303-01A-2 1.

6L Engine 303-01A-1

SECTION 303-01A 1.6L Engine

VEHICLE APPLICATION: 2001.5 Ikon

CONTENT PAGE
DESCRIPTION AND OPERATION

Engine............................................................................................................................................. 303-01A-3
General use............................................................................................................................... 303-01A-3

DIAGNOSIS AND CHECKS

Engine........................................................................................................................................... 303-01A-11

VEHICLE REPAIRS

Intake manifold .................................................................................................... (21 183 0) 303-01A-12

Aiming cap............................................................................................................ (21 140 0) 303-01A-17
Front crankshaft oil seal........................................................................................ (21 467 0) 303-01A-20
Valve seals........................................................................................................... (21 238 0) 303-01A-23
Camshaft ............................................................................................................. (21 283 0) 303-01A-26
Timing chain ............................................................................................................................ 303-01A-29
Crankshaft rear oil seal............................................................................................................. 303-01A-33
Exhaust manifold.................................................................................................. (21 186 0) 303-01A-35
Cylinder head........................................................................................................ (21 163 0) 303-01A-38
Sump.................................................................................................................... (21 154 0) 303-01A-48
Oil pump............................................................................................................... (21 154 0) 303-01A-52

DISASSEMBLY

Engine................................................................................................................... (21 132 0) 303-01A-54

DISASSEMBLY

Engine................................................................................................................... (21 134 8) 303-01A-65

DISASSEMBLY AND ASSEMBLY OF SUB-COMPONENTS

Cylinder head........................................................................................................ (21 165 6) 303-01A-74

ASSEMBLY

Engine................................................................................................................... (21 134 8) 303-01A-81

FACILITY

Engine................................................................................................................... (21 132 0) 303-01A-92

SPECS

Specs .......................................................................................................................................... 303-01A-103

Engine data........................................................................................................................... 303-01A-103
Engine oil................................................................................................................................ 303-01A-103
Lubricants, fluids, sealants and adhesives............................................................................ 303-01A-103
Filling capacities...................................................................................................................... 303-01A-103
Oil pressure........................................................................................................................... 303-01A-104
Crankshaft............................................................................................................................. 303-01A-104

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Piston......................................................................................................................................
Connecting rod.......................................................................................................................
Valve train............................................................................................................................... 303-01A-105
Monoblock ............................................................................................................................. 303-01A-105
Camshaft................................................................................................................................ 303-01A-105
Tightening torques.................................................................................................................. 303-01A-105
303-01A-106
303-01A-106

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DESCRIPTION AND OPERATION

Engine

General use

new development and includes the following

technical features:
The SOHC Zetec-Rocam engine has a capacity of 1.6 • Lightweight pistons with three piston rings
litres and a power output of 63 kW/85.5 PS.
The engine is a four-cylinder, in-line, four-stroke unit
with a single overhead camshaft and cross-flow cylinder
head. The engine is a
• Cast iron monoblock with integrated timing chain
housing
• Cast iron crankshaft with five main bearings

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DESCRIPTION AND OPERATION (CONTINUED)

• Cast aluminum alloy cylinder head with integrated (IAC) valve, manifold absolute pressure sensor with
timing chain housing and camshaft bearings integrated temperature and manifold absolute pressure
• Single overhead camshaft with five bearings (T-MAP) sensor and fuel rail with four injectors
• Two valves per cylinder • Four-into-one exhaust manifold
• Roller finger cam followers • Crankshaft driven oil pump
• Automatic clearance adjusters • Lightweight plastic coolant flow control housing with
• Laminated steel head gasket (two layers) integrated dual-acting thermostat, coolant bypass and
mounting nipple for engine coolant temperature (ECT)
• Structural aluminum crankcase
sensor
• Plastic intake manifold with integrated throttle body
• Electronic Engine Control (EEC V) engine
including throttle position (TP) sensor, idle air control
management system

Location of serial number and engine code

The engine serial number and

engine code are stamped on the rear face of the monoblock.

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DESCRIPTION AND OPERATION

Valve train

The five-bearing camshaft runs directly in the aluminum

Ref. Description
cylinder head.
1 Camshaft bearing cap An additional reference cam is provided for the camshaft
2 Camshaft position (CMP) sensor.
3 Reference cam The cam followers are supported along the automatic
lash adjusters and valves, and the camshaft operates the
4 Roller finger cam follower cam followers through its roller bearings.
5 Automatic lash adjuster This has the advantage of reducing friction and
6 Cylinder head consequently increasing durability.

