Piston Ford Focus III

Piston

MATERIALS SPECIFICATIONS

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1. Refer to: «PISTON INSPECTION»(ref-515962-S40286710892012120400000) .

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1. Indicates front of engine.
2. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
3. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
4. NOTE: The upper and lower compression rings are to be fitted with the identification marks on the upper side. NOTE: Arrows faces the front of the engine. NOTE: Align the piston rings on the piston. Upper compression ring gap location. Lower compression ring gap location. Upper oil control segment ring gap location. Expander ring gap location. Lower oil control segment ring gap location.

SPECIAL TOOL(S) / GENERAL EQUIPMENT 100-002 Holding Fixture with Dial Indicator Gauge 205-153 Handle 303-096 Installer, Camshaft Front Oil Seal TKIT-2009TC-F 303-103 Holding Tool, Flywheel TKIT-2009TC-F 303-1247/2 Installer, VCT Spark Plug Tube Seal 303-1252/2 Tool, Stretchy Belt Installer 303-1521 Alignment Tool, Crankshaft Position Sensor 303-1565 Alignment Tool, Camshaft 303-1567 Sizer, Teflon Seal 303-328 Replacer, Rear Seal TKIT-1988-F TKIT-1988-FLM TKIT-1988-LM TKIT-2009TC-F 303-462 Installer, Connecting Rod 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM 303-D032 Compressor, Piston Ring 303-D055 Strap Wrench 310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM Hose Clamp Remover/Installer Round-Ended Steel Rule

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MATERIALS SPECIFICATIONS

Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement.

Note. Refer to exploded views in Description and Operation .

