Engine Valve Clearance Check Procedure

303-01-1 Engine — 2.0L and 2.
3L 303-01-1
GENERAL PROCEDURES
Valve Clearance Check 3. NOTE: The number on the valve tappet only
reflects the digits that follow the decimal. For
example, a tappet with the number 0.650 has
1. Remove the valve cover. For additional
the thickness of 3.650 mm.
information, refer to Valve Cover in this
section. NOTE: A midrange clearance is the most
desirable:
2. CAUTION: Turn the engine clockwise • intake: 0.22-0.28 mm (0.008-0.011 in).
only, and use the crankshaft bolt only.
• exhaust: 0.27-0.33 mm (0.010-0.013 in).
NOTE: Measure each valve’s clearance at base
Select tappets using this formula: tappet
circle, with the lobe pointed away from the
thickness = measured clearance + the base
tappet, before removing the camshafts. Failure
tappet thickness - most desirable thickness.
to measure all clearances prior to removing the
camshafts will necessitate repeated removal and Select the tappets and mark the installation
installation and wasted labor time. location.
Use a feeler gauge to measure each valve’s 4. If any tappets do not measure within
clearance and record its location. specifications, install new tappets in these
locations. For additional information, refer to
Valve Train Components — Exploded View
and Valve Tappets in this section.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Valve Cover
Item Part Number Description Item Part Number Description

1 14A464 Camshaft position (CMP) 3 14A464 Ignition coil-on-plug electrical
sensor electrical connector connector (4 required)
(part of 12B637) 4 W500215 Ignition coil-to-valve cover
2 14A464 Cylinder head temperature bolt (4 required)
(CHT) sensor electrical 5 12A192 Ignition coil (4 required)
connector (part of 12B637)
6 6853 Crankcase breather tube
(Continued)
(Continued)
303-01-2 Engine — 2.0L and 2.3L 303-01-2
IN-VEHICLE REPAIR (Continued)
7 14A464 Fuel rail pressure and 8 — Vacuum tube retainer (part of
temperature sensor electrical 9E498)
(Continued)
Item Part Number Description 2. Disconnect the camshaft position (CMP) sensor
9 W500215 Valve cover retainer (14 electrical connector.
required)
3. Lift up the connector boot and disconnect the
10 6582 Valve cover
cylinder head temperature (CHT) sensor
11 6584 Valve cover gasket electrical connector.
Removal 4. Disconnect the ignition coil-on-plug electrical
connectors.
All vehicles
5. Remove the 4 ignition coil-to-valve cover bolts
CAUTION: During engine repair and the ignition coils.
procedures, cleanliness is extremely important.
Any foreign material, including any material 6. Disconnect the breather tube from the valve
created while cleaning gasket surfaces, that cover.
enters the oil passages, coolant passages or the
oil pan can cause engine failure.
1. Disconnect the battery ground cable. For

additional information, refer to Section 414-01.
303-01-3 Engine — 2.0L and 2.3L 303-01-3
7. Disconnect the fuel rail pressure and All vehicles
temperature sensor and the fuel injector
electrical connectors. Detach the wiring harness 10. Detach all of the wiring harness retainers from
retainers. the valve cover studs and position the harness
aside.
8. Remove the radio interference capacitor bracket

bolt and position the bracket aside. 11. Remove the 14 valve cover retainers, the valve
cover and gasket.
• Discard the valve cover gasket.
Vehicles with secondary air injection (AIR)
9. Disconnect the heated oxygen sensor (HO2S) Installation

electrical connector.
All vehicles
1. CAUTION: Do not use metal scrapers,

wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces.
These tools cause scratches and gouges which
make leak paths.
Clean and inspect the sealing surfaces.
303-01-4 Engine — 2.0L and 2.3L 303-01-4
2. Install the valve cover, a new gasket and the 14 All vehicles
retainers.
• Tighten in the sequence shown to 10 Nm 5. Position the radio interference capacitor bracket
(89 lb-in). and install the bolt.
• Tighten to 10 Nm (89 lb-in).
3. Position the wiring harness and attach all of the

wiring harness retainers to the valve cover 6. Attach the wiring harness retainers. Connect the
studs. fuel rail pressure and temperature sensor and
the fuel injectors electrical connectors.
Vehicles with secondary air injection (AIR)

7. Install the breather tube on the valve cover.
4. Connect the HO2S electrical connector.
8. Install the ignition coils and the 4 ignition
coil-to-valve cover bolts.
9. Connect the ignition coil-on-plug electrical

connectors.
10. Connect the CHT sensor electrical connector

and install the connector boot.
11. Connect the CMP sensor electrical connector.

303-01-5 Engine — 2.0L and 2.3L 303-01-5
12. Connect the battery ground cable. For additional
information, refer to Section 414-01.
303-00-1 Engine System — General Information 303-00-1
GENERAL PROCEDURES
Valve Guide Inner Diameter
NOTE: Refer to the appropriate Section 303-01 for

the specification.
1. NOTE: Valve guides tend to wear in an

hourglass pattern. The ball gauge can be
inserted into the combustion chamber side of
the valve guide if necessary.
Use a ball gauge to determine the inner
diameter of the valve guides in 2 directions at
the top, middle and bottom of the valve guide.
3. If the valve guide is not within specifications,
install a new cylinder head assembly.
2. Measure the ball gauge with a micrometer.

GENERAL PROCEDURES
Valve Inspection
1. Inspect the following valve areas:

1 The end of the stem for grooves or scoring.
2 The valve face and the edge for pits,
grooves or scores.
3 The valve head for signs of burning,
erosion, warpage and cracking.
4 The valve margin for wear.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Material
Valve Seals
Item Specification
Special Tool(s) Motorcraft SAE 5W-20 WSS-M2C930-A
Premium Synthetic Blend
Compressor, Valve Spring Motor Oil
303-350 (T89P-6565-A) XO-5W20-QSP (US);
Motorcraft SAE 5W-20
Super Premium Motor Oil
CXO-5W20-LSP12
(Canada); or equivalent
Multi-Purpose Grease ESB-M1C93-B
XG-4 and/or XL-5
Compressor, Valve Spring
303-300 (T87C-6565-A) Removal
CAUTION: During engine repair

Any foreign material, including any material
created while cleaning gasket surfaces, that
Compressor, Valve Spring enters the oil passages, coolant passages or the
303-472 (T94P-6565-AH)
1. With the vehicle in NEUTRAL, position it on a

hoist. For additional information, refer to
Section 100-02.
Remover, Valve Stem Oil Seal 2. Remove the camshafts. For additional
303-468 (T94P-6510-AH) information, refer to Camshafts in this section.
3. CAUTION: If the camshafts and valve

tappets are to be reused, mark the location
of the valve tappets to make sure they are
assembled in their original positions.
Installer, Valve Stem Oil Seal
303-470 (T94P-6510-CH) NOTE: The number on the valve tappets only
Remove and inspect the valve tappets. For
Slide Hammer
307-005 (T59L-100-B) 4. Remove the spark plugs. For additional
303-01-2 Engine — 2.0L and 2.3L 303-01-2
5. WARNING: Always wear protective Installation

goggles when working with compressed air.
This can prevent injury. Failure to follow 1. Install the valve stem seal installation sleeve.
these instructions can result in personal
injury.
CAUTION: Use compressed air at 7 to
10 bars (100-150 psi). Do not disconnect the
compressed air from the cylinder until the
valve spring, valve spring retainer and valve
collet is installed.
Connect the compressed air supply to the No. 1
cylinder.
6. NOTE: Place all parts in order to one side.

Apply compressed air to the cylinder and
remove the valve spring.
2. Using the special tool, install the valve seal.
• Using the special tools, compress the valve
spring and remove the valve collet, using
some grease and a small screwdriver.
• Remove the valve spring retainer and the
valve spring.
3. NOTE: Check the seating of the valve collet.

Using the special tools, install the valve spring.
• Insert the valve spring and the valve spring
retainer.
7. Using the special tools, remove and discard the • Compress the valve spring and install the
valve seal. valve collet using some grease and a small
screwdriver.
303-01-3 Engine — 2.0L and 2.3L 303-01-3
4. Disconnect the compressed air supply. 7. Coat the valve tappets with clean engine oil and
insert them.
5. Repeat the appropriate removal and installation
steps for all of the other cylinders. 8. Install the camshafts. For additional
information, refer to Camshafts in this section.
6. Install the spark plugs. For additional
GENERAL PROCEDURES
Valve Seat Inspection
Valve and Seat Refacing Measurements

the specification.
NOTE: After grinding valves or valve seats, check

valve clearance.
1. Check the valve head and seat.

• Check valve angles.
• Check margin width. 2. Inspect for abnormalities on the valve face and
• Be sure margin width is within specification. seat. Install a new cylinder head assembly if
abnormalities are found.
GENERAL PROCEDURES
Valve Spring Free Length
1. Measure the free length of each valve spring.

• Refer to the appropriate section in Group
303 for the procedure.
• If out of specification, install new
components as necessary. Refer to the
appropriate section in Group 303 for the
procedure.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Valve Springs Removal
Special Tool(s) CAUTION: During engine repair

303-350 (T89P-6565-A) Any foreign material, including any material

303-300 (T87C-6565-A) of the valve tappets to make sure they are
NOTE: The number on the valve tappets only
Compressor, Valve Spring Remove the valve tappets. For additional
303-472 (T94P-6565-AH) information, refer to Valve Tappets in this
section.
2. WARNING: Always wear protective

goggles when working with compressed air.
This can prevent injury. Failure to follow
Material these instructions can result in personal
injury.
Item Specification
CAUTION: Use compressed air at 7 to
Motorcraft SAE 5W-20 WSS-M2C930-A
Premium Synthetic Blend 10 bars (100-150 psi). Do not disconnect the
Motor Oil compressed air from the cylinder until the
XO-5W20-QSP (US); valve spring, valve spring retainer and valve
Motorcraft SAE 5W-20 collet is installed.
CXO-5W20-LSP12 Unscrew the spark plug on the cylinder being
(Canada); or equivalent serviced and connect the compressed air supply.
XG-4 and/or XL-5
303-01-2 Engine — 2.0L and 2.3L 303-01-2
3. NOTE: Place all parts in order to one side.
Apply compressed air to the cylinder and
remove the valve spring.
• Using the special tools, compress the valve
spring and remove the valve collet, using
some grease and a small screwdriver.
• Remove the valve spring retainer and the
valve spring.
2. NOTE: Do not tighten the spark plug at this

time.
Disconnect the compressed air supply and
install the spark plug.
Installation
1. NOTE: Check the seating of the valve collet.

Using the special tools, install the valve spring.
• Insert the valve spring and the valve spring
retainer.
• Compress the valve spring and install the
valve collet using some grease and a small 3. Repeat the appropriate removal and installation
screwdriver. steps for all of the other cylinders.
4. Install the plugs and tighten to 15 Nm (11

lb-ft).
5. Install the valve tappets. For additional

information, refer to Valve Tappets in this
section.
GENERAL PROCEDURES
Valve Spring Squareness
1. Measure the out-of-square on each valve spring.

• Turn the valve spring and observe the space
between the top of the valve spring and the
square. Install a new valve spring if out of
square. Refer to the appropriate section in
Group 303 for the procedure.
GENERAL PROCEDURES
Valve Spring Strength
Special Tool(s)
Pressure Gauge, Valve/Clutch
Spring
303-006 (TOOL-6513-DD) or
equivalent

the specification.
1. Use the special tool to check the valve spring

for correct strength at the specified valve spring
length.
GENERAL PROCEDURES
Valve Stem Diameter
1. Measure the diameter of each intake and

exhaust valve stem at the points shown. Verify
the diameter is within specification.
procedure.
GENERAL PROCEDURES
Valve Tappet Inspection
1. Inspect the valve tappet for damage, especially

in the indicated areas. If any damage is evident,
inspect the camshaft lobes and valves for
damage. Install new components as necessary.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Valve Tappets 3. CAUTION: If the camshafts and valve
Material of the valve tappets to make sure they are
Item Specification
Motorcraft SAE 5W-20 WSS-M2C930-A NOTE: The number on the valve tappets only
Premium Synthetic Blend reflects the digits that follow the decimal. For
Motor Oil example, a tappet with the number 0.650 has
XO-5W20-QSP (US); the thickness of 3.650 mm.
Super Premium Motor Oil Remove and inspect the valve tappets. For
CXO-5W20-LSP12 additional information refer to Section 303-00.
4. To install, reverse the removal procedure.
Removal and Installation
• Coat the valve tappets with clean engine oil
prior to installation.

Section 100-02.
2. Remove the camshafts. For additional

information, refer to Camshafts in this section.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Valve Train Components — Exploded
View
Item Part Number Description 1. For additional information, refer to the

1 6500 Valve tappet (16 required) procedures in this section.
2 6518 Valve collet (16 required)
3 6514 Valve spring retainer (16
required)
4 6513 Valve spring (16 required)
5 6517 Valve seal (16 required)
GENERAL PROCEDURES
Camshaft Bearing Journal Diameter
1. Measure each camshaft journal diameter in 2

directions.
procedure.
GENERAL PROCEDURES
Camshaft End Play — OHC Engines 4. Move the camshaft to the front of the cylinder
head. Note and record the camshaft end play.
Special Tool(s) • If camshaft end play exceeds specifications,
install a new camshaft and recheck end play.
Dial Indicator Gauge with
Holding Fixture • If camshaft end play exceeds specification
100-002 (TOOL-4201-C) or after camshaft installation, install a new
equivalent cylinder head.

the specification.
1. Using the special tool, measure the camshaft

end play.
2. Position the camshaft to the rear of the cylinder

head.
3. Zero the indicator.

GENERAL PROCEDURES
Camshaft Lobe Lift
Special Tool(s)
Holding Fixture
100-002 (TOOL-4201-C) or
equivalent
1. Use a Dial Indicator Gauge with Holding

Fixture to measure camshaft intake/exhaust lobe
lift.
• Rotate the camshaft and subtract the lowest
indicator reading from the highest indicator
reading to figure the camshaft lobe lift.
GENERAL PROCEDURES
Camshaft Runout
Special Tool(s)
Holding Fixture
100-002 (TOOL-4201-C) or
equivalent

the specification.
1. NOTE: Camshaft journals must be within

specifications before checking runout.
Using the special tool, measure the camshaft
runout.
• Rotate the camshaft and subtract the lowest
indicator reading from the highest indicator
reading.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Camshafts 2. Disconnect the battery negative cable. For
Special Tool(s)
3. Remove the degas bottle. For additional
Alignment Plate, Camshaft information, refer to Section 303-03.
303-465 (T94P-6256-CH)
4. Check the valve clearance. For additional
information, refer to Valve Clearance Check in
this section.
5. Remove the accessory drivebelt. For additional

Timing Peg, Crankshaft information, refer to Section 303-05.
303-507
6. CAUTION: Failure to position the No.
1 piston at top dead center (TDC) can result
in damage to the engine. Turn the engine in
the normal direction of rotation only.
Using the crankshaft pulley bolt, turn the
Material crankshaft clockwise to position the No. 1
piston at TDC.
Item Specification
• The hole in the crankshaft pulley should be
Silicone Gasket and WSE-M4G323-A4
Sealant in the 6 o’clock position.
TA-30
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
Removal

Any foreign material (including any material
created while cleaning gasket surfaces) that
CAUTION: Do not rotate the camshafts

unless instructed to in this procedure. Rotating
the camshafts or crankshaft with timing
components loosened or removed can cause
serious damage to the valves and pistons.

