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Focus 1999 (08.1998-12.2004)

Engine - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec) - Engine Focus 1999 (08/1998-12/2004)
Assembly

Special Tool(s)

Universal Flange Holding Wrench

205 - 072 (15 - 030 A)

Installer, Oil Seal

303 - 039 (21 - 009 B)

Installer, Oil Seal

303 - 291 (21 - 141)

Timing Plate, Camshaft Alignment

303 - 376 (21 - 162 B)

Locking Tool, Flywheel

303 - 254 (21 - 135)

Aligner, Clutch Plate

308 - 204 (16 - 067)

Timing Peg, Crankshaft TDC

303 - 574 (21 - 163)

Socket, Cylinder Head Bolts

303 - 392 (21 - 167)
General Equipment
Piston ring compressor
Spatula
Steel straightedge
Workshop hoist
Materials
Name
Specification
High-temperature grease
ESD - M1C220 - A 
Sealer remover
WSK - M2G348 - A4 
Sealer, joins between cylinder block and oil pump/oil seal housing
WSK - M4G320 - A 
Sealer, camshaft bearing cap
WSK - M2G348 - A5 
Sealer, oil pan
WSS - M4G323 - A7 
Engine oil
WSS - M2C912 - A1 
Silicone grease, spark plug connector seal
A696 - M1C171 - AA 

Assembly

  1. Preparatory operations
      CAUTION:
      CAUTION:Do not damage the cylinder liners.
    • Remove the ring of carbon from the upper edge of the cylinders.
    • Thoroughly clean all threaded bores.
  1. Check for cylinder head distortion.
    For additional information, refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).

  1. Install the crankshaft.
    • Insert the main bearing shells in the cylinder block and the main bearing caps and coat them with engine oil.
    • Coat the crankshaft main bearing with engine oil.
    1. Insert the crankshaft.
      NOTE:
      NOTE:Do not tighten the main bearing cap bolts yet.
    1. Attach the main bearing caps.

  1. NOTE:
    NOTE:The connecting rods are numbered consecutively from the timing belt end. The recesses in the piston crown point towards the inlet side (1.8L only), the arrow points towards the timing belt end.
    Install the piston.
    • Lubricate the pistons and cylinder liners with engine oil .
    • Distribute the piston ring gaps and the elements of the oil scraper ring evenly around the circumference (120 degrees).
    • Press pistons one and four into the cylinders using a hammer handle. Big-end bearing journals one and four must be in the BDC position.
      NOTE:
      NOTE:The Ford trademark on the connecting rod points towards the drive belt side.
    • Check the bearing shells are clean and dry and insert them into the associated connecting rods and bearing caps.
      NOTE:
      NOTE:Use new big-end bearing cap bolts.
      NOTE:
      NOTE:Do not yet tighten the big-end bearing cap bolts.
    • Coat the big-end bearing journals and big-end bearing shells with engine oil.
    • Fit the bearing caps.
    • Rotate the crankshaft through 180 degrees and insert pistons two and three.

  1. NOTE:
    NOTE:The crankshaft must turn freely. Check the bearing clearances and correct if necessary.
    Tighten the main bearings and the big-end bearings.
    1. Tighten the main bearing cap bolts to 83 Nm.
    1. Tighten the big-end bearing bolts in two stages.
    • Stage 1: 15 Nm
    • Stage 2: 90 degrees

  1. Attach the rear oil seal housing and the CKP sensor with its bracket.
    • Position the oil seal housing with a new oil seal and fit the bolts finger tight.
    1. Align the oil seal carrier so that the mating face of the oil seal carrier is located between 0,3 mm and 0,8 mm below the cylinder block.
    1. Tighten the bolts.
    1. Fit the CKP sensor bracket.