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DESCRIPTION AND OPERATION (CONTINUED)

The use of automatic lash adjusters eliminates the need for valve clearance adjustment.

Rear oil seal retainer

The rear oil seal retainer is made of plastic. This

Ref. Description incorporates an integral crankshaft oil seal (made of
1 Rear oil seal retainer PTFE) and a monoblock to retainer gasket.
2 Crankcase contact surface NOTE: A special "Assembly Guide" (for retainer
installation) is provided with each new rear oil seal
3 Screw
retainer.
4 Assembly Guide NOTE: The sealing lip must be free of oil.

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DESCRIPTION AND OPERATION

Ref. Description 1 M8 screws

2 M11 screws
3 Cylinder head gasket.
4
Guide pins

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DESCRIPTION AND OPERATION (CONTINUED)

The cylinder head is made of cast aluminum alloy and is securely attached to the cylinder block with two guide

Cylinder head

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DESCRIPTION AND OPERATION

pins.
The cylinder head gasket of laminated design (two
layers) is made of steel.
NOTE: Always use a new gasket when installing the
cylinder head.

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DESCRIPTION AND OPERATION

The structural housing is made of cast aluminum and

Oil pan

provides a mounting bracket for the air conditioning

(A/C) compressor.
The one-piece crankcase gasket has an aluminum core
with a vulcanized rubber outer surface.
NOTE: Always use a new gasket when installing the
crankcase.

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DESCRIPTION AND OPERATION

The overhead camshaft is driven by the crankshaft via

Camshaft chain drive

the timing chain.

Ref. Description
1 Camshaft sprocket The steel camshaft sprocket has 38 teeth and is produced
by the "fine milling" process which allows for the flat
2 Crankshaft gear wheel design. The position of the camshaft sprocket is fixed by
means of a guide tab to a slot in the camshaft. The timing
3 Chain guide (intake side) mark is stamped on the face of the sprocket.
4 Tensioner arm (exhaust side)
5 Timing chain
6 Hydraulic chain tensioner

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DESCRIPTION AND OPERATION (CONTINUED)

The sintered steel crankshaft sprocket has 19 teeth and is The plastic chain guide and tensioner arm are fixed to the
held in position by a woodruff key. The timing mark is monoblock with one screw each. The chain guide and
stamped on the sprocket. tensioner arm reduce chain vibration and noise.
The single timing chain has 114 links. The alignment of The hydraulic chain tensioner is operated by engine oil
the chain and sprocket is indicated by the colored chain pressure.
links.

Coolant flow control housing

WARNING: The cooling system must be

The coolant flow control housing is made of plastic
depressurized before the ECT sensor retaining
and is bolted to the rear of the cylinder head.
clip is removed.

The ECT sensor is attached by a clip to its mount which is

integrated into the coolant flow control housing.
NOTE: Install a new gasket if the original is damaged.
The gasket is made of rubber.

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DIAGNOSIS AND CHECKS

Engine

SEE section 303-00.

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VEHICLE REPAIRS

Intake manifold (21 183 0)

Materials Specification
Clamps

Disassembly
1. Disconnect the battery ground cable.

2. Remove the air filter inlet tube.

3. ZWARNING: Look for and collect any

leaking fuel. Observe safety regulations
for working with fuel.
Disconnect the fuel lines.

4. Disconnect the throttle cable.

1. Remove the clip and pull the cable from the
retaining bracket.
2. Disconnect the inner cable.

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VEHICLE REPAIRS (CONTINUED)

5. Remove the hoses and electrical connector.

1.EVAP solenoid valve vacuum hose
2.Positive crankcase ventilation (PCV) hose.
3. Crankcase breather hose.
4.Engine coolant temperature (ECT) sensor
electrical connector.
5.Brake booster vacuum hose

6. Disconnect the electrical connectors.

1. Powertrain Control Module (PCM)
2. Camshaft Position (CMP) Sensor

7. Raise and support the vehicle. For more

information, see section 100-02.

8. Remove the protection under the engine.

9. Remove the lower intake manifold retaining bolts

(shown with engine removed).