Section 100-02.
303-01-2 Engine — 2.0L and 2.3L 303-01-2
7. CAUTION: The special tool 303-465 is

for camshaft alignment only. Using this tool
to prevent engine rotation can result in
engine damage.
NOTE: The camshaft timing slots are offset. If
the special tool cannot be installed, rotate the
crankshaft one complete revolution clockwise to
correctly position the camshafts.
Install the special tool in the slots on the rear of
both camshafts.
8. Remove the engine plug bolt.
10. CAUTION: Only hand-tighten the bolt

or damage to the front cover can occur.
Install a standard 6 mm (0.23 in) x 18 mm (0.7
in) bolt through the crankshaft pulley and
thread it into the front cover.
9. NOTE: The special tool will contact the

crankshaft and prevent it from turning past
TDC. However, the crankshaft can still be
rotated in the counterclockwise direction. The
crankshaft must remain at the TDC position
during the camshaft removal and installation.
Install the special tool.
303-01-3 Engine — 2.0L and 2.3L 303-01-3
11. Remove the lower front cover timing hole plug 13. Reposition the special tool to the slot on the
from the engine front cover. rear of the intake camshaft only.
12. Remove the upper front cover timing hole plug

from the engine front cover.
303-01-4 Engine — 2.0L and 2.3L 303-01-4
14. NOTE: Releasing the ratcheting mechanism in
the timing chain tensioner allows the plunger to
collapse and create slack in the timing chain.
Installing an M6 x 30 mm (1.18 in) bolt into
the upper front cover timing hole will hold the
tensioner arm in a retracted position and allow
enough slack in the timing chain for removal of
the exhaust camshaft gear.
Using a small pick tool, unlock the chain
tensioner ratchet through the lower front cover
timing hole.
• Using the flats of the camshaft, have an
assistant rotate the exhaust camshaft
clockwise to collapse the timing chain
tensioner plunger.
• Insert an M6 x 30 mm (1.18 in) bolt into
the upper front cover timing hole to hold the
tensioner arm in place.
303-01-5 Engine — 2.0L and 2.3L 303-01-5
15. Remove the special tool.
18. Using the flats on the camshaft to prevent

camshaft rotation, remove the bolt and intake
16. Using the flats on the camshaft to prevent camshaft drive gear.
camshaft rotation, remove the bolt and exhaust
camshaft drive gear.
17. Remove the timing chain from the intake

camshaft drive gear.
303-01-6 Engine — 2.0L and 2.3L 303-01-6
19. Mark the position of the camshaft lobes on the Installation
No. 1 cylinder for installation reference.
1. CAUTION: Install the camshafts with
the alignment slots in the camshafts lined up
so the Camshaft Alignment Plate can be
installed without rotating the camshafts.
Make sure the lobes on the No. 1 cylinder
are in the same position as noted in the
removal procedure. Rotating the camshafts
when the timing chain is removed, or
installing the camshafts 180 degrees out of
position can cause severe damage to the
valves and pistons.
NOTE: Lubricate the camshaft journals and
bearing caps with clean engine oil.
20. CAUTION: Failure to follow the Install the camshafts and bearing caps. Tighten
camshaft loosening procedure can result in the bearing caps in the sequence shown in 3
damage to the camshafts. stages:
Remove the camshafts from the engine. • Stage 1: Tighten the camshaft bearing cap
• Loosen the camshaft bearing cap bolts, in bolts one turn at a time until finger tight.
sequence, one turn at a time. • Stage 2: Tighten to 7 Nm (62 lb-in).
• Repeat the first step until all tension is • Stage 3: Tighten to 16 Nm (12 lb-ft).
released from the camshaft bearing caps.
• Remove the camshaft bearing caps.
• Remove the camshafts.
2. Install the special tool.

303-01-7 Engine — 2.0L and 2.3L 303-01-7
3. Install the intake camshaft drive gear and 5. NOTE: The timing chain must be correctly
hand-tighten the bolt. engaged on the teeth of the crankshaft timing
sprocket and the intake camshaft drive gear in
order to install the exhaust camshaft drive gear
onto the exhaust camshaft.
Position the exhaust camshaft drive gear in the
timing chain and install the gear and bolt on the
exhaust camshaft.
• Hand-tighten the bolt.
4. Install the timing chain on the intake camshaft

drive gear.
6. NOTE: Releasing the tensioner arm will

remove the slack from the timing chain release.
Remove the M6 x 30 mm bolt from the upper
front cover timing hole to unlock the tensioner
arm.
303-01-8 Engine — 2.0L and 2.3L 303-01-8
7. CAUTION: The special tool 303-465 is 9. Remove the 6 mm (0.23 in) x 18 mm (0.7 in)
for camshaft alignment only. Using this tool bolt.
engine damage.
Using the flats on the camshafts to prevent
camshaft rotation, tighten the bolts.
• Tighten to 72 Nm (53 lb-ft).
11. Install the upper front cover timing hole plug.


303-01-9 Engine — 2.0L and 2.3L 303-01-9
12. Apply silicone gasket and sealant to the threads
of the lower front cover timing hole plug.
• Install the plug and tighten to 12 Nm (9
lb-ft).
14. Install the accessory drivebelt. For additional

15. Install the valve cover. For additional

information, refer to Valve Cover in this
13. Install the engine plug bolt. section.
• Tighten to 20 Nm (15 lb-ft). 16. Install the degas bottle. For additional
17. Connect the battery negative cable. For

GENERAL PROCEDURES
Camshaft Surface Inspection
1. Inspect camshaft lobes for pitting or damage in

the contact area. Minor pitting is acceptable
outside the contact area.
• If excessive pitting or damage is present,
install new components as necessary. Refer
to the appropriate section in Group 303 for
the procedure.
GENERAL PROCEDURES
Crankshaft End Play 4. Move the crankshaft to the front of the cylinder
block. Note and record the crankshaft end play.
Special Tool(s) • If crankshaft end play exceeds
specifications, install a new crankshaft thrust
Holding Fixture washer or crankshaft thrust main bearing.
100-002 (TOOL-4201-C) or Refer to the appropriate section in Group
equivalent 303 for the procedure.
1. Measure the crankshaft end play. Use a Dial

Indicator Gauge with Holding Fixture to
measure crankshaft end play.
2. Position the crankshaft to the rear of the

cylinder block.
3. Zero the indicator.

303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Crankshaft Front Seal Removal
Special Tool(s) CAUTION: Do not loosen or remove the

crankshaft pulley bolt without first installing the
Installer, Front Oil Seal
303-096 (T74P-6150-A) special tools as instructed in this procedure. The
crankshaft pulley and the crankshaft timing
sprocket are not keyed to the crankshaft. The
crankshaft, the crankshaft sprocket and the
pulley are fitted together by friction, using
diamond washers between the flange faces on
each part. For that reason, the crankshaft
Remover, Seal sprocket and the pulley are fitted together by
303-409 (T92C-6700-CH)
friction, using diamond washers between the
flange faces on each part. For that reason, the
crankshaft sprocket is also unfastened if you
loosen the pulley bolt. Before any repair
requiring loosening or removal of the crankshaft
pulley bolt, the crankshaft and camshafts must
Material be locked in place by the special service tools,
otherwise severe engine damage can occur.
Item Specification
Motorcraft SAE 5W-20 WSS-M2C930-A CAUTION: During engine repair
Premium Synthetic Blend procedures, cleanliness is extremely important.
Motor Oil
XO-5W20-QSP (US); Any foreign material, including any material
Motorcraft SAE 5W-20 created while cleaning gasket surfaces, that
Super Premium Motor Oil enters the oil passages, coolant passages or the
CXO-5W20-LSP12 oil pan can cause engine failure.
1. Remove the crankshaft pulley. For additional
information, refer to Lower End Components —
Exploded View and Crankshaft Pulley in this
section.
2. CAUTION: Use care not to damage

the engine front cover or the crankshaft
when removing the seal.
Using the special tool, remove the crankshaft
front oil seal.
303-01-2 Engine — 2.0L and 2.3L 303-01-2
Installation
1. NOTE: Remove the through-bolt from the

special tool.
NOTE: Lubricate the oil seal with clean engine
oil.
Using the special tool, install the crankshaft
front oil seal.
2. Install the crankshaft pulley. For additional

information, refer to Lower End Components —
Exploded View and Crankshaft Pulley in this
section.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Crankshaft Pulley Removal
Special Tool(s) CAUTION: Do not loosen or remove the

Alignment Plate, Camshaft
303-465 (T94P-6256-CH) special tools as instructed in this procedure. The
Timing Peg, Crankshaft sprocket is also unfastened if you loosen the
303-507
pulley bolt. Before any repair requiring
loosening or removal of the crankshaft pulley
bolt, the crankshaft and camshafts must be
locked in place by the special service tools,
Holding Fixture, Drive Pinion CAUTION: During engine repair

Flange
205-126 (T78P-4851-A) procedures, cleanliness is extremely important.
Adapter for 205-126 1. With the vehicle in NEUTRAL, position it on a

(205-072-02) hoist. For additional information, refer to
Section 100-02.
2. Remove the accessory drive belt. For additional

3. Remove the valve cover. For additional

Material information, refer to Valve Cover in this
Item Specification section.
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
303-01-2 Engine — 2.0L and 2.3L 303-01-2

crankshaft clockwise to position the No. 1
piston at TDC.
in the 6 o’clock position.

during the crankshaft pulley removal and
installation.

engine damage.
both camshafts.

303-01-3 Engine — 2.0L and 2.3L 303-01-3
8. Assemble the special tools using 4 hardened
washers in the locations shown.
Installation
1. CAUTION: Do not install the

crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil on the seal area
before installing.
Position the crankshaft pulley onto the
crankshaft with the hole in the pulley at the 6
o’clock position.
9. CAUTION: The crankshaft must

remain in the TDC position during removal
of the pulley bolt or damage to the engine
can occur. Therefore, the crankshaft pulley
must be held in place with the special tool
and the bolt should be removed using an air
impact wrench (1/2-in drive minimum).
CAUTION: If the crankshaft sprocket
diamond washer comes off with the
crankshaft pulley, it must be installed back
onto the crankshaft.
Using the special tools and an air impact
wrench, remove the crankshaft pulley.
• Remove and discard the crankshaft pulley
bolt and washer.
• Remove the crankshaft pulley.
303-01-4 Engine — 2.0L and 2.3L 303-01-4
2. CAUTION: Only hand-tighten the 6 4. CAUTION: The crankshaft must

mm (0.23 in) bolt or damage to the front remain in the TDC position during
cover can occur. installation of the pulley bolt or damage to
NOTE: This step will correctly align the the engine can occur. Therefore, the
crankshaft pulley to the crankshaft. crankshaft pulley must be held in place with
the special tool and the bolt should be
Install a standard 6 mm (0.23 in) x 18 mm (0.7 installed using hand tools only.
thread it into the front cover. CAUTION: Do not reuse the
crankshaft pulley bolt.
Install a new crankshaft pulley bolt. Using the
special tools to hold the crankshaft pulley in
place, tighten the crankshaft pulley bolt in 2
stages:
• Stage 1: Tighten to 100 Nm (74 lb-ft).
• Stage 2: Tighten an additional 90 degrees
(1/4 turn).

5. Remove the 6 mm (0.23 in) x 18 mm (0.7 in)

bolt.
303-01-5 Engine — 2.0L and 2.3L 303-01-5
6. Remove the special tool. 10. NOTE: Only turn the engine in the normal
direction of rotation.
Turn the crankshaft clockwise until the
crankshaft contacts the special tool.
8. NOTE: Only turn the engine in the normal

Turn the crankshaft clockwise 1 and 3/4 turns. 11. CAUTION: Only hand-tighten the bolt
9. Install the special tool. Using the 6 mm (0.23 in) x 18 mm (0.7 in)
bolt, check the position of the crankshaft pulley.
• If it is not possible to install the bolt, the
engine valve timing must be corrected by
repeating this procedure.
303-01-6 Engine — 2.0L and 2.3L 303-01-6
12. Using the special tool, check the position of the
camshafts.
• If it is not possible to install the special
tool, the engine valve timing must be
corrected by repeating this procedure.
16. Install the engine plug bolt.

17. Install the accessory drive belt. For additional

14. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) 18. Install the valve cover. For additional
bolt. information, refer to Valve Cover in this
section.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Crankshaft Rear Seal with Retainer Installation
Plate
1. Using the special tool, position the crankshaft
Special Tool(s) rear oil seal with retainer plate onto the
crankshaft.
Installer, Crankshaft Rear Main
Oil Seal
303-328 (T88P-6701-B1)
Material
Item Specification
Motorcraft Metal Surface WSE-M5B392-A
Cleaner
ZC-21
Sealant 2. Install the crankshaft rear oil seal with retainer
TA-30 plate and 6 bolts.
Premium Synthetic Blend • Tighten in the sequence shown to 10 Nm
Motor Oil (89 lb-in).
XO-5W20-QSP (US);
CXO-5W20-LSP12
Removal

Section 100-02.
2. Remove the flywheel or flexplate. For

additional information, refer to Flywheel or
Flexplate in this section.
3. Remove the oil level indicator and tube. For wire brushes, power abrasive discs or other
additional information, refer to Oil Level abrasive means to clean the sealing surfaces.
Indicator and Tube in this section. These tools cause scratches and gouges,
which make leak paths. Use a plastic
4. CAUTION: If the oil pan is not scraping tool to remove traces of sealant.
removed damage to the rear oil seal retainer Clean and inspect all the oil pan, cylinder block
joint can occur. and front cover flange mating surfaces.
Remove the 17 bolts and the oil pan.
5. Remove the 6 bolts and the crankshaft rear oil

seal with retainer plate.
303-01-2 Engine — 2.0L and 2.3L 303-01-2
4. NOTE: If the oil pan is not secured within 4
minutes of sealant application, the sealant must
be removed and the sealing area cleaned with
metal surface cleaner. Allow to dry until there
is no sign of wetness, or 4 minutes, whichever
is longer. Failure to follow this procedure can
cause future oil leakage.
NOTE: The oil pan must be installed and the
bolts tightened within 4 minutes of applying the
silicone gasket and sealant.
Apply a 2.5 mm (0.10 in) bead of silicone
gasket and sealant to the oil pan.
• Install the oil pan and the 2 bolts 6. Install the remaining oil pan bolts.
finger-tight. • Tighten in the sequence shown to 25 Nm
(18 lb-ft).
5. Install the 4 bolts.

• Tighten to 10 Nm (89 lb-in). 7. Install the oil level indicator and tube. For
additional information, refer to Oil Level
Indicator and Tube in this section.
8. Install the flywheel or flexplate. For additional

information, refer to Flywheel or Flexplate in
this section.
GENERAL PROCEDURES
Cylinder Block Core Plug Cup-Type
Replacement
1. CAUTION: Use care during this
Special Tool(s) procedure so as not to disturb or distort the
cup sealing surface.
Slide Hammer
100-001 (T50T-100-A) CAUTION: When installed, the flanged
edge must be below the chamfered edge of
the bore to effectively seal the bore.
Use a tool suitable to seat the cup-type cylinder
block core plug.
Material
Item Specification
Threadlock 262 WSK-M2G351-A6
TA-26
1. Use a slide hammer or tools suitable to remove

the cylinder block core plug.
Expansion-Type
1. CAUTION: Do not contact the crown

when installing an expansion-type cylinder
block core plug. This could expand the plug
before seating and result in leakage.
Use tool suitable to seat the expansion-type
cylinder block core plug.
2. Inspect the cylinder block plug bore for any
damage that would interfere with the correct
sealing of the plug. If the cylinder block plug
bore is damaged, bore for the next oversize
plug.
3. NOTE: Oversize plugs are identified by the OS

stamped in the flat located on the cup side of
the plug.
Coat the cylinder block core plug and bore
lightly with Threadlock 262 and install the
cylinder block core plug.
GENERAL PROCEDURES
Cylinder Block Distortion
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent

the specification.
1. NOTE: Use a straightedge that is calibrated by

the manufacturer to be flat within 0.005 mm
(0.0002 in) per running foot of length, such as
Snap-On GA438A or equivalent. For
example, if the straightedge is 61 cm (24 in)
long, the machined edge must be flat within
0.010 mm (0.0004 in) from end to end.
Use a straightedge and a feeler gauge to inspect
the cylinder block for flatness.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
DISASSEMBLY AND ASSEMBLY

OF SUBASSEMBLIES
Material
Cylinder Head
Item Specification
Special Tool(s) Motorcraft SAE 5W-20 WSS-M2C930-A
Impact Hammer Motor Oil
307-005 (T59L-100-B) XO-5W20-QSP (US);
CXO-5W20-LSP12
XG-4 and/or XL-5
Valve Spring Compressor Set
303-300 (T87C-6565-A)
Valve Stem Seal Remover

303-468 (T94P-6510-AH)
Valve Stem Seal Replacer

303-470 (T94P-6510-CH)
Valve Spring Compressor

303-350 (T89P-6565-A)

303-472 (T94P-6565-AH)
303-01-2 Engine — 2.0L and 2.3L 303-01-2
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Item Part Number Description Disassembly

1 W500225 Exhaust gas recirculation
(EGR) valve bolts (2 1. NOTE: One lifting eye shown, other lifting eye
required) similar.
2 9D475 EGR valve Remove the bolts and the 2 lifting eyes.
3 9D476 EGR valve gasket
4 6G004 Cylinder head temperature
(CHT) sensor
5 12405 Spark plug (4 required)
6 6500 Valve tappet (16 required)
7 6518 Valve collet (16 required)
8 6514 Valve spring retainer (16
required)
10 6517 Valve seal (16 required)
11 6505 Intake valve (8 required)
12 6507 Exhaust valve (8 required)
13 6049 Cylinder head
303-01-3 Engine — 2.0L and 2.3L 303-01-3
2. Remove and discard the cylinder head
temperature (CHT) sensor.
6. CAUTION: Note the location of the

tappets prior to removal.
3. Remove the bolts and the exhaust gas Remove the 16 tappets.
recirculation (EGR) valve.
7. Using the special tools, compress the valve

4. Remove the EGR tube. spring and remove the valve spring retainer
keys, the valve spring retainers and the valve
springs.
5. Remove the spark plugs.

