Engine - 2.0L and 2.3L: Component Locations Ford Focus II

Special Tool(s)

SPECIAL TOOLS Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Timing Peg, Crankshaft TDC 303-507

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

1. 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). (Scheme 88): Installing Crankshaft TDC Timing Peg
2. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC. (Scheme 89): Locating Balancer Unit And Shafts Mark
3. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled. Remove the 4 bolts and the balancer unit. (Scheme 90): Locating Balancer Unit Bolts
4. Remove the adjustment shims from the seat faces of the balancer unit.
5. NOTE: Visually inspect the balancer unit gear for damage and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit. Install the master adjustment shims (No. 50) on the seat faces of the balancer unit.
6. With the balancer unit shaft marks at 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. (Scheme 91): Locating Balancer Unit And Shafts Reference Mark
7. 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). (Scheme 92): Identifying Balancer Unit Bolts Tightening Sequence
8. Remove the Crankshaft TDC Timing Peg. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear. (Scheme 93): Installing Crankshaft TDC Timing Peg
9. 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. (Scheme 94): Installing Crankshaft TDC Timing Peg
10. 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. (Scheme 95): Measuring Gear Backlash
11. NOTE: If maximum backlash exceeds 0.101 mm (0.003 in), install a new balancer unit. Using the backlash measurement, select the proper shims from the Adjustment Shim Selection Table. Remove the balancer unit from the cylinder block. Install the selected adjustment shims on the seat faces of the balancer unit. (Scheme 96): Adjustment Shim Selection Chart
12. 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 TDC. (Scheme 97): Installing Crankshaft TDC Timing Peg
13. 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. (Scheme 98): Locating Balancer Unit And Shafts Reference Mark
14. 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 13: Identifying Balancer Unit Bolts Tightening Sequence
15. NOTE: Remeasure 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. If the backlash exceeds the specified range of 0.005 to 0.101 mm (0.00019 to 0.0039 in), install a new balancer unit and repeat the procedure.

Measuring Gear Backlash. Scheme 99

SPECIAL TOOL(S) 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 100

Scheme 101

Scheme 102

SPECIAL TOOL(S) Installer, Front Oil Seal 303-096 (T74P-6150-A) Remover, Seal 303-409 (T92C-6700-CH)

SPECIAL TOOL(S) Locking Tool, Flexplate 303-103 (T74P-8375-A)

Scheme 103

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-255374) .
2. Remove the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE-TRANSMISSION»(ref-255393) .
3. Install the special tool and remove the 6 flexplate bolts and the flexplate.

Scheme 104

Scheme 105

1. Install the flexplate.
2. Install the special tool.
3. 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 (50 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
4. Install the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE-TRANSMISSION»(ref-255393) .

SPECIAL TOOL(S) Locking Tool, Flywheel 303-103 (T74P-8375-A)

Scheme 106

Scheme 107

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-255374) .
2. Remove the manual transaxle and clutch. For additional information, refer to «CLUTCH»(ref-255424) and «MANUAL TRANSAXLE-TRANSMISSION»(ref-255407) .
3. Install the special tool and remove the 6 bolts and the flywheel.

SPECIAL TOOL(S) Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1)

Scheme 108

SPECIAL TOOL(S) Alignment Plate, Camshaft 303-465 (T949-6256-CH)

SPECIAL TOOL(S) Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Timing Peg, Crankshaft 303-507

SPECIAL TOOL(S) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH)

Scheme 109

SPECIAL TOOL(S) 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 110

Scheme 111

Scheme 112