10. Lower the vehicle.

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VEHICLE REPAIRS (CONTINUED)

11. Remove the intake manifold.

Facility

1. NOTE: Install a new gasket if the original is

damaged.
Install the intake manifold.

2. Raise and support the vehicle. For more information,

see section 100-02.

3. Install the lower intake manifold retaining bolts

(shown with engine removed).

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VEHICLE REPAIRS (CONTINUED)

4. Install the under-engine guard.

5. Lower the vehicle.

6. Connect the PCM and CMP electrical connectors.

7. Install the hoses and connect the electrical

connector.
1. EVAP solenoid valve vacuum hose
2. PCV hose.
3. Crankcase breather hose.
4. ECT sensor electrical connector.
5. Brake booster vacuum hose

8. Install the throttle cable.

1. Connect the inner cable.
2. Install the cable into the retaining bracket, check
the cable seating and secure it using the clip.

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VEHICLE REPAIRS (CONTINUED)

9. Connect the fuel lines.

10. Install the air filter intake tube.

11. Connect the battery ground cable.

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VEHICLE REPAIRS

Aiming cap (21 140 0)

Disassembly
1. Disconnect the battery ground cable.

2. Disconnect the electrical connectors.

1. Disconnect the powertrain control
module (PCM).
2. Disconnect the camshaft position
(CMP) sensor.
3. Disconnect the electronic ignition (EI)
coil.

3. ATTENTION: Do not pull on the wire when removing the spark plug connector. If necessary,
remove the ignition wires from the ignition coil
to avoid twisting the wires. Rotate the spark
plug connector slightly before removal to
loosen the seal.
CAUTION: Remove spark plug connectors in
line with spark plugs (for bent spark plug
connectors use special tool 303-622).
Disconnect the spark plug wires from the spark
plugs.

4. Disconnect the hoses.

1. EVAP solenoid valve vacuum hose
2. Positive crankcase ventilation hose
3. Crankcase breather hose

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VEHICLE REPAIRS (CONTINUED)

5. Remove the sight cover.

Facility

1. NOTE: Install a new gasket if the original is

damaged.
Install the aiming cap.

2. Connect the hoses.

1.Connect the vacuum hose to the EVAP valve.
2. Connect the PCV hose.
3.Connect the crankcase breather hose.

3. Connect the spark plug wires to the spark plugs.

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VEHICLE REPAIRS (CONTINUED)

4. Connect the electrical connectors of the PCM,

CMP sensor and EI coil.

5. Connect the battery ground cable.

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VEHICLE REPAIRS

Front crankshaft oil seal (21 467 0)

Special tools
Oil seal puller 303-112 (21-051)

q 21051

Special tools
Oil Seal Installer 303-656 (21-233)

( TO ( . N \
\ 9)) 60)
303656

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Disassembly
1. Remove the accessory band. For more information,
refer to section 303-05.
• Turn the belt tensioner clockwise and slide the belt
off the pulleys.

2. Raise and support the vehicle. For more information,

see section 100-02.

3. Remove the accessory drive belt cover.

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UED)

4. Remove the crankshaft pulley.

5. Using the special tool, remove the oil seal.

(Shown with crankcase removed.)

Facility

1. NOTE: The pulley, installation sleeve, housing

and sealing lip must be free of oil.
NOTE: The new oil seal is supplied with a plastic
installation sleeve.
Install the oil seal onto the crankshaft pulley.
1. Place the installation sleeve on the
crankshaft pulley.
2. Carefully install the oil seal onto the
crankshaft pulley.
• Remove the installation sleeve.

2. Using the special tool, install the crankshaft

pulley.
1. Crankshaft pulley screw.
2. Special tool.

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3. Crankshaft pulley
4. New oil seal.

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VEHICLE REPAIRS (CONTINUED)

3. NOTE: To avoid damage to the oil seal, do not pull the

crankshaft pulley out more than 3 mm during seal installation.
Tighten the crankshaft pulley bolt until the oil seal is fully
installed.

4. Remove the crankshaft pulley bolt.

5. Install the crankshaft pulley bolt.

6. Install the accessory drive belt cover.

7. Lower the vehicle.

8. Install the accessory drive belt.

• Turn the drive belt tensioner clockwise and install the
belt onto the pulleys.

