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Assembly|Installation > < In-vehicle Repair|Disassembly|Engine

Focus RS 2003 (09.2002-)

Engine - 2.0L Duratec-RS (Zetec) - Engine Focus RS 2003 (09/2002-)
Assembly

Special Tool(s)

Flange Holding Wrench, Universal

205-072 (15-030 A)

Installer, Timing Cover Oil Seal

303-039 (21-009 B)

Locking Tool, Flywheel

303-254 (21-135)

Installer, Crankshaft Rear Oil Seal

303-291 (21-141)

Timing Plate, Camshaft Alignment

303-376 (21-162 B)

Socket, Cylinder Head Bolt

303-392 (21-167)

Installer, Crankshaft Seal

303-395 (21-171)

Mounting Stand

303-435 (21-187)

Mounting Plate for 303-435

303-435-04 (21-064)

Timing Peg, Crankshaft TDC

303-574 (21-163)

Installer, Crankshaft Front Seal

303-684 (21-243)
General Equipment
Steel straight edge
Engine hoist
M10 x 70 mm bolt
Ten M6 x 20 mm studs
Materials
Name
Specification
Sealer
WSK-M4G320-A 
Sealer
WSK-M2G348-A5 
Sealer
WSS-M4G323-A7 
Engine oil
WSS-M2C912-A1 
Silicon grease
A696-M1C171-AA 

Assembly
  1. NOTE:
    NOTE:Install a new crankshaft rear oil seal carrier gasket.
    NOTE:
    NOTE:Do not fully tighten the crankshaft rear oil seal carrier retaining bolts at this stage.
    Install the rear oil seal carrier.

  1. Install the crankshaft position (CKP) sensor and mounting bracket.

  1. CAUTION:
    CAUTION:The oil seal must be inserted as far as its stop onto the special tool.
    Insert a new crankshaft rear oil seal into the special tool.
    • For correct installation lay the special tool on a vice and use the handle of a hammer to press in the oil seal.
    1. Incorrect installation
    1. Correct installation

  1. NOTE:
    NOTE:Install a new crankshaft rear oil seal.
    Using the special tool and two old flywheel bolts, install the crankshaft rear oil seal.

  1. Align the crankshaft rear oil seal carrier so that the sealing surface of the oil seal carrier is 0.3 mm - 0.8 mm below the cylinder block and tighten the retaining bolts.

  1. Remove the special tool.

  1. NOTE:
    NOTE:Install a new oil pump gasket.
    NOTE:
    NOTE:Do not fully tighten the oil pump retaining bolts at this stage.
    Install the oil pump.

  1. NOTE:
    NOTE:Make sure that the sealing lip is correctly seated on the installing sleeve.
    Slide the crankshaft oil seal onto the special tool until it is approximately in the center.
  1. Slide the special tool onto the crankshaft until it makes contact.

  1. Slide the cranksahft front oil seal along the special tool by hand onto the crankshaft until it touches the oil seal carrier.
  1. Remove the special tool.

  1. NOTE:
    NOTE:Use the crankshaft vibration damper bolt.
    Using the special tool, install the crankshaft front oil seal until it is home.

  1. Align the oil pump on both sides so that the mating face is between 0.3 mm - 0.8 mm above the lower edge of the cylinder block.

  1. Tighten the oil pump retaining bolts.

  1. NOTE:
    NOTE:Install the lower crankcase within 10 minutes of applying the sealer.
    Apply a 4 mm bead of sealer to the areas shown.

  1. NOTE:
    NOTE:If the permissible amounts for protrusion or gap are exceeded, install shims as described in the following steps.
    Align the lower crankcase.
    • Using a steel straight edge, align the lower crankcase so that the cylinder block and the lower crankcase are flush, or do not exceed 0.10 mm protrusion to 0.25 mm gap.
    • Position the lower crankcase with a new gasket and tighten the bolts finger tight.

  1. Install lower crankcase shims as necessary.
    • with a gap of 0.26 - 0.50 mm, install a 0.25 mm shim.
    • with a gap of 0.51 - 0.75 mm, install a 0.50 mm shim.

  1. NOTE:
    NOTE:Install a new oil pump pickup tube gasket.
    Install the lower crankcase.
    1. Tighten the bolts and check the alignment as described in the previous step, correct as necessary.
    1. Install the oil pump pickup tube.

