Assembly Special Tool(s) | Universal Flange Holding Wrench 205-072 | | Lifting Bracket, Engine 303-122 | | Alignment Plate, Camshaft 303-376 | | Socket, Cylinder Head Bolt 303-392 | | Locking Tool, Flywheel 303-393 | | Installer, Crankshaft Seal 303-395 | | Mounting Stand 303-435 | | Mounting Bracket for 303-435 303-435-06 | | Mounting Plate for 303-435-06 303-435-14A | | Socket, Spark Plug 303-499 | | Locking Tool, Crankshaft 303-748 | | Locking Tool, Timing Belt Tensioner 303-1054 | General Equipment Five M8 x 20 mm studs Engine hoist Materials Name Specification Silicone Sealant WSE-M4G323-A4 Sealant WSK-M2G348-A2 Engine Oil - 5W-30 WSS-M2C913-B | -
- Install the special tools.
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NOTE:Install a new crankshaft rear seal carrier. NOTE:A new crankshaft rear seal carrier is supplied with an installation sleeve which must not be removed before installation. NOTE:Do not lubricate the seal lip. Install the crankshaft rear seal carrier. | | -
Install the crankshaft position (CKP) sensor bracket. | | -
NOTE:Install new flywheel retaining bolts. Install the flywheel and the special tool. - Tighten the bolts in the sequence shown in two stages.
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Install the clutch disc and pressure plate. For additional information, refer to: Clutch Disc and Pressure Plate (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission (iB5), Removal and Installation). | | -
NOTE:Install a new oil pump gasket. Install the oil pump. | | -
NOTE:Install a new oil pump pickup pipe gasket. Install the oil pump pickup pipe. | | -
Using the special tool, install the crankshaft front seal. | | -
CAUTION:The crankcase may be damaged if sealant enters the blind holes. | | -
NOTE:Attach the oil pan within ten minutes of applying sealant and tighten the bolts within a further five minutes. Apply a 3 to 4 mm diameter thick bead of sealant to the oil pan flange. | | -
NOTE:Align the oil pan so that the cylinder block is flush with the oil pan on the flywheel side. Install the oil pan, loosely install the retaining bolts. - Remove the studs and install retaining bolts.
- Tighten the oil pan retaining bolts in the sequence shown in two stages.
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NOTE:Inspect the oil pan drain plug seal for damage. Install a new drain plug and seal if required. Install the drain plug. | | -
Install the positive crankcase ventilation (PCV) cover. | | -
CAUTION:The knock sensor (KS) cable must not touch the cylinder head or the PCV cover. Position the KS cable at approximately the 10 o'clock position. Install the KS. | | -
NOTE:Install a new thermostat housing gasket. Install the thermostat housing together with the coolant thermostat. | | -
Install the oil pressure switch. | | -
CAUTION:Do not damage the coolant pump impeller. NOTE:Install a new coolant pump gasket. Install the coolant pump. | | -
Rotate the crankshaft against its normal direction, until piston No. one is approximately 25 mm before top dead center (TDC). | | -
CAUTION:The thickness of the new cylinder head gasket must be the same as that of the old one (hole marked). NOTE:Install a new cylinder head gasket. NOTE:Position the cylinder head onto the two guide sleeves. Using the special tool, install the cylinder head. - Tighten the cylinder head bolts in the sequence shown in three stages.
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Install the intake manifold lower retaining bolts. | | -
Attach the oil level indicator tube to the intake manifold. | | -
Connect the PCV hose to the PCV cover. | | -
NOTE:Identification numbers are provided on the outer face of the camshaft bearing caps. Apply sealant to the points indicated on the camshaft bearing cap no. 1 and to the mating face of the cylinder head. | | -
Coat the camshafts and the camshaft bearing caps with clean engine oil. | | -
CAUTION:Position the camshafts in place so that none of the cams are at full lift. NOTE:The camshaft bearing cap numbering starts at the timing belt end with E1 on the exhaust side and with I1 on the intake side. NOTE:The exhaust camshaft has an additional cam for the camshaft position (CMP) sensor. Install the camshafts and camshaft bearing caps. - Tighten the camshaft bearing cap retaining bolts in the sequence shown in three stages.
- Stage 1: One half turn on each bolt until all of the camshaft bearing caps are in contact with the cylinder head.
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Adjust the valve clearences. For additional information, refer to: Valve Clearance Adjustment (303-01A Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), General Procedures). | | -
NOTE:Install new camshaft seals. Using the special tool, install the camshaft seals. | | -
Install the timing belt rear cover. | | -
Rotate the camshafts to top dead center (TDC) on cylinder number 1 and install the special tool. | | -
NOTE:Do not fully tighten the camshaft pulley retaining bolts at this stage. Make sure the camshaft pulleys turn on the camshafts. Install the camshaft pulleys. | | -
Install the crankshaft timing belt pulley. | | -
WARNING:Do not remove the special tool, until the timing belt is correctly positioned. Failure to follow this instruction may result in personal injury, or may damage the automatic timing belt tensioner. Install the timing belt tensioner. | | -
NOTE:Install a new timing belt. NOTE:Install the timing belt, beginning with the crankshaft timing belt pulley working counterclockwise. Install the timing belt. | | -
Remove the blanking plug and install the special tool. - Carefully rotate the crankshaft against the special tool.
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Measuring the depth of the threaded hole in the crankshaft. - Depth of the threaded = 42 mm: Use an M12x29 mm crankshaft pulley center bolt.
- Depth of the threaded = 52 mm: Use an M12x44,5 mm crankshaft pulley center bolt.
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Install the timing belt lower cover. | | -
NOTE:Install a new crankshaft pulley retaining bolt. Install the crankshaft pulley. - Tighten the crankshaft pulley retaining bolt in two stages.
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CAUTION:Install a hose (order no. E890438S) to the special tool studs, to prevent damage to the camshaft pulleys. CAUTION:Do not tighten the camshaft pulley bolts against the timing plate. NOTE:Install new camshaft pulley retaining bolts. Using the special tool, tighten the camshaft pulleys. | | -
NOTE:Only rotate the crankshaft in its normal direction of rotation. Rotate the crankshaft two revolutions. | | -
Install the special tool. - Carefully rotate the crankshaft against the special tool.
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Check the valve timing. - If necessary loosen the camshaft pulleys and correct the camshaft alignment.
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Install the blanking plug. | | -
Using the special tool, install the spark plug. | | -
Install the valve cover. - Tighten the bolts in the sequence shown in three stages.
- Stage 1: Tighten bolt 1 by three to four turns.
- Stage 2: Tighten bolts 1 through 13 to 3 Nm.
- Stage 3: Tighten bolts 1 through 13 to 9 Nm.
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CAUTION:Coat the inside of the spark plug connector with silicone grease to prevent damage to the spark plug connector gasket. Connect the spark plug electrical connectors. - Attach the spark plug wires to the valve cover
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Install the timing belt upper cover. | | -
Install the engine front mount bracket. - Tighten the bolts in the sequence shown in three stages.
- Stage 1: Finger tighten bolt 1.
- Stage 2: Tigthen bolts 2 to 55 Nm.
- Stage 3: Tighten bolt 3 to 55 Nm.
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Install the coolant pump pulley. | | -
NOTE:Install a new oil filter. Install the oil filter. | | -
Fill the engine with clean engine oil. For additional information, refer to: Specifications (303-01A Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Specifications). | | -
Install the engine wiring harness. | | -
Using the special tool, attach the engine to the engine hoist. | | -
Remove the special tools. | | |