  1. CAUTION:
    CAUTION:The oil seal must be installed in Special Tool 303-291 as far as the stop.
    Fit the new crankshaft rear seal in the special tool.
    • To fit it correctly, place the special tool in a vise and press in the seal using the handle of a hammer.
    1. Incorrect position
    1. Correct position

  1. NOTE:
    NOTE:Use two flywheel bolts.
    Draw in the oil seal using the special tool.

  1. Align the oil pump.
    • Position the oil pump with the new gasket and tighten the bolts finger tight.
    • Align the oil pump on both sides so that the mating face is between 0,3 mm and 0,8 mm above the lower edge of the cylinder block.

  1. Attach the oil pump with new crankshaft front oil seal.
    • Tighten the bolts and check the alignment as described in the previous step. Correct if necessary.

  1. NOTE:
    NOTE:Install the lower crankcase within 10 minutes of applying sealer.
    Apply sealer onto the indicated areas (bead diameter: 4 mm).

  1. CAUTION:
    CAUTION:If the permissible limits for protrusion and gaps are exceeded, fit spacer shims as described in the next step.
    NOTE:
    NOTE:Do not tighten the bolts for the moment.
    NOTE:
    NOTE:Install a new lower crankcase gasket.
    Align the lower crankcase.
    • Align the lower crankcase with a steel straightedge so that the cylinder block and the lower crankcase are flush, or the following tolerances are not exceed:

        • 1. MTX 75 manual transmission: 0,10 mm projection to 0,25 mm clearance.

        2. Automatic transmission: 0.00 to 0.25 mm gap.

  1. NOTE:
    NOTE:From 01/99 onwards only round spacer shims will be used.
    If necessary, fit lower crankcase spacer shims.
    • Use 0.25 mm spacer shims for a gap of 0.26 to 0.50 mm.
    • Use 0.50 mm spacer shims for a gap of 0.51 to 0.75 mm.

  1. Attach the lower crankcase and the oil intake pipe with new gasket.
    1. Tighten the bolts and check the alignment as described in the previous step, correct as necessary.
    1. Oil intake pipe bolts

  1. CAUTION:
    CAUTION:Use stud bolts. The lower crankcase may be damaged if sealer enters the blind holes.
    Screw 10 studs (M6 x 20) into the blind holes shown.

  1. NOTE:
    NOTE:Once contact is made with the lower crankcase, do not remove the sump again.
    NOTE:
    NOTE:Attach the oil pan within 10 minutes of applying sealant.
    Apply a 3 mm bead of sealant to the oil pan mating surface.

  1. NOTE:
    NOTE:Tightening sequence.
    Attach the oil pan and tighten in two stages.
    • Stage 1: 6 Nm
    • Stage 2: 10 Nm

  1. NOTE:
    NOTE:Use new bolts.
    NOTE:
    NOTE:Remove any residue of thread-locking compound from the threaded bores.
    Attach the flywheel.
    • Attach the special tool and tighten the bolts.
  1. NOTE:
    NOTE:Apply a layer of high-temperature grease. This should be so thin that no grease is expelled from the splines when the clutch disc is pushed on to the transmission input shaft.
    Coat the clutch plate splines evenly with high-temperature grease .

  1. Centralize the clutch plate on the clutch pressure plate using the special tool.

  1. Attach the clutch.
    1. Locate the clutch pressure plate in position with the centered clutch disk.
    1. Working diagonally in several stages, tighten the bolts one turn at a time.
    1. Check the centering and correct as necessary.
    • Remove the special tool.

  1. Fabricate two locating studs as shown in the diagram.

  1. CAUTION:
    CAUTION:The choice of cylinder head gasket depends on the cast cylinder block number (1).
    Fit a new cylinder head gasket onto the cylinder block.
    1. Cylinder block number
    1. Fit the new cylinder head gasket.
    1. Screw in the locating studs made in the previous step.
    1. Check that the locating bushes are seated correctly.
  1. Fit the cylinder head.
    • Hook the cylinder head into the workshop hoist by the engine lifting eyes and move it into position.

