Engine - 2.0L and 2.3L: Other Ford Focus I facelift

Valve Clearance Check

1. Remove the valve cover. For additional information, refer to «Valve Cover»(ref-278254-S19664308962008012400000) .
2. Use a feeler gauge to measure each valve's clearance and record its location.
3. Select the closest tappet size available and mark the installation location.
4. If any tappets do not measure within specifications, install new tappets in these locations. For additional information, refer to «Valve Train Components - Exploded View»(ref-278254-S12463370972008012400000) and «Valve Tappets»(ref-278254-S09584338262008012400000) .

Intake Manifold

Material

Measuring Gear Backlash. Scheme 40

Scheme 41

Crankshaft Pulley

Special Tools Illustration Tool Name Tool Number Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Timing Peg, Crankshaft 303-507 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Adapter for 205-126 (205-072-02)

Scheme 42

Material

Crankshaft Front Seal

Special Tools Illustration Tool Name Tool Number Installer, Front Oil Seal 303-096 (T74P-6150-A) Remover, Seal 303-409 (T92C-6700-CH)

Scheme 43

Material

Flexplate

Special Tools Illustration Tool Name Tool Number Locking Tool, Flexplate 303-103 (T74P-8375-A)

Flywheel

Special Tools Illustration Tool Name Tool Number Locking Tool, Flywheel 303-103 (T74P-8375-A)

Crankshaft Rear Seal with Retainer Plate

Special Tools Illustration Tool Name Tool Number Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1)

Scheme 44

Material

Engine Front Cover

Special Tools Illustration Tool Name Tool Number Remover, Oil Seal 303-409 (T92C-6700-CH) Installer, Front Oil Seal 303-096 (T74P-6150-A) Steering Pump Pulley Remover 211-016 Steering Pump Pulley Installer 211-185 Installer Set, Teflon® Seal 211-D207

Scheme 45

Material

Scheme 46

Scheme 47

Timing Drive Components

Special Tools Illustration Tool Name Tool Number Alignment Plate, Camshaft 303-465 (T94P-6256-CH)

Camshafts

Special Tools Illustration Tool Name Tool Number Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Timing Peg, Crankshaft 303-507

Material

Valve Springs

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH)

Scheme 48

Scheme 49

Material

Valve Seals

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH) Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH) Slide Hammer 307-005 (T59L-100-B)

Scheme 50

Scheme 51

Material

Valve Tappets

Material

Cylinder Head

Special Tools Illustration Tool Name Tool Number Alignment Plate, Camshaft 303-465 (T94P-6256-CH)

Material

Scheme 52

Oil Filter Adapter

Material

Engine Oil Pressure (EOP) Switch

Material

Oil Pan

Material

Oil Pump

Material

Oil Level Indicator and Tube

Material

Scheme 53

Engine Mount

Special Tools Illustration Tool Name Tool Number 3-Bar Engine Support Kit 303-F072

Scheme 54

Special Tools Illustration Tool Name Tool Number Impact Hammer 307-005 (T59L-100-B) Valve Spring Compressor Set 303-300 (T87C-6565-A) Valve Stem Seal Remover 303-468 (T94P-6510-AH) Valve Stem Seal Replacer 303-470 (T94P-6510-CH) Valve Spring Compressor 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH)

Material

Scheme 55

Engine Block

For engine block, crankshaft and piston assembly installation procedures, refer to ENGINE BLOCK - 2.3L .

Engine (Except Block)

Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Timing Peg, Crankshaft 303-507 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Adapter for 205-126 (205-072-02) Installer, Front Oil Seal 303-096 (T74P-6150-A) Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1) Aligner, Clutch Disc 308-006 (T71P-7137-H)

Scheme 56

Material

Scheme 57

Identifying Lower Engine Block Components (View 2). Scheme 58

ITEM DESCRIPTION

Scheme 59

Scheme 60

Scheme 61

Note. Early build engines are equipped with an oil pump drive chain guide. Late build engines do not have an oil pump drive chain guide. Also, late build engines use an updated design for the oil pump drive chain and tensioner. Therefore, the oil pump drive components are not interchangeable between early build and late build engines.