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1. Torque : 4 Nm
2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
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 and install the original main bearing beam bolts finger tight.
4. Torque : Stage 1: 5 Nm Stage 2: 25 Nm Stage 3: Tighten an additional 90°
5. Measure each crankshaft block main bearing bore diameter.
6. Using the chart, select the crankshaft main bearings.
7. Using the original connecting rod cap bolts, install the connecting caps and bolts and tighten the bolts in 2 stages: Torque : Stage 1: 29 Nm Stage 2: Tighten an additional 90°
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.
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.
10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
11. Remove the 10 bolts in the sequence shown in illustration and the main bearing beam.
12. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
13. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
14. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
15. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
16. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
17. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 5 Nm Stage 2: 25 Nm Stage 3: Tighten an additional 90°
18. Measure crankshaft end play. Special Tool(s) : 100-002 (Holding Fixture with Dial Indicator Gauge) 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 0.2-0.43 mm (0.008-0.017 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
19. Piston to be assembled with the arrow pointing to the front of the engine.
20. Connecting rod to be assembled with the front marks pointing to the front of the engine.
21. Install the piston and connecting rod assemblies. Special Tool(s) : 303-D032 (Compressor, Piston Ring) , 303-462 (Installer, Connecting Rod) Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
22. Install the connecting rod caps and the new bolts and tighten the bolts in 2 stages: Torque : Stage 1: 29 Nm Stage 2: Tighten an additional 90°
23. Install the special tool and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the special tool. The engine is now at TDC. Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
24. Material : Motorcraft® Metal Surface Prep / ZC-31-A Torque : Stage 1: 10 Nm Stage 2: 20 Nm
25. Torque : 25 Nm
26. Install the diamond washer and the crankshaft sprocket.
27. Install the chain on the oil pump sprocket and install the tensioner and the 2 shoulder bolts. Torque : 10 Nm Push the tensioner spring down and position the spring under the shoulder bolt.
28. Position the crankshaft rear oil seal with retainer plate onto the crankshaft. Special Tool(s) : 303-328 (Replacer, Rear Seal) Torque : 10 Nm
29. Torque : 10 Nm
30. Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
31. Finger-tight.
32. Align the front surface of the oil pan flush with the front surface of the engine block. General Equipment : Round-Ended Steel Rule
33. Torque : 20 Nm
34. Torque : Stage 1: 7 Nm Stage 2: 15 Nm Stage 3: 45 Nm Stage 4: 90° Stage 5: Tighten an additional 90°
35. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
36. Material : flange sealant (WSS-M2G348-A11)
37. Install the camshaft bearing caps in their original location and orientation and tighten the camshaft bearing cap bolts in pairs in the sequence shown in illustration in 2 stages: Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 7 Nm Stage 2: 16 Nm
38. If camshafts were replaced, check that the camshaft end play is within specification.
39. If camshafts were replaced, check the valve clearance. Refer to: «Valve Clearance Check»(ref-515979-S00510071122012120400000) .
40. Install the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
41. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : 10 Nm
42. Finger tight.
43. Torque : 10 Nm
44. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
45. Using the edge of a vise, compress the timing chain tensioner plunger.
46. Using a small pick, push back and hold the ratchet mechanism.
47. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
48. Install a holding pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
49. Install the timing chain tensioner and the 2 bolts, then remove the holding pin to release the piston. Torque : 10 Nm
50. Torque : Stage 1: 50 Nm Stage 2: Tighten an additional 90°
51. Clean and inspect the mounting surfaces of the engine and the front cover. Material : Motorcraft® Silicone Gasket Remover / ZC-30
52. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft Metal Surface Prep.
53. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft Metal Surface Prep.
54. Install engine front cover. Torque : Stage 1: Tighten bolts 1 through 17 to 10 Nm Stage 2: Tighten bolts 19 through 21 to 48 Nm Stage 3: Tighten bolt 22 to 25 Nm Stage 4: Tighten bolt 18 to 48 Nm
55. Special Tool(s) : 303-096 (Installer, Camshaft Front Oil Seal) Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
56. NOTE: Install a new diamond washer.
57. Position the crankshaft pulley onto the crankshaft with the crankshaft pulley TDC guide hole at the 6 o'clock position. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
58. Install a standard bolt through the crankshaft pulley TDC guide hole and into the engine front cover.