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VEHICLE REPAIRS

Valve seals (21 238 0)

Special tools Special tools

Air Supply Adapter (Cylinder Adapter for 303-461 303-461-01
Head) 303-363 (21-157) (21-194-01)

21157 2119401

Valve Spring Compressor 303-461

(21-194) Valve Stem Oil Seal Pliers 303-
508 (21-211)
either
~ 21194 PZ21211

Disassembly
1. Remove the sight cover. For more information, see the Aiming Cap procedure included in this section.

2. Remove the camshaft. For more information, refer to the Camshaft procedure included in this section.

3. Remove the spark plugs.

4. Remove the camshaft roller followers (cylinder head shown removed).

5. Install the camshaft without the cam followers. For

more information, refer to the Camshaft procedure
included in this section.

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TINUED)

6. Install the special tool and high pressure air pipe.

• Connect a pressurized air supply at 710 bar.

7. NOTE: To aid in proper assembly, keep all parts in the

disassembled order.
Using the special tools, remove the valve spring.
1. Compress the valve spring.
2. Remove the valve collars, valve spring retainer
and valve spring.

8. Using the special tool, remove the valve seals.

Facility

1.NOTE: Valve seals are completely installed by valve

spring pressure.
Using the special tool, install the valve seals.

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VEHICLE REPAIRS (CONTINUED)

2. Using the special tools, install the valve springs.

1. Compress the valve spring and valve
spring retainer.
2. Insert the valve collars.

3. Remove the high pressure air pipe and special tool.

4. Remove the camshaft. For more information, refer

to the Camshaft procedure included in this section.

5. Install the roller finger cam followers. (Cylinder

head shown disassembled.)

6. Install the camshaft. For more information, refer

to the Camshaft procedure included in this
section.

7. Install the spark plugs.

8. Install the aiming cap. For more information, see

the Aiming Cap procedure included in this
section.

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VEHICLE REPAIRS

Camshaft (21 283 0)

Special tools Materials Specification

Universal flange clamping wrench
N© Hypoid oil SQM-2C9002-AA
205-072 (15-030 A)

GES 15030A
(

Disassembly
1. Remove the sight cover. For more information, see the Aiming Cap procedure included in this section.

2. NOTE: The timing mark on the camshaft sprocket and both colored links on the timing chain must be aligned.
Bring the engine to TDC on cylinder No. 1. and the
cable along with the chain and sprocket.

3. Remove the hydraulic timing chain tensioner.

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NUED)

4. Using the special tool, remove the camshaft

sprocket.

5. NOTE: Loosening sequence.

NOTE: Keep the camshaft bearing caps in order for
installation.
Loosen each camshaft bearing cap screw one turn
until the camshaft comes free.

6. Remove the camshaft bearing caps and camshaft.

Facility

1. NOTE: Make sure the sprocket alignment slot on the

camshaft is at the top (12 o'clock) when installing the
camshaft.
NOTE: Apply one drop of hypoid oil (WSQ-2C9002-
AA) to each camshaft bearing half (upper and lower).
Install the camshaft and tighten the bolts in two
stages.
1. Tighten each camshaft bearing cap bolt 90
degrees in the sequence shown.
2. Tighten the bolts to the specified torque in the
sequence listed.

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INUED)

2. NOTE: The mark on the camshaft sprocket and

both colored links on the timing chain must be aligned.
Remove the cable tie and using the special tool,
install the camshaft sprocket with timing chain.

3. Install the hydraulic timing chain tensioner.

4. Install the aiming cap. For more information,

see the Aiming Cap procedure included in this
section.

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VEHICLE REPAIRS

Timing chain

Special tools
Universal flange clamping wrench
©
205-072 (15-030 A)

GSaF 15030A
(it

Disassembly
1. Remove the oil pump. For more information,
refer to the Oil Pump procedure included in this
section.

2. Lower the vehicle.

3. Remove the sight cover. For more information,

see the Aiming Cap procedure included in this
section.

4. NOTE: The timing mark on the camshaft sprocket

and both colored links of the timing chain must be
aligned.
Bring the engine to TDC on cylinder #1.

5. Remove the hydraulic timing chain tensioner.

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VEHICLE REPAIRS (CONTINUED)

6. Using the special tool, remove the camshaft sprocket.

7. Raise and support the vehicle. For more information, see

section 100-02.