All engines

Scheme 62

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Scheme 71

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Scheme 85

1. NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly. NOTE: The front bulkhead does not have an oil squirter. Install the 4 oil squirters. Tighten to 4 Nm (35 lb-in). see scheme 389: Locating Oil Squirters
2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal. see scheme 390: Identifying Measuring Directions Of Crankshaft Main Bearing Journal Diameter
3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block. see scheme 391: Locating Main Bearing Beam
4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts. Tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten an additional 90 degrees. see scheme 392: Identifying Main Bearing Beam Bolts Tightening Sequence
5. Measure each crankshaft block main bearing bore diameter. Remove the bolts and the main bearing beam. Discard the main bearing beam bolts. see scheme 393: Identifying Crankshaft Block Main Bearing Bore Diameter
6. Using the chart, select the crankshaft main bearings. see scheme 394: Crankshaft Main Bearings Chart
7. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. Using the original connecting rod cap bolts, install the connecting caps and bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 29 Nm (21 lb-ft). Stage 2: Tighten an additional 90 degrees.
8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod. Remove the bolts and the connecting rod cap. Discard the connecting rod cap bolts. see scheme 395: Identifying Connecting Rod Large End Bore Measuring Directions
9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal. see scheme 396: Identifying Measuring Directions Of Crankshaft Connecting Rod Bearing Journal Diameters
10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal. see scheme 397: Connecting Rod Bearings Chart
11. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. NOTE: The center bulkhead is the thrust bearing. Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block. see scheme 398: Locating Upper Crankshaft Main Bearings
12. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam. see scheme 399: Locating Crankshaft Main Bearings
13. Lubricate journals on the crankshaft with clean engine oil.
14. Position the crankshaft in the cylinder block. see scheme 400: Locating Crankshaft
15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil. see scheme 401: Locating Main Bearing Beam Side Fit Surfaces
16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block. see scheme 402: Locating Main Bearing Beam
17. NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil. NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts. Install and tighten the 10 new main bearing beam bolts. Tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten an additional 90 degrees. see scheme 403: Identifying Main Bearing Beam Bolts Tightening Sequence
18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play. Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge with Holding Fixture. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary. see scheme 404: Measuring Crankshaft End Play
19. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal. NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil. NOTE: Make sure the piston arrow on top is facing toward the front of the engine. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies. When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap. The position of the upper and lower compression ring gaps are not controlled for installation. see scheme 405: Identifying Piston Ring Compressor And Connecting Rod Installer
20. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten. NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation. Install the connecting rod caps and the new bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 29 Nm (21 lb-ft). Stage 2: Tighten an additional 90 degrees. see scheme 406: Locating Connecting Rod Cap Bolts
21. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center (TDC). see scheme 407: Installing Crankshaft TDC Timing Peg
22. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled. NOTE: The original adjustment shims must be installed in their original position. NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit. Install the adjustment shims in their original position on the seat faces of the balancer unit.
23. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear. see scheme 408: Locating Balancer Unit And Shafts Reference Mark
24. Install the balancer unit bolts. Tighten in the sequence shown in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 50 Nm (37 lb-ft). see scheme 409: Identifying Balancer Unit Bolts Tightening Sequence
25. Remove the Crankshaft TDC Timing Peg. see scheme 410: Installing Crankshaft TDC Timing Peg
26. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
27. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. Remove the Crankshaft TDC Timing Peg. see scheme 411: Installing Crankshaft TDC Timing Peg
28. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements. NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing. NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown. Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash. Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in). If the backlash exceeds the specified range, carry out the balance shaft backlash procedure. For additional information, refer to the «Balance Shaft Backlash»(ref-278254-S06085621632010040500000) procedure in this section. see scheme 412: Measuring Gear Backlash
29. Install the intermediate shaft bearing bracket and 3 bolts. Tighten to 40 Nm (30 lb-ft).
30. Turn the crankshaft clockwise to position the No. 1 piston at TDC.
31. Remove the engine plug bolt.
32. Install the special tool.
33. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft).
34. Install a new oil pump pickup tube gasket and the pickup tube. Tighten to 10 Nm (89 lb-in).
35. Using the special tool, install the crankshaft rear main oil seal.
36. Tighten the 6 crankshaft rear main oil seal bolts in the sequence shown to 10 Nm (89 lb-in).
37. Clean and inspect all mating surfaces.
38. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger-tight.
39. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
40. Install the remaining 13 oil pan bolts and tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).
41. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
42. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
43. Apply silicone gasket and sealant to the locations shown.
44. Install a new head gasket.
45. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (11 lb-ft). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
46. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages: Stage 1: Tighten one turn at a time until tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (12 lb-ft).
47. Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket. The crankshaft sprocket flange must be facing away from the engine block.
48. Install the oil pump chain, sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
49. Install the oil pump drive chain tensioner shoulder bolt. Tighten to 10 Nm (89 lb-in).
50. Install the oil pump drive chain guide and the 3 shoulder bolts. Tighten to 10 Nm (89 lb-in).
51. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
52. Install the special tool in the slots on the rear of both camshafts.
53. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
54. Install the LH timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
55. Install the timing chain.
56. Install the RH timing chain guide.
57. Using the edge of a vise, compress the timing chain tensioner plunger.
58. Using a small pick, push back and hold the ratchet mechanism.
59. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
60. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
61. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston. Tighten to 10 Nm (89 lb-in).
62. Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft sprocket bolts to 72 Nm (53 lb-ft).
63. Clean and inspect the mounting surfaces of the engine and the front cover.
64. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the front cover.
65. Install the engine front cover. Tighten the 22 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).
66. Using the special tool, install a new crankshaft front oil seal.
67. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
68. 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.
69. Assemble the special tools using 4 hardened washers in the locations shown.
70. Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn).
71. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
72. Remove the special tool.
73. Remove the special tool.
74. Turn the crankshaft clockwise 1 and 3/4 turns.
75. Install the special tool.
76. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
77. 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, the engine valve timing must be corrected.
78. Install the special tool to check the position of the camshafts. If it is not possible to install the special tool, the engine valve timing must be corrected.
79. Remove the special tool.
80. Install a new CKP sensor and the 2 bolts. Do not tighten the bolts at this time.
81. Adjust the CKP sensor with the alignment tool. Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
82. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
83. Remove the special tool.
84. Install the engine plug bolt. Tighten to 20 Nm (15 lb-ft).
85. Clean the valve cover gasket surface with metal surface cleaner.