59. Special Tool(s) : 303-D055 (Strap Wrench) Torque : Stage 1: 100 Nm Stage 2: Tighten an additional 90°
60. Finger tight.
61. Install the special tool to set the CKP sensor position and tighten the 2 bolts. Special Tool(s) : 303-1521 (Alignment Tool, Crankshaft Position Sensor) Torque : 7 Nm
62. Clean and inspect the sealing surfaces of the valve cover.
63. Special Tool(s) : 205-153 (Handle) , 303-1247/2 (Installer, VCT Spark Plug Tube Seal)
64. NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft Metal Surface Prep.
65. Torque : 10 Nm
66. If equipped. Torque : 3 Nm
67. NOTE: Inspect the ignition coil boot for rips, nicks or tears. Remove and discard the damaged ignition coil boots.
68. Material : Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A) Torque : 10 Nm
69. Torque : 10 Nm
70. Torque : Stage 1: 8 Nm Stage 2: Tighten an additional 60°
71. Torque : 20 Nm
72. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
73. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
74. Turn the crankshaft clockwise until the fuel injection pump cam lobe is at BDC.
75. Install the fuel injection pump and loosely install 2 new fuel injection pump bolts, alternately tighten each bolt one complete revolution until seated. Torque : Stage 1: 20 Nm Stage 2: Tighten an additional 45°
76. Torque : 48 Nm
77. Torque : 25 Nm
78. Torque : 20 Nm
79. Torque : 25 Nm
80. Torque : 10 Nm
81. Pull the lower Teflon® seal away from the injector with narrow tip pliers.
82. Carefully cut and discard the lower fuel injector Teflon® seals.
83. Place the special tool, knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed. Special Tool(s) : 303-1567 (Sizer, Teflon Seal)
84. Install the new lower Teflon® seals on the narrow end of the Arbor (part of the special tool), then install the Arbor on the fuel injector tips. Special Tool(s) : 310-207 (Installer, Fuel Injector Seal Assembly) , 303-1567 (Sizer, Teflon Seal)
85. Using the Pusher Tool (part of the special tool), slide the Teflon® seals off of the Arbor and into the groove on the fuel injectors. Special Tool(s) : 310-207 (Installer, Fuel Injector Seal Assembly) , 303-1567 (Sizer, Teflon Seal)
86. Slide the special tool off the end of the fuel injector to size the seal. Special Tool(s) : 303-1567 (Sizer, Teflon Seal)
87. Install the new upper fuel injector O-ring seal support rings and the new upper fuel injector O-ring seals. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
88. NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup. NOTE: The fuel rail pressure sensor must be replaced if it is removed from the fuel rail.
89. Install the fuel rail by pushing down on the fuel rail face above the injectors and install the 4 bolts. Torque : 25 Nm
90. Hand tighten the high pressure fuel tube-to-fuel rail flare nut. Hand tighten the high pressure fuel tube-to-fuel injection pump flare nut.
91. Finger tight.
92. Torque : Stage 1: 15 Nm Stage 2: 45°
93. Tighten the high pressure fuel tube-to-fuel injection pump flare nut in the following 2 stages: Torque : Stage 1: 15 Nm Stage 2: 45°
94. Torque : 10 Nm
95. NOTE: Use care when installing the fuel injection pump noise insulator. Spreading the openings will aid in installing the fuel injection pump noise insulator and reduce the risk of damage.
96. General Equipment : Hose Clamp Remover/Installer
97. NOTE: Inspect and install new intake manifold gaskets if necessary.
98. Finger tight.
99. Torque : 20 Nm
100. Refer to: «QUICK RELEASE COUPLING»(ref-515980-S11306190512012120400000) .
101. Torque : 10 Nm
102. NOTE: Install the generator stud before the generator is installed. Torque : Tighten the generator stud to 8 Nm Torque : Tighten the nut and 2 bolts to 25 Nm
103. General Equipment : Hose Clamp Remover/Installer
104. Torque : 25 Nm
105. Torque : 10 Nm
106. Finger tight.
107. Torque : 25 Nm
108. NOTE: Under no circumstances should the A/C compressor belt, accessory drive belt, tensioner or pulleys be lubricated as potential damage to the belt material and tensioner damping mechanism will occur. Do not apply any fluids or belt dressing to the A/C compressor belt, accessory drive belt or pulleys.
109. Tighten. Torque : 20 Nm
110. Position the A/C compressor belt onto the A/C compressor pulley and around the special tool on the crankshaft pulley. Make sure that the belt is engaged with the crankshaft pulley and rotate the crankshaft clockwise to install the A/C compressor belt. Special Tool(s) : 303-1252/2 (Tool, Stretchy Belt Installer)
111. Torque : 17 Nm
112. Torque : 10 Nm
113. Refer to: «QUICK RELEASE COUPLING»(ref-515980-S11306190512012120400000) .
114. Remove the engine from the engine stand.
115. If equipped with a automatic transmission. Special Tool(s) : 303-103 (Holding Tool, Flywheel) Torque : Stage 1: 50 Nm Stage 2: 80 Nm Stage 3: 112 Nm
116. If equipped with a manual transmission. Special Tool(s) : 303-103 (Holding Tool, Flywheel) Torque : Stage 1: 50 Nm Stage 2: 80 Nm Stage 3: 112 Nm
117. Position the clutch disc on the clutch pressure plate. Using a clutch aligner, centralize the clutch disc to the clutch pressure plate.
118. Using a clutch aligner, position the clutch disc and clutch pressure plate on the flywheel. Torque : 29 Nm

