Engine - 1.3L Duratec-8V (Rocam)/1.

6L
Streetka 2003.5 (01/2003-07/2005)
Duratec-8V (Rocam) - Specifications
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Engine Data - 1.3L/60 PS

Description
Engine code BAA
Bore 73.95 mm
Stroke 75.48 mm
Cubic capacity 1297 cc
Compression ratio 10.2 : 1
Power output at 5500 rpm 44 kW (60 PS)
Torque at 2500 rpm 99 Nm
Max. engine speed (intermittent) 6175 rpm
Max. engine speed (continuous) 5950 rpm
Idle speed 750 rpm
Number of main bearings 5
Camshaft drive Chain
Maximum oil consumption 0.5L/1000 km
Engine Data - 1.3L/70 PS

Description
Engine code A9A/A9B
Bore 73.95 mm
Stroke 75.48 mm
Cubic capacity 1297 cc
Compression ratio 10.2 : 1
Power output at 5500 rpm 51 kW (70 PS)
Torque at 2800 rpm 108 Nm
Max. engine speed (intermittent) 6175 rpm
Max. engine speed (continuous) 5950 rpm
Idle speed 750 rpm
Number of main bearings 5
Camshaft drive Chain
Maximum oil consumption 0.5L/1000 km
Engine Data - 1.6L/95 PS

Description
Engine code CDB/CDC
Engine code - Vehicles with convertible top CDRA/CDRB
Bore 82.07 mm
Stroke 75.48 mm
Cubic capacity 1597 cc
Compression ratio 9.5 : 1
Power output at 5500 rpm 70 kW (95 PS)
Torque at 2500 rpm 134 Nm
Max. engine speed (intermittent) 6175 rpm
Max. engine speed (continuous) 5950 rpm
Idle speed 880 rpm
Number of main bearings 5
Camshaft drive Chain
Maximum oil consumption 0.5L/1000 km
Engine Oil

Viscosity Specification
Engine oil
SAE 5W-20 WSS-M2C948-B
SAE 5W-30 WSS-M2C913-C
Alternative engine oils (for top-up only)
SAE 5W-30 ACEA A5/B5
Lubricants, Fluids, Sealers and Adhesives

Item Specification
Sealant WSK-M2G349-A4
Sealant WSEM-4G323-A4
High-temperature grease WSD-M1C230-A
Capacities

Litres
Engine oil, initial fill including filter 4.45
Engine oil, including filter change 4.10
Engine oil, excluding filter change 3.70
Oil System

Description bar
Pressure relief valve opening pressure 5.0 - 6.0
Valves - 1.3L

Description mm
Valve spring free length 43.20
Valve spring inner diameter (intake and exhaust) 18.80 - 19.20
Valve spring material diameter 3.70
Number of valve spring coils 6.70
Valve (intake) overall length 109.37 - 109.83
Valve (exhaust) overall length 109.68 - 110.05
Valve head (intake) diameter 34.97 - 35.23
Valve head (exhaust) diameter 29.57 - 29.83
Valve stem diameter (intake and exhaust) 5.957 - 5.975
Valve stem to valve guide clearance (intake and exhaust) 0.025 - 0.073
Valve lift (intake and exhaust) 9.74
Valves - 1.6L

Description mm
Valve spring free length 43.20
Valve spring inner diameter (intake and exhaust) 18.80 - 19.20
Valve spring material diameter 3.70
Number of valve spring coils 6.70
Valve (intake) overall length 109.37 - 109.83
Valve (exhaust) overall length 109.68 - 110.05
Valve head (intake) diameter 39.87 - 40.13
Valve head (exhaust) diameter 33.87 - 34.13
Valve stem diameter (intake and exhaust) 5.967 - 5.985
Valve stem to valve guide clearance (intake and exhaust) 0.015 - 0.053
Valve lift (intake and exhaust) 9.74
Camshaft

Description mm
Valve lift cam (intake and exhaust) 9.74
Camshaft bearing journal diameter 23.96 - 23.98
Camshaft bearing journal bore diameter 24.00 - 24.03
Camshaft end float 0.075 - 0.185
Valve Timing - 1.3L

Description Degrees
Valve timing, intake opens (1 mm lift) after TDC 14
Valve timing, intake closes (1 mm lift) after BDC 26
Valve timing, exhaust opens (1 mm lift) before BDC 26
Valve timing, exhaust closes (1 mm lift) before TDC 14
Valve Timing - 1.6L