8. Inspect the valve spring, valve spring retainer
and valve spring retainer key. For additional
303-01-4 Engine — 2.0L and 2.3L 303-01-4
9. CAUTION: Note the location of the

valves if they are to be reused.
NOTE: Mark each valve if the original valves
are to be used.
Remove the valves.
2. NOTE: Use the protector provided with the

replacement kit to prevent damage to the valve
seals.
Lubricate the valve stems and guides with clean
engine oil and, using the special tool, install the
valve seals onto the cylinder head valve guides.
10. Using the special tools, remove and discard the
valve seals.
3. Place the valve spring in position over the valve

and install the valve spring retainer.
11. Inspect the valves. For additional information,
4. Using the special tools, compress the valve
refer to Section 303-00. Install new parts, as
spring and install the valve spring retainer keys.
necessary.
Assembly
1. NOTE: If installing the original valves, make

sure the valves are installed in the same
position from which they were removed. Coat
the valve stems with motor oil.
Install the valves.
303-01-5 Engine — 2.0L and 2.3L 303-01-5
5. NOTE: Be sure to install the tappets in the 8. Install the EGR tube.
same location from which they were removed. • Tighten to 55 Nm (41 lb-ft).
Install the 16 tappets.
9. Install the EGR valve, gasket and 2 bolts.

6. Install a new CHT sensor. • Tighten to 20 Nm (15 lb-ft).
10. NOTE: One lifting eye shown, other lifting eye

7. Install the spark plugs. similar.
• Tighten to 12 Nm (9 lb-ft). Install the 2 lifting eyes and the bolts.
GENERAL PROCEDURES
Cylinder Head Distortion
Special Tool(s)
Straight Edge
303-D039 (D83L-4201-A) or
equivalent
1. Use a straight edge and a feeler gauge to

inspect the cylinder head for flatness. If the
cylinder head is distorted, install a new cylinder
head.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Cylinder Head
Special Tool(s)
303-465 (T94P-6256-CH)
Material
Item Specification
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
Silicone Gasket Remover —
ZC-30
Motorcraft Metal Surface —
Prep
ZC-31
Sealant
TA-30
303-01-2 Engine — 2.0L and 2.3L 303-01-2

1 14A464 Exhaust gas recirculation 7 8W005 Engine coolant vent hose
(EGR) valve electrical 8 — Heater hose clamp (part of
connector (part of 12B637) 18K580)
2 8287 Upper radiator hose clamp 9 18K580 Heater hose
3 8260 Upper radiator hose 10 W525958 Bypass hose clamp
4 W52592 EGR coolant tube clamp 11 8548 Bypass hose
5 18K580 EGR coolant hose (part of 12 6065 Cylinder head bolt (10
heater hose) required)
6 — Engine coolant vent hose 13 6050 Cylinder head
clamp (part of 8W005)
14 6051 Cylinder head gasket
(Continued)
303-01-3 Engine — 2.0L and 2.3L 303-01-3
Removal
CAUTION: Do not loosen or remove the

special tools as instructed in this procedure. The
sprocket and the pulley are fitted together by
flange faces on each part. For that reason, the 6. Remove the 2 bolts and the catalytic converter
crankshaft sprocket is also unfastened if you support bracket from the engine.
be locked in place by the special service tools,

All engines
7. NOTE: All 2.3L engines and some 2.0L
engines are equipped with a heat shield that
1. Release the fuel system pressure. For additional must be positioned aside to access the catalytic
information, refer to Section 310-00. converter-to-engine nuts.
2. Remove the battery tray. For additional If equipped, remove the 4 heat shield bolts and
information, refer to Section 414-01. position the heat shield aside.
3. Drain the cooling system. For additional

4. Check the valve clearance. For additional

information, refer to Valve Clearance Check in
this section.
5. Remove the nuts and disconnect the catalytic

converter from the exhaust assembly.
• Remove and discard the gasket.
303-01-4 Engine — 2.0L and 2.3L 303-01-4
8. Disconnect the exhaust sensor electrical 12. Remove the intake manifold. For additional
connectors. information, refer to Intake Manifold in this
section.
13. Remove the timing drive components. For

additional information, refer to Timing Drive
Components in this section.
9. Remove and discard the catalytic

converter-to-engine nuts.
• Position aside the catalytic converter and
support with mechanic’s wire.
• Remove and discard the catalytic converter
gasket.
15. Mark the position of the camshaft lobes on the
No. 1 cylinder for installation reference.
10. Remove the generator. For additional

11. Remove the fuel injection supply manifold. For

303-01-5 Engine — 2.0L and 2.3L 303-01-5
16. CAUTION: Failure to follow the

camshaft loosening procedure can result in
damage to the camshafts.
Remove the camshafts from the engine.
• Loosen the camshaft bearing cap bolts, in
sequence, one turn at a time.
• Repeat the first step until all tension is
released from the camshaft bearing caps.
20. If equipped, disconnect the hoses from the AIR

control valve.

of the valve tappets to make sure they are
assembled in their original positions. 21. If equipped, disconnect the upper exhaust
Remove the valve tappets. sensor electrical connector and retainer.
18. NOTE: The number on the valve tappets only

Inspect the valve tappets. For additional
2.0L engines
19. If equipped, disconnect the secondary air

injection (AIR) vacuum regulator electrical
connector and vacuum hose.
All engines
22. Disconnect the exhaust gas recirculation (EGR)

valve electrical connector.
23. Disconnect the coolant hoses from the coolant

bypass.
303-01-6 Engine — 2.0L and 2.3L 303-01-6
24. Remove the 4 bolts, coolant bypass and gasket. 2. Clean the cylinder head bolt holes in the
• Discard the gasket. cylinder block. Make sure all coolant, oil or
other foreign material is removed.
25. Disconnect the EGR coolant hose.
3. Inspect the cylinder head for distortion. For
26. Remove the bolts and the cylinder head. additional information, refer to Section 303-00.
• Discard the bolts. 4. Apply silicone gasket and sealant to the
locations shown.
27. Remove and discard the head gasket.
28. Inspect the cylinder head mating surfaces. For

Installation
All engines

These tools cause scratches and gouges that
make leak paths. Use a plastic scraping tool
to remove all traces of the head gasket. 5. Install a new head gasket.
CAUTION: Observe all warnings or 6. NOTE: The cylinder head bolts are
cautions and follow all application directions torque-to-yield and must not be reused. New
contained on the packaging of the silicone cylinder head bolts must be installed.
gasket remover and the metal surface prep.
NOTE: Lubricate the bolts with clean engine
NOTE: If there is no residual gasket material oil prior to installation.
present, metal surface prep can be used to clean
and prepare the surfaces. Install new cylinder head bolts. Tighten the
bolts in the sequence shown in 5 stages.
Clean the cylinder head-to-cylinder block
mating surface of both the cylinder head and • Stage 1: Tighten to 5 Nm (44 lb-in).
the cylinder block. • Stage 2: Tighten to 15 Nm (11 lb-ft).
1 Remove any large deposits of silicone or • Stage 3: Tighten to 45 Nm (33 lb-ft).
gasket material with a plastic scraper. • Stage 4: Turn 90 degrees.
2 Apply silicone gasket remover, following • Stage 5: Turn an additional 90 degrees.
package directions, and allow to set for
several minutes.
3 Remove the silicone gasket remover with a
plastic scraper. A second application of
silicone gasket remover may be required if
residual traces of silicone or gasket material
remain.
4 Apply metal surface prep, following
package directions, to remove any traces of
oil or coolant, and to prepare the surfaces to
bond with the new gasket. Do not attempt
to make the metal shiny. Some staining of
the metal surfaces is normal.
303-01-7 Engine — 2.0L and 2.3L 303-01-7
7. Install the EGR coolant hose.
8. Using a new gasket, install the coolant bypass

and the 4 bolts.
9. Connect the coolant hoses onto the coolant

bypass.
10. Connect the EGR valve electrical connector.
11. Clean and inspect the catalytic converter flange.

• Using a straightedge and a feeler gauge,
place the straightedge across the catalytic 14. NOTE: All 2.3L engines and some 2.0L
converter flange surface and check for engines are equipped with a heat shield that
warping with the feeler gauge. If the reading must be positioned aside to access the catalytic
is greater than the maximum specification, converter-to engine nuts.
install a new catalytic converter, gasket and If equipped, position the heat shield and install
nuts. the 4 heat shield bolts.
12. Using a new gasket and 7 nuts, install the

catalytic converter. 15. Install the catalytic converter support bracket
• Tighten to 55 Nm (41 lb-ft). and the 2 bolts to the engine.
13. Connect the exhaust sensor electrical

connectors.
303-01-8 Engine — 2.0L and 2.3L 303-01-8
2.0L engines
16. If equipped, connect the upper exhaust sensor

electrical connector and retainer.
All engines
19. NOTE: Lubricate the valve tappets with clean

engine oil.
Install the valve tappets in their original
17. If equipped, connect the hoses to the AIR positions.
control valve.
18. If equipped, connect the AIR vacuum regulator

electrical connector and vacuum hose.
303-01-9 Engine — 2.0L and 2.3L 303-01-9
20. CAUTION: Install the camshafts with 21. Install the timing drive components. For
the alignment notches in the camshafts lined additional information, refer to Timing Drive
up so the camshaft alignment plate can be Components in this section.
installed. Make sure the lobes on the No. 1
cylinder are in the same position at noted in 22. Install the intake manifold. For additional
the removal procedure. Failure to follow information, refer to Intake Manifold in this
this procedure can cause severe damage to section.
the valves and pistons.
23. Install the fuel injector supply manifold. For
NOTE: Lubricate the camshaft journals and additional information, refer to Section 303-04.
Install the camshafts and bearing caps. Tighten 24. Install the generator. For additional information,
the bolts in the sequence shown in 3 stages. refer to Section 414-02.
• Stage 1: Tighten the camshaft bearing cap
25. Connect the radio interference capacitor
bolts, one turn at a time, until the cam is
fully seated.
• Stage 2: Tighten the bolts to 7 Nm (62 26. Install the dual cooling fans and connect the
lb-in). electrical connectors.
• Stage 3: Tighten the bolts to 16 Nm (12
lb-ft). 27. Install the battery tray. For additional
28. Drain the engine oil and change the filter.

• Tighten the plug to 28 Nm (21 lb-ft).
29. Fill the engine with clean engine oil.
30. Fill and bleed the cooling system. For

31. Fill the power steering system. For additional

303-01-1 Engine — 2.0L and 2.3L 303-01-1
ASSEMBLY
Special Tool(s)
Engine
Special Tool(s) 303-096 (T74P-6150-A)
Heavy Duty Floor Crane

014-00071 or equivalent
Installer, Crankshaft Rear Main

Oil Seal
303-328 (T88P-6701-B1)
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
Aligner, Clutch Disc

308-006 (T71P-7137-H)

303-465 (T94P-6256-CH)
Material
Item Specification
Timing Peg, Crankshaft
303-507 Motorcraft SAE 5W-20 WSS-M2C930-A
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
Holding Fixture, Drive Pinion
Flange Motorcraft Metal Surface WSE-M5B392-A
205-126 (T78P-4851-A) Cleaner
ZC-21
Sealant
TA-30
Silicone Gasket Remover —
Adapter for 205-126 ZC-30
(205-072-02) Motorcraft Metal Surface —
Prep
ZC-31
Silicone Brake Caliper ESE-M1C171-A
Grease and Dielectric
Compound
XG-3-A
(Continued)
(Continued)
303-01-2 Engine — 2.0L and 2.3L 303-01-2
ASSEMBLY (Continued)
Material
Item Specification
Motorcraft Premium Gold WSS-M97B51-A1
Engine Coolant with
Bittering Agent (US only)
VC-7-B (US); CVC-7-A
(yellow color)
High-Temp 4x4 Front ESA-M1C198-A
Axle and Wheel Bearing
Grease
E8TZ-19590-A
Lower Engine Block

303-01-3 Engine — 2.0L and 2.3L 303-01-3
1 6010 Cylinder block 7 9278 Oil pressure sensor
2 6K318 Crankshaft rear oil seal and 8 6A636 Oil filter adapter gasket
retainer 9 6A785 Crankcase vent oil separator
3 6477 Flywheel 10 8575 Thermostat assembly
4 6675 Oil pan 11 6622 Oil pump screen and pickup
5 6714 Oil filter tube
6 6884 Oil filter adapter
(Continued)
303-01-4 Engine — 2.0L and 2.3L 303-01-4
Front Engine Block
303-01-5 Engine — 2.0L and 2.3L 303-01-5
1 19A216 Drive belt pulley idler 13 6019 Engine front cover
(without A/C) 14 6378 Friction washer
2 6C301 Accessory drive belt (without 15 6306 Crankshaft sprocket
A/C)
16 6378 Friction washer
3 6C301 Accessory drive belt (with
A/C) 17 6K254 Timing chain tensioner
4 6A340 Crankshaft pulley bolt 18 6K255 Timing chain tensioner arm
5 6316 Crankshaft damper 19 6268 Timing chain
6 6700 Crankshaft front seal 20 6K297 Timing chain guide
7 6C315 Crankshaft position (CKP) 21 6A895 Oil pump chain
sensor 22 6C271 Oil pump chain tensioner
8 10300 Generator 23 6652 Oil pump drive gear
9 3A696 Power steering pump 24 6M256 Oil pump chain guide (early
10 8501 Coolant pump and pulley build)
11 19A216 Drive belt pulley idler (with 25 6600 Oil pump
A/C) 26 6010 Cylinder block
12 6A228 Drive belt tensioner
(Continued)
303-01-6 Engine — 2.0L and 2.3L 303-01-6
Cylinder Head
303-01-7 Engine — 2.0L and 2.3L 303-01-7
1 12A366 Coil-on-plug assembly 17 6049 Cylinder head
2 6M293 Valve cover 18 6505 Exhaust valve (8 required)
3 12K073 Camshaft position (CMP) 19 6507 Intake valve (8 required)
sensor 20 6051 Head gasket
4 6766 Oil filler cap 21 6010 Cylinder block
5 6M293 Valve cover gasket 22 6C251 Camshaft sprocket (2
6 6A284 Camshaft bearing caps required)
7 6A272 Camshaft (exhaust) 23 9448 Catalytic converter gasket
(with secondary air injection
8 6A271 Camshaft (intake)
(AIR)
9 6500 Valve tappet (16 required)
24 5E211 2.0L catalytic converter (with
10 6518 Valve spring retainer key (16 AIR)
required)
25 9448 Catalytic converter gasket
11 6514 Valve spring retainer (16 (without AIR)
required)
26 5E211 2.3L catalytic converter
27 9448 2.0L catalytic converter
13 6A517 Valve stem seal (16 required) gasket (without AIR)
14 6G004 Cylinder head temperature 28 5G232 2.0L catalytic converter
(CHT) sensor
15 12405 Spark plug (4 required)
16 6065 Cylinder head bolt (10
required)
(Continued)
303-01-8 Engine — 2.0L and 2.3L 303-01-8
Intake Manifold

1 9288 Fuel supply tube 8 12A699 Knock sensor
2 9F491 AIR valve and bracket (if 9 6754 Oil level indicator tube
equipped) 10 9F715 Idle air control (IAC) valve
3 8K556 Coolant outlet assembly
4 9D475 Exhaust gas recirculation 11 9424 Intake manifold
(EGR) valve 12 9439 Intake manifold gasket
5 9E926 Throttle body assembly 13 8A582 Coolant hose
6 6051 Cylinder head gasket 14 6049 Cylinder head
7 6010 Cylinder block 15 9F593 Fuel injector (4 required)
(Continued) (Continued)
303-01-9 Engine — 2.0L and 2.3L 303-01-9
Item Part Number Description
16 9H487 Fuel rail

sprocket and the pulley are fitted together by 2. CAUTION: Failure to position the No.
friction, using diamond washers between the 1 piston at top dead center (TDC) can result
flange faces on each part. For that reason, the in damage to the engine. Turn the engine in
crankshaft sprocket is also unfastened if you the normal direction of rotation only.
loosen the pulley bolt. Before any repair Turn the crankshaft clockwise to position the
requiring loosening or removal of the crankshaft No. 1 piston at TDC.
be locked in place by the special service tools, 3. Remove the engine plug bolt.

Any foreign material (including any material
created while cleaning gasket surfaces) that
oil pan, can cause engine failure.
NOTE: Early build engines are equipped with an

oil pump drive chain guide. Late build engines do
not have an oil pump drive chain guide. Also, late
build engines use an updated design for the oil
pump drive chain and tensioner. Therefore, the oil
pump drive components are not interchangeable
between early build and late build engines.
All engines
1. Install the intermediate shaft bearing bracket

and 3 bolts.
303-01-10 Engine — 2.0L and 2.3L 303-01-10
until the timing drive components and
crankshaft pulley are installed.
6. Install a new oil pump pickup tube gasket and

the pickup tube.
7. Using the special tool, install the crankshaft

rear main oil seal.
5. NOTE: Clean the oil pump and cylinder block

mating surfaces with metal surface cleaner.
Install the oil pump assembly. Tighten the 4
• Stage 1: Tighten to 10 Nm (89 lb-in).
303-01-11 Engine — 2.0L and 2.3L 303-01-11
8. Tighten the 6 crankshaft rear main oil seal bolts 11. Using a suitable straight edge, align the front
in the sequence shown to 10 Nm (89 lb-in). surface of the oil pan flush with the front
surface of the engine block.

