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Ford Focus 2002 Workshop Manual

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2002 Focus Workshop Manual
SECTION 303-01B: Engine — 2.0L SPI
ASSEMBLY
Engine
Special Tool(s)
Crankshaft Rear Seal Pilot
303-329 (T88P-6701-B2)
Crankshaft Rear Seal Replacer
303-328 (T88P-6701-B1)
Oil Pump Seal Replacer
303-164 (T81P-6700-A)
Strap Wrench
303-D055 (D85L-6000-A) or equivalent
Material
Engine oil
Silicone gasket and
F6AZ-19562-AA or equivalent Ford specification WSE-
sealant
1.
CAUTION: Do not use abrasive grinding discs to remove the gasket material; use only plastic manual scrapers. Do not scratch or gouge aluminium sealing
surfaces.
NOTE: All bearing surfaces must be lubricated before assembly or installation.
NOTE: The crankshaft main bearings are precision selective fit. For additional information, refer to Section 303-00.
Install the main bearings.
1. Upper crankshaft main bearing.
2. Crankshaft thrust main bearing.
2. Install the crankshaft.
3. NOTE: The crankshaft main bearings are numbered 1 to 5 with No. 1 at the front of the engine. Make sure the arrow faces the front of the engine.
NOTE: Apply axial load to the rear of the crankshaft simultaneously to tightening of the bolts. For additional information, refer to Section 303-00.
Install the five lower crankshaft main bearings and the five main bearing caps.
4. Install the piston and connection rod assemblies.
http://www.fordtechservice.dealerconnection.com/pubs/content/~WS2Y/~MUS~LEN/20/S...
WSS-M2C153-H
M4G323-A6
Page 1 of 9
2002 Focus Workshop Manual
Procedure revision date: 12/14/2000
6/19/2008

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Summary of Contents for Ford Focus 2002

  • Page 1 Material Engine oil WSS-M2C153-H Silicone gasket and F6AZ-19562-AA or equivalent Ford specification WSE- sealant M4G323-A6 CAUTION: Do not use abrasive grinding discs to remove the gasket material; use only plastic manual scrapers. Do not scratch or gouge aluminium sealing surfaces.
  • Page 2 2002 Focus Workshop Manual Page 2 of 9 5. Install the four crankshaft rod caps. 6. NOTE: Coat the rear oil seal area and the crankshaft rear oil seal lip with engine oil. NOTE: Make sure the crankshaft rear oil seal is on correctly and that the edges are not rolled over. Using the special tools, install a new crankshaft rear oil seal.
  • Page 3 13. NOTE: Install the oil pan within ten minutes after the sealant is applied. Apply silicone gasket and sealant F6AZ-19562-AA or equivalent Ford specification WSE-M4G323-A6 approximately 3 mm (0.125 In) wide at the oil pan to cylinder block joints and the crankshaft rear oil seal retainer to cylinder block joints.
  • Page 4 2002 Focus Workshop Manual Page 4 of 9 17. Install the timing belt guide and the crankshaft sprocket. 18. Install the water pump. Use a new gasket. 19. Install the timing belt tensioner. 20. Line up the timing marks of the crankshaft. 21.
  • Page 5 2002 Focus Workshop Manual Page 5 of 9 23. Rotate the crankshaft two turns and recheck the timing marks. 24. Install the upper timing belt cover. 25. Install the timing belt cover. 26. NOTE: Using the special tool, hold the crankshaft pulley. Install the crankshaft pulley.
  • Page 6 2002 Focus Workshop Manual Page 6 of 9 30. NOTE: Tighten the bolts evenly. Install the exhaust manifold. Use a new gasket. 31. Install the accessory drive bracket. 32. Install the generator (if necessary). 33. NOTE: Wrap the threads with Teflon® tape. Install the oil pressure sender unit.
  • Page 7 2002 Focus Workshop Manual Page 7 of 9 36. Install the coil bracket, coil and spark plug wires. 37. Connect the spark plug wires. 38. Install a new gasket and the intake manifold. Tighten the nuts and bolts to 10 Nm and 90 degrees. 39.
  • Page 8 2002 Focus Workshop Manual Page 8 of 9 42. Connect the fuel pressure sensor electrical connectors. 43. Connect the oil pressure sender unit and the knock sensor electrical connectors. 44. Connect the idle air control valve and the throttle position sensor. 45.
  • Page 9 2002 Focus Workshop Manual Page 9 of 9 49. Install the EGR tube to the EGR valve. 50. Remove the engine from the stand. 51. Install the flywheel. Tighten the bolts fingertight. Install the special tool. Tighten the bolts. 52. Install the clutch (if equipped). For additional information, refer to Section 308-01A. 53.