  1. CAUTION:
    CAUTION:The lower crankcase may be damaged if sealant enters the blind holes.
    Install ten M6 x 20 mm studs into the blind holes as shown.

  1. NOTE:
    NOTE:Attach the oil pan within ten minutes of applying the sealant.
    Apply a 3 mm thick bead of sealant on to the oil pan mating face.

  1. NOTE:
    NOTE:The oil pan must not be removed once it comes into contact with the lower crankcase housing.
    Install the oil pan.
    1. Remove the studs.
    • Install and tighten the bolts in the sequence shown in two stages.
    • Stage 1: 6 Nm
    • Stage 2: 10 Nm

  1. NOTE:
    NOTE:Install new flywheel retaining bolts.
    NOTE:
    NOTE:Remove any residual thread-locking compound from the threaded bores.
    Using the special tool, install the flywheel.
  1. Install the clutch disc and pressure plate. For additional information, refer to Section  308-01C Clutch.

  1. CAUTION:
    CAUTION:The choice of cylinder head gasket depends on the cast cylinder block number.
    Install the cylinder head gasket.
    1. Cylinder block number
    1. Position a new cylinder head gasket on the cylinder block.
    1. Install the locating studs.
    1. Check that the guide bushes are correctly seated.

  1. CAUTION:
    CAUTION:The cylinder head bolts must only be used twice. Mark the cylinder head bolts using a center punch to indicate usage.
    CAUTION:
    CAUTION:Install new cylinder head bolts as necessary.
    Install the cylinder head.
    • Using the special tool, tighten the cylinder head bolts in the sequence shown in three stages.
    • Stage 1: 20 Nm
    • Stage 2: 40 Nm
    • Stage 3: 90 degrees
  1. NOTE:
    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine until piston number 1 is approximately 60 degrees before top dead center (BTDC).

  1. NOTE:
    NOTE:The identification numbers are provided on the outer face of the camshaft bearing caps.
    Apply sealer to the marked areas on camshaft bearing cap numbers 0 and 5 in the area shown.
  1. Coat the camshaft and the camshaft bearing caps with clean engine oil.
  1. Install the camshaft so that none of the cams are at full lift.

  1. NOTE:
    NOTE:Install the camshaft bearing cap retaining bolts evenly, in the sequence shown, one half turn at a time.
    Tighten the camshaft bearing cap retaining bolts.
    • Tighten the bolts in the sequence shown in two stages.
    • Stage 1: 10 Nm
    • Stage 2: 19 Nm
  1. Coat the camshaft and the oil seal lip with clean engine oil .

  1. Using the special tool, a washer and a M10 x 70 mm bolt, install the camshaft oil seals.
  1. NOTE:
    NOTE:Cylinders 1 and 4 are at TDC when the Woodruff key is at the 12 o'clock position.
    NOTE:
    NOTE:Only turn the engine in its normal direction of rotation.
    Turn the engine until piston no. 1 is approximately 45 degrees before TDC.

  1. Remove the blanking plug and install the special tool.
    • Carefully turn the crankshaft against the special tool.

  1. Align the camshafts and install the special tool.
  1. NOTE:
    NOTE:Do not fully tighten the camshaft pulley bolts at this stage. The camshaft pulleys must rotate freely on the camshafts.
    Attach the camshaft pulleys to the camshafts.

  1. Install a new water pump gasket.
    1. Position the gasket on the water pump.
    1. Secure the gasket by bending over the tabs.

  1. Install the water pump.

  1. Install the crankshaft timing pulley and thrust washer to the crankshaft.

  1. NOTE:
    NOTE:Do not fully tighten the bolt at this stage.
    Install the timing belt tensioner.

  1. Install the timing belt idler pulley.

  1. Install the timing belt tensioner.

  1. CAUTION:
    CAUTION:Do not kink the timing belt, the bend diameter must not be less than 35 mm.
    CAUTION:
    CAUTION:Do not turn the crankshaft. If necessary check whether the crankshaft is touching to the timing peg.
    NOTE:
    NOTE:The clip of the timing belt tensioner must not be hooked into the pressed steel cover.
    NOTE:
    NOTE:Install a new timing belt.
    Install the timing belt.
    • Beginning with the crankshaft timing pulley and working counterclockwise, install the timing belt.
  1. Make sure that piston No. 1 is still at top dead center (TDC).