These tools cause scratches and gouges,
scraping tool to remove traces of sealant.
Clean and inspect all mating surfaces.

cause future oil leakage. 12. Install the remaining 13 oil pan bolts and
Apply a 2.5 mm (0.10 in) bead of silicone tighten the oil pan bolts in the sequence shown
gasket and sealant to the oil pan. Install the oil to 25 Nm (18 lb-ft).
pan. Install the 2 oil pan bolts finger-tight.
303-01-12 Engine — 2.0L and 2.3L 303-01-12
13. Install the cylinder head alignment dowels. 15. Apply silicone gasket and sealant to the
Dowels must be fully seated in the cylinder locations shown.
block.
16. Install a new head gasket.

These tools cause scratches and gouges that
make leak paths. Use a plastic scraping tool
to remove all traces of the head gasket.
CAUTION: Observe all warnings and
cautions and follow all application directions
contained on the packaging of the silicone
gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material
present, metal surface prep can be used to clean
and prepare the surfaces.
Clean the cylinder head-to-cylinder block
mating surface of both the cylinder head and
the cylinder block.
1 Remove any large deposits of silicone or
gasket material with a plastic scraper.
2 Apply silicone gasket remover, following
package directions, and allow to set for
several minutes.
3 Remove the silicone gasket remover with a
plastic scraper. A second application of
silicone gasket remover may be required if
residual traces of silicone or gasket material
remain.
4 Apply metal surface prep, following
package directions, to remove any traces of
oil or coolant, and to prepare the surfaces to
bond with the new gasket. Do not attempt
to make the metal shiny. Some staining of
the metal surfaces is normal.
303-01-13 Engine — 2.0L and 2.3L 303-01-13
17. NOTE: The cylinder head bolts are
torque-to-yield and must not be reused. New
cylinder head bolts must be installed.
NOTE: Lubricate the bolts with clean engine
oil prior to installation.
Install 10 new cylinder head bolts. Tighten the
• Stage 4: Turn 90 degrees.
• Stage 5: Turn an additional 90 degrees. 19. NOTE: Install a crankshaft sprocket diamond
washer on both sides of the crankshaft sprocket.
Install the crankshaft sprocket, crankshaft
sprocket diamond washers, oil pump chain and
oil pump sprocket.
• The crankshaft sprocket flange must be
facing away from the engine block.
18. CAUTION: Install the camshafts with

the alignment slots in the camshafts lined up
so the Camshaft Alignment Plate can be
installed without rotating the camshafts.
Make sure the lobes on the No. 1 cylinder
are in the same position as noted in the
disassembly procedure. Rotating the 20. Install the oil pump chain, sprocket and bolt.
camshafts when the timing chain is removed,
or installing the camshafts 180 degrees out of
position, can cause severe damage to the
valves and pistons.
NOTE: Lubricate the camshaft journals and
Install the camshafts and bearing caps. Tighten
the bolts in the sequence shown in 3 stages.
• Stage 1: Tighten one turn at a time until
tight.
303-01-14 Engine — 2.0L and 2.3L 303-01-14
Late build vehicles
21. Install the oil pump drive chain tensioner

shoulder bolt.

engine damage.
both camshafts.
Early build vehicles
22. Install the oil pump drive chain guide and the 3
shoulder bolts.
25. Install the camshaft sprockets and the bolts. Do

not tighten the bolts at this time.
All vehicles
23. Install the oil pump chain tensioner and bolt.

Hook the tensioner spring around the shoulder
bolt.
303-01-15 Engine — 2.0L and 2.3L 303-01-15
26. Install the LH timing chain guide and the 2
bolts.
30. Using a small pick, push back and hold the

ratchet mechanism.
27. Install the timing chain.
31. While holding the ratchet mechanism, push the

ratchet arm back into the tensioner housing.
28. Install the RH timing chain guide.
29. CAUTION: Do not compress the

ratchet assembly. This will damage the
ratchet assembly.
Using the edge of a vise, compress the timing
chain tensioner plunger.
303-01-16 Engine — 2.0L and 2.3L 303-01-16
32. Install a paper clip into the hole in the tensioner
housing to hold the ratchet assembly and the
plunger in during installation.
33. Install the timing chain tensioner and the 2

bolts. Remove the paper clip to release the
piston.

wire brushes, power abrasive disks or other
abrasive means to clean sealing surfaces.
make leak paths.
Clean and inspect the mounting surfaces of the
engine and the front cover.

engine damage.
camshaft rotation, tighten the camshaft sprocket
bolts to 72 Nm (53 lb-ft).
303-01-17 Engine — 2.0L and 2.3L 303-01-17
36. NOTE: The engine front cover must be
installed and the bolts tightened within 4
minutes of applying the silicone gasket and
sealant.
gasket and sealant to the cylinder head and oil
pan joint areas. Apply a 2.5 mm (0.10 in) bead
of silicone gasket and sealant to the front cover.

special tool.
oil.
Using the special tool, install a new crankshaft
front oil seal.
37. Install the engine front cover. Tighten the 22

bolts in the sequence shown to the following
specifications:
• Tighten the 8 mm bolts to 10 Nm (89 lb-in).
• Tighten the 13 mm bolts to 48 Nm (35
lb-ft).
303-01-18 Engine — 2.0L and 2.3L 303-01-18
39. CAUTION: Do not install the 41. Assemble the special tools using 4 hardened
crankshaft pulley bolt at this time. washers in the locations shown.
NOTE: Apply clean engine oil on the seal area
before installing.
Position the crankshaft pulley onto the
crankshaft with the hole in the pulley at the 6
o’clock position.
40. CAUTION: Only hand-tighten the 6

mm (0.23 in) bolt or damage to the front
cover can occur.
NOTE: This step will correctly align the
crankshaft pulley to the crankshaft.
303-01-19 Engine — 2.0L and 2.3L 303-01-19

remain in the TDC position during
installation of the pulley bolt or damage to
the engine can occur. Therefore, the
crankshaft pulley must be held in place with
the special tool and the bolt should be
installed using hand tools only.
CAUTION: Do not reuse the
crankshaft pulley bolt.
Install a new crankshaft pulley bolt. Using the
special tools to hold the crankshaft pulley in
place, tighten the crankshaft pulley bolt in 2
stages: 45. Remove the special tool.
• Stage 2: Tighten an additional 90 degrees
(1/4 turn).
46. NOTE: Only turn the engine in the normal

Turn the crankshaft clockwise 1 and 3/4 turns.
bolt.

303-01-20 Engine — 2.0L and 2.3L 303-01-20
48. NOTE: Only turn the engine in the normal 50. Using the special tool, check the position of the
direction of rotation. camshafts.
Turn the crankshaft clockwise until the • If it is not possible to install the special
crankshaft contacts the special tool. tool, the engine valve timing must be
corrected.

Using the 6 mm (0.23 in) x 18 mm (0.7 in)
bolt, check the position of the crankshaft pulley.
• If it is not possible to install the bolt, the
engine valve timing must be corrected.
303-01-21 Engine — 2.0L and 2.3L 303-01-21
52. NOTE: Whenever the crankshaft position
(CKP) sensor is removed, a new one must be
installed using the alignment tool supplied with
the new part.
Install a new CKP sensor and the 2 bolts.
• Do not tighten the bolts at this time.
53. NOTE: The CKP sensor alignment tool is

supplied with the new sensor and is not
available separately.
Adjust the CKP sensor with the alignment tool.
• Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
56. Install the engine plug bolt.


bolt.

make leak paths.
Clean the valve cover gasket surface with metal
surface cleaner.
303-01-22 Engine — 2.0L and 2.3L 303-01-22
58. Apply silicone gasket and sealant to the
locations shown.
61. NOTE: Apply dielectric compound to the

inside of the coil-on-plug boots.
Install the 4 coil-on-plugs, 4 bolts and the
59. NOTE: The valve cover must be secured crankcase vent tube.
within 4 minutes of silicone gasket application.
If the valve cover is not secured within 4 • Tighten to 10 Nm (89 lb-in).
minutes, the sealant must be removed and the
sealing area cleaned with metal surface cleaner.
Install the valve cover.
• Tighten the 14 bolts in the sequence shown
to 10 Nm (89 lb-in).
62. If equipped, install the block heater.

60. CAUTION: Only use hand tools when

removing or installing the spark plugs,
damage can occur to the cylinder head or
spark plug.
Install a new cylinder head temperature (CHT)
sensor and the spark plugs.
• Tighten the CHT sensor to 12 Nm (9 lb-ft).
• Tighten the spark plugs to 12 Nm (9 lb-ft).
303-01-23 Engine — 2.0L and 2.3L 303-01-23
63. NOTE: The knock sensor (KS) must not touch 66. Connect the coolant bypass hose.
the crankcase vent oil separator.
Install the crankcase vent oil separator and the
KS.
• Tighten the 8 oil separator bolts to 10 Nm
(89 lb-in).
• Tighten the KS to 20 Nm (15 lb-ft).
67. Install the coolant hose.
64. Install the coolant bypass hose.
68. Position the engine control wiring harness on

the engine and connect the CHT sensor and
install the rubber boot.
65. Using a new gasket, install the coolant bypass

and 4 bolts.
303-01-24 Engine — 2.0L and 2.3L 303-01-24
69. Connect the coil-on-plug and camshaft position
(CMP) sensor electrical connectors.
72. Connect the fuel charging wiring harness.

• Connect the fuel rail pressure and
temperature sensor electrical connector.
70. CAUTION: Use O-ring seals that are
• Connect the 4 fuel injector electrical
made of special fuel-resistant material. Use of
connectors.
ordinary O-rings can cause the fuel system to
leak. Do not reuse the O-ring seals. • Attach the wiring harness retainers.
Install new fuel injector O-rings.
• Separate the fuel injectors from the fuel rail.
• Remove and discard the fuel injector
O-rings.
• Install new O-rings and lubricate with clean
engine oil.
• Install the fuel injectors onto the fuel rail.
73. Connect the wiring harness retainers to the

valve cover studs.
71. Install the fuel rail with the fuel injectors and
the 2 bolts.
303-01-25 Engine — 2.0L and 2.3L 303-01-25
74. Install the radio interference capacitor bracket 2.3L engines
and bolt.
• Tighten to 10 Nm (89 lb-in). 78. NOTE: Be sure to install the bolts in the
previously marked locations.
Install the intake manifold and the 7 mounting
bolts.
75. Install the EGR tube.

79. NOTE: Lubricate the O-ring with clean engine

oil.
Install the oil level indicator tube assembly and
2 bolts.
76. Inspect and install new intake manifold gaskets

if necessary.
77. Position the intake manifold and connect the

positive crankcase ventilation (PCV) hose.
303-01-26 Engine — 2.0L and 2.3L 303-01-26
80. Connect the swirl valve electrical connectors
and pin-type retainers.
83. Connect the swirl control valve electrical

connector.
2.0L engines
81. NOTE: Be sure to install the bolts in the

bolts.
84. If equipped, connect the secondary air injection

(AIR) vacuum supply hose.

oil.
Install the oil level indicator tube assembly and
bolt.
303-01-27 Engine — 2.0L and 2.3L 303-01-27
All engines
85. Connect the manifold absolute pressure (MAP)

89. Connect the idle air control (IAC) valve

electrical connector and wiring harness pin-type
retainer.
86. Connect the intake manifold runner control

(IMRC) actuator electrical connector.
90. Connect the throttle position (TP) sensor

retainer.
87. Attach the wiring harness pin-type retainer.
88. Connect the fuel rail pressure and temperature

sensor vacuum hose.
303-01-28 Engine — 2.0L and 2.3L 303-01-28
91. Install the lower intake bolt. 94. Install a new oil filter.
• Tighten to 18 Nm (13 lb-ft). • Tighten the oil filter 3/4 turn after the oil
filter gasket makes contact with the oil filter
adapter.
92. Connect the KS electrical connector and

pin-type retainer.
95. Connect the oil pressure sensor electrical
connector.
93. NOTE: Clean the gasket mating surfaces with

metal surface cleaner.
Install the oil filter adapter with a new gasket. 96. NOTE: Clean and inspect the thermostat
housing gasket. Install a new gasket if
• Tighten to 25 Nm (18 lb-ft). necessary.
Install the thermostat housing and 3 bolts.
303-01-29 Engine — 2.0L and 2.3L 303-01-29
97. Connect the heater hose to the thermostat 100. If equipped, install the accessory drive belt
housing. idler pulley.
98. NOTE: Clean the coolant pump mating surface

with metal surface cleaner. 101. Install the accessory drive belt idler pulley.
NOTE: Lubricate the coolant pump O-ring with • Tighten to 25 Nm (18 lb-ft).
clean engine coolant.
Position the coolant pump and install the 3
bolts.
102. Install the accessory drivebelt tensioner and 2

bolts.
99. Install the coolant pump pulley and 3 bolts.

303-01-30 Engine — 2.0L and 2.3L 303-01-30
103. Install the generator, bolt and 2 stud bolts.
107. Connect the CKP sensor and the wiring

harness pin-type retainers.
104. Install the wiring harness retainer and nut.

108. Using the heavy duty floor crane and spreader

bar, remove the engine from the engine stand.
109. Install the flexplate and the 6 bolts. Tighten

105. Connect the generator electrical connections, the bolts in the sequence shown in 3 stages:
harness retainer and install the nut.
106. Install the generator heat shield and 2 nuts.

303-01-31 Engine — 2.0L and 2.3L 303-01-31
Engines equipped with a manual 112. NOTE: If reusing the clutch pressure plate
transmission and flywheel, align the marks made during
removal.
110. Lubricate the transaxle input shaft pilot Position the clutch pressure plate and install
bearing with front axle grease. the 7 bolts. Tighten the bolts in a star pattern
sequence to 27 Nm (20 lb-ft).
111. Using the special tool, position the clutch disc

on the flywheel.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
DESCRIPTION AND OPERATION

Engine
The 2.0L and 2.3L engines are 4 valve-per-cylinder,
dual overhead camshaft engines. The engines use a
coil-on-plug ignition system. The cylinder blocks
are made of aluminum and the bearing caps are
integrated into the ladder assemblies. An aluminum
oil pan bolts to the bottom of the lower cylinder
block and to the transmission to provide greater
strength. The camshafts are mounted in the cylinder
heads and act against valve tappets to open and
close the valves. The camshafts are driven off the
front of the cylinder head by one timing chain. The
chain is driven by a sprocket that is located on the
crankshaft. The piston assembly is an aluminum
piston with a powdered metal cast iron connecting
rod. The oil pump is driven by the crankshaft via a
dedicated chain that is driven by the same sprocket
that drives the timing chain.

Engine The engine incorporates the following features.
Refer to the appropriate section in Group 303 for
CAUTION: When repairing engines, all the procedure.
parts must be contamination free. If
contamination/foreign material is present when • Crankcase ventilation or breather system
repairing an engine, premature engine failure • Exhaust emission control system
can occur.
• Evaporative emission control system
NOTE: Specifications show the expected minimum
Some engines incorporate a fail-safe cooling system.
or maximum condition. Refer to the appropriate
Refer to the appropriate section in Group 303 for
section in Group 303 for the procedure.
the procedure.
NOTE: If a component fails to meet the
The engine, fuel system, ignition system, emissions
specifications, it is necessary to refinish it or install
system and exhaust system all affect exhaust
a new component. Wear limits are provided as an
emission levels and must be maintained according
aid to determine if the component can be refinished.
to the maintenance schedule. Refer to the scheduled
A new component must be installed when any
Maintenance Guide.
component fails to meet specifications and cannot
be refinished. Correct engine identification is required to order
parts. Refer to the appropriate section in Group 303
NOTE: This section contains information, steps and
for the procedure.
procedures that may not be specific to your engine.
For complete vehicle and engine identification
This section covers general procedures and
codes, refer to Section 100-01.
diagnosis and testing of the engine system, except
for exhaust emission control devices, which are
covered in the Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
DISASSEMBLY
Special Tool(s)
Engine
Holding Fixture, Drive Pinion
Special Tool(s) Flange
205-126 (T78P-4851-A)
Adapter for 205-126

(205-072-02)
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
Remover, Oil Seal

303-409 (T92C-6700-CH)
Locking Tool, Flywheel

303-103 (T74P-8375-A)
Engine Stand

303-465 (T94P-6256-CH)
Timing Peg, Crankshaft

303-507
(Continued)
303-01-2 Engine — 2.0L and 2.3L 303-01-2
DISASSEMBLY (Continued)
CAUTION: Do not loosen or remove the Vehicles equipped with a manual

transmission
crankshaft pulley and the crankshaft timing 1. WARNING: The clutch disc and clutch
sprocket are not keyed to the crankshaft. The pressure plate are heavy and may fall if not
crankshaft, the crankshaft sprocket and the held when the bolts are removed. Failure to
pulley are fitted together by friction, using follow these instructions may result in
diamond washers between the flange faces on personal injury.
CAUTION: Loosen the bolts evenly to
prevent pressure plate damage.
flange faces on each part. For that reason, the Remove the 7 bolts, clutch pressure plate and
crankshaft sprocket is also unfastened if you clutch disc.

created while cleaning gasket surfaces that enters
the oil passages, coolant passages or the oil pan,
can cause engine failure.
CAUTION: Due to the precision fit and

All vehicles
timing of the balancer shaft assembly, it cannot
be removed from the engine block.
2. Install the special tool and remove the flywheel
NOTE: For additional information, refer to the or flexplate.
exploded view under the assembly procedure in this
section.

pump drive components are not interchangeable
between early build and late build engines.
3. Mount the engine on a suitable engine stand.