Description Degrees
Valve timing, intake opens (1 mm lift) after TDC 12
Valve timing, intake closes (1 mm lift) after BDC 24
Valve timing, exhaust opens (1 mm lift) before BDC 24
Valve timing, exhaust closes (1 mm lift) before TDC 12
Crankshaft

Description mm
Crankshaft main bearing journal diameter (standard) 56.980 - 57.00
Crankshaft main bearing journal diameter (undersize) 56.726 - 56.746
Crankshaft main bearing journal shell width 18.290 - 18.690
Crankshaft connecting rod journal diameter (standard) 40.990 - 41.010
Crankshaft connecting rod journal diameter (undersize) 40.740 - 40.760
Crankshaft connecting rod journal diameter (service 0.508) 40.490 - 40.510
Crankshaft connecting rod journal diameter (service 0.762) 40.240 - 40.260
Crankshaft end play 0.075 - 0.285
Crankshaft thrust washer thickness (standard) 2.800 - 2.850
Crankshaft thrust washer thickness (oversize) 2.99 - 3.040

NOTICE: The crankshaft must not be machined.

Pistons - 1.3L

Description mm
Piston diameter, class 1 73.917 - 73.932
Piston diameter (oversize 0.15 mm) 74.067 - 74.082
Piston diameter (oversize 0.50 mm) 74.417 - 74.432
Piston to cylinder bore clearance 0.020 - 0.050
Piston ring end gap (installed) (top) 0.20 - 0.40
Piston ring end gap (installed) second 0.25 - 0.50
Piston ring end gap (installed) oil 0.25 - 0.75
Piston ring-to-groove clearance (top) 0.020 - 0.055
Piston ring-to-groove clearance (second) 0.030 - 0.060
Piston ring end gap position, top 120 degrees offset from second ring end gap
Piston ring end gap position, second Aligned with piston pin
Piston ring end gap position, oil 120 degrees offset from second ring end gap*
Piston pin length 51.700 - 52.000
Piston pin diameter 18.030 - 18.034
Piston pin to bore diameter interference 0.012 - 0.036
 Description mm
Piston pin slide clearance (21°C) 0.012 - 0.020
*) Rails and expander 120 degrees.

Pistons - 1.6L

Description
Piston diameter, class 1 82.035 - 82.050 mm
Piston diameter (oversize 0.15 mm) 82.185 - 82.200 mm
Piston diameter (oversize 0.50 mm) 82.535 - 82.550 mm
Piston to cylinder bore clearance 0.020 - 0.050 mm
Piston ring end gap (installed) (top) 0.20 - 0.40 mm
Piston ring end gap (installed) second 0.25 - 0.50 mm
Piston ring end gap (installed) oil 0.25 - 1.0 mm
Piston ring-to-groove clearance (top) 0.040 - 0.075 mm
Piston ring-to-groove clearance (second) 0.030 - 0.070 mm
120 degrees offset from second ring
Piston ring end gap position, top
end gap
Piston ring end gap position, second Aligned with piston pin
120 degrees offset from second ring
Piston ring end gap position, oil
end gap*
Piston pin length 53.300 - 53.600 mm
Piston pin diameter 18.030 - 18.034 mm
Piston pin to connecting rod small end diameter,
0.012 - 0.036 mm
interference
Piston pin to pin bore clearance (21°C) 0.012 - 0.020 mm
*) Rails and expander 120 degrees.

Connecting Rods

Description mm
Connecting rod large end bore diameter 43.99 - 44.01
Connecting rod small end bore diameter 17.998 - 18.018
Connecting rod bearing shell, vertical inner diameter, standard 41.016 - 41.050
Connecting rod bearing shell, vertical inner diameter, undersize 0.254 mm 40.966 - 41.000
Connecting rod bearing shell, vertical inner diameter, undersize 0.508 mm 40.516 - 40.550
Connecting rod bearing shell, vertical inner diameter, undersize 0.762 mm 40.226 - 40.300
Connecting rod bearing shell, vertical inner diameter, undersize 1.016 mm 40.016 - 40.050
Connecting rod bearing clearance (radial) 0.006 - 0.026
Connecting rod bearing clearance (axial) 0.100 - 0.250
Cylinder Head