  1. CAUTION:
    CAUTION:The cylinder head bolts must not be retightened.
    NOTE:
    NOTE:Screw in the cylinder head bolts unoiled.
    NOTE:
    NOTE:Using Special Tool 303 - 392, tighten the cylinder head bolts in 3 stages in the indicated sequence.
    Attach the cylinder head.
    • Stage 1: 20 Nm
    • Stage 2: 40 Nm
    • Stage 3: 90 degrees
  1. Coat the valve tappets with engine oil and insert in the correct order.

  1. NOTE:
    NOTE:The identification numbers are located on the outside of the camshaft bearing caps.
    Apply sealer to the marked areas on camshaft bearing caps 0 and 5.
  1. Set the crankshaft to approx. 60 degrees before TDC.

  1. NOTE:
    NOTE:Lay the camshaft in place so that none of the cams is at full lift.
    Lubricate the camshafts and camshaft bearing caps with engine oil and insert.

  1. NOTE:
    NOTE:Working in several stages, evenly screw in the camshaft bearing cap bolts in the indicated sequence, half a turn at a time, and then tighten them in two stages.
    Tighten the camshaft bearing caps.
    • Stage 1: 10 Nm
    • Stage 2: 19 Nm

  1. Install the camshaft oil seals.
    • Lubricate the camshafts and the sealing lip of the oil seals with engine oil.
    • Draw in the new oil seals using the special tool, a washer and an M10x70 bolt.

  1. Turn the crankshaft to TDC of cylinder no. 1.

  1. NOTE:
    NOTE:Cylinders 1 and 4 are at TDC when the Woodruff key is pointing towards the pistons.
    Remove the blanking plug and align the crankshaft to TDC using the special tool.

  1. Turn the camshafts to ignition point on cylinder no. 1 and insert the special tool into the camshafts.
  1. NOTE:
    NOTE:Do not tighten the bolts. The camshaft timing pulleys must be able to turn freely on the camshafts.
    Slide the timing pulleys onto the camshafts and screw in the bolts.

  1. Fit a new gasket to the coolant pump.
    1. Lay the gasket in place.
    1. Secure the gasket by bending over the tabs.
CAUTION:
CAUTION:Do not kink the timing belt (bend diameter must not be less than 35 mm).
  1. CAUTION:
    CAUTION:Do not turn the crankshaft. If necessary check whether the crankshaft is touching Special Tool 303-574.
    Fit the new timing belt.
    1. Slide the crankshaft timing pulley and the thrust washer onto the crankshaft.
    1. Attach the coolant pump.
    1. Attach the lower idler pulley.
    1. Attach the upper idler pulley.
    1. Working counter-clockwise from the crankshaft timing pulley, lay the timing belt in place, keeping it taut at all times.
    1. Attach the timing belt tensioner and screw in the bolt 5 turns.

  1. CAUTION:
    CAUTION:Do not turn the crankshaft. If necessary check whether the crankshaft is touching Special Tool 303 - 620.
    NOTE:
    NOTE:Version without lower idler pulley shown (built from approx. 01/99).
    NOTE:
    NOTE:The tab on the timing belt tensioner must not be hooked into the metal cover.
    Fit the new timing belt.
    1. Slide the crankshaft timing pulley and the thrust washer onto the crankshaft.
    1. Attach the coolant pump.
    1. Fit the idler pulley.
    1. Working counter-clockwise from the crankshaft timing pulley, lay the timing belt in place, keeping it taut at all times.
    1. Attach the timing belt tensioner and screw in the bolt 5 turns.

  1. CAUTION:
    CAUTION:Only tension the timing belt tensioner by turning it counter-clockwise.
    NOTE:
    NOTE:If the belt tension is incorrect, this will lead to incorrect valve timing.
    Tension the timing belt.
    1. Attach the timing belt tensioner to the metal cover.
    1. Tension the timing belt by turning the tensioner counter-clockwise until the arrow and the marking line up, then tighten the bolt.