  1. Rotate the timing belt tensioner washer counterclockwise, tension the timing belt.
    1. Hook the timing belt tensioner into the pressed steel cover.
    1. Rotate the timing belt tensioner washer counterclockwise until the arrow points the mark and tighten the bolt.
    1. Check if the arrow points the mark after tightening the bolt.

  1. CAUTION:
    CAUTION:Do not tighten the camshaft pulley bolts against the timing plate.
    NOTE:
    NOTE:The crankshaft must remain at TDC.
    Using the special tool, tighten the camshaft pulleys.

  1. Remove the special tool.

  1. Remove the special tool.
  1. NOTE:
    NOTE:Cylinders 1 and 4 are at TDC when the Woodruff key is at the 12 o'clock position.
    NOTE:
    NOTE:Only turn the engine in its normal direction of rotation.
    Turn the engine two revolutions.

  1. Install the special tool.
    • Carefully turn the crankshaft against the special tool.

  1. Check the valve timing.
    • If necessary loosen the camshaft pulleys and correct the camshaft alignment.
    • Remove the special tools.

  1. Install the blanking plug.
  1. Check the valve clearance and if necessary adjust.
    For additional information, refer to Valve Clearance Adjustment in this section.

  1. Apply sealer to the camshaft front bearing caps.

  1. Install the valve cover.
    • Tighten the bolts in two stages.
    • Stage 1: 2 Nm
    • Stage 2: 7 Nm

  1. Install the spark plugs.
  1. Coat the inside of the spark plug electrical connector with silicone grease to a depth of 5 - 10 mm.

  1. CAUTION:
    CAUTION:Use a suitable blunt object to avoid damage to the spark plug connector gasket.
    Connect the spark plug electrical connectors.

  1. Install the heat shield.
    1. Install the nut.
    1. Tighten the bolts and the nut.

  1. Install the timing belt lower cover.

  1. Install the special tool.

  1. Install the crankshaft pulley.

  1. NOTE:
    NOTE:Position the timing belt upper cover and the engine front mount bracket.
    Install the engine front mount bracket.

  1. NOTE:
    NOTE:Check the seating of the timing belt upper cover gasket and correct it if necessary.
    Install the timing belt upper cover retaining bolts.

  1. Install the accessory drive belt idler pulley.

  1. Install the water pump pulley.

  1. NOTE:
    NOTE:Install a new positive crankcase ventilation (PCV) gasket.
    Install the PCV housing.
    • Connect the hose.

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket.
    Install the exhaust manifold.

  1. Install the air conditioning (A/C) compressor bracket.

  1. Install the power steering pump bracket.

  1. Install the oil level indicator and tube.

  1. Install the turbocharger retaining bolts.

  1. Attach the turbocharger coolant supply line to the cylinder head.

  1. Install the exhaust manifold heat shield.

  1. Install the positive crankcase ventilation (PCV) heat shield.
    • Install the PCV heat shield retaining clip.

  1. Install the PCV heat shield retaining nut.
  1. Using a suitable engine hoist, attach the engine to the engine lifting bracket.

  1. Connect the wastegate control valve solenoid vacuum hose to the turbocharger.

  1. Remove the mounting bracket from the mounting plate.

  1. Remove the mounting plate from the engine.

  1. Attach the turbocharger oil supply line to the cylinder block.

  1. NOTE:
    NOTE:Install a new oil cooler gasket.
    Install the oil cooler.

  1. NOTE:
    NOTE:Install a new oil filter.
    NOTE:
    NOTE:Coat the oil filter seal with clean engine oil.
    Install the oil filter.

  1. NOTE:
    NOTE:Install new intake manifold gaskets.
    Install the intake manifold (five bolts and two nuts).

  1. Install the generator bracket.

  1. Install the generator.
    1. Connect the positive cable.
    1. Install the bolt.
    1. Tighten the bolt.

  1. Install the oil pressure switch.

  1. Connect the oil pressure switch electrical connector.

  1. NOTE:
    NOTE:Install a new oil return line gasket.
    Attach the turbocharger oil return line to the cylinder block.

  1. Install the intermediate shaft center bearing bracket.

  1. Install the catalytic converter and the retaining clamp (turbocharger heat shield shown removed for clarity).

  1. Attach the catalytic converter to the support bracket.

  1. Install the catalytic converter upper retaining bolts.

Assembly|Installation > < In-vehicle Repair|Disassembly|Engine