcase with a new gasket and tighten the bolts finger tight. 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: 10 mm protrusion to 0.25 mm gap.
28. Install lower crankcase spacer washers as necessary. With a gap of 0.26 - 0.50 mm, install 0.25 mm spacer washers. With a gap of 0.51 - 0.75 mm, install 0.50 mm spacer washers.
29. 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.
30. Install 10 studs, M6 x 20, in the dead end bores shown.
31. Clean off any residues of oil or oil sludge from the oil pan.
32. Apply a 3 mm bead of sealant to the oil pan flange.
33. Tighten the bolts in two stages. Stage 1: 6 Nm. Stage 2: 12 Nm.
34. Rotate the crankshaft to approximately 60 degrees BDC.
35. Install the cylinder head. Tighten the cylinder head bolts in three stages in the indicated sequence. Stage 1: 20 Nm. Stage 2: 40 Nm. Stage 3: 90 degrees.
36. Lubricate the valve tappets with engine oil and install them in the correct order.
37. Install the camshafts in place with none of the cams at full lift.
38. Coat the camshafts and camshaft bearing caps with engine oil and insert them.
39. Install the camshafts. Tighten the bolts in the sequence shown.
40. Using a suitable set of feeler gauges, measure the valve clearance. Permitted valve clearance, inlet - 0.21 -0.29 mm Permitted valve clearance, exhaust - 0.32 -0.40 mm
41. Remove the camshafts.
42. Determine the tappet thickness required. Remove the valve tappet and read the thickness from the underside. Calculate the valve tappet thickness required and insert the correct tappet. Inlet valves: tappet thickness required = thickness of currently installed tappets + measured valve clearance - 0.25 mm. Exhaust valves: tappet thickness required = thickness of currently installed tappets + measured valve clearance - 0.36 mm.
43. Install the camshafts. Tighten the bolts in the sequence shown.
44. Apply sealer to the marked areas on the oil feed flange.
45. Install the oil feed flange.
46. Recheck the valve clearance.
47. Install the exhaust camshaft seal. 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.
48. Rotate the camshafts to the ignition point on cylinder number 1 and insert the special tool into the camshafts.
49. Turn the crankshaft to TDC on cylinder number 1.
50. Remove the blanking plug and align the crankshaft at TDC using the special tool.
51. Install the camshaft pulleys.
52. Install a new coolant pump gasket by bending over the tabs. Lay the gasket in place. Secure the gasket by bending over the tabs.
53. Position a new timing belt. Slide the crankshaft timing pulley with a thrust washer onto the crankshaft. Attach the coolant 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 tighten the bolt five turns.
54. 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 hexagonal key slot in the tensioner adjusting washer to the 4 o'clock position. Using a 6 mm hexagonal key tighten the bolt enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated
55. Using the hexagonal 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).
56. While holding the adjusting washer in position, tighten the bolt.
57. Tighten the camshaft pulley retaining bolts.
58. Remove special tool.
59. Remove special too.
60. Rotate the engine two revolutions.
61. Using the special tool, check the position of the crankshaft.
62. Using the special tool, check the position of the camshafts.
63. Install the intake camshaft pulley blanking plug.
64. Remove the special tools.
65. Install the blanking plug.
66. Install the valve cover.
67. Connect the spark plug electrical connectors. Push on the spark plug electrical connectors until they click in place.
68. Connect the variable camshaft timing (VCT) sensor electrical connector.
69. Install the spark plug cables cover.
70. Connect the camshaft position (CMP) sensor electrical connector.
71. 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. Coolant pump belt pulley.
72. Install the positive crankcase ventilation housing. Three bolts. One bolt.
73. Connect the engine coolant temperature (ECT) sensor electrical connector.
74. Install the exhaust manifold.
75. Install the engine oil level indicator tube.
76. Install the exhaust manifold heat shield.
77. Install the catalytic converter mounting bracket.
78. Install the intermediate shaft mounting bracket.
79. Attach the knock sensor (KS) electrical connector to the intake manifold inner section.
80. Connect the throttle position (TP) sensor electrical connector.
81. Connect the idle air control (IAC) sensor electrical connector.
82. Connect the fuel injector electrical connectors.
83. Connect the vacuum line to the fuel pulse damper.
84. Connect the vacuum line to the fuel pressure sensor.
85. Connect the fuel pressure sensor electrical connector.
86. Install the intake manifold lower retaining bolt.
87. Attach the ancillary components on the exhaust side. Air conditioning compressor bracket. Power steering pump bracket. Power steering pump-to-cylinder block bracket.
88. Install the oil cooler.
89. 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.
90. Clean the inside diameter of the cylinder block bore and surface.
91. Install the block heater with the electrical connector of the block heater at the 9 o'clock position.
92. Tighten the block heater.
93. Connect the block heater electrical connector.
94. Install the generator. Tighten the bolt. Tighten the bolt. Connect the positive cable.
95. Connect the oil pressure switch and the KS electrical connectors.
96. Remove the engine from the engine stand.
97. Install the spacer plate and dowels.
98. Install the flywheel. Using the special tool, lock the flywheel in position.
99. Remove the special tool.
100. Using a suitable clutch disc locator, install the clutch disc and pressure plate.
101. Tighten the clutch disc and pressure plate retaining bolts.