Description mm
Maximum distortion 0.02
Cylinder Block - 1.3L

Description mm
73.9525 -
Cylinder bore diameter, standard
73.9675
74.1025 -
Cylinder bore diameter (oversize 0.15)
74.1175
74.4525 -
Cylinder bore diameter (oversize 0.50)
74.4675
Center main bearing width (without thrust half-rings 22.040 - 22.100
Main bearing shells, vertical inner diameter (installed), standard 57.009 - 57.036
Main bearing shells, vertical inner diameter (installed), undersize 0.25 56.755 - 56.782
 Description mm
mm
Main bearing shells, vertical inner diameter (installed), undersize 0.508
56.509 - 56.528
mm
Main bearing shells, vertical inner diameter (installed), undersize 0.762
56.247 - 56.274
mm
Main bearing parent bore diameter, standard 60.623 - 60.636
Main bearing parent bore diameter, oversize 61.003 - 61.016
Cylinder Block - 1.6L

Description mm
82.0775 -
Cylinder bore diameter, standard
82.085
82.2275 -
Cylinder bore diameter (oversize 0.15)
82.235
82.5775 -
Cylinder bore diameter (oversize 0.50)
82.585
Center main bearing width (without thrust half-rings 22.040 - 22.100
Main bearing shells, vertical inner diameter (installed), standard 57.009 - 57.036
Main bearing shells, vertical inner diameter (installed), undersize 0.25 mm 56.755 - 56.782
Main bearing shells, vertical inner diameter (installed), undersize 0.508
56.509 - 56.528
mm
Main bearing shells, vertical inner diameter (installed), undersize 0.762
56.247 - 56.274
mm
Main bearing parent bore diameter, standard 60.623 - 60.636
Main bearing parent bore diameter, oversize 61.003 - 61.016
Torque Specifications

Description Nm lb-ft lb-in

Oil gallery plug, 1/2" 22 16 -
Crankshaft main bearing retaining bolts 95 70 -
Crankshaft rear oil seal retainer retaining bolts 10 - 89
Crankshaft position (CKP) sensor retaining bolt 10 - 89
Crankshaft pulley retaining bolt 125 92 -
Connecting rod retaining bolts a - -
Hydraulic timing chain tensioner 40 30 -
Timing chain tensioner arm retaining bolt 26 19 -
Timing Chain guide retaining bolt 26 19 -
Oil pump retaining bolts 20 15 -
Oil pickup pipe retaining bolt 10 - 89
Oil pan baffle retaining nuts 19 14 -
Oil pan retaining bolts a - -
Oil filter adaptor 20 15 -
Oil pressure switch 20 15 -
Oil drain plug 25 18 -
Oil level indicator tube retaining bolts 20 15 -
Accessory drive belt idler pulley retaining bolt 48 35 -
Coolant pump retaining bolts 10 - 89
Coolant pump pulley retaining bolts 12 9 -
Coolant expansion tank retaining bolt 8 - 71
Power steering pump retaining bolts 25 18 -
Power steering supply line retaining bracket retaining bolt 20 20 -
Flywheel retaining bolts 67 49 -
Air Conditioning (A/C) compressor retaining bolts 25 18 -
Starter motor retaining bolts 35 26 -
 Description Nm lb-ft lb-in
Battery tray support bracket retaining bolts 25 18 -
Ground lead to side member retaining bolt 15 11 -
Engine lifting eye 20 15 -
Cylinder head bolts a - -
Camshaft sprocket retaining bolt 75 55 -
Camshaft bearing cap retaining bolts 9 - 80
Camshaft position (CMP) sensor retaining bolt 5 - 44
Valve cover retaining bolts 9 - 80
Ignition coil retaining bolts 6 - 53
Coolant flow control housing retaining bolts 10 - 89
Spark plug 15 11 -
Intake manifold retaining nuts 18 13 -
Intake manifold retaining bolts 18 13 -
Exhaust manifold retaining nuts a - -
Exhaust manifold heat shield upper retaining bolts 10 - 89
Exhaust manifold heat shield lower retaining bolts 10 - 89
Engine front mount to engine front mount retaining bracket 48 35 -
Engine front mount retaining bracket to cylinder head bolts 25 18 -
Flexible exhaust pipe to exhaust manifold retaining nuts 47 35 -
Engine rear mount center bolt 90 66 -
Transaxle upper retaining bolt 44 32 -
Transaxle lower retaining bolts 44 32 -
Transaxle left-hand retaining bolt 44 32 -
Transaxle right-hand retaining bolts 44 32 -
Engine support insulator to crossmember retaining bolts 48 35 -
Engine support insulator retaining bolt M10 70 52 -
Engine support insulator retaining bolt M12 120 89 -
Engine support insulator to transaxle retaining bolts 48 35 -
Strut and spring assembly top mount retaining nuts 25 18 -
a) Refer to procedure in this section.

