Section 250 (Engine Mechanical - 2.0L DURATEC): Assembly: Engine

WARNING: This page is about a different car, the 2014 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S) DESCRIPTION

	100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
	205-153 (T80T-4000-W) Handle
	303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal TKIT-2009TC-F
	303-103 (T74P-6375-A) Holding Tool, Flywheel TKIT-2009TC-F T74P-77000-A
	303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
	303-1252 Stretchy Belt Remover/Installer Tool TKIT-2006UF-FLM TKIT-2006UF-ROW
	303-1521 Alignment Tool, Crankshaft Position Sensor TKIT-2010C-FLM TKIT-2010C-FLM
	303-1565 Alignment Tool, Camshaft TKIT-2010C-FLM TKIT-2010C-FLM
	303-1567 Sizer, Teflon Seal TKIT-2010C-FLM TKIT-2010C-FLM
	303-328 (T88P-6701-B1) Replacer, Rear Seal TKIT-1988-F TKIT-1988-FLM TKIT-1988-LM
	303-462 Installer, Connecting Rod
	303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW
	303-D032 (D81L-6002-C) Compressor, Piston Ring
	303-D055 (D85L-6000-A) Strap Wrench
	310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM
Hose Clamp Remover/Installer
Round-Ended Steel Rule

MATERIALS SPECIFICATION

Name	Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.) XO-5W20-QSP (U.S.)	WSS-M2C945-A
Motorcraft® Silicone Gasket Remover ZC-30-A	-
Flange Sealant CU7Z-19B508-A	WSS-M2G348-A11
Motorcraft® Metal Surface Prep ZC-31-B	-
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A	ESE-M1C171-A

NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the 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 sprocket is also unfastened if the pulley bolt is loosened. 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, otherwise severe engine damage can occur.

NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement.

NOTE: Refer to EXPLODED VIEWS in Description and Operation.

NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly.

NOTE: The front bulkhead does not have an engine piston oil cooler.

Torque : 35 lb.in (4 Nm)
Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block and install the original main bearing beam bolts finger tight.
Torque :
Stage 1: 44 lb.in (5 Nm)

Stage 2: 18 lb.ft (25 Nm)

Stage 3: 90°
Measure each crankshaft block main bearing bore diameter.
Using the chart, select the crankshaft main bearings.
Using the original connecting rod cap bolts, install the connecting caps and bolts and tighten the bolts in 2 stages:
Torque :

Stage 1: 21 lb.ft (29 Nm)

Stage 2: 90°
- Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.
- Remove the bolts and the connecting rod cap.
- Discard the connecting rod cap bolts.
Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.
Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
NOTE: Discard the main bearing beam bolts.

Remove the 10 bolts in the sequence shown in illustration below and the main bearing beam.
NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

NOTE: The center bulkhead is the thrust bearing.

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
NOTE: Lubricate the main bearing beam bolt threads and under the bolt heads with clean engine oil.

NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)

Torque :

Stage 1: 44 lb.in (5 Nm)

Stage 2: 18 lb.ft (25 Nm)

Stage 3: 90°
- Measure crankshaft end play.
  Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge .
- Position the crankshaft to the rear of the cylinder block.
- Zero the Dial Indicator Gauge with Holding Fixture.
- Move the crankshaft to the front of the cylinder block.
- Note and record the crankshaft end play.
- Acceptable crankshaft end play is 0.2-0.43 mm (0.008-0.017 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
Piston to be assembled with the arrow pointing to the front of the engine.
Connecting rod to be assembled with the front marks pointing to the front of the engine.
NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.

NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil

NOTE: Make sure the piston arrow on top is facing toward the front of the engine.

NOTE: When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap. The position of the upper and lower compression ring gaps are not controlled for installation.

Install the piston and connecting rod assemblies.

Use Special Service Tool: 303-D032 (D81L-6002-C) Compressor, Piston Ring ., 303-462 Installer, Connecting Rod .

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.

NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.