8. Remove the timing chain.

1. Remove the chain tensioner arm.
2. Remove the chain guide.
• Remove the timing chain and crankshaft sprocket.

Facility

1. NOTE: The timing mark on the crankshaft sprocket and the

single colored link in the timing chain must be aligned.
NOTE: The crankshaft sprocket timing mark must be at the 6
o'clock position.
Install the crankshaft sprocket and timing chain.

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VEHICLE REPAIRS (CONTINUED)

2. Install the timing chain tensioner arm and chain guide.

1. Install the chain tensioner arm.
2. Install the chain guide.

3. Lower the vehicle.

4. NOTE: The timing mark on the camshaft sprocket and

both colored links on the timing chain must be aligned.
NOTE: The mark on the camshaft sprocket must be at
the 12 o'clock position.
Install the timing chain onto the camshaft sprocket.

5. Using the special tool, tighten the camshaft sprocket

retaining screw.

6. Install the hydraulic timing chain tensioner.

VEHICLE REPAIRS (CONTINUED)

7. Install the aiming cap. For more information, see

the Aiming Cap procedure included in this

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section.

8. Install the oil pump. For more information, refer

to the Oil Pump procedure included in this
section.

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VEHICLE REPAIRS

Crankshaft rear oil seal

Disassembly
1. Remove the transaxle. For more information, see section 308-03.

2. Remove the clutch. For more information, see section 308-01.

3. Remove the steering wheel.

4. Remove the crankcase. For more information, refer

to the Crankcase procedure included in this section.

5. Remove and discard the rear oil seal retainer and

gasket.

Facility

1. NOTE: An alignment guide is supplied with each new rear oil seal retainer.
NOTE: The sealing lip must be free of oil.
NOTE: Make sure the alignment pins are located.
Install a rear oil seal retainer
new.

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VEHICLE REPAIRS (CONTINUED)

2. Install the crankcase. For more information,

refer to the Crankcase procedure included in
this section.

3. Install the steering wheel.

4. Install the clutch. For more information, see

section 308-01.

5. Install the transaxle. For more information,

see section 308-03.

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VEHICLE REPAIRS

Exhaust manifold (21 186 0)

Disassembly
1. Disconnect the battery ground cable.

2. Raise and support the vehicle. For more

information, see section 100-02.

3. Disconnect the catalytic converter from the

exhaust manifold and set it aside.
1. Remove the nuts.
2. Separate the insulator from the exhaust hanger.
• Remove and discard the gasket.

4. Lower the vehicle.

5. △CAUTION: Do not pull on the wire when

removing the spark plug connector. If
necessary, remove the ignition wires from
the ignition coil to avoid bending the wires.
Rotate the spark plug connector slightly
before removal to loosen the seal.
CAUTION: Remove spark plug connectors in line
with the spark plug (for bent spark plug
connectors use special tool 303-662).
Remove the spark plug connector.

6. Remove the electronic ignition (EI) coil and set it

aside.

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VEHICLE REPAIRS (CONTINUED)

7. Remove the upper heat shield (shown on

disassembled engine).

8. Remove the exhaust manifold (shown on

disassembled engine).
• Remove and discard the gasket.

Facility

1. NOTE: Use a new gasket.

Install the exhaust manifold.

2. Install the upper heat shield.

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VEHICLE REPAIRS (CONTINUED)

3. Install the EI coil.

4. Install the spark plug electrical connectors.

5. Raise and support the vehicle. For more

information, see section 100-02.

6. Connect the catalytic converter to the exhaust

manifold.
1. Put the nuts on.
2. Attach the exhaust hanger insulator.

7. Lower the vehicle.

8. Connect the battery ground cable.

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VEHICLE REPAIRS

Cylinder head (21 163 0)

Workshop equipment
Special tools
Cylinder head screw socket Trolley cat
303-392 (21-167)
Materials Specification
Sealer WSK-M2G349-A4
21167
Engine oil WSS-M2C913-A/ WSS-
Universal Cable Tie Clamping
M2C912-A1
Tool 205-072 (15-030 A)

SESW
( 1 5030A
Screw tightening angle gauge
303-174 (21-540)

21540

Disassembly
1. Disconnect the battery ground cable.

2. Remove the air filter inlet tube.

3. Z WARNING: Leaking fuel. Observe safety regulations for working with fuel.
Disconnect the fuel lines.

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NUED)

4. Disconnect the throttle cable.

1.Remove the clip and pull the cable out of the
retaining bracket.
2. Disconnect the internal cable.