Engine - 1.3L Duratec-8V (Rocam)/1.6L

Streetka 2003.5 (01/2003-07/2005)
Duratec-8V (Rocam) - Engine
 Print 

Description and Operation

Overview
General

The Duratec 8V engine is a transversely mounted straight 4 engine with one overhead
camshaft and a cross-flow cylinder head.

Features of the Duratec 8V engine:

 Cast iron cylinder block with integrated timing chain housing

 Crankshaft runs on 5 bearings
 Cast aluminium alloy cylinder head with integrated timing chain housing
 Camshaft drive provided via hydraulically tensioned timing chain
 Camshaft runs on 5 bearings
 2 valves per cylinder
 Roller cam followers
 Valve clearance adjustment via hydraulic tappets
 2-layer cylinder head gasket
 Aluminium oil pan with reinforcing ribs
 Oil pump driven via the crankshaft
Engine identification

The engine serial number is located on the rear of the cylinder block.

In addition, at the same place there is a summary of the Vehicle Identification Number
(VIN) and a safety symbol.

The engine serial number, VIN and a safety symbol can also be found on a plate on the
timing chain end of the cylinder head.
 

Item
Part Number
Description
1
-
Safety symbol
2
-
VIN
3
-
Engine code
Engine views
 

Item
Part Number
Description
1
-
Camshaft Position (CMP) sensor
2
-
Electronic Ignition (EI) module
3
-
Thermostat housing
4
-
Flywheel
5
-
Oil filter
6
-
Air intake module
 

Item
Part Number
Description
1
-
Exhaust manifold
2
-
Hydraulic chain tensioner
3
-
Timing chain
4
-
Air intake module
5
-
Oil filter
 

Item
Part Number
Description
1
-
Camshaft
2
-
Intake valve
3
-
Exhaust valve
4
-
Thermostat housing
5
-
Pistons
6
-
Flywheel
7
-
Oil intake pipe
8
-
Belt pulley
 9
-
Coolant pump
Cylinder head and valve train

Cylinder head cover

Item
Part Number
Description
1
-
Oil filler cap
2
-
CMP sensor
3
-
Positive Crankcase Ventilation (PCV) valve
4
-
EI module
The cylinder head cover is bolted to the cylinder head with ten bolts.

The cylinder head cover gasket is T-shaped and is secured in the groove of the cylinder
head cover.

The CMP sensor is attached to the cylinder head cover and is used to identify the
position of cylinder no. 1.

The EI module is attached with four retaining bolts to the side of the cylinder head
cover.

Cylinder head
The cylinder head is made of an aluminium alloy and features two valves per cylinder.

It is a cross-flow cylinder head.

The valve angles on the intake and exhaust valves are asymmetrical. The valve angle of
the intake valves is 10°, and the valve angle of the exhaust valves is 6°.

The spark plugs are located on the exhaust side.

The valve guides and valve seats are made of sintered metal.

The timing chain housing is an integral part of the cylinder head and the cylinder block.

Valve train
 

Item
Part Number
Description
1
-
Camshaft bearing cap
2
-
Camshaft
3
-
Reference cam
4
-
Roller cam follower
5
-
Hydraulic tappet
6
-
Cylinder head
The camshaft is held in place with five bearing caps, and runs directly in the cylinder
head without bearing shells.

An additional reference cam is located on the camshaft for identification of cylinder no.
1.
The camshaft actuates the roller cam followers.

As the cam followers run on rollers, the frictional losses of the valve train are reduced.

As a result of the use of hydraulic tappets, no valve clearance adjustments are required.

Intake and exhaust valves

Item
Part Number
Description
1
-
Intake valve
2
-
Exhaust valve
The intake valve is made entirely from a single material.