SPECIAL TOOL SPECIFICATIONS Spreader Bar 303-D089 (D93P-6001-A3) Remover/Installer, Cooling Hose Clamp 412-108 (T96P-18539-A) Lifting Bracket, Engine 303-050 (T70P-6000)

Scheme 1140

Scheme 1141

Scheme 1142

GENERAL EQUIPMENT SPECIFICATIONS

MATERIAL SPECIFICATIONS

All vehicles

Scheme 1143

Scheme 1144

Scheme 1145

Scheme 1146

Scheme 1147

Scheme 1148

Scheme 1149

Scheme 1150

Scheme 1151

Scheme 1152

Scheme 1153

Scheme 1154

Scheme 1155

Scheme 1156

Scheme 1157

Scheme 1158

Scheme 1159

Scheme 1160

Scheme 1161

Scheme 1162

Scheme 1163

Scheme 1164

Scheme 1165

Scheme 1166

Scheme 1167

Scheme 1168

Scheme 1169

Scheme 1170

Scheme 1171

Scheme 1172

Scheme 1173

Scheme 1174

Scheme 1175

Scheme 1176

Scheme 1177

Scheme 1178

Scheme 1179

Scheme 1180

Scheme 1181

Scheme 1182

Scheme 1183

Scheme 1184

1. Install the transaxle.
2. Install the transaxle LH retaining bolts.
3. Install the transaxle RH retaining bolts.
4. Install the starter motor. Attach the ground cable to the transaxle.
5. Connect the starter motor electrical connectors.
6. Install the transaxle upper retaining bolts.
7. Using a retaining strap, secure the engine and transmission assembly on the assembly stand. Remove the special tools.
8. Position the engine and transmission assembly under the vehicle. Carefully lower the vehicle.
9. Install the engine front mount.
10. Install the engine rear mount.
11. Remove the retaining strap from the engine and transmission assembly, and remove the assembly stand.
12. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
13. Attach the RH halfshaft and the intermediate shaft to the transaxle. Install the center bearing cap.
14. Attach the LH halfshaft to the transaxle.
15. Install the flexible exhaust pipe.
16. Attach the catalytic converter to the exhaust manifold. Install the heated oxygen (HO2S) sensor.
17. Install the catalytic converter bracket. Install the catalyst monitor sensor (CMS).
18. Lower the vehicle.
19. Tighten the engine rear mount nuts and bolts.
20. Tighten the engine front mount nuts.
21. Install the power steering pump bracket.
22. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
23. Install the power steering pump lower retaining bolts.
24. Connect the power steering pressure switch electrical connector.
25. Connect the crankshaft position sensor electrical connector.
26. Connect the radiator lower coolant hose to the coolant pump housing.
27. Connect the radiator lower coolant hose to the oil cooler.
28. Connect the reversing lamp switch electrical connector. Clip on the wiring loom.
29. Connect the vehicle speed sensor (VSS) electrical connector.
30. Install the crossmember.
31. Connect the oil cooler hose.
32. Attach the gearshift cables to the transaxle. Attach the retaining bracket to the transaxle. Attach the gearshift cable and the selector cable to the selector levers.
33. Connect the starter field wire electrical connector.
34. Install the power steering pump upper bolts.
35. Attach the coolant hoses to the thermostat housing.
36. Attach the fuel pipes to the fuel rail.
37. Attach the brake servo vacuum hose to the intake manifold.
38. Attach the vacuum hoses to the throttle body.
39. Attach the power steering line bracket to the cylinder head.
40. Install the power assisted steering (PAS) reservoir.
41. Install the coolant expansion tank.
42. Connect the wiring harness connectors.
43. Attach the clutch supply line to the clutch slave cylinder. Install the clip.
44. Bleed the hydraulic clutch operating system. For additional information, refer to «MANUAL TRANSMISSION, CLUTCH & TRANSFER CASE - GENERAL INFORMATION»(ref-207765) .
45. Connect the ignition coil pack electrical connector. Connect the radio capacitor.
46. Connect the generator electrical connector.
47. Connect the fuel injector wiring harness.
48. Install the ignition coil pack cover.
49. Attach the accelerator cable and the speed control cable (if equipped) to the throttle body.
50. Install the splash shield.
51. Connect the engine block heater (if equipped).
52. Connect the intake manifold runner control (IMRC). Rotate the IMRC lever. Connect the IMRC actuator cable.
53. Install the air cleaner intake tube and resonator.
54. Tighten the strut and spring assembly upper mounting retaining nuts.
55. Attach the ground cable to the inner fender.
56. Install the air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-207759) .
57. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
58. Install and connect the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
59. Fill the transaxle. For additional information, refer to «MANUAL TRANSMISSION, CLUTCH & TRANSFER CASE - GENERAL INFORMATION»(ref-207765) .
60. Install the air conditioning (A/C) compressor.
61. Fill the engine with engine oil.
62. Fill the cooling system. For additional information, refer to «ENGINE COOLING»(ref-207748) .
63. Fill and bleed the PAS system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-207742) .