5. Remove the hoses and electrical connector.

1.EVAP solenoid valve vacuum hose
2.Positive crankcase ventilation (PCV) hose.
3. Crankcase breather hose.
4.Engine coolant temperature (ECT) sensor
electrical connector.
5. Brake booster vacuum hose

6. Disconnect the electrical connectors.

1. Powertrain Control Module (PCM)
2. Camshaft Position (CMP) Sensor
3. Electronic ignition coil (EI).

7. ATTENTION: Do not pull on the wire when

removing the spark plug connector. If
necessary, remove the ignition wires from
the ignition coil to avoid twisting the wires.
Rotate the spark plug connector slightly
before removal to loosen the seal.
CAUTION: Remove spark plug connectors in line
with spark plugs (for bent spark plug
connectors, use special tool 303-622).
Remove the spark plugs.

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• Disconnect the electrical connectors.

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NUED)

8. Z WARNING: There is a risk of burns if

the engine is hot.
Drain the coolant (shown from below).
• Install the drain plug after draining.

9. Disconnect the coolant hoses.

10. Raise and support the vehicle. For more

information, see section 100-02.

11. Remove the protection under the engine.

12. Remove the lower intake manifold bolts (engine

shown disassembled for clarity).

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NUED)

13. Separate the catalytic converter from the exhaust

manifold and set it aside.
1. Remove the nuts.
2. Disconnect the insulator from the hanger.
• Remove and discard the gasket.

14. Lower the vehicle.

15. Remove the sight cover.

16. NOTE: The camshaft sprocket mark and both

colored links on the timing chain must be aligned.
NOTE: The camshaft sprocket timing mark must be at
the 12 o'clock position.
Bring the engine to TDC on cylinder #1.

17. Remove the hydraulic timing chain tensioner.

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NUED)

18. Remove the oil level indicator tube retaining

screw.

19. NOTE: Secure the timing chain to a cable

hanger to prevent it from falling into the crankcase.
Using the special tool, remove the camshaft
sprocket.

20. Place a trolley jack with a block of wood under the

crankcase and slowly raise until the front engine
mount is stress-free.

21. Remove the intake manifold.

22. Remove the front engine mounting bracket.

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TINUED)

23. NOTE: Loosen the screws in the sequence

indicated.
Using the special tool, remove the cylinder
head.
• Remove and discard the gasket.

Facility
1. ATTENTION: Use new cylinder head
bolts.
NOTE: Use a new gasket.
Using the special tool, tighten the screws in four
stages.
• Step 1: Tighten all M11 bolts in the
numerical sequence indicated to 40 Nm.
• Step 2: Tighten all M8 bolts in the
alphabetical order listed to 15 Nm.
• Step 3: Tighten all M8 bolts in the
alphabetical order listed to 45 degrees.
• Step 4: Tighten all M11 bolts in the
indicated numerical sequence to 120 degrees.

2. Install the front engine mounting bracket.

3. Disassemble the trolley jack.

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INUED)

4. NOTE: The timing mark on the camshaft

sprocket and both colored links of the timing chain
must be aligned.
Install the timing chain onto the camshaft
sprocket.
• The camshaft sprocket timing mark should be at
the 12 o'clock position.

5. Using the special tool, install the camshaft

sprocket.

6. NOTE: If the oil level indicator tube was

removed, apply sealant (WSK-M2G349- A4) to the
lower end.
Tighten the oil level gauge tube screw.

7. Install the hydraulic timing chain tensioner.

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TINUED)

8. NOTE: Install a new gasket if the original is

damaged.
Install the intake manifold.

9. Raise and support the vehicle. For more

information, see section 100-02.

10. Connect the catalytic converter.

1. Put the nuts on.
2. Connect the retaining hanger insulator.

11. Install the lower intake manifold retaining bolts

(engine shown removed for clarity).

12. Install the under-engine guard.

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13. Lower the vehicle.

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NUED)

14. Connect the coolant hoses.

1. To the coolant expansion tank
2. To the cabin heater
3. From the cabin heater

15. NOTE: Install a new gasket if the original is

damaged.
Install the aiming cap.

16. Install the spark plugs and connect the spark

plug wires.