The exhaust valve is designed as a bi-metal valve.

Cylinder head gasket

The cylinder head gasket is designed as a 2-layer metal gasket.

Cylinder block and crank assembly

Cylinder block

Item
Part Number
Description
1
-
Connection to coolant reservoir
2
-
Oil gallery plug

NOTICE: The oil gallery plug must not be removed.

The cylinder head is made of cast iron.

The cylinder block does not have any cylinder liners. The running surfaces of the
cylinders are worked directly into the cylinder block.

The connection to the coolant reservoir is located at the rear of the cylinder block.

Crankshaft and bearing caps

 

Item
Part Number
Description
1
-
Bolts (6x)
2
-
Bolts with stud extensions (4x)
3
-
Main bearing caps
4
-
Main bearing shells (without oil groove)
5
-
Crankshaft
6
-
Main bearing shells (with oil groove)
7
-
Thrust washers
8
-
Chamfered edge
 9
-
Cylinder block
10
-
Oil spray nozzles
The crankshaft runs on five bearings and has four crank webs.

The main bearing caps are numbered and are marked with an arrow to indicate the
installation position and orientation. The arrows must point towards the timing chain
end after installation.

The main bearing shells which are inserted in the main bearing caps do not have an oil
groove.

The main bearing shells which are inserted in the cylinder block do have an oil groove.

Four of the retaining bolts for the main bearing caps feature stud extensions which are
used to secure the oil baffle plate and the intake pipe for the oil pump.

The end float of the crankshaft is limited with two thrust washers.

Connecting rod

The connecting rods are made of forged steel.

The connecting rods are available in three different weight classes.

Pistons and piston rings

 

Item
Part Number
Description
1
-
Piston recess
2
-
Upper compression ring
3
-
Lower compression ring
4
-
Oil scraper ring
5
-
Coating
The lightweight construction pistons are made of aluminium.

The piston recess helps to optimise the swirl of the air/fuel mixture.

The pistons have a special coating at the piston skirt in order to improve their
durability.

Only one diameter of piston is installed in production.

The upper compression ring is a rectangular-section ring and is made of steel.

The lower compression ring is an L-section ring and is made of cast iron.

The oil scraper ring consists of 3 parts and is chromium plated.

Crankshaft rear oil seal carrier

 

Item
Part Number
Description
1
-
Assembly sleeve
2
-
Guide stud bores
3
-
Oil seal carrier
The assembly sleeve is made of plastic.

The oil seal is integrated into the oil seal carrier. The oil seal is made of
polytetrafluoroethylene (PTFE).

The oil seal carrier is centred with two guide studs and then attached to the cylinder
block with four bolts.

Oil baffle plate and oil intake pipe

 

Item
Part Number
Description
1
-
Oil intake pipe
2
-
Retaining nut
3
-
Oil baffle plate
4
-
O-ring
5
-
Retaining bolt
The oil baffle plate prevents excessive foaming of the engine oil.

The oil baffle plate and the oil intake pipe are attached with the stud extensions of the
bearing cap retaining bolts.

The oil intake pipe is sealed at the oil pump by means of an O-ring.

Oil pan
 

Item
Part Number
Description
1
-
Oil pan gasket
2
-
Oil pan
The oil pan is made of an aluminium alloy and features reinforcing ribs.

The bracket for the A/C compressor is integrated into the oil pan.

The oil pan gasket consists of an aluminium base to which a rubber coating is applied.

Flywheel

Item
Part Number
Description
1
-
Centring spigot
2
-
Flywheel
3
-
Screws
The flywheel is made of cast iron.

The flywheel is bolted to the crankshaft with 6 bolts and aligned with a centring spigot.
Camshaft drive

Item
Part Number
Description
1
-
Camshaft sprocket
2
-
Crankshaft sprocket
3
-
Front chain guide rail
4
-
Rear chain guide rail
5
-
Timing chain
6
-
Hydraulic chain tensioner
Camshaft sprocket and crankshaft sprocket
 

Item
Part Number
Description
1
-
Timing mark
2
-
Woodruff key
The camshaft sprocket is made of steel and has 38 teeth.

The timing mark is stamped on the front.

The crankshaft sprocket is made of sintered steel and has 19 teeth.

The installation position of the crankshaft sprocket is defined by a Woodruff key.