  1. CAUTION:
    CAUTION:Do not tighten the camshaft timing pulley bolts against Special Tool 303 - 376; use Special Tool 205 - 072 to counterhold.
    NOTE:
    NOTE:The crankshaft must remain at TDC on cylinder number 1.
    Tighten the bolts of the camshaft timing pulleys.
  1. Unscrew and remove Special Tool 303-574.
  1. Remove Special Tool 303 - 376 from the camshafts.
  1. NOTE:
    NOTE:Turn the engine by the crankshaft two turns in the normal direction of rotation.
    Check the valve timing by inserting the special tools, if necessary correct the adjustment.
    • Screw in Special Tool 303-574 and make sure that the crankshaft is touching it.
    • Insert Special Tool 303 - 376 into the camshafts - if necessary loosen the timing pulleys and correct the camshaft alignment.
    • Remove the special tools.

  1. Fit the blanking plug.
  1. Check the valve clearance and adjust if necessary.
    For additional information, refer to: Valve Clearance (303-01B Engine - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec), General Procedures).

  1. CAUTION:
    CAUTION:When applying silicone grease, use a blunt object (e.g. a plastic cable tie), to prevent damaging the spark plug connector seal.
    CAUTION:
    CAUTION:Push on the spark plug connector in line with the spark plug axis.
    NOTE:
    NOTE:Coat the inner side of the spark plug connector down to a depth of 5 to 10 mm with silicone grease.
    Install the cylinder head cover and the spark plugs.
    1. Screw in the spark plugs.
    1. Screw in the cylinder head cover bolts in two stages.

        2. 1. Stage 1: 2 Nm

        2. Stage 2: 7 Nm

    • Push on the spark plug connectors until they engage.

  1. Attach the timing belt covers and the belt pulleys.
    1. Lower timing belt cover
    1. Crankshaft pulley/vibration damper
      NOTE:
      NOTE:Check the seating of the timing belt upper cover gasket and correct it if necessary.
    1. Upper timing belt cover
    1. Middle timing belt cover/front engine mounting bracket
    1. Drive belt idler pulley
    1. Coolant pump belt pulley

  1. Attach the positive crankcase ventilation using a new gasket.
    1. Three bolts
    1. One bolt

  1. Attach the ancillary components on the exhaust side.
    1. A/C compressor bracket.
    1. Power steering pump bracket to cylinder head.
    1. Power steering pump bracket to cylinder head.
  1. Suspend the engine by the engine lifting eyes from the workshop hoist and detach it from the assembly stand.
    • Place the engine on the assembly table and leave it hooked into the workshop hoist.

  1. NOTE:
    NOTE:Coat the oil filter seal with clean engine oil.
    Attach the ancillary components on the intake side.
    1. Oil pressure switch
    1. Attach the new oil filter.
    1. Generator bracket to cylinder block
    1. Generator bracket to cylinder head

  1. Install the intake manifold.
    • Install the seven bolts and two nuts.

  1. CAUTION:
    CAUTION:Always follow the correct installation sequence for the catalytic converter in order to prevent damage.
    Loosen the catalytic converter bracket so that it can move freely.

  1. NOTE:
    NOTE:Use a new gasket.
    NOTE:
    NOTE:Do not yet tighten the nuts/bolts.
    Position the catalytic converter on the exhaust manifold.

  1. Using a nut and bolt, temporarily secure the catalytic converter to the bracket at the rear.

  1. Tighten the catalytic converter to the exhaust manifold.

  1. Attach the catalytic converter.
    1. Install the catalytic converter bracket bolts.
    1. Install the heat shield.

  1. Attach the catalytic converter bracket.
    • Tighten the bolts.
    • Remove the temporary bolt from the rear catalytic converter bracket.

  1. Install the generator.
    1. Install and tighten the bolt.
    1. Tighten the bolt.
    1. Attach the positive cable.

  1. Push the electrical connector onto the oil pressure switch.

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