17. Connect the electrical connectors of the PCM,

CMP sensor and EI coil.
1. PCM connector
2. CMP connector
3. EI coil connector

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NUED)

18. Install the hoses and electrical connector.

1. EVAP solenoid valve vacuum hose
2. PCV
3. Crankcase breather hose
4. ECT sensor electrical connector
5. Brake booster vacuum hose

19. Install the throttle cable.

1. Hook the inner cable.
2. Install the cable into the bracket, adjust the cable
and secure it with the clip.

20. Connect the fuel lines.

21. Install the air filter intake tube.

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22. Fill the cooling system. For more information, see section 303-03.

23. Connect the battery ground cable.

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VEHICLE REPAIRS

Crankcase (21 154 0)

Materials Specification
Sealer WSEM-4G323-A

Engine oil WSS-M2C913-A/ WSS-

M2C912-A1

Disassembly
All vehicles
1. Remove the transaxle. For more information,
see section 308-03.

2. Remove the clutch. For more information, see

section 308-01.

3. Remove the steering wheel.

4. Lower the vehicle.

5. Turn the belt tensioner clockwise and remove

the belt.

6. Raise and support the vehicle. For more

information, see section 100-02.

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VEHICLE REPAIRS (CONTINUED)

Vehicles with air conditioning

7. Remove the air conditioning compressor and
secure it to the radiator crossmember.

All vehicles
8. Drain the engine oil.

9. Install the drain plug.

10. Remove the crankcase.

• Remove and discard the gasket.

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VEHICLE REPAIRS (CONTINUED)

Facility
All vehicles
1. Preparatory operations.
NOTE: Do not damage the contact surfaces.
• Using a spatula or scraper remove any traces of
sealant or gasket residue from the mating faces.
NOTE: Contact faces must be free of oil and gasket
residue.
• Clean the crankcase to remove any oil or sludge
residue.

2. NOTE: Apply a 3 to 5 mm bead of sealant

(WSEM- 4G323-A) to the marked areas.
NOTE: Install the crankcase within 5 minutes of
applying the sealant beads.
Using a ruler, align the crankcase flush with the
rear surface of the block.
• Do not wait more than 5 minutes to install the
crankcase gasket.

3. Install and tighten the crankcase retaining bolts

(step 1).

4. Tighten the crankcase retaining bolts (step 2).

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VEHICLE REPAIRS (CONTINUED)

Vehicles with air conditioning

5. Install the A/C compressor.

All vehicles
6. Lower the vehicle.

7. Install the accessory drive belt.

• Turn the belt tensioner clockwise and install the
belt.

8. Raise and support the vehicle. For more

information, see section 100-02.

9. Install the steering wheel.

10. Install the clutch and pressure plate. For more

information, see section 308-01.

11. Install the transaxle. For more information, see

section 308-03.

12. Fill the engine with low friction oil that meets
Ford specification WSS-M2C913-A or WSS-
M2C912-A1.

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VEHICLE REPAIRS

Oil pump (21 154 0)

Special tools
Oil seal puller 303-112 (21-051)

q 21051

Disassembly
1. Remove the crankcase. For more information,
refer to the Crankcase procedure included in this
section.

2. Remove the crankshaft pulley.

3. Using the special tool, remove the front oil seal.

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VEHICLE REPAIRS (CONTINUED)

4. Remove the oil pump.

• Remove and discard the oil pump and gasket.

Facility

1.NOTE: Make sure the gasket contact surfaces are

clean.
NOTE: Use a new oil pump and gasket.
NOTE: The oil pump sealing edge must be within
±20mm of the lower sealing edges of the block.
Install the oil pump bolts.

2. Install a new front oil seal. For more information,

refer to the Front Oil Seal procedure included in
this section.

3. Install the crankcase. For more information, refer

to the Crankcase procedure included in this
section.

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DISASSEMBLY Disassembly
All vehicles
Engine (21 132 1. General notes.
0) • The location of the engine mounts and engine
support insulators are described looking from
Workshop the transaxle to the engine.
equipment • Steps that apply only to particular variants are
Retaining band indicated with a note.
Assembly bench • If necessary, cut the cable ties and install new
ones during installation.

2. Remove the battery. For more information, see

section 414-01.

