engine FORD FIESTA 2007 Workshop Manual

303-01 B-98 Engine - 2.OL Duratec-HE (M14) 303-01 B-98
ASSEMBLY
Stage 5: 90 degrees. Stage 2: 16 Nm.
18. N0TE:Only rotate the crankshaft in its
21. Install the special tool.
normal direction of rotation.
Rotate the crankshaft until piston No.
I is
approximately
45 degrees before top dead
center (TDC).
19. Install the valve tappets.
20m &~~~l~~:lnstall the camshafts
approximately at valve overlap position on
cylinder No.
4.
Install the camshafts.
Working in several stages, evenly tighten the
camshaft bearing cap bolts in the sequence
shown, one half turn at a time.
Goat the camshaft bearing caps with oil.
Tighten the bolts in two stages.
Stage I: 7 Nm.
22. N0TE:lnstall a new rear friction washer.
Install the rear friction washer.
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303-01 B-99 Engine - 2.OL Duratec-HE (M14) 303-01 B-99
ASSEMBLY
23. lnstall the crankshaft sprocket. 26. Using the special tools, tighten the oil pump
sprocket retaining bolt.
24. N0TE:lnstall a new front friction washer.
lnstall the front friction washer.
27. lnstall the oil pump chain tensioner.
25. lnstall the oil pump chain.
I. lnstall the oil pump chain and the oil pump
sprocket.
2. lnstall the oil pump sprocket retaining bolt.
28. Install the oil pump chain guide.
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303-01 B-100 Engine - 2.OL Duratec-HE (M14) 303-01 B-I 00
ASSEMBLY
29. Install the timing chain tensioner.
30. Install the timing chain guides.
31 ' ACAUTION:D~ not fully tighten the
camshaft sprocket retaining bolts at this
stage. Make sure the camshaft sprockets
turn on the camshafts.
Install the camshaft sprockets.
Install the timing chain.
32. Tension the timing chain.
Apply pressure to the timing chain and
remove the securing pin.
,
33m ACAUTION:H~I~ each camshaft by the
hexagon with an open-ended wrench to
stop
it from turning.
Tighten the camshaft sprockets retaining
bolts.
34. Clean the mating face of the engine front
cover with a suitable metal surface cleaner.
35. N0TE:lnstall the engine front cover within
10 minutes of applying the sealant.
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303-01 B-I 01 Engine - 2.OL Duratec-HE (M14) 303-01 B-101
ASSEMBLY
Apply a 3 mm bead of sealant to the engine Tighten bolts 20 through 22 to 48 Nm.
. front cover.
i
37. Remove the cylinder block lower blanking
36. Install the engine front cover. plug from
the cylinder block and install the
special tool.
Tighten the bolts in the sequence shown.
Tighten bolts 1 through 8 to 10 Nm.
Tighten bolt 9 to 48 Nm.
Tighten bolts 10 through 19 to 10 Nm.
38. N0TE:Only rotate the crankshaft in the
normal direction of rotation.
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303-01 B-I 02 Engine - 2.OL Duratec-HE (M14) 303-01 B=102
ASSEMBLY
Using the crankshaft pulley retaining bolt, Stage 2: 90 degrees.
rotate the crankshaft until piston No. 1 is at
TDC.
39. Remove the crankshaft pulley retaining
bolt.
Discard the bolt.
40m &AUTION:O~I~ tighten the crankshaft
pulley securing bolt finger tight.
Install the crankshaft pulley onto the
crankshaft and secure the crankshaft pulley
to the front cover using a
M6 x 18 mm bolt.
41.
N0TE:lnstall a new crankshaft pulley
retaining bolt.
Using the special tools, prevent the
crankshaft pulley from rotating and tighten
the crankshaft pulley retaining bolt.
Tighten, the bolt in two stages.
Stage 1: 100 Nm.
42. Remove the crankshaft pulley securing bolt.
'.
43. Remove the special tool.
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303-01 B-103 Engine - 2.OL Duratec-HE (M14) 303-01 B-I 03
ASSEMBLY
44. Remove the special tool.
Using a M6 x 18 mm bolt, check the position
of the crankshaft pulley.
45. N0TE:Only rotate the crankshaft in the
normal direction of rotation.
49. N0TE:lf it is not possible to install the
Rotate the crankshaft two revolutions. special tool,
correct the engine timing.
46. Install the special tool. Using the special tool,
check the position of
the camshafts.
47. N0TE:Only rotate the crankshaft in the
normal direction of rotation. 50. Remove the special tool.
Rotate the crankshaft until piston No.
I is at
TDC.
48m ACAUTION:O~I~ tighten the crankshaft
pulley securing bolt finger tight.
N0TE:lf it is not possible to install the crankshaft
pulley securing bolt, correct the engine timing.
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303-01 B-I 04 Engine - 2.OL Duratec-HE (M14) 303-01 B-I 04
ASSEMBLY
51. Remove the crankshaft pulley securing bolt. 2. Insert the alignment tool supplied, so that it
is hooked in the crankshaft pulley teeth.
I
52. Remove the special tool.
53. Install the cylinder block lower blanking
plug9
54. N0TE:When installing a new crankshaft
pulley or engine front cover, the crankshaft
position
(CKP) sensor must be aligned
using the alignment tool supplied with the
new component.
N0TE:Do not tighten the bolts at this stage.
Align the CKP sensor.
1.
Loosen the CKP sensor retaining bolts.
55. Install the CKP sensor.
I. Tighten the CKP sensor retaining bolts.
2. Remove the alignment tool.
56. Install the coolant pump pulley.
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303-01 B-I 05 Engine - 2.OL Duratec-HE (M14) 303-01 B-105 -- -
ASSEMBLY
57. Install the accessory drive belt idler pulley. Tighten the bolts in the sequence shown.
58. 1 nstall the accessory drive belt tensioner. 61 Install the evaporative emission (EVAP)
valve support bracket.
59. Apply a small bead of sealant to the areas
as shown.
62. Using the special tool, install the spark
plugs.
60. N0TE:lnstall a new valve cover gasket if
necessary.
Install the valve cover.
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303-01 B-I 06 Engine - 2.OL Duratec-HE (M14) 303-01 B-106
ASSEMBLY
63. Using the special tool, connect the spark 66. Connect the positive crankcase ventilation
plug electrical connectors.
(PCV) hose to the intake manifold.
{-
64. Install the power steering pump. 67. Install the intake manifold.
65. Using the special tool, install the coolant 68. Install the oil level indicator tube and oil
hoses. level indicator.
69. N0TE:lnstall a new exhaust manifold
gasket.
N0TE:Do not tighten the exhaust manifold
retaining nuts at this stage.
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303-01 B-107 Engine - 2.OL Duratec-HE (M14) 303-01 B-107
ASSEMBLY
Install the exhaust manifold.
i
72. Attach the starter motor electrical
connector to the intake manifold.
70, Install the exhaust manifold lower retaining
bolts.
73. Connect the intake manifold runner control
(IMRC) electrical connector.
71. Connect the manifold absolute pressure
(MAP) sensor electrical connector. 74.
Connect the throttle body
(TB) electrical
connector.
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