303-01-3 Engine — 2.0L and 2.3L 303-01-3
4. Disconnect the crankshaft position (CKP) sensor 7. Remove the nut and the wiring harness retainer.
and the wiring harness pin-type retainers.
8. Remove the bolt, the 2 stud bolts and the

5. Remove the 3 nuts and the generator heat generator.
shield.
9. Remove the 2 bolts and the accessory drive belt

6. Remove the nut and disconnect the generator tensioner.
electrical connections and wiring harness
retainer.
303-01-4 Engine — 2.0L and 2.3L 303-01-4
10. Loosen the bolt and remove the accessory 13. Remove the 3 bolts and the coolant pump.
drivebelt idler pulley.
14. Disconnect the heater hose from the thermostat

11. If equipped, loosen the bolt and remove the housing.
accessory drive belt idler pulley.
15. Remove the 3 bolts and the thermostat housing.

12. Remove the 3 bolts and the coolant pump
pulley.
303-01-5 Engine — 2.0L and 2.3L 303-01-5
16. Disconnect the oil pressure sensor electrical
connector.
20. Remove the lower intake manifold bolt.
17. Remove the engine oil filter.
21. Disconnect the throttle position (TP) sensor

retainer.
18. Remove the 4 bolts and the oil filter adapter.
• Discard the gasket.
19. Disconnect the knock sensor (KS) electrical

connector and pin-type retainer.
303-01-6 Engine — 2.0L and 2.3L 303-01-6
22. Disconnect the idle air control (IAC) valve
retainer.
26. Disconnect the manifold absolute pressure

(MAP) sensor electrical connector.
23. Disconnect the fuel rail pressure and

temperature sensor vacuum hose.
2.0L engines

injection (AIR) vacuum supply hose.
24. Detach the wiring harness pin-type retainer.
25. Disconnect the intake manifold runner control

303-01-7 Engine — 2.0L and 2.3L 303-01-7
28. Disconnect the swirl control valve electrical 2.3L engines
connector.
31. Disconnect the swirl valve electrical connectors
29. Remove the bolt and the oil level indicator

tube.
32. Remove the 2 bolts and the oil level indicator
and tube.
30. NOTE: There are 3 different size bolts used.

Mark the location of the bolts to make sure of
correct installation. 33. NOTE: There are 3 different size bolts used.
Remove the 7 intake manifold bolts. Mark the location of the bolts to make sure of
correct installation.
Remove the 7 intake manifold bolts.
303-01-8 Engine — 2.0L and 2.3L 303-01-8
All engines
34. Disconnect the positive crankcase ventilation

(PCV) hose and remove the intake manifold.
38. Disconnect the fuel charging wiring harness.

• Disconnect the fuel rail pressure and
temperature sensor electrical connector.
• Disconnect the 4 fuel injector electrical
connectors.
35. Remove the exhaust gas recirculation (EGR)
tube. • Detach the wiring harness retainers.
36. Remove the radio interference capacitor bracket 39. Remove the 2 bolts and the fuel rail with the
bolt and position the bracket aside. fuel injectors.
37. Disconnect the wiring harness retainers from

the valve cover studs and position aside.
303-01-9 Engine — 2.0L and 2.3L 303-01-9
40. Disconnect the coil-on-plug and camshaft 43. Disconnect the coolant bypass hose.
position (CMP) sensor electrical connectors.
44. Remove the 4 bolts and the coolant bypass.

41. Position the rubber boot aside and disconnect
the cylinder head temperature (CHT) sensor
electrical connector. Remove the wiring harness
from the engine.
45. Disconnect and remove the coolant bypass hose.
42. Disconnect and remove the coolant hose.

303-01-10 Engine — 2.0L and 2.3L 303-01-10
46. Remove the bolt and the KS.
50. CAUTION: Only use hand tools when

removing or installing the spark plugs,
47. Remove the 8 bolts and the crankcase vent oil damage can occur to the cylinder head or
separator. spark plug.
Remove the spark plugs and the CHT sensor.
• Discard the CHT.
48. If equipped, remove the block heater.
51. Remove the bolts and the valve cover.
49. Remove the crankcase vent tube and the

coil-on-plugs.
303-01-11 Engine — 2.0L and 2.3L 303-01-11

crankshaft clockwise to position the No. 1
piston at TDC.
in the 6 o’clock position.

during disassembly.

engine damage.
both camshafts.

303-01-12 Engine — 2.0L and 2.3L 303-01-12

front oil seal.

remain in the TDC position during removal
of the pulley bolt or damage to the engine
can occur. Therefore, the crankshaft pulley 59. NOTE: Whenever the CKP sensor is removed,
must be held in place with the special tool a new one must be installed using the alignment
and the bolt should be removed using an air jig supplied with the new part.
impact wrench (1/2-in drive minimum). Remove and discard the CKP sensor.
CAUTION: If the crankshaft sprocket
diamond washer comes off with the
crankshaft pulley, it must be installed back
onto the crankshaft.
Using the special tools and an air impact
wrench, remove the crankshaft pulley.
• Remove and discard the crankshaft pulley
bolt and washer.
• Remove the crankshaft pulley.
303-01-13 Engine — 2.0L and 2.3L 303-01-13
60. Remove the 22 bolts and the engine front 62. Remove the RH timing chain guide.
cover.
63. Remove the timing chain.
61. Remove the timing chain tensioner.

64. Remove the 2 bolts and the LH timing chain
1 Compress the timing chain tensioner, and guide.
insert a paper clip into the hole to retain the
tensioner.
2 Remove the 2 bolts and timing chain
tensioner.
303-01-14 Engine — 2.0L and 2.3L 303-01-14
65. CAUTION: Do not rely on the

Camshaft Alignment Plate to prevent
camshaft rotation. Damage to the tool or the
camshaft can occur.
Using the flats on the camshaft to prevent
camshaft rotation, remove the bolts and the
camshaft sprockets.
All vehicles
68. NOTE: Remove the crankshaft sprocket

diamond washers located in front of and behind
the crankshaft sprocket.
NOTE: The oil pump chain sprocket must be
held in place.
Remove the oil pump chain and sprockets.
Early build vehicles
1 Remove the bolt.
66. Remove the oil pump drive chain tensioner and 2 Remove the chain and sprockets.
guide.
1 Release the tension on the tensioner spring.
2 Remove the tensioner and the shoulder bolt.
3 Remove the guide.
Late build vehicles
67. Remove the oil pump drive chain tensioner.

2 Remove the tensioner and the 2 shoulder
bolts.
303-01-15 Engine — 2.0L and 2.3L 303-01-15
69. Mark the position of the camshaft lobes on the
No. 1 cylinder for assembly reference.
72. Remove the cylinder head alignment dowels.
70. CAUTION: Failure to follow the

camshaft loosening procedure can result in
damage to the camshafts.
Remove the camshafts from the engine.
• Loosen the camshaft bearing bolts in the
sequence shown, one turn at a time. Repeat
until all the tension is released.
73. Remove the 13 bolts and the oil pan.
71. Remove the cylinder head.

• Remove and discard the 10 cylinder head
bolts.
• Remove the cylinder head.
• Remove and discard the cylinder head
gasket.
303-01-16 Engine — 2.0L and 2.3L 303-01-16
74. Remove the 6 bolts and the rear crankshaft seal. 76. Remove the 4 bolts and the oil pump.
75. Remove the 2 bolts, oil pump pickup tube and 77. Remove the 3 bolts and the intermediate shaft
gasket. bearing bracket.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Special Tool(s)
Engine Front Cover
Steering Pump Pulley Installer
Special Tool(s) 211-185
Remover, Oil Seal

303-409 (T92C-6700-CH)
Installer Set, Teflon Seal

211-D207

303-096 (T74P-6150-A)
Material
Item Specification
Steering Pump Pulley Remover
211-016 Motorcraft SAE 5W-20 WSS-M2C930-A
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
(Continued)
Sealant
TA-30
303-01-2 Engine — 2.0L and 2.3L 303-01-2
1 6700 Crankshaft front seal 3 — PSP tube bracket (part of
3F784)
2 W520414 Power steering pressure (PSP)
tube bracket nut
(Continued)

4 3A733 Power steering pulley 7 14A464 PSP switch electrical
5 3F784 PSP tube
8 W500315 Power steering pump bolt (4
6 3F886 Teflon O-ring seal
required)
(Continued)
(Continued)
303-01-3 Engine — 2.0L and 2.3L 303-01-3
Item Part Number Description 2. Remove the accessory drive belt and idler
9 3A696 Power steering pump pulleys. For additional information, refer to
Section 303-05.
10 — Wiring harness retainer (2
required) (part of 12B637)
3. Remove the crankshaft pulley. For additional
11 W500221 Coolant pump pulley bolt (3
required) information, refer to Crankshaft Pulley in this
section.
12 8509 Coolant pump pulley
13 14A464 Crankshaft position (CKP) 4. Remove the engine mount. For additional
sensor electrical connector information, refer to Engine Mount in this
(part of 12B637)
section.
14 — Wiring harness retainer (2
required) (part of 12B637)
5. If equipped, detach the 2 wiring harness
15 6C315 CKP sensor retainers from the power steering reservoir.
16 W701219 CKP sensor bolt (2 required)
17 W500215 Engine front cover bolt (22 6. Disconnect the power steering pressure (PSP)
required) switch electrical connector.
18 6019 Engine front cover
7. Using the special tool, remove the power
Removal steering pump pulley.

crankshaft sprocket is also unfastened if you 8. Remove the PSP tube bracket nut.
requiring loosening or removal of the crankshaft 9. NOTE: A new Teflon O-ring seal must be
pulley bolt, the crankshaft and camshafts must installed any time the PSP tube is disconnected
be locked in place by the special service tools, from the power steering pump.
Disconnect the PSP tube from the power
CAUTION: During engine repair steering pump.
procedures, cleanliness is extremely important. • Remove and discard the Teflon O-ring
Any foreign material, including any material seal.
enters the oil passages, coolant passages or the 10. Remove the 4 power steering pump mounting
oil pan can cause engine failure. bolts and position the power steering pump
aside.
Section 100-02.
303-01-4 Engine — 2.0L and 2.3L 303-01-4

front oil seal.
12. Remove the 3 bolts and the coolant pump

pulley.
13. Disconnect the crankshaft position (CKP) sensor

• Detach the 2 wiring harness retainers from
the engine front cover.
Installation
14. NOTE: Whenever the CKP sensor is removed,
a new part must be installed, using the 1. CAUTION: Do not use metal scrapers,
alignment jig supplied with the new part. wire brushes, power abrasive disks or other
Remove and discard the CKP sensor. abrasive means to clean sealing surfaces.
15. Remove the bolts and the engine front cover. make leak paths.
Clean and inspect the mounting surfaces of the
engine and the front cover.
303-01-5 Engine — 2.0L and 2.3L 303-01-5
2. NOTE: The engine front cover must be
installed and the bolts tightened within 4
minutes of applying the silicone gasket and
sealant.
gasket and sealant to the cylinder head and oil
pan joint areas. Apply a 2.5 mm (0.10 in) bead
of silicone gasket and sealant to the front cover.
4. Install the coolant pump pulley and the 3 bolts.


special tool.
oil.
Using the special tool, install the crankshaft
3. Install the engine front cover. Tighten the bolts front oil seal.
in the sequence shown, to the following
specifications:
• Tighten the 8-mm bolts to 10 Nm (89 lb-in).
• Tighten the 13-mm bolts to 48 Nm (35
lb-ft).
303-01-6 Engine — 2.0L and 2.3L 303-01-6
6. Install the engine mount. For additional
information, refer to Engine Mount in this
section.
7. Install the crankshaft pulley. For additional

information, refer to Crankshaft Pulley in this
section.

11. Connect the CKP sensor electrical connector.
• Attach the 2 wiring harness retainers to the
engine front cover.

bolt.
9. Install the CKP sensor and the 2 bolts.

• Do not tighten the bolts at this time.
13. Position the power steering pump and install the

bolts.
14. Using the special tool, install a new Teflon

O-ring seal to the PSP tube.
10. Adjust the new CKP sensor with the alignment

jig.
• Tighten the 2 bolts to 7 Nm (62 lb-in).
303-01-7 Engine — 2.0L and 2.3L 303-01-7
15. Install the PSP tube onto the power steering 18. Connect the PSP switch electrical connector.
pump.
• Tighten to 65 Nm (48 lb-ft). 19. If equipped, attach the 2 wiring harness
retainers to the power steering reservoir.
16. Install the PSP tube bracket nut.
20. Install the accessory drive belt and idler
• Tighten to 11 Nm (8 lb-ft). pulleys. For additional information, refer to
Section 303-05.
17. Using the special tool, install the power steering
pump pulley. 21. Fill the power steering system. For additional
303-01-1 Engine — 2.0L and 2.3L 303-01-1
INSTALLATION
Engine Vehicles equipped with a 2.0L engine and
automatic transmission
Special Tool(s)
1. NOTE: Lubricate the torque converter pilot hub
Heavy Duty Floor Crane with multi-purpose grease.
Check the installation depth of the torque
converter.
1 Lay a straightedge on the automatic
transaxle flange.
2 Check the installation depth between the
Spreader Bar transaxle flange and the torque converter
303-D089 (D93P-6001-A3) or centering spigot for the correct clearance.
equivalent
Powertrain Lift with Tilting

Plate
Universal Adapter Brackets

014-0001
Lifting Brackets, Engine

303-050 (T70P-6000)
Material
Item Specification
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
XG-4 and/or XL-5
303-01-2 Engine — 2.0L and 2.3L 303-01-2
INSTALLATION (Continued)
All vehicles
2. Install new dowel pins in the engine block.
4. Using the special tools, raise the engine and

transaxle assembly onto the lift table.
3. Using the engine crane, install the transaxle

onto the engine.
1 Install the 2 bolts at the dowel pins.
X Tighten to 48 Nm (35 lb-ft).
2 Install the remaining bolts.
X Tighten to 48 Nm (35 lb-ft).
5. Using the special tools, secure the engine and

transaxle assembly to the lift table.
303-01-3 Engine — 2.0L and 2.3L 303-01-3
Vehicles equipped with a 2.0L engine and automatic transmission
6. Connect the solenoid body and the transmission 9. NOTE: If new parts are not being used, be
range (TR) sensor electrical connectors. sure to align the marks on the flexplate and the
stud made during engine removal.
Install the 4 torque converter nuts.
7. Connect the turbine shaft speed (TSS) sensor

Vehicles equipped with a manual

transmission
10. Connect the vehicle speed sensor (VSS)

8. Connect the output shaft speed (OSS) sensor

All vehicles
11. Using the lift table, position the engine and

transaxle assembly in the vehicle.
303-01-4 Engine — 2.0L and 2.3L 303-01-4
12. Install the transaxle mount center nut. 15. Install the 2 lower bellhousing-to-oil pan bolts.
• Tighten to 133 Nm (98 lb-ft). • Tighten to 48 Nm (35 lb-ft).
13. Install the 2 motor mount nuts. 16. Install the starter motor isolator.
17. Install the starter motor and the 3 bolts.

14. Install the 2 oil pan-to-bellhousing bolts. • Tighten to 25 Nm (18 lb-ft).
303-01-5 Engine — 2.0L and 2.3L 303-01-5
18. Install the transaxle roll restrictor and 2 bolts.
22. Install both of the lower control arms to the

knuckles.
1 Connect the suspension arm ball joint.
19. NOTE: Install a new snap ring. 2 Install the bolt.
Install the LH front drive halfshaft. X Tighten to 63 Nm (46 lb-ft).
20. Install the RH front halfshaft together with the 23. Install both of the tie-rod ends to the knuckles.
intermediate shaft.
21. Install the front drive intermediate shaft bearing

mounting bracket.
303-01-6 Engine — 2.0L and 2.3L 303-01-6
24. Connect the stabilizer bar to the LH strut and 27. Install the brake hose onto the support bracket.
install the nut.
Vehicles equipped with air conditioning
25. Tighten the LH strut and spring assembly top 28. NOTE: Install new O-ring seals.
mount nuts. Install the manifold and tube assembly onto the
• Tighten to 30 Nm (22 lb-ft). A/C compressor.
26. Install the caliper.

1 Position the caliper and install the bolts. 29. Install the A/C compressor and the 3 bolts.
X Tighten to 28 Nm (21 lb-ft). • Tighten to 25 Nm (18 lb-ft).
2 Install the bolt covers.
303-01-7 Engine — 2.0L and 2.3L 303-01-7
30. Connect the A/C compressor electrical 33. Install the generator coolant pipe.
connector.
34. Position the ground cable and install the bolt.