86. Apply silicone gasket and sealant to the locations shown.
87. Install the valve cover. Tighten the 14 bolts in the sequence shown to 10 Nm (89 lb-in).
88. Install a new cylinder head temperature (CHT) sensor and the spark plugs. Tighten the CHT sensor to 12 Nm (9 lb-ft). Tighten the spark plugs to 12 Nm (9 lb-ft).
89. Install the 4 coil-on-plugs, 4 bolts and the crankcase vent tube. Tighten to 10 Nm (89 lb-in).
90. If equipped, install the block heater. Tighten to 21 Nm (15 lb-ft).
91. Install the crankcase vent oil separator and the KS. Tighten the 8 oil separator bolts to 10 Nm (89 lb-in). Tighten the KS to 20 Nm (15 lb-ft).
92. Install the coolant bypass hose.
93. Using a new gasket, install the coolant bypass and 4 bolts. Tighten to 10 Nm (89 lb-in).
94. Connect the coolant bypass hose.
95. Install the coolant hose.
96. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
97. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
98. Install new fuel injector O-rings. Separate the fuel injectors from the fuel rail. Remove and discard the fuel injector O-rings. Install new O-rings and lubricate with clean engine oil. Install the fuel injectors onto the fuel rail.
99. Install the fuel rail with the fuel injectors and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
100. Connect the fuel charging wiring harness. Connect the fuel rail pressure and temperature sensor electrical connector. Connect the 4 fuel injector electrical connectors. Attach the wiring harness retainers.
101. Connect the wiring harness retainers to the valve cover studs.
102. Install the radio interference capacitor bracket and bolt. Tighten to 10 Nm (89 lb-in).
103. Install the EGR tube. Tighten to 55 Nm (41 lb-ft).
104. Inspect and install new intake manifold gaskets if necessary.
105. Position the intake manifold and connect the positive crankcase ventilation (PCV) hose.
106. Install the intake manifold and the 7 mounting bolts. Tighten to 18 Nm (13 lb-ft).
107. Install the oil level indicator tube assembly and 2 bolts.
108. Connect the swirl valve electrical connectors and pin-type retainers.
109. Install the intake manifold and the 7 mounting bolts. Tighten to 18 Nm (13 lb-ft).
110. Install the oil level indicator tube assembly and bolt. Tighten to 10 Nm (89 lb-in).
111. Connect the swirl control valve electrical connector.
112. If equipped, connect the secondary air injection (AIR) vacuum supply hose.
113. Connect the manifold absolute pressure (MAP) electrical connector.
114. Connect the intake manifold runner control (IMRC) actuator electrical connector.
115. Attach the wiring harness pin-type retainer.
116. Connect the fuel rail pressure and temperature sensor vacuum hose.
117. Connect the idle air control (IAC) valve electrical connector and wiring harness pin-type retainer.
118. Connect the throttle position (TP) sensor electrical connector and wiring harness pin-type retainer.
119. Install the lower intake bolt. Tighten to 18 Nm (13 lb-ft).
120. Connect the KS electrical connector and pin-type retainer.
121. Install the oil filter adapter with a new gasket. Tighten to 25 Nm (18 lb-ft).
122. Install a new oil filter. Tighten the oil filter 3/4 turn after the oil filter gasket makes contact with the oil filter adapter.
123. Connect the oil pressure sensor electrical connector.
124. Install the thermostat housing and 3 bolts. Tighten to 10 Nm (89 lb-in).
125. Connect the heater hose to the thermostat housing.
126. Position the coolant pump and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
127. Install the coolant pump pulley and 3 bolts. Tighten to 20 Nm (15 lb-ft).
128. If equipped, install the accessory drive belt idler pulley. Tighten to 25 Nm (18 lb-ft).
129. Install the accessory drive belt idler pulley. Tighten to 25 Nm (18 lb-ft).
130. Install the accessory drivebelt tensioner and 2 bolts. Tighten to 25 Nm (18 lb-ft).
131. Install the generator, bolt and 2 stud bolts. Tighten to 25 Nm (18 lb-ft).
132. Install the wiring harness retainer and nut. Tighten to 25 Nm (18 lb-ft).
133. Connect the generator electrical connections, harness retainer and install the nut. Tighten to 8 Nm (71 lb-in).
134. Install the generator heat shield and 2 nuts. Tighten to 18 Nm (13 lb-ft).
135. Connect the CKP sensor and the wiring harness pin-type retainers.
136. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
137. Install the flexplate and the 6 bolts. Tighten the bolts in the sequence shown in 3 stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
138. Lubricate the transaxle input shaft pilot bearing with front axle grease.
139. Using the special tool, position the clutch disc on the flywheel.
140. Position the clutch pressure plate and install the 7 bolts. Tighten the bolts in a star pattern sequence to 27 Nm (20 lb-ft).

Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Powertrain Lift with Tilting Plate 014-00765 or equivalent Universal Adapter Brackets 014-0001 Lifting Brackets, Engine 303-050 (T70P-6000)

Scheme 86

Material

Vehicles equipped with a 2.0L engine and automatic transmission

1. Check the installation depth of the torque converter. Lay a straightedge on the automatic transaxle flange. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
2. Install new dowel pins in the engine block.
3. Using the engine crane, install the transaxle onto the engine. Install the 2 bolts at the dowel pins. Tighten to 48 Nm (35 lb-ft). Install the remaining bolts. Tighten to 48 Nm (35 lb-ft).
4. Using the special tools, raise the engine and transaxle assembly onto the lift table.
5. Using the special tools, secure the engine and transaxle assembly to the lift table.
6. Connect the solenoid body and the transmission range (TR) sensor electrical connectors.
7. Connect the turbine shaft speed (TSS) sensor electrical connector.
8. Connect the output shaft speed (OSS) sensor electrical connector.
9. Install the 4 torque converter nuts. Tighten to 35 Nm (26 lb-ft).
10. Connect the vehicle speed sensor (VSS) electrical connector.
11. Using the lift table, position the engine and transaxle assembly in the vehicle.
12. Install the transaxle mount center nut. Tighten to 133 Nm (98 lb-ft).
13. Install the 2 motor mount nuts. Tighten to 90 Nm (66 lb-ft).
14. Install the 2 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
15. Install the 2 lower bellhousing-to-oil pan bolts. Tighten to 48 Nm (35 lb-ft).
16. Install the starter motor isolator.
17. Install the starter motor and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
18. Install the transaxle roll restrictor and 2 bolts. Tighten to 48 Nm (35 lb-ft).
19. Install the LH front drive halfshaft.
20. Install the RH front halfshaft together with the intermediate shaft.
21. Install the front drive intermediate shaft bearing mounting bracket. Tighten to 25 Nm (18 lb-ft).
22. Install both of the lower control arms to the knuckles. Connect the suspension arm ball joint. Install the bolt. Tighten to 63 Nm (46 lb-ft).
23. Install both of the tie-rod ends to the knuckles. Tighten to 40 Nm (30 lb-ft).
24. Connect the stabilizer bar to the LH strut and install the nut. Tighten to 55 Nm (41 lb-ft).
25. Tighten the LH strut and spring assembly top mount nuts. Tighten to 30 Nm (22 lb-ft).
26. Install the caliper. Position the caliper and install the bolts. Tighten to 28 Nm (21 lb-ft). Install the bolt covers.
27. Install the brake hose onto the support bracket.
28. Install the manifold and tube assembly onto the A/C compressor. Tighten to 21 Nm (15 lb-ft).
29. Install the A/C compressor and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
30. Connect the A/C compressor electrical connector.
31. Install the power steering pressure (PSP) tube brackets and nuts. Tighten to 11 Nm (8 lb-ft).
32. Connect the starter motor electrical connections. Tighten the small nut to 5 Nm (44 lb-in). Tighten the large nut to 12 Nm (9 lb-ft).
33. Install the generator coolant pipe.
34. Position the ground cable and install the bolt. Tighten to 48 Nm (35 lb-ft).
35. Connect the lower radiator hose.
36. Install the cooling fan.
37. Connect the cooling fan electrical connectors.
38. Install the coolant expansion tank and the bolt. Tighten to 10 Nm (89 lb-in).
39. Connect the coolant hoses.
40. Connect the heater hose to the "T" fitting.
41. Connect the transmission cooler hoses.
42. Connect the transmission shifter cable.
43. Connect the reversing lamp switch electrical connector.
44. Connect the clutch slave cylinder supply tube. Install the clip.
45. Attach the transaxle cables to the bracket. Attach the shifter cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders. Attach the selector cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
46. Attach the gearshift cables. Attach the shifter cable to the shift mass. Attach the selector cable to the selector lever.
47. Adjust the gearshift cables and bleed the clutch system. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION»(ref-278302) article.
48. Connect the 3 main engine wiring harness connectors and attach the connectors to the bracket.
49. Connect the power distribution harness eyelet and install the nut. Tighten to 10 Nm (89 lb-in).
50. Attach the wiring harness retainers.
51. Connect the power distribution wiring harness electrical connector.
52. Connect the fuel charging wiring harness electrical connector.
53. Connect the fuel charging wiring harness electrical connector and harness retainer.
54. Install the ground eyelet and bolt. Tighten to 10 Nm (89 lb-in).
55. Connect the upper radiator hose, the heater hose and the coolant vent hose to the coolant bypass.
56. Connect the exhaust gas recirculation (EGR) valve electrical connector.
57. Install the power brake booster vacuum tube into the quick release fitting.
58. If equipped, connect the secondary air injection (AIR) vacuum regulator electrical connector.
59. If equipped, connect the AIR hose.
60. Connect the evaporative emissions tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-278301) article.
61. Connect the fuel tube quick connect coupling onto the fuel rail. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-278301) article.
62. Connect the accelerator cable and speed control cable (if equipped). Install the accelerator cable bracket and bolts. Tighten to 10 Nm (89 lb-in). Connect the accelerator and speed control cable (if equipped) to the throttle body.
63. Install the accelerator control snow shield. Position the snow shield and install the screw and pin-type retainer. Tighten to 10 Nm (89 lb-in). Attach the evaporative emissions hose pin-type retainer.
64. Install the air cleaner outlet pipe and air intake resonator into the grommets and install the bolt.
65. Tighten the air cleaner outlet pipe and connect the vent tube.
66. Clean and inspect the catalytic converter flange. Using a straightedge and a feeler gauge, place the straightedge across the catalytic converter flange surface and check for warping with the feeler gauge. If the reading is greater than the maximum specification, install a new catalytic converter, gasket and nuts.
67. Using a new gasket and nuts, install the catalytic converter. Tighten in the sequence shown to 55 Nm (41 lb-ft).
68. If equipped, connect the AIR hose.
69. If equipped, connect the upper exhaust sensor electrical connector and retainer.
70. Connect the exhaust sensor electrical connectors.
71. If removed, install the heat shield and 4 bolts. Tighten to 10 Nm (89 lb-in).
72. Install the catalytic converter support bracket and 4 bolts. Tighten to 47 Nm (35 lb-ft).
73. Using a new gasket and 2 nuts, connect the catalytic converter to exhaust system. Tighten to 47 Nm (35 lb-ft).
74. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-278287) article.
75. Fill the engine with clean engine oil.
76. Install the power steering pump. For additional information, refer to «POWER STEERING»(ref-278244) article.
77. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-278264) article.
78. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-278250) article.
79. Evacuate and charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-278284) article.