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20L Duratec-HE Engine Disassembly and Assembly

Engine - 2.0L Duratec-HE (MI4) - Engine S-MAX/Galaxy 2006.5 (03/2006-)

Installation

Special Tool(s)
303-122
Lifting Bracket, Engine
Materials
Name
Specification
Grease
SA-M1C9107-A
General Equipment
Hose clamp remover/installer
Hydraulic jib crane
Mounting table set
Securing Strap
  1. Torque: 48 Nm

  1. Torque: 48 Nm

  1. WARNING:
    WARNING:Support the engine/transmission on wood blocks and secure with suitable straps.
    General Equipment: Mounting table set
    General Equipment: Securing Strap

  1. Remove the Special Tool(s): 303-122
    General Equipment: Hydraulic jib crane

  1. Torque: 48 Nm

  1. CAUTION:
    CAUTION:Make sure that no components catch.
    Lower the vehicle to take the load off the engine mountings.

  1. Loosen: 2 turn(s)

  1. Torque: 133 Nm

  1. Torque: 15 Nm

  1.  
    1. Torque: 80 Nm
    1. NOTE:
      NOTE:Only tighten the bolts finger tight at this stage.
  1. Remove the assembly stand.

  1. Torque: 80 Nm

  1. Torque: 90 Nm

Vehicles with PCM safety plate
Vehicles with PCM security shield

  1. Tighten the shear bolt until the head is sheared off.

  1. Torque: 3 Nm
All vehicles

  1. Torque: 25 Nm

  1. CAUTION:
    CAUTION:No sealant must be used upstream of the catalytic converter.
    NOTE:
    NOTE:Only tighten the nuts finger tight at this stage.

  1. NOTE:
    NOTE:The flexible exhaust pipe must not be twisted.
    NOTE:
    NOTE:Only tighten the nuts finger tight at this stage.
    Grease the stud bolt.
    Material: Grease

  1. Torque: 55 Nm

  1. NOTE:
    NOTE:The flexible exhaust pipe must not be twisted.
    Torque: 48 Nm

  1. Torque: 48 Nm

  1. Torque: 48 Nm

  1.  
    1. Torque: 48 Nm
    1. Torque: 10 Nm
  1. Install the following items:
    1. Refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).
    1. Refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
    1. Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).

  1. Torque: 25 Nm

  1. General Equipment: Hose clamp remover/installer

  1. CAUTION:
    CAUTION:The gearshift cables must not be kinked or twisted.

  1. Torque: 12 Nm

  1.  
    1. Torque: 25 Nm
    1. Torque: 15 Nm

  1. Torque: 12 Nm

  1. Torque: 12 Nm
  1. Refer to: Gearshift Cable Adjustment - Vehicles With: 5-Speed Manual Transmission (MTX-75) (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  1. Install the following items:
    1. Refer to: Accessory Drive Belt (303-05A Accessory Drive - 2.0L Duratec-HE (MI4)/2.3L Duratec-HE (MI4), Removal and Installation).
    1. Right-hand headlamp
      Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
    1. Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

  1. Refer to: Power Steering System Filling (211-00 Steering System - General Information, General Procedures).
  1. Refer to: Power Steering System Bleeding (211-00 Steering System - General Information, General Procedures).
  1. Refer to: Cooling System Draining, Filling and Bleeding (303-03A Engine Cooling - 2.0L Duratec-HE (MI4)/2.3L Duratec-HE (MI4), General Procedures).

  1. Check the toe setting and adjust as necessary on both sides.
    Refer to: Front Toe Adjustment (204-00 Suspension System - General Information, General Procedures).

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