Install the connecting rod caps and the new bolts and tighten the bolts in 2 stages:

Torque :

Stage 1: 21 lb.ft (29 Nm)

Stage 2: 90°
Install the special tool and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the special tool. The engine is now at TDC .
Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
NOTE: Clean the oil pump and cylinder block mating surfaces with Motorcraft Metal Surface Prep.

Material : Motorcraft® Metal Surface Prep/ZC-31-B

Torque :

Stage 1: 89 lb.in (10 Nm)

Stage 2: 177 lb.in (20 Nm)
Torque : 18 lb.ft (25 Nm)
NOTE: Before installation, clean and inspect the diamond washer for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.

Install the diamond washer.
1. Install the chain on the oil pump sprocket and install the tensioner and the 2 shoulder bolts.
  Torque : 89 lb.in (10 Nm)
2. Push the tensioner spring down and position the spring under the shoulder bolt.
Position the crankshaft rear oil seal with retainer plate onto the crankshaft.
Use Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal .

Torque : 89 lb.in (10 Nm)
NOTE: Install a new gasket.

Torque : 89 lb.in (10 Nm)
NOTE: If the oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
Finger-tight.
Align the front surface of the oil pan flush with the front surface of the engine block.
Use the General Equipment: Round-Ended Steel Rule
Torque : 177 lb.in (20 Nm)
NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

Torque :

Stage 1: 62 lb.in (7 Nm)

Stage 2: 133 lb.in (15 Nm)

Stage 3: 26 lb.ft (35 Nm)

Stage 4: 90°

Stage 5: 135°
NOTE: Install the 16 valve tappets in their original positions.

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: The exhaust camshaft rear bearing cap must be secured within 10 minutes of Gasket Maker application. If the exhaust camshaft rear bearing cap is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft Metal Surface Prep.

NOTE: Do not allow Gasket Maker to enter the camshaft bearing journal. If Gasket Maker is applied to the camshaft bearing journal, the journal and sealing area must be cleaned with Motorcraft Metal Surface Prep.

Material : Flange Sealant/CU7Z-19B508-A (WSS-M2G348-A11)
NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the special tool 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: Failure to follow the camshaft bearing cap tightening procedure can result in damage to the camshafts.

NOTE: Lubricate the cylinder head and camshaft journals with clean engine oil and position the camshafts onto the cylinder head in their original location and orientation.

NOTE: Lubricate the bearing cap journals with clean engine oil prior to installation.

Install the camshaft bearing caps in their original location and orientation and tighten the camshaft bearing cap bolts in pairs in the sequence shown in illustration below in 2 stages:

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)

Torque :

Stage 1: 62 lb.in (7 Nm)

Stage 2: 142 lb.in (16 Nm)
If camshafts were replaced, check that the camshaft end play is within specification.
If camshafts were replaced, check the valve clearance.
Refer to: VALVE CLEARANCE CHECK .
NOTE: The special tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Install Special Service Tool: 303-1565 Alignment Tool, Camshaft .
NOTE: Lubricate the VCT oil control solenoids with clean engine oil.

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)

Torque : 89 lb.in (10 Nm)
NOTE: The VCT unit bolts are final torqued in the timing drive installation.

Finger tight.
Torque : 89 lb.in (10 Nm)
NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Using the edge of a vise, compress the timing chain tensioner plunger.
Using a small pick, push back and hold the ratchet mechanism.
While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
Install a holding pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
Install the timing chain tensioner and the 2 bolts, then remove the holding pin to release the piston.
Torque : 89 lb.in (10 Nm)
NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

NOTE: Using the flats on the camshafts to prevent camshaft rotation.

Torque :

Stage 1: 37 lb.ft (50 Nm)

Stage 2: 90°
NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean and inspect the mounting surfaces of the engine and the front cover.

Material : Motorcraft® Silicone Gasket Remover/ZC-30-A
NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft Metal Surface Prep.
NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft Metal Surface Prep.
Install engine front cover.
Torque :

Stage 1: Tighten bolts 1 through 17 to:: 89 lb.in (10 Nm)

Stage 2: Tighten bolts 19 through 21 to:: 35 lb.ft (48 Nm)

Stage 3: Tighten bolt 22 to:: 18 lb.ft (25 Nm)

Stage 4: Tighten bolt 18 to:: 35 lb.ft (48 Nm)
NOTE: Remove the through-bolt from the special tool.