3. Remove the battery tray.

1. Cut the cable ties.
2. Remove the screws.

4. Remove the air filter inlet tube.

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DISASSEMBLY (CONTINUED)

5. Remove the hoses.

1.EVAP solenoid valve vacuum hose
2. Positive crankcase ventilation hose
3. Brake booster vacuum hose

6. Z WARNING: Leaking fuel. Observe safety

regulations for working with fuel.
Disconnect the fuel lines.

7. Remove the throttle cable.

1. Remove the clip and pull the cable out of the
bracket.
2. Unhook the inner cable.

8. Z WARNING: There is a risk of burns if the

engine is hot.
Drain the coolant (shown from below).
• Screw the drain plug back on after draining.

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DISASSEMBLY (CONTINUED)

9. Remove the coolant hoses.

10. Remove the right coolant hose bracket.

11. Remove the left coolant hose bracket.

12. Disconnect the ground cable, electrical connectors,

and transmission breather.
1. Disconnect the ground wire.
2. Disconnect the electrical connector from the
generator.
3. Disconnect the electrical connector from the
starter motor.
4. Disconnect the breather from the transmission.

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DISASSEMBLY (CONTINUED)

13. Disconnect the electrical connectors.

1. Disconnect the heated oxygen sensor (HO2S).
2. Disconnect the powertrain control module
(PCM).
3. Disconnect the electronic ignition (EI) coil.
4. Disconnect the vehicle speed sensor (VSS).

14. Disconnect the electrical connector from the

reverse light switch.

15. Disconnect the speedometer drive cable from

the transaxle.

16. Disconnect the hydraulic line from the clutch

slave cylinder.

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DISASSEMBLY (CONTINUED)

17. Disconnect the electrical connectors from

the cooling fan.

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18. Remove the cooling fan.
• First slide the fan up and then remove it
from under the vehicle.

19.NOTE: Use an Allen wrench to prevent the

piston rod from rotating.
Loosen the suspension bar retaining nut
five turns on both sides (right side
shown).

20. Remove the accessory drive belt.

• Turn the belt tensioner clockwise and
slide the belt off the pulleys.

21. Raise and support the vehicle. For more

information, see section 100-02.

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22. Remove the protection under the engine.

23. Remove the accessory drive belt cover.

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Vehicles with air conditioning
24. Remove the A/C compressor and secure it
to the radiator crossmember.

All vehicles
25. Disconnect the catalytic converter from
the exhaust manifold and set it aside.
1. Remove the nuts.
2. Separate the exhaust hanger insulator.
3. Remove and discard the gasket.

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DISASSEMBLY (CONTINUED)

26.

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Remove the center section of the lower exhaust heat shield.

27. Disconnect the shift rod and stabilizer from the shift
lever.
1. Remove the shift rod.
2. Remove the shift lever stabilizer.

28. Disconnect the lower arm from the wheel handle on both
sides (left side shown).

29. Remove the inner constant velocity (CV) joint boot clamp
on both sides (right side shown).

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DISASSEMBLY (CONTINUED)

30. ZAUTTION: To avoid damage to the half-

shaft joints and boots, do not bend the
inner half-shaft joints more than 18
degrees, the outer one no more than 45
degrees.
NOTE: Remove grease from the outside of the
housing.

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Remove the half-shafts on both sides (left side
shown).
• Secure the half arrows to one side.

31. NOTE: The engine bearing restrictor is under

tension.
Remove the engine bearing restrictor.

32. Remove the coolant return hose.

33. Place the assembly bench with wooden blocks

under the vehicle.

34. Carefully lower the vehicle until the engine and

transaxle assembly rests on the assembly bench.

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DISASSEMBLY (CONTINUED)

engine.

engine.

35. Secure the engine and transaxle assembly on the

assembly bench with retaining straps.

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36. Remove the rear mounting bracket from the
DISASSEMBLY
37. Remove (CONTINUED)
the front mounting bracket from the
38. Move the assembly bench forward with the engine
and transaxle assembly. 40. Disconnect the electrical connectors from the
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39. Install an engine lifting eye. 1. Remove the electrical connectors from the
generator.
2. Remove the oil pressure switch

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3. Remove the CKP sensor.

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41. Remove the starter motor and left transaxle flange
bolt.

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DISASSEMBLY (CONTINUED)

44. Remove the upper transaxle flange bolt.

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45. Separate the transaxle from the engine.

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