Timing chain

Item
 Part Number
Description
1
-
Timing chain
2
-
Chain guide rail (intake side)
3
-
Chain guide rail (exhaust side)
4
-
Hydraulic chain tensioner
The timing chain is a sleeve type chain with 114 links.

The chain guide rails are made of plastic.

Both chain guide rails are positioned via a retaining bolt.

The chain guide rail on the intake side is also located via a recess in the cylinder head.

The chain guide rail on the exhaust side can slide and is moved via the hydraulic chain
tensioner.

Hydraulic chain tensioner

Item
Part Number
Description
1
-
Oil feed
2
-
Pistons
The hydraulic chain tensioner is moved by the engine oil pressure.

The piston pushes against the chain guide rail (exhaust side) and exerts a defined
contact pressure on the timing chain.

Oil circuit
 

Item
Part Number
Description
1
-
From the oil intake pipe to the oil pump
2
-
From the oil pump to the oil filter
3
-
From the oil filter to the main oil gallery
4
-
From the main oil gallery to the main bearings
5
-
Oil gallery leading to the cylinder head and to the camshaft
6
-
Return channel
7
-
Oil jet
 

Item
Part Number
Description
1
-
From the oil intake pipe to the oil pump
2
-
From the oil pump to the oil filter
3
-
From the oil filter to the main oil gallery
4
-
Oil gallery leading to the cylinder head and to the camshaft
5
-
Oil supply to the hydraulic chain tensioner
6
-
Return channel
7
-
Oil jet
Oil pump
 

Item
Part Number
Description
1
-
Cylinder block
2
-
Oil and coolant pump gasket
3
-
Oil pump
4
-
Oil pump pulley
The oil pump is a G-rotor pump which is driven directly by the engine.

The crankshaft oil seal (PTFE) is located in the housing of the oil pump.

The gasket of the oil pump housing is a rubber-coated metal gasket.

Oil intake pipe

 

Item
Part Number
Description
1
-
Oil strainer
Engine oil is pumped from the oil pan through the oil intake pipe to the oil pump.

The oil intake pipe is made of steel.

A strainer is located on the underside of the oil intake pipe. This strainer protects the oil
pump against damage from particles in the oil.

Oil filter and oil filter adapter

Item
Part Number
Description
1
-
Gasket
2
-
Oil filter and oil filter adapter
3
-
Retaining bolt
NOTE: The gasket must not be reused after disassembling the oil filter adapter.
The oil filter adapter is made of an aluminium alloy.

The metal gasket of the oil filter adapter is rubber coated.

PCV

Overview

Item
Part Number
Description
1
-
Cylinder head cover with integrated oil separator
2
-
From the PCV valve
3
-
To the intake manifold
PCV valve
 

Item
Part Number
Description
1
-
Spring
2
-
Pistons
The PCV valve is located on the upper side of the cylinder head cover.

The crankcase gases are sucked by the PCV valve into the intake manifold.

The PCV valve is opened by the vacuum in the intake manifold.

The amount of crankcase gases depends on the engine speed. The quantity sucked in is
determined by the spring and the shape of the piston.

Deflection panel

Item
Part Number
Description
1
-
Deflection plate
The deflection plate is integrated into the cylinder head cover.

It prevents oil from being sucked in and burned in the combustion process.

The oil drops condense on the deflection plate and are then returned to the oil circuit.

Engine - 1.3L Duratec-8V (Rocam)/1.6L

Streetka 2003.5 (01/2003-07/2005)
Duratec-8V (Rocam) - Cylinder Head
  Print 

Disassembly and Assembly of Subassemblies

Special Tool(s)
Compressor, Valve Spring

303-461 (21-194)

Adapter for 303-461

303-461-01 (21-194-01)

Pliers, Valve Stem Seal

303-508 (21-211)

Materials
Name
Specification
Hypoid oil
SQM-2C 9002-AA 

Disassembly
1. Remove the coolant flow control housing.

2. Remove the engine front mount retaining bracket.

3. NOTE: Keep all parts in order for assembly.
Remove the camshaft bearing caps and the camshaft.
 Loosen each bolt of the camshaft bearing caps by one turn until the camshaft
is released.
 Remove the camshaft bearings caps.
 Remove the camshaft.