SPECIAL TOOL(S) / GENERAL EQUIPMENT 014-00001 ADJUSTABLE GRIP 1735A 300-OTC1585AE Powertrain Lift 300-OTC1819E 2, 200# Floor Crane, Fold Away 303-D089 Spreader Bar Hose Clamp Remover/Installer Wooden Block

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MATERIALS SPECIFICATIONS

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1. Lift the engine and position the engine and transaxle together. Special Tool(s) : 300-OTC1819E (2, 200# Floor Crane, Fold Away) , 303-D089 (Spreader Bar)
2. NOTE: Use caution not to damage the transmission wiring harness or sensors. NOTE: If using the existing automatic transmission clutch assembly, align the index marks on the flexplate and the clutch stud made during removal. NOTE: Automatic transmission shown in illustration, manual transmission similar. If equipped with automatic transmission, install the 4 bellhousing-to-engine fasteners. Torque : 45 Nm If equipped with manual transmission, install the 5 bellhousing-to-engine fasteners. Torque : 45 Nm
3. Torque : 20 Nm
4. Torque : 45 Nm
5. Raise the engine and transaxle assembly onto the lift table. Special Tool(s) : 300-OTC1819E (2, 200# Floor Crane, Fold Away) , 303-D089 (Spreader Bar)
6. Attach the powertrain to the powertrain lift. Special Tool(s) : 014-00001 (ADJUSTABLE GRIP 1735A) , 300-OTC1585AE (Powertrain Lift) General Equipment : Wooden Block
7. If equipped with an automatic transmission.
8. Torque : Stage 1: Tighten nuts 1, 5 and 3 to 12 Nm Stage 2: Tighten all nuts to 25 Nm
9. Refer to: «STARTER MOTOR»(ref-515986-S31532406002012120400000) .
10. If equipped with automatic transmission.
11. Position the powertrain into the vehicle.
12. Torque : 150 Nm
13. Torque : Stage 1: Tighten the 2 nuts to 80 Nm Stage 2: Tighten the 2 bolts to 90 Nm
14. Torque : 86 Nm
15. Torque : 48 Nm
16. Torque : 48 Nm
17. Refer to: «COOLING FAN MOTOR AND SHROUD»(ref-515984-S02312130842012120400000) .
18. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 8 Nm Stage 2: 180°
19. General Equipment : Hose Clamp Remover/Installer
20. NOTE: Install 2 new O-ring seals. Torque : Tighten the nuts to 20 Nm Torque : Tighten the bolt to 25 Nm
21. Torque : 18 Nm
22. Refer to: «FRONT HALFSHAFT RH»(ref-515957-S40462304762012120400000) . Refer to: «FRONT HALFSHAFT LH»(ref-515957-S22611759492012120400000) .
23. If equipped with a manual transmission. Torque : 48 Nm
24. If equipped with a manual transmission.
25. If equipped with an automatic transmission. Torque : 10 Nm
26. If equipped with an automatic transmission.
27. If equipped with an automatic transmission.
28. If equipped with an automatic transmission.
29. Refer to: «QUICK RELEASE COUPLING»(ref-515980-S11306190512012120400000) .
30. Refer to: «QUICK RELEASE COUPLING»(ref-515980-S11306190512012120400000) .
31. Torque : 17 Nm
32. Using a new gasket, position the catalytic converter and install the 5 new catalytic converter manifold-to-cylinder head nuts and tighten in 2 stages in the sequence shown in illustration. Torque : Stage 1: 55 Nm Stage 2: Re-tighten to 55 Nm
33. Torque : 25 Nm
34. Torque : Tighten the first nut to 48 Nm Torque : Tighten the second nut to 48 Nm Torque : Re-tighten the first nut to 48 Nm
35. Torque : 25 Nm
36. Torque : 10 Nm
37. Refer to: «HEATED OXYGEN SENSOR (HO2S)»(ref-515938-S11048006112012120400000) .
38. If equipped.
39. General Equipment : Hose Clamp Remover/Installer
40. Torque : 20 Nm
41. NOTE: The electrical connector is located behind the PCM case.
42. Refer to: «POWERTRAIN CONTROL MODULE (PCM)»(ref-515938-S13817209062012120400000) .
43. If equipped with automatic transmission.
44. Install the following items: Refer to: «AIR CLEANER»(ref-515968-S10605516232012120400000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-515968-S05863009252012120400000) . Refer to: «BATTERY TRAY»(ref-515950-S24858593422012120400000) . Refer to: «DEGAS BOTTLE»(ref-515984-S37240734712012120400000) .
45. If equipped with manual transmission, fill and bleed the clutch system. Refer to: «CLUTCH SYSTEM BLEEDING»(ref-515987-S04809855252012120400000) .
46. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-515984-S15674360012012120400000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-515984-S18220348442012120400000) .
47. Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-515934-S32792027622012120400000) .
48. Fill the engine with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)