All vehicles
31. Install the power steering pressure (PSP) tube

brackets and nuts.
35. Connect the lower radiator hose.
32. Connect the starter motor electrical connections.

• Tighten the small nut to 5 Nm (44 lb-in).
• Tighten the large nut to 12 Nm (9 lb-ft).
303-01-8 Engine — 2.0L and 2.3L 303-01-8
36. Install the cooling fan.
39. Connect the coolant hoses.
40. Connect the heater hose to the ‘‘T’’ fitting.

37. Connect the cooling fan electrical connectors.
38. Install the coolant expansion tank and the bolt.

303-01-9 Engine — 2.0L and 2.3L 303-01-9
Vehicles equipped with a 2.0L engine and 44. WARNING: Escaping brake fluid. Do
not allow brake fluid to come into contact
with the skin or the eyes. If brake fluid does
41. Connect the transmission cooler hoses. come into contact with the skin or eyes, rinse
the affected areas with water immediately.
Failure to follow these instructions may
result in personal injury.
CAUTION: If brake fluid is spilled on
the paintwork, the affected area must be
immediately washed down with cold water.
Connect the clutch slave cylinder supply tube.
• Install the clip.
42. Connect the transmission shifter cable.

transmission
43. Connect the reversing lamp switch electrical

connector.
303-01-10 Engine — 2.0L and 2.3L 303-01-10
45. NOTE: The shift cable abutment sleeve is All vehicles
colored white.
NOTE: The selector cable abutment sleeve is 48. Connect the 3 main engine wiring harness
colored black. connectors and attach the connectors to the
bracket.
Attach the transaxle cables to the bracket.
1 Attach the shifter cable to the bracket,
turning the abutment sleeves
counterclockwise to open. Position the
cables into the metal holders.
2 Attach the selector cable to the bracket,
turning the abutment sleeves
counterclockwise to open. Position the
cables into the metal holders.
49. Connect the power distribution harness eyelet

and install the nut.
46. Attach the gearshift cables.

1 Attach the shifter cable to the shift mass.
2 Attach the selector cable to the selector
lever.
50. Attach the wiring harness retainers.
47. Adjust the gearshift cables and bleed the clutch

system. For additional information, refer to
Section 308-00.
303-01-11 Engine — 2.0L and 2.3L 303-01-11
51. Connect the power distribution wiring harness
55. Connect the upper radiator hose, the heater hose

and the coolant vent hose to the coolant bypass.
52. Connect the fuel charging wiring harness

56. Connect the exhaust gas recirculation (EGR)

53. Connect the fuel charging wiring harness

electrical connector and harness retainer.
54. Install the ground eyelet and bolt.

303-01-12 Engine — 2.0L and 2.3L 303-01-12
57. Install the power brake booster vacuum tube
into the quick release fitting.
61. Connect the fuel tube quick connect coupling

onto the fuel rail. For additional information,
refer to Section 310-00.
58. If equipped, connect the secondary air injection
(AIR) vacuum regulator electrical connector.
62. Connect the accelerator cable and speed control

cable (if equipped).
59. If equipped, connect the AIR hose. 1 Install the accelerator cable bracket and
bolts.
X Tighten to 10 Nm (89 lb-in).
2 Connect the accelerator and speed control
cable (if equipped) to the throttle body.
60. Connect the evaporative emissions tube. For

303-01-13 Engine — 2.0L and 2.3L 303-01-13
63. Install the accelerator control snow shield. 66. Clean and inspect the catalytic converter flange.
• Position the snow shield and install the • Using a straightedge and a feeler gauge,
screw and pin-type retainer. place the straightedge across the catalytic
X Tighten to 10 Nm (89 lb-in). converter flange surface and check for
warping with the feeler gauge. If the reading
• Attach the evaporative emissions hose is greater than the maximum specification,
pin-type retainer. install a new catalytic converter, gasket and
nuts.
64. Install the air cleaner outlet pipe and air intake
resonator into the grommets and install the bolt. 67. Using a new gasket and nuts, install the
catalytic converter.
• Tighten in the sequence shown to 55 Nm
(41 lb-ft).
65. Tighten the air cleaner outlet pipe and connect

the vent tube.
303-01-14 Engine — 2.0L and 2.3L 303-01-14
68. If equipped, connect the AIR hose.
72. Install the catalytic converter support bracket

and 4 bolts.
69. If equipped, connect the upper exhaust sensor • Tighten to 47 Nm (35 lb-ft).
electrical connector and retainer.
73. NOTE: Clean the mating surfaces of the

70. Connect the exhaust sensor electrical muffler assembly and catalytic converter.
connectors.
Using a new gasket and 2 nuts, connect the
catalytic converter to exhaust system.
71. If removed, install the heat shield and 4 bolts.

74. Install the battery tray. For additional

303-01-15 Engine — 2.0L and 2.3L 303-01-15
75. Fill the engine with clean engine oil. 78. Fill and bleed the cooling system. For
76. Install the power steering pump. For additional
information, refer to Section 211-02. Vehicles equipped with air conditioning
77. Install the accessory drive belt. For additional 79. Evacuate and charge the A/C system. For
information, refer to Section 303-05. additional information, refer to Section 412-00.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Engine Lubrication Components —
Exploded View
Oil Filter Adapter and Oil Pressure Sender

1 14A464 Oil pressure sender electrical 4 6881 Oil filter adapter
connector (part of 12 B637) 5 6840 Oil filter adapter gasket
2 9278 Oil pressure sender
3 W500225 Oil filter adapter bolt (4
required)
(Continued)
303-01-2 Engine — 2.0L and 2.3L 303-01-2
Oil Pan, Oil Pump Screen and Pickup Tube
NOTE: Automatic transmission shown, manual transmission similar.

1 — Positive battery cable pin-type 5 W500124 Upper bellhousing-to-engine
retainer (2 required) stud bolt
2 14A464 Transmission wire harness 6 W500121 Upper bellhousing-to-engine
connector bolt
3 W520103 Heated oxygen sensor 7 W500125 Front lower
(HO2S) and catalyst monitor bellhousing-to-engine bolts (3
sensor wire connector bracket required for manual
nut (2 required) transmission) (2 required for
automatic transmission)
4 14301 HO2S and catalyst monitor
sensor wire connector bracket
(Continued)
303-01-3 Engine — 2.0L and 2.3L 303-01-3

8 W500124 Rear lower 13 W500215 Engine front cover-to-oil pan
engine-to-bellhousing stud bolt (4 required)
bolt 14 W706284 Oil pan bolt (2 required)
9 W500120 Rear lower 15 W500224 Oil pan bolt (11 required)
engine-to-bellhousing bolt
16 6675 Oil pan
10 W500121 Bellhousing-to-oil pan bolt (2
required) 17 W706282 Oil pump screen and pickup
tube bolt (2 required)
11 W500121 Oil pan-to-bellhousing bolt (2
required) 18 6622 Oil pump screen and pickup
tube
12 6730 Oil pan drain plug
19 6625 Oil pump screen and pickup
(Continued)
tube gasket
303-01-4 Engine — 2.0L and 2.3L 303-01-4
Oil Pump

1 W703651 Oil pump drive chain guide 5 6A895 Oil pump drive chain
shoulder bolt (2 required) 6 W704397 Oil pump sprocket bolt
(late build)
7 6652 Oil pump sprocket
2 6M256 Oil pump drive chain guide
(late build) 8 W703647 Oil pump bolt (4 required)
3 W703651 Oil pump drive chain 9 6600 Oil pump
tensioner shoulder bolt
4 6C271 Oil pump drive chain 1. For additional information, refer to the
tensioner procedures in this section.
(Continued)
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Engine Mount
Special Tool(s)
3-Bar Engine Support Kit
303-F072
Item Part Number Description

1 W520214 Engine mount bracket nut (2
required)
2 W709417 Engine mount bracket bolt (3
required)
3 6F012 Engine mount
Removal and Installation
1. Remove the expansion tank bolt.

• To install, tighten to 10 Nm (89 lb-in).
303-01-2 Engine — 2.0L and 2.3L 303-01-2
2. Lift the coolant expansion tank out of the
retainer and position it aside.
4. Remove the 2 engine mount nuts.

• To install, tighten to 90 Nm (66 lb-ft).
3. Install the special tool. 5. Remove the 3 bolts and the engine mount.
6. To install, reverse the removal procedure.

303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Engine Oil Pressure (EOP) Switch 2. Disconnect the battery ground cable. For
Material
3. Disconnect the electrical connector from the oil
Item Specification pressure sender.
Thread Sealant with PTFE WSK-M2G350-A2
TA-24 4. Remove the oil pressure sender.
Removal and Installation • To install, tighten to 15 Nm (11 lb-ft).
5. NOTE: Apply Thread Sealant with PTFE to the

1. With the vehicle in NEUTRAL, position it on a sender threads.
Section 100-02. To install, reverse the removal procedure.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
REMOVAL
Special Tool(s)
Engine
Tie-Rod End Remover
Special Tool(s) 211-001 (TOOL-3290-D) or
equivalent
Transaxle Plugs
308-152 (T88C-7025-AH)
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
Slide Hammer
100-001 (T50T-100-A)
Powertrain Lift with Tilting

Plate
Front Drive Halfshaft Remover

205-241 (T86P-3514-A)
Universal Adapter Brackets

014-0001
All vehicles
Torque Converter Holding Tool 1. With the vehicle in NEUTRAL, position it on a

307-346 (T97T-7902-A)
Section 100-02.
2. Release the fuel system pressure. For additional

Lifting Bracket, Engine 3. Remove the accessory drive belt. For additional
303-050 (T70P-6000) information, refer to Section 303-05.
4. Remove the battery tray. For additional

5. Remove the power steering pump. For

(Continued) additional information, refer to Section 211-02.
303-01-2 Engine — 2.0L and 2.3L 303-01-2
REMOVAL (Continued)
6. Recover the A/C system. For additional

All vehicles
7. Drain the engine cooling system. For additional

8. Drain the engine oil.

• Install the drain plug and tighten to 28 Nm
(21 lb-ft). 11. NOTE: All 2.3L engines and some 2.0L
engines are equipped with a heat shield that
must be positioned aside to access the catalytic
If equipped, remove the 4 heat shield bolts and
position the heat shield aside.
9. Remove the 2 nuts and disconnect the catalytic

converter from the muffler assembly.
• Remove and discard the gasket.
12. Disconnect the exhaust sensor electrical

connectors.
10. Remove the 4 bolts and the catalytic converter

support bracket.
303-01-3 Engine — 2.0L and 2.3L 303-01-3
REMOVAL (Continued)
13. If equipped, disconnect the upper exhaust 16. Loosen the clamp and disconnect the vent tube
sensor electrical connector and retainer. from the air cleaner outlet pipe.
14. If equipped, disconnect the secondary air 17. Remove the 2 bolts and detach the air intake
injection (AIR) hose. resonator from the grommets.
• Remove the air intake resonator and outlet
pipe.
15. Remove and discard the 7 catalytic

• Position aside the catalytic converter and 18. Remove the accelerator control snow shield.
support with mechanic’s wire. • Detach the evaporative emissions (EVAP)
• Remove and discard the catalytic converter hose pin-type retainer.
gasket. • Remove the screw, the pin-type retainer and
the snow shield.
303-01-4 Engine — 2.0L and 2.3L 303-01-4
REMOVAL (Continued)
19. Disconnect the accelerator cable and speed
control cable (if equipped).
1 Disconnect the accelerator and speed control
cable (if equipped) from the throttle body.
2 Remove the 3 bolts and position the
accelerator control cables and bracket aside.
22. If equipped, disconnect the AIR hose.
20. Disconnect the fuel tube quick connect coupling

from the fuel rail and position the fuel tube
aside. For additional information, refer to
Section 310-00.
23. If equipped, disconnect the AIR vacuum

regulator electrical connector.
21. Disconnect the evaporative emissions tube. For

303-01-5 Engine — 2.0L and 2.3L 303-01-5
REMOVAL (Continued)
24. Disconnect the power brake booster vacuum 27. Remove the bolt and ground eyelet.
tube.
• Depress the quick connect locking ring.
• Pull the vacuum tube out of the quick
connect fitting.
28. Disconnect the fuel charging wiring harness

electrical connector and harness retainer.
25. Disconnect the exhaust gas recirculation (EGR)

29. Disconnect the fuel charging wiring harness

26. Disconnect the upper radiator hose, the heater

hose and the coolant vent hose from the coolant
bypass.
303-01-6 Engine — 2.0L and 2.3L 303-01-6
REMOVAL (Continued)
30. Disconnect the power distribution wiring 33. Disconnect the 3 main engine wiring harness
harness electrical connector. electrical connectors and detach the connectors
from the bracket.
31. Detach the wiring harness retainers.

transmission
34. NOTE: Press the locking tab.

Detach the gearshift cables from the transaxle.
1 Detach the shifter cable from the shift mass.
2 Detach the selector cable from the selector
lever.
32. Remove the nut and the power distribution

wiring harness eyelet.
303-01-7 Engine — 2.0L and 2.3L 303-01-7
REMOVAL (Continued)
35. Detach the gearshift cables from the bracket. 37. Disconnect the reversing lamp switch electrical
1 Detach the shifter cable from the retaining connector.
bracket, turning the abutment sleeves
counterclockwise.
2 Detach the selector cable from the retaining
bracket, turning the abutment sleeves
counterclockwise.
Vehicles equipped with a 2.0L engine and

38. Disconnect the transmission shifter cable and

position it aside.
36. WARNING: Escaping brake fluid. Do

not allow brake fluid to come into contact
with the skin or the eyes. If brake fluid does
come into contact with the skin or eyes, rinse
the affected areas with water immediately.
Failure to follow these instructions may
result in personal injury.
CAUTION: If brake fluid is spilled on
the paintwork, the affected area must be
immediately washed down with cold water.
Remove the clutch slave cylinder supply tube.
• Remove the clip.
39. Disconnect the transmission cooler hoses.
• Remove the supply tube and secure it to one
side using cable ties.
303-01-8 Engine — 2.0L and 2.3L 303-01-8
REMOVAL (Continued)
All vehicles 43. Remove the coolant expansion tank.
• Lift the coolant expansion tank out of the
40. Disconnect the heater hose from the ‘‘T’’ fitting retainer.
and position it aside.
44. Disconnect the cooling fan electrical connectors.

41. Disconnect the coolant hoses from the coolant
expansion tank.
42. Remove the coolant expansion tank bolt.

303-01-9 Engine — 2.0L and 2.3L 303-01-9
REMOVAL (Continued)
45. Release the top cooling fan retaining clips, lift
up and remove the cooling fan.
48. Remove the generator cooling pipe.
49. Disconnect the starter motor electrical terminals.

46. Disconnect the lower radiator hose.
47. Remove the bolt and the ground cable.

303-01-10 Engine — 2.0L and 2.3L 303-01-10
REMOVAL (Continued)
50. Remove the 2 nuts and detach the PSP tube 53. Loosen the bolt and remove the A/C
brackets from the stud bolts. compressor.
• Lower the A/C compressor to access the
manifold bolt.
• Discard the O-ring seals.
51. Disconnect the A/C compressor electrical

connector. All vehicles
54. Detach the LH brake hose from the support

bracket.
52. Remove the 3 A/C compressor bolts.

303-01-11 Engine — 2.0L and 2.3L 303-01-11
REMOVAL (Continued)
55. Detach the LH caliper. 58. Remove the nut and disconnect the LH
1 Remove the bolt covers. stabilizer bar at the strut.
2 Remove the 2 bolts.
59. Remove the LH tie-rod end nut.
56. CAUTION: Suspend the caliper to

prevent load from being placed on the brake
hose.
Support the brake caliper.
60. Remove the RH tie-rod end nut.
57. Loosen the LH strut and spring assembly top

mount nuts by 4 turns.
303-01-12 Engine — 2.0L and 2.3L 303-01-12
REMOVAL (Continued)
61. Using the special tool, disconnect both tie rods 64. Remove the intermediate shaft and RH front
from the knuckles. drive halfshaft assembly from the transaxle.
Position it aside and support with mechanic’s
wire.
• Install a plug into the transaxle opening.
62. Remove the bolts and disconnect both lower

control arms from the knuckles.
65. Using the special tools, remove the LH front

drive halfshaft from the transaxle. Position it
aside and support with mechanic’s wire.
• Install a plug into the transaxle opening.
63. Remove the 2 nuts and the intermediate shaft

bearing bracket.
66. Remove the 2 bolts and the transaxle roll

restrictor.
303-01-13 Engine — 2.0L and 2.3L 303-01-13
REMOVAL (Continued)
67. Remove the 3 bolts and the starter.
70. Remove the 2 oil pan-to-bellhousing bolts.
68. Remove the starter isolator.
71. Using the special tools, fasten the engine to the

lift table.
69. Remove the 2 lower bellhousing bolts.
303-01-14 Engine — 2.0L and 2.3L 303-01-14
REMOVAL (Continued)
72. Remove the 2 engine mount nuts. Vehicles equipped with a 2.0L engine and
76. NOTE: Mark one stud and the flexplate for

assembly reference.
Remove the 4 torque converter nuts.
73. Remove the transaxle mount center nut.
77. Disconnect the output shaft speed (OSS) sensor

74. Lower the engine and transaxle assembly from

the vehicle.

transmission
75. Disconnect the vehicle speed sensor (VSS) 78. Disconnect the turbine shaft speed (TSS) sensor
electrical connector. electrical connector.
303-01-15 Engine — 2.0L and 2.3L 303-01-15
REMOVAL (Continued)
79. Disconnect the solenoid body and the 81. Remove the remaining bellhousing bolts and
transmission range (TR) sensor electrical separate the engine and transmission.
connectors.
82. Remove and discard the dowel pins.
All vehicles
Vehicles equipped with a 2.0L engine and
80. NOTE: Lower the engine to within a few
inches of the floor.
83. Install the special tool, to prevent damage to the
Using the engine crane, remove the engine and
torque converter.
transaxle assembly from the lift table.
GENERAL PROCEDURES
Exhaust Manifold Cleaning and 2. NOTE: New exhaust manifold gaskets, studs,
Inspection nuts and/or bolts must be installed when an
exhaust manifold is serviced.
Special Tool(s) NOTE: Use a straightedge that is calibrated by
the manufacturer to be flat within 0.005 mm
Feeler Gauge Set (0.0002 in) per running foot of length, such as
303-D027 (D81L-4201-A) or
equivalent Snap-On GA438A or equivalent. For
example, if the straightedge is 61 cm (24 in)
long, the machined edge must be flat within
0.010 mm (0.0004 in) from end to end.
Using the precision straight edge and a feeler
gauge, check the exhaust manifold sealing
1. Clean the exhaust manifold using a suitable surface for warpage. If the warpage is greater
solvent. Use a plastic scraping tool to clean the than 0.76 mm (0.0299 in), install a new exhaust
gasket sealing surfaces. manifold.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Flexplate 2. Install the special tool.
Special Tool(s)
Locking Tool, Flexplate
303-103 (T74P-8375-A)
Removal

hoist. For additional information, refer to 3. Tighten the bolts in the sequence shown in 3
Section 100-02. stages:
2. Remove the transaxle. For additional • Stage 1: Tighten to 50 Nm (37 lb-ft).

information, refer to Section 307-01. • Stage 2: Tighten to 80 Nm (50 lb-ft).
3. Install the special tool and remove the 6
flexplate bolts and the flexplate.
4. Install the transaxle. For additional information,

Installation
1. NOTE: Special bolts are used for installation.

Do not use standard bolts.
Install the flexplate.
GENERAL PROCEDURES
Flywheel Inspection 7. NOTE: The clutch disc should be discarded
due to possible hub spline wear or friction
Special Tool(s) material wear.
Remove the clutch disc and pressure plate. For
Holding Tool, Flywheel
303-103 (T74P-6375-A) additional information, refer to Section 308-01.
• Discard the clutch disc.
8. Inspect the clutch pressure plate and diaphragm

spring segments and discard as necessary.
• Inspect the clutch pressure plate for scoring,
cracks or discoloration. Any minor scoring
CAUTION: Do not clean the dual mass or discoloration should be removed with a
flywheel with any kind of fluid, use a dry cloth fine grade of emery cloth.
only.
• Inspect the clutch diaphragm spring
segments for damage, uneven height,
CAUTION: Do not clean the gap between
scoring, cracks or discoloration. Any minor
the primary and secondary mass. Only clean the
scoring or discoloration should be removed
bolt connection surface and the clutch surface.
with a fine grade of emery cloth.
1. Check the transaxle fluid level and fill to the
9. NOTE: The flywheel cannot be machined.
correct level as necessary.
With the dual mass flywheel installed on the
2. With the engine operating at idle and the engine, inspect the dual mass flywheel surface
transaxle in NEUTRAL, listen and check for for scoring, cracks, discoloration or damage. If
unacceptable noise. Determine if any any of these conditions exist, install a new
unacceptable noise is reduced when the clutch flywheel.
pedal is depressed.
10. With the dual mass flywheel installed on the
3. If unacceptable noise is identified, remove the engine, inspect the dual mass flywheel internal
transaxle. For additional information, refer to spring operation using the following Steps
Section 308-03. 11-13.
4. Inspect the clutch slave cylinder for leaks. If a 11. Install the special tool.
leak is identified, install a new clutch slave
cylinder. For additional information, refer to
Section 308-03.
5. Inspect the sliding surfaces of the clutch release

hub and bearing. Any scoring or burr should be
removed with a fine grade of emery paper.
6. Inspect the transaxle input shaft for spline wear,

scoring or burrs. Any scoring or burr should be
removed with a fine grade of emery paper. If
spline wear is identified, install a new transaxle.
For additional information, refer to Section
308-03.
GENERAL PROCEDURES (Continued)
12. Using a suitable long screwdriver or bar, firmly
rotate the secondary mass clockwise. The
secondary mass should begin to engage the
internal spring past the freeplay movement of
19 mm (0.750 in) maximum. The secondary
mass should continue to rotate and engage the
internal spring with increasing spring pressure.
If the secondary mass does not rotate, install a
new dual mass flywheel.
15. Inspect the dual mass flywheel friction control

plate for damage or melting and install a new
dual mass flywheel if necessary.
16. NOTE: The dual mass flywheel rotational

freeplay inspection cannot be carried out if the
friction control plate is off center or damaged.
With the dual mass flywheel installed on the
engine, inspect the dual mass flywheel
rotational freeplay using the following Steps
13. Using a suitable long screwdriver or bar, firmly 17-21.
rotate the secondary mass counterclockwise.
The secondary mass should begin to engage the 17. Check that the dual mass flywheel friction
internal spring past the freeplay movement of control plate is centered between the secondary
19 mm (0.750 in) maximum. The secondary mass notches.
mass should continue to rotate and engage the
internal spring with increasing spring pressure.
If the secondary mass does not rotate, install a
new dual mass flywheel.
14. Using a suitable long screwdriver or bar, firmly

rotate the secondary mass clockwise and
counterclockwise until the dual mass flywheel
friction control plate is centered between the
secondary mass notches.
18. Place a reference mark on the secondary mass 21. Measure the rotational freeplay XX between the
of the dual mass flywheel. 2 reference marks on the primary mass of the
dual mass flywheel. If the rotational freeplay
exceeds 19 mm (0.750 in), install a new dual
mass flywheel.
19. Using light hand pressure, rotate the secondary

mass clockwise to the end of the freeplay. Place
a reference mark on the primary mass of the
dual mass flywheel, in line with the reference 22. Inspect the dual mass flywheel when removed
mark on the secondary mass. from the engine and placed on a bench, using
the following Steps 23-24.
23. NOTE: Blocks must be placed under the dual

mass flywheel to make sure it is level and
stable.
Remove the dual mass flywheel and place it on
a firm and level surface.
• Discard the dual mass flywheel retaining
bolts and remove the special tool.
20. Using light hand pressure, rotate the secondary

mass counterclockwise to the end of the
freeplay. Place a second reference mark on the
primary mass of the dual mass flywheel, in line
with the reference mark on the secondary mass.
24. NOTE: Axial movement of the secondary mass
flywheel is normal and the dual mass flywheel
should not be discarded based on this
movement.
Using a suitable dial indicator gauge and
holding fixture, inspect the dual mass flywheel
hub bush for wear and install new as necessary.
• Place a dial indicator gauge at a point on
the outer upper surface of the secondary
mass.
• Using light hand pressure, press downward
at the opposite point on the outer upper
surface of the secondary mass and note the 26. Inspect the transaxle mounting face.
deflection on the dial indicator gauge. • Make sure that the 2 dowel pin holes are
• Repeat this measurement at 120 degree not elongated or damaged.
intervals around the dual mass flywheel and
note any deflection. If the deflection exceeds 27. Inspect the dual mass flywheel crankshaft
1.5 mm (0.060 in) at any point, install a mounting flange for residual thread locking
new dual mass flywheel. compound or rust and clean as necessary.
28. NOTE: Install new dual mass flywheel

retaining bolts.
Loosely install the dual mass flywheel.
25. Inspect the rear face of the engine block.

1 Make sure that the 2 engine dowel pins are
correctly installed and are not damaged,
install new dowel pins as necessary.
2 Inspect the upper and lower engine block
rear face plates for damage or warping and
install new plates as necessary.
3 Inspect the crankshaft flange for residual
thread locking compound or rust, and clean
as necessary.
30. Tighten the dual mass flywheel retaining bolts 31. NOTE: A new clutch disc should be installed
in the sequence shown to 112 Nm (83 lb-ft). due to possible hub spline wear or friction
material wear.
Install the clutch disc and pressure plate. For
32. Install the transaxle. For additional information,

303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Flywheel 1. Inspect the pilot bearing. Install a new pilot
bearing as necessary.
Special Tool(s)
2. Install the flywheel and the 6 bolts.
Locking Tool, Flywheel
303-103 (T74P-8375-A) 3. Install the special tool.
Removal
1. With vehicle in NEUTRAL, position it on a

Section 100-02.
2. Remove the manual transaxle and clutch. For

additional information, refer to Section 308-01
and Section 308-03. 4. NOTE: Special bolts are used for installation.
Do not use standard bolts.
3. Install the special tool and remove the 6 bolts
Tighten the bolts in the sequence shown in 3
and the flywheel.
stages.
Installation
NOTE: Engine balancing is not required. Balance

weights should not be installed on the new
flywheel.
5. Install the clutch and manual transaxle. For
NOTE: Special bolts are used for installation. Do additional information, refer to Section 308-01
not use standard bolts. and Section 308-03.
2007 Ford FOCUS
Submodel: SE | Engine Type: L4 | Liters: 2.0
Fuel Delivery: FI | Fuel: GAS
GROUP 03: Engine
SECTION 303-00: Engine System — General Information

SECTION 303-01: Engine — 2.0L and 2.3L
SECTION 303-03: Engine Cooling
SECTION 303-04: Fuel Charging and Controls — 2.0L and 2.3L
SECTION 303-05: Accessory Drive
SECTION 303-06: Starting System
SECTION 303-07: Engine Ignition — 2.0L and 2.3L
SECTION 303-08: Engine Emission Control — 2.0L and 2.3L
SECTION 303-12: Intake Air Distribution and Filtering
SECTION 303-13: Evaporative Emissions
SECTION 303-14: Electronic Engine Controls
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Intake Manifold
Material
Item Specification
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
303-01-2 Engine — 2.0L and 2.3L 303-01-2

1 W504692 Snow shield mounting screw 7 14A464 Idle air control (IAC) motor
electrical connector (part of
2 W709419 Snow shield pushpin
12B637)
3 — Evaporative emissions hose
8 9D289 Fuel vapor return hose
pin-type retainer
9 19D848 Power brake booster vacuum
4 9E766 Snow shield
supply hose
5 9A758 Accelerator cable assembly
10 9D430 Fuel rail pressure and
6 14A464 Throttle position (TP) sensor temperature vacuum tube
electrical connector
11 14A464 Pin-type retainer (part of
(Continued) 12B637)
(Continued)
303-01-3 Engine — 2.0L and 2.3L 303-01-3
12 14A464 Intake manifold runner 15 14A464 Knock sensor (KS) electrical
control (IMRC) electrical connector (part of 12B637)
connector 16 14A464 Oil pressure sender electrical
13 14A464 Manifold absolute pressure connector (part of 12B637)
(MAP) sensor electrical 17 12B637 Engine control wiring harness
connector (part of 12B637) retainer
14 14A464 Swirl control valve electrical
(Continued)
Item Part Number Description Removal

18 W500311 Intake manifold bolt (8
required) All engines
19 — Crankcase vent hose clamp
(part of 6758) 1. With vehicle in NEUTRAL, position it on a
20 6758 Positive crankcase ventilation hoist. For additional information, refer to
(PCV) hose Section 100-02.
21 9E470 Exhaust gas recirculation
(EGR) tube 2. Remove the cooling fan motor and shroud
22 9424 Intake manifold assembly. For additional information, refer to
23 9461 Intake manifold gasket Section 303-03.
303-01-4 Engine — 2.0L and 2.3L 303-01-4
3. Remove the lower intake manifold bolt. 6. Disconnect the accelerator cable and speed
control cable (if equipped).
1 Disconnect the accelerator and speed control
cable (if equipped) from the throttle body.
2 Remove the 3 bolts and position the
accelerator control cables and bracket aside.
4. Remove the air cleaner outlet pipe.

• Loosen the clamps.
• Disconnect the vent tube and remove the
outlet pipe.
7. Disconnect the throttle position (TP) sensor

retainer.
8. Disconnect the idle air control (IAC) valve

retainer.
9. Disconnect the fuel vapor return hose.
10. Disconnect the power brake booster vacuum

tube.
• Depress the quick release locking ring.
5. Remove the accelerator snow shield.
• Pull the vacuum tube out of the quick
• Detach the evaporative emissions hose release fitting.
pin-type retainer.
• Remove the screw and pin-type retainer.
• Remove the snow shield.
303-01-5 Engine — 2.0L and 2.3L 303-01-5
11. Disconnect the fuel rail pressure and
temperature sensor vacuum hose.
17. Remove the bolt and the oil level indicator

tube.
12. Detach the wiring harness pin-type retainer.
13. Disconnect the intake manifold runner control

14. Disconnect the manifold absolute pressure

(MAP) sensor electrical connector.
2.0L engines

injection (AIR) vacuum supply hose.
18. NOTE: There are 3 different size bolts used.

Mark the location of the bolts to make sure
installation is in the correct location.
16. Disconnect the swirl control valve electrical

connector.
303-01-6 Engine — 2.0L and 2.3L 303-01-6
2.3L engines All engines
19. Disconnect the swirl valve electrical connectors 22. Raise the intake manifold enough to gain
and pin-type retainers. clearance to disconnect the knock sensor (KS)
23. Disconnect the positive crankcase ventilation

(PCV) hose and remove the intake manifold.
24. Remove the exhaust gas recirculation (EGR)

tube.
Installation
All engines
1. NOTE: 2.0L engine shown, 2.3L engine

similar.
20. Remove the 2 bolts and the oil level indicator Inspect and install new intake manifold gaskets
tube. if necessary.
21. NOTE: There are 3 different size bolts used. 2. Install the EGR tube and tighten to 55 Nm (41
Mark the location of the bolts to make sure lb-ft).
installation is in the correct location.
3. Position the intake manifold and connect the

PCV hose.
303-01-7 Engine — 2.0L and 2.3L 303-01-7
4. Connect the KS electrical connector.
2.3L engines

NOTE: To ease installation of the intake
manifold, lower center mounting bolt, use a
6-inch long, 5/16-inch diameter hose.
bolts.
2.0L engines

bolts.

oil.
Install the oil level indicator tube and 2 bolts.

oil.
Install the oil level indicator tube and bolt.
7. Connect the swirl valve electrical connectors

303-01-8 Engine — 2.0L and 2.3L 303-01-8
10. Connect the swirl control valve electrical 13. Connect the MAP sensor electrical connector.
connector.
14. Connect the IMRC actuator electrical connector.
15. Attach the wiring harness pin-type retainer.
11. If equipped, connect the AIR vacuum supply

hose.
16. Connect the fuel rail pressure and temperature

sensor vacuum hose.
17. Connect the power brake booster vacuum tube.

• Push the vacuum tube into the quick release
fitting.
All engines
12. Install the lower intake manifold bolt.

18. Connect the fuel vapor return hose.
19. Connect the IAC valve electrical connector and

wiring harness pin-type retainer.
20. Connect the TP sensor electrical connector and

wiring harness pin-type retainer.
303-01-9 Engine — 2.0L and 2.3L 303-01-9
21. Connect the accelerator cable and speed control
cable (if equipped).
1 Install the accelerator cable bracket and 3
bolts.
X Tighten to 10 Nm (89 lb-in).
2 Connect the accelerator and speed control
cable (if equipped) to the throttle body.
23. Install the air cleaner outlet pipe.

• Tighten the clamps to 4 Nm (35 lb-in).
22. Install the accelerator control snow shield.

• Position the snow shield and tighten the
retainer to 10 Nm (89 lb-in).
• Attach the evaporative emissions hose
pin-type retainer.
24. Install the cooling fan motor and shroud

assembly. For additional information, refer to
Section 303-03.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Lower End Components — Exploded
View
Crankshaft Pulley and Crankshaft Front Seal

1 6K340 Crankshaft pulley bolt 3 6316 Crankshaft pulley
2 — Crankshaft pulley washer 4 6700 Crankshaft front seal
(part of 6K340)
(Continued)
303-01-2 Engine — 2.0L and 2.3L 303-01-2
Flexplate, Flywheel and Crankshaft Rear Seal with Retainer Plate

1 6379 Flexplate or flywheel bolt (6 6 6675 Oil pan
required) 7 W500212 Crankshaft rear oil seal with
2 6477 Flexplate or flywheel retainer plate bolt (6 required)
3 W500215 Engine front cover bolt (4 8 6K318 Crankshaft rear oil seal with
required) retainer plate
4 W706284 Oil pan bolt (2 required)
5 W500224 Oil pan bolt (11 required) 1. For additional information, refer to the
(Continued) procedures in this section.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Oil Filter Adapter 2. Disconnect the oil pressure sender electrical
connector.
Material
3. Remove the oil filter.
Item Specification
Motorcraft SAE 5W-20 WSS-M2C930-A 4. Remove the 4 bolts and the oil filter adapter.
Premium Synthetic Blend • Discard the gasket.
Motor Oil
XO-5W20-QSP (US); • To install, tighten to 25 Nm (18 lb-ft).
Super Premium Motor Oil 5. To install, reverse the removal procedure.
CXO-5W20-LSP12
(Canada); or equivalent • Install a new oil filter adapter gasket.
Removal and Installation 6. Top off the engine with clean engine oil.

Section 100-02.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Oil Level Indicator and Tube
Material
Item Specification
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
Item Part Number Description Removal and Installation

1 6750 Oil level indicator
2 W500211 Oil level indicator tube bolt 1. NOTE: 2.3L engine shown, 2.0L engine similar
with only one retaining bolt.
3 6754 Oil level indicator tube
4 6754-B O-ring seal Remove the oil level indicator and position
aside.
303-01-2 Engine — 2.0L and 2.3L 303-01-2
2. Remove the 2 bolts for 2.3L engines or the 1 3. To install, reverse the removal procedure.
bolt for 2.0L engines and the oil level indicator
tube.
• To install, tighten to 10 Nm (89 lb-in).
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Oil Pan
Material
Item Specification
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12
Cleaner 5. Remove the 2 nuts and position the heated
ZC-21 oxygen sensor (HO2S) and catalyst monitor
Silicone Gasket and WSE-M4G323-A4 sensor wire connector bracket aside.
Sealant
TA-30
6. CAUTION: To prevent damage to the
Removal transmission, do not loosen the
transmission-to-engine bolts more than 5 mm
1. With the vehicle in NEUTRAL, position it on a (0.19 in).
hoist. For additional information, refer to Loosen the upper bellhousing-to-engine bolt and
Section 100-02. stud bolt 5 mm (0.19 in).
2. Remove the battery tray. For additional 7. Remove the oil level indicator and tube. For
information, refer to Section 414-01. additional information, refer to Oil Level
3. Detach the 2 positive battery cable pin-type
retainers and position aside. 8. Loosen the 3 (manual transmission) or 2
(automatic transmission) front lower
bellhousing-to-engine bolts 5 mm (0.19 in).
9. Loosen the rear lower engine-to-bellhousing

bolt and stud bolt 5 mm (0.19 in).
10. Remove the 2 bellhousing-to-oil pan bolts.
12. Slide the transmission rearward 5 mm (0.19 in).
4. Detach the transmission connector wire harness

pin-type retainer and position aside.
303-01-2 Engine — 2.0L and 2.3L 303-01-2
13. Remove the 2 bolts and the accessory drive belt
splash shield.
14. Drain the engine oil.

• Install the drain plug.
15. Remove the 4 engine front cover-to-oil pan

bolts.
16. Remove the 13 bolts and the oil pan.
Installation
3. Position the oil pan onto the engine and install
1. CAUTION: Do not use metal scrapers, the oil pan bolts finger-tight.
abrasive means to clean the sealing surfaces. 4. CAUTION: The engine front
These tools cause scratches and gouges, cover-to-oil pan bolts must be tighten first to
which make leak paths. Use a plastic align the front surface of the oil pan flush
scraping tool to remove traces of sealant. with the front surface of the engine block.
Clean and inspect all mating surfaces. Install the 4 engine front cover-to-oil pan bolts.
gasket and sealant to the oil pan-to-engine
block and to the oil pan-to-engine front cover
mating surface.
303-01-3 Engine — 2.0L and 2.3L 303-01-3
5. Tighten the oil pan bolts in the sequence 10. Install the 2 oil pan-to-bellhousing bolts.
shown. • Tighten to 48 Nm (35 lb-ft).
11. Install the oil level indicator and tube. For
additional information, refer to Oil Level
12. Tighten the top bellhousing-to-engine bolt and

stud bolt.
13. Position the HO2S and catalyst monitor sensor

wire connector bracket and install the 2 nuts.
14. Position and attach the transmission connector

wire harness pin-type retainer.
6. Install the accessory drive belt splash shield and
the 2 bolts.
15. Position and attach the 2 positive battery cable

pin-type retainers.
7. Alternate tightening the 1 front

bellhousing-to-engine and 1 rear
engine-to-bellhousing lower bolts to slide the
transmission and engine together.
8. Tighten the remaining 1 (automatic

transmission) or 2 (manual transmission) lower
front bellhousing-to-engine bolt(s) and the
remaining rear engine-to-bellhousing stud bolt.
9. Install the 2 bellhousing-to-oil pan bolt.

303-01-4 Engine — 2.0L and 2.3L 303-01-4
16. Install the battery tray. For additional 17. Fill the engine with clean engine oil.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Oil Pump Early build vehicles
Material 7. Remove the oil pump drive chain tensioner and

guide.
Item Specification
Premium Synthetic Blend 2 Remove the 2 shoulder bolts and the
Motor Oil tensioner.
XO-5W20-QSP (US);
Motorcraft SAE 5W-20 3 Remove the 2 shoulder bolts and the guide.
CXO-5W20-LSP12
Sealant
TA-30
Cleaner
ZC-21
Removal

Late build vehicles
pump drive components are not interchangeable 8. Remove the oil pump drive chain tensioner.
between early build and late build engines. • Release the tension on the tensioner spring.
All vehicles • Remove the tensioner and the 2 shoulder
bolts.
1. With the engine in NEUTRAL, position it on a
Section 100-02.
2. Remove the engine front cover. For additional

information, refer to Engine Front Cover in this
section.
3. Drain the engine oil, then install the drain plug.

5. Remove the 13 bolts and the oil pan. All vehicles
6. NOTE: Discard the gasket and clean and

9. Remove the chain from the oil pump sprocket.
inspect the gasket mating surfaces.
Remove the 2 bolts and the oil pump screen 10. Remove the bolt and oil pump sprocket.
and pickup tube.
• To install, tighten to 10 Nm (89 lb-in). 11. Remove the 4 bolts and the oil pump.
303-01-2 Engine — 2.0L and 2.3L 303-01-2
Installation Early build vehicles
All vehicles 5. Install the oil pump drive chain guide and the
shoulder bolts.
1. NOTE: Clean the oil pump and cylinder block • Tighten to 10 Nm (89 lb-in).
mating surfaces with metal surface cleaner.
Install the oil pump assembly. Tighten the 4
bolts in the sequence shown in 2 stages:
All vehicles
6. Install the oil pump chain tensioner and bolt.

Hook the tensioner spring around the shoulder
bolt.
2. Install the oil pump sprocket and bolt. • Tighten to 10 Nm (89 lb-in).
3. Install the chain onto the oil pump sprocket.
Late build vehicles
4. Install the oil pump drive chain tensioner

shoulder bolt.
7. Install the oil pump screen and pickup tube and

the 2 bolts.

These tools cause scratches and gouges,
scraping tool to remove traces to sealant.
Clean all mating surfaces with metal surface
cleaner.
303-01-3 Engine — 2.0L and 2.3L 303-01-3
Apply a 2.5 mm (0.09 in) bead of sealant
gasket and sealant to the oil pan.
• Position the oil pan onto the engine and
install the 2 rear oil pan bolts finger-tight.
10. Using a suitable straight edge, align the front

surface of the oil pan flush with the front 11. Install the remaining oil pan bolts.
surface of the engine block. • Tighten in the sequence shown to 25 Nm
(18 lb-ft).
12. Install the 4 oil pan-to-bellhousing bolts.

303-01-4 Engine — 2.0L and 2.3L 303-01-4
13. Install the engine front cover. For additional 14. Fill the engine with clean engine oil.
section.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Oil Pump Screen and Pickup Tube
Material
Item Specification
Sealant
TA-30
Motor Oil
XO-5W20-QSP (US);
CXO-5W20-LSP12 Installation
1. Clean and inspect all mating surfaces.
Removal
2. Install the 2 oil pump screen and pickup tube
1. With the vehicle in NEUTRAL, position it on a bolts and the oil pump screen and pickup tube
hoist. For additional information, refer to with a new mounting gasket.
Section 100-02.
2. Remove the oil pan. For additional information,
3. Install the oil pan. For additional information,
refer to Oil Pan in this section.
refer to Oil Pan in this section.
3. Remove the 2 bolts and the oil pump screen
and pickup tube.
• Discard the gasket.
2007 Ford FOCUS
SECTION 303-00:
Engine System — General Information
SPECIFICATIONS
Engine
DIAGNOSIS AND TESTING
Engine
Inspection and Verification
Symptom Chart
Component Tests
Compression Test — Compression Gauge Check
Cylinder Leakage Detection
Excessive Engine Oil Consumption
Intake Manifold Vacuum Test
Excessive Engine Oil Consumption
Valve Train Analysis — Engine Off, Valve Cover Removed
GENERAL PROCEDURES
Sprockets
Camshaft Bearing Journal Diameter
Camshaft End Play — OHC Engines
Camshaft Surface Inspection
Camshaft Lobe Lift
Camshaft Runout
Crankshaft End Play
Valve Stem Diameter
Valve Inspection
Valve Guide Inner Diameter
Valve Spring Free Length
Valve Spring Squareness
Valve Spring Strength
Valve Seat Inspection
Flywheel Inspection
Cylinder Head Distortion
Cylinder Block Distortion
Exhaust Manifold Cleaning and Inspection
Cylinder Block Core Plug Replacement
Spark Plug Inspection
Valve Tappet Inspection
2007 Ford FOCUS
SECTION 303-01:
Engine — 2.0L and 2.3L
SPECIFICATIONS
Engine
DIAGNOSIS AND TESTING
Engine
GENERAL PROCEDURES
Valve Clearance Check
IN-VEHICLE REPAIR
Intake Manifold
Valve Cover
Lower End Components — Exploded View
Crankshaft Pulley
Crankshaft Front Seal
Flexplate
Flywheel
Crankshaft Rear Seal with Retainer Plate
Engine Front Cover
Timing Drive Components
Camshafts
Valve Train Components — Exploded View
Valve Springs
Valve Seals
Valve Tappets
Cylinder Head
Engine Lubrication Components — Exploded View
Oil Filter Adapter
Engine Oil Pressure (EOP) Switch
Oil Pan
Oil Pump Screen and Pickup Tube
Oil Pump
Oil Level Indicator and Tube
Engine Mount
REMOVAL
Engine
DISASSEMBLY
Engine
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Cylinder Head
ASSEMBLY
Engine
INSTALLATION
Engine
GENERAL PROCEDURES
Spark Plug Inspection 3. Inspect for carbon fouling. Look for black, dry,
fluffy carbon deposits on the insulator tips,
exposed shell surfaces and electrodes, caused by
1. Inspect the spark plug for a bridged gap.
a spark plug with an incorrect heat range, dirty
• Check for deposit build-up closing the gap air cleaner, too rich a fuel mixture or excessive
between the electrodes. Deposits are caused idling.
by oil or carbon fouling.
• Install new spark plugs.
• Clean the spark plug.
4. Inspect for normal burning.

2. Check for oil fouling.
• Check for light tan or gray deposits on the
• Check for wet, black deposits on the firing tip.
insulator shell bore electrodes, caused by
excessive oil entering the combustion
chamber through worn rings and pistons,
excessive valve-to-guide clearance or worn
or loose bearings.
• Correct the oil leak concern.
• Install a new spark plug.
5. Inspect for pre-ignition, identified by melted
electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate
engine damage. This may be caused by
incorrect ignition timing, wrong type of fuel or
the unauthorized installation of a heli-coil
insert in place of the spark plug threads.
7. Inspect for fused deposits, identified by melted

or spotty deposits resembling bubbles or
blisters. These are caused by sudden
acceleration.
• Install new spark plugs.
6. Inspect for overheating, identified by white or

light gray spots and with a bluish-burnt
appearance of electrodes. This is caused by
engine overheating, wrong type of fuel, loose
spark plugs, spark plugs with an incorrect heat
range, low fuel pump pressure or incorrect
ignition timing.
GENERAL PROCEDURES
Sprockets
1. Inspect the sprockets for cracks and worn or

chipped teeth.
303-01-1 Engine — 2.0L and 2.3L 303-01-1
IN-VEHICLE REPAIR
Timing Drive Components
Special Tool(s)
303-465 (T949-6256-CH)
Removal
3. Remove the RH timing chain guide.
crankshaft sprocket is also unfastened if you
requiring loosening or removal of the crankshaft 4. Remove the timing chain.

1. Remove the engine front cover. For additional

section.
2. Remove the timing chain tensioner.

1 Compress the timing chain tensioner and
insert a paper clip into the hole.
2 Remove the bolts and timing chain
tensioner.
303-01-2 Engine — 2.0L and 2.3L 303-01-2
5. Remove the bolts and the LH timing chain Installation
guide.
6. CAUTION: Do not rely on the

Camshaft Alignment Plate to prevent 2. CAUTION: Do not rotate the
camshaft rotation. Damage to the tool or the camshafts. Damage to the valves and pistons
camshaft can occur. can occur.
If necessary, remove the bolts and the camshaft If the camshaft sprockets were not removed,
sprockets. use the flats on the camshafts to prevent
• Use the flats on the camshaft to prevent camshaft rotation and loosen the sprocket bolts.
camshaft rotation.
3. If removed, install the camshaft sprockets and

the bolts. Do not tighten the bolts at this time.
303-01-3 Engine — 2.0L and 2.3L 303-01-3
4. Install the LH timing chain guide and bolts.
5. Install the timing chain.

6. Install the RH timing chain guide. engine damage.
camshaft rotation, tighten the sprocket bolts.
7. Install the timing chain tensioner and the bolts.

Remove the paper clip to release the piston.
303-01-4 Engine — 2.0L and 2.3L 303-01-4
10. Install the front cover. For additional
section.

Engine Valve Clearance Check Procedure

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Engine Valve Clearance Check Procedure

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303-01-1 Engine — 2.0L and 2.

Item Part Number Description Item Part Number Description

1. Disconnect the battery ground cable. For

8. Remove the radio interference capacitor bracket

Vehicles with secondary air injection (AIR)

9. Disconnect the heated oxygen sensor (HO2S) Installation

1. CAUTION: Do not use metal scrapers,

3. Position the wiring harness and attach all of the

Vehicles with secondary air injection (AIR)

9. Connect the ignition coil-on-plug electrical

10. Connect the CHT sensor electrical connector

11. Connect the CMP sensor electrical connector.

NOTE: Refer to the appropriate Section 303-01 for

1. NOTE: Valve guides tend to wear in an

2. Measure the ball gauge with a micrometer.

1. Inspect the following valve areas:

CAUTION: During engine repair

1. With the vehicle in NEUTRAL, position it on a

3. CAUTION: If the camshafts and valve

5. WARNING: Always wear protective Installation

6. NOTE: Place all parts in order to one side.

3. NOTE: Check the seating of the valve collet.

Valve and Seat Refacing Measurements

NOTE: Refer to the appropriate Section 303-01 for

NOTE: After grinding valves or valve seats, check

1. Check the valve head and seat.

1. Measure the free length of each valve spring.

Special Tool(s) CAUTION: During engine repair

1. CAUTION: If the camshafts and valve

2. WARNING: Always wear protective

2. NOTE: Do not tighten the spark plug at this

1. NOTE: Check the seating of the valve collet.

4. Install the plugs and tighten to 15 Nm (11

5. Install the valve tappets. For additional

1. Measure the out-of-square on each valve spring.

NOTE: Refer to the appropriate Section 303-01 for

1. Use the special tool to check the valve spring

1. Measure the diameter of each intake and

1. Inspect the valve tappet for damage, especially

1. With the vehicle in NEUTRAL, position it on a

2. Remove the camshafts. For additional

Item Part Number Description 1. For additional information, refer to the

1. Measure each camshaft journal diameter in 2

NOTE: Refer to the appropriate Section 303-01 for

1. Using the special tool, measure the camshaft

2. Position the camshaft to the rear of the cylinder

3. Zero the indicator.

1. Use a Dial Indicator Gauge with Holding

NOTE: Refer to the appropriate Section 303-01 for

1. NOTE: Camshaft journals must be within

5. Remove the accessory drivebelt. For additional

CAUTION: During engine repair

CAUTION: Do not rotate the camshafts

1. With the vehicle in NEUTRAL, position it on a

7. CAUTION: The special tool 303-465 is

8. Remove the engine plug bolt.

10. CAUTION: Only hand-tighten the bolt

9. NOTE: The special tool will contact the

12. Remove the upper front cover timing hole plug

18. Using the flats on the camshaft to prevent

17. Remove the timing chain from the intake

2. Install the special tool.

4. Install the timing chain on the intake camshaft