Use Special Service Tool: 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal .

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: Before installation, clean and inspect the diamond washer for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.

Install the diamond washer.
NOTE: 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 crankshaft pulley TDC guide hole at the 6 o'clock position.

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Install a standard bolt through the crankshaft pulley TDC guide hole and into the engine front cover.
NOTE: The crankshaft must 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 a new bolt should be installed using hand tools only.

NOTE: Do not reuse the crankshaft pulley bolt. Install a new crankshaft pulley bolt

Use Special Service Tool: 303-D055 (D85L-6000-A) Strap Wrench .

Torque :

Stage 1: 74 lb.ft (100 Nm)

Stage 2: 90°
Finger tight.
Install the special tool to set the CKP sensor position and tighten the 2 bolts.
Use Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor .

Torque : 62 lb.in (7 Nm)
NOTE: 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 of the valve cover.
NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.

Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer ., 205-153 (T80T-4000-W) Handle .
NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft Metal Surface Prep.
NOTE: Install a new valve cover gasket.

Torque : 89 lb.in (10 Nm)
If equipped.
Torque : 27 lb.in (3 Nm)
NOTE: Inspect the ignition coil boot for rips, nicks or tears. Remove and discard the damaged ignition coil boots.
NOTE: Apply a small amount of silicone brake caliper grease and dielectric compound to the inside of the ignition coil-on-plug boots before installation.

Material : Silicone Brake Caliper Grease and Dielectric Compound/XG-3-A (ESE-M1C171-A)

Torque : 89 lb.in (10 Nm)
Torque : 89 lb.in (10 Nm)
Torque :
Stage 1: 71 lb.in (8 Nm)

Stage 2: 60°
Torque : 177 lb.in (20 Nm)
NOTE: The cam lobe for the fuel injection pump must be at BDC for the fuel injection pump installation.

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: Only rotate the crankshaft clockwise or damage to the engine may occur.

Turn the crankshaft clockwise until the fuel injection pump cam lobe is at BDC .
Install the fuel injection pump and loosely install 2 new fuel injection pump bolts, alternately tighten each bolt one complete revolution until seated.
Torque :

Stage 1: 177 lb.in (20 Nm)

Stage 2: 45°
Torque : 35 lb.ft (48 Nm)
Torque : 18 lb.ft (25 Nm)
NOTE: The RH KS must be installed in the 6 o'clock position and the LH KS must be installed in the 4 o'clock position. Failure to follow these instructions may result in damage to the engine.

Torque : 177 lb.in (20 Nm)
NOTE: Install a new gasket.

Torque : 18 lb.ft (25 Nm)
NOTE: Install a new gasket.

Torque : 89 lb.in (10 Nm)
NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.

NOTE: Be very careful when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.

Pull the lower Teflon® seal away from the injector with narrow tip pliers.
Carefully cut and discard the lower fuel injector Teflon® seals.
Place the special tool, knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed.
Use Special Service Tool: 303-1567 Sizer, Teflon Seal .
NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

Install the new lower Teflon® seals on the narrow end of the Arbor (part of the special tool), then install the Arbor on the fuel injector tips.

Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly ., 303-1567 Sizer, Teflon Seal .
NOTE: Once the Teflon® seal is installed on the Arbor, it should immediately be installed onto the fuel injector to avoid excessive expansion of the seal.

Using the Pusher Tool (part of the special tool), slide the Teflon® seals off of the Arbor and into the groove on the fuel injectors.

Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly ., 303-1567 Sizer, Teflon Seal .
NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the seal.

Slide the special tool off the end of the fuel injector to size the seal.

Use Special Service Tool: 303-1567 Sizer, Teflon Seal .
NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.

NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

NOTE: Lubricate the upper fuel injector O-ring seals with clean engine oil.

NOTE: Install the fuel injectors into the cylinder head within 15 minutes due to Teflon® seal expansion.

Install the new upper fuel injector O-ring seal support rings and the new upper fuel injector O-ring seals.

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.

NOTE: The fuel rail pressure sensor must be replaced if it is removed from the fuel rail.
NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

Install the fuel rail by pushing down on the fuel rail face above the injectors and install the 4 bolts.

Torque : 18 lb.ft (25 Nm)
1. Hand tighten the high pressure fuel tube-to-fuel rail flare nut.
2. Hand tighten the high pressure fuel tube-to-fuel injection pump flare nut.
Finger tight.
NOTE: Calculate the correct torque wrench setting for the following torque. REFER to Torque Wrench Adapter Formulas in illustration below.

Torque :

Stage 1: 133 lb.in (15 Nm)

Stage 2: 45°
NOTE: Calculate the correct torque wrench setting for the following torque. REFER to Torque Wrench Adapter Formulas in illustration below.

Tighten the high pressure fuel tube-to-fuel injection pump flare nut in the following 2 stages:

Torque :

Stage 1: 133 lb.in (15 Nm)

Stage 2: 45°
Torque : 89 lb.in (10 Nm)
NOTE: Use care when installing the fuel injection pump noise insulator. Spreading the openings will aid in installing the fuel injection pump noise insulator and reduce the risk of damage.
Use the General Equipment: Hose Clamp Remover/Installer
NOTE: Inspect and install new intake manifold gaskets if necessary.
NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Finger tight.
Torque : 177 lb.in (20 Nm)
Refer to: QUICK RELEASE COUPLING .
NOTE: Install a new gasket.

Torque : 89 lb.in (10 Nm)
NOTE: Install the generator stud before the generator is installed.
- Tighten the generator stud to:
  Torque : 71 lb.in (8 Nm)
- Tighten the nut and 2 bolts to:
  Torque : 18 lb.ft (25 Nm)
Use the General Equipment: Hose Clamp Remover/Installer
Torque : 18 lb.ft (25 Nm)
NOTE: Install a new O-ring seal.

Torque : 89 lb.in (10 Nm)
Finger tight.
Torque : 18 lb.ft (25 Nm)
NOTE: Under no circumstances should the A/C compressor belt, accessory drive belt, tensioner or pulleys be lubricated as potential damage to the belt material and tensioner damping mechanism will occur. Do not apply any fluids or belt dressing to the A/C compressor belt, accessory drive belt or pulleys.
Tighten.
Torque : 177 lb.in (20 Nm)
NOTE: After installation, make sure the A/C compressor belt is correctly seated on the crankshaft and the A/C compressor pulleys.

Position the A/C compressor belt onto the A/C compressor pulley and around the special tool on the crankshaft pulley. Make sure that the belt is engaged with the crankshaft pulley and rotate the crankshaft clockwise to install the A/C compressor belt.

Use Special Service Tool: 303-1252 Stretchy Belt Remover/Installer Tool .
Torque : 150 lb.in (17 Nm)
Torque : 89 lb.in (10 Nm)
Refer to: QUICK RELEASE COUPLING .
Remove the engine from the engine stand.
NOTE: Special bolts are used for installation. Do not use standard bolts.

If equipped with a automatic transmission.

Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .

Torque :

Stage 1: 37 lb.ft (50 Nm)

Stage 2: 59 lb.ft (80 Nm)

Stage 3: 83 lb.ft (112 Nm)
NOTE: Special bolts are used for installation. Do not use standard bolts.

If equipped with a manual transmission.

Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .

Torque :

Stage 1: 37 lb.ft (50 Nm)

Stage 2: 59 lb.ft (80 Nm)

Stage 3: 83 lb.ft (112 Nm)
NOTE: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

NOTE: Clean the clutch pressure plate and flywheel with a commercial alcohol-based solvent so surfaces are free from oil film. Do not use cleaners with a petroleum base. Do not immerse the clutch pressure plate in solvent.

Position the clutch disc on the clutch pressure plate. Using a clutch aligner, centralize the clutch disc to the clutch pressure plate.
NOTE: Install new bolts.

Using a clutch aligner, position the clutch disc and clutch pressure plate on the flywheel.

Torque : 21 lb.ft (29 Nm)