4. NOTE: Keep all parts in order for assembly.

Remove the camshaft followers.
5. NOTE: Keep all parts in order for assembly.
Remove the hydraulic lash adjusters.

6. Install the camshaft and the camshaft bearing caps.

 Install the camshaft.
 Install the camshaft bearing caps.

7. NOTE: Keep all parts in order for assembly.

Using the special tools, remove the valve springs.
 Compress the valve springs.
 Remove the valve collets, the valve spring retainers and the valve springs.
 8. Using the special tool, remove the valve seals.

9. NOTE: Keep all parts in order for assembly.

Remove the valves.
1. Remove the exhaust valve.
2. Remove the intake valve.

10. NOTE: Keep all parts in order for assembly.

Remove the camshaft bearing caps and the camshaft.
1. Remove the camshaft bearings caps.
2. Remove the camshaft.
 Assembly
1. Install the camshaft and the camshaft bearing caps.
 Install the camshaft bearing caps.
 Install the camshaft.

2. Install the valves.

1. Install the exhaust valve.
2. Install the intake valve.
3. NOTE: The valve seals are fully pressed in by valve spring pressure.
Using the special tool, install the valve seals.

4. Using the special tools, install the valve spring.

 Compress the valve spring and the valve spring retainer.
 Install the valve collets.

5. Remove the camshaft bearing caps and the camshaft.

1. Remove the camshaft bearing caps.
2. Remove the camshaft.
6. Install the hydraulic lash adjusters.

7. Install the camshaft followers.

8. NOTE: Apply a drop of hypoid oil to each camshaft bearing half.
NOTE: The camshaft sprocket alignment slot must be in the 12 o’clock
position.
NOTE: Working in several stages, tighten each camshaft bearing cap retaining
bolt two turns at a time.
Install the camshaft and the camshaft bearing caps.
 Tighten the bolts in the sequence shown.

9. Install the engine front mount retaining bracket.

 10. NOTE: Install a new coolant flow control housing gasket if necessary.
Install the coolant flow control housing.

Engine - 1.3L Duratec-8V (Rocam)/1.6L

Streetka 2003.5 (01/2003-07/2005)
Duratec-8V (Rocam) - Engine
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Assembly
Special Tool(s) / General Equipment
Universal Flange Holding Wrench

205-072 (15-030A)

Lifting Bracket, Engine

303-122 (21-068A)

Socket, Cylinder Head Bolt

303-392 (21-167)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435-06 (21-031B)
 Mounting Plate for 303-435-06

303-435-11 (21-146C)

Piston ring compressor

Straightedge
Materials
Name
Specification
Engine oil
WSS-M2C913-B 
Sealant
WSEM-4G323-A 
Sealant
WSK-M2G349-A4 

Assembly
1. Install the crankshaft main bearing shells.

2. NOTE: The bearing cap numbering starts from the front of the engine to which
the arrows also point.
NOTE: Make sure that the cylinder No. 1 is at top dead center (TDC) position.
Install the crankshaft.
 Lubricate the main bearing journals and bearing shells with clean engine oil.
3. NOTE: The grooves in the crankshaft thrust half-washers must be face
outwards.
Install the crankshaft thrust half-washers.

4. NOTE: The connecting rod numbering starts from the front of the engine. The
arrow on the piston crown points towards the front of the engine.
Using a suitable piston ring compressor, install the pistons.
 Lubricate the pistons and cylinder liners with clean engine oil.
 Distribute the piston ring end gaps uniformly around the circumference. This
also applies to the elements of the oil scraper ring.
 Using the handle of a hammer, press pistons No. 1 and 4 into the cylinders.
The connecting rod bearing journal must be at bottom dead center (BDC).
 Check the bearing shells are clean and dry and install them in the associated
connecting rods and bearing caps.
 Turn the crankshaft through 180 degrees and install pistons No. 2 and 3.
5. NOTICE: Install new connecting rod retaining bolts.
NOTE: The connecting rods and connecting rod bearing caps have the same
numbering.
Install the crankshaft bearing caps.
 Lubricate the bearing shells and journals with clean engine oil.
 Tighten the crankshaft bearing cap retaining bolts in two stages.
 Stage 1: 4 Nm
 Stage 2: 90 degrees

6. Install the oil baffle.

 7. Install the timing chain guide, timing chain tensioner arm and the crankshaft
sprocket.

8. NOTE: The mark on the crankshaft timing sprocket and the single colored link
of the timing chain must line up.
Install the timing chain.

9. NOTICE:

Only install the oil pump together with the crankshaft pulley.
 When installing a new oil pump, do not remove the crankshaft pulley or
the assembly clip before installation.
NOTE: Install a new oil pump gasket.
NOTE: A new oil pump is supplied as an assembly with a crankshaft front seal
and a crankshaft pulley.
NOTE: Do not tighten the oil pump retaining bolts at this stage.
Install the oil pump assembly.

10. Using the special tool, tighten the crankshaft pulley retaining bolt.
 Remove the assembly clip.

11. NOTE: The oil pump sealing flange must be within ± 0.20 mm of cylinder
block bottom sealing flanges.
Using a suitable straightedge, align the oil pump to the cylinder block sealing
flanges.
12. NOTE: Install new pre-sealed bolts in positions 1 and 3.
Tighten the oil pump retaining bolts.
 Tighten the bolts in the sequence shown.

13. NOTE: Make sure that the O-ring seal is correctly seated.
Install the oil pump screen and pickup tube.
14. NOTICE: Do not remove the installation sleeve before installation.
NOTE: Install a new crankshaft rear seal carrier.
NOTE: A new rear seal carrier is supplied preassembled on an installation
sleeve.
NOTE: Do not touch the dust lip and the sealing lip.
NOTE: The sealing lip must be free of oil.
NOTE: Make sure that the dowel pins are correctly seated.
Install the crankshaft rear seal carrier.

15. NOTICE: CAUTION: Install the oil pan gasket within five minutes of
applying the sealant.
Apply sealant to the cylinder block joints.
16. NOTE: Do not tighten the oil pan retaining bolts at this stage.
Using a straight edge, align the oil pan to the cylinder block.
 Maximum oil pan face underflush: 0.25 mm.
 Maximum oil pan face protrusion: 0.10 mm.

17. Tighten the oil pan retaining bolts in the sequence shown (stage 1).

18. Tighten the oil pan retaining bolts in the sequence shown (stage 2).
19. Install the adapter plate.

20. Install the flywheel.

 21. Install the water pump.

22. Install the water pump pulley.

23. NOTE: Install a new cylinder head gasket.

NOTE: Install new cylinder head bolts.
NOTE: Guide the timing chain through the cylinder head and secure it to the
cylinder head.
Using the special tool, install the cylinder head.
 Tighten the cylinder head bolts in the sequence shown in four stages.
  Stage 1: Tighten bolts 1 through 10 to 40 Nm.
 Stage 2: Tighten the front two bolts (M8) to 15 Nm.
 Stage 3: Tighten the front two bolts (M8) bolts to 45 degrees.
 Stage 4: Tighten bolts 1 through 10 to 120 degrees.

24. NOTE: The camshaft sprocket timing mark must be in the 12 o’clock position.
NOTE: The camshaft sprocket timing mark and the marked links of the timing
chain must line up.
Install the timing chain to the camshaft sprocket.
 The camshaft sprocket timing mark must be at the 12 o’clock position with
cylinder No. 1 at TDC.

25. Using the special tool, install the camshaft sprocket.

26. Install the oil level indicator and oil level indicator tube.
 Apply sealant to base end of the oil level indicator tube.

27. Install the timing chain hydraulic tensioner.

28. NOTE: Install a new coolant flow control housing gasket if necessary.
Install the coolant flow control housing.

29. NOTE: Install a new oil filter adapter gasket.

Install the oil filter adapter.

30. Install the crankshaft position (CKP) sensor.

 31. Install a new oil filter.
32. Install the oil pressure switch.

33. NOTE: Install a new valve cover gasket if necessary.

Install the valve cover.
34. NOTE: Install a new intake manifold gasket if necessary.
Install the intake manifold.

35. Connect the camshaft position (CMP) sensor and engine coolant
temperature (ECT) sensor electrical connectors.

36. Connect the positive crankcase ventilation (PCV) hose to the intake
manifold.
37. Install the generator bracket.

38. Install the generator.

39. Install the engine front mount retaining bracket.

40. Install the special tool.

41. Remove the special tools.

42. NOTE: Install a new exhaust manifold gasket and new exhaust manifold
retaining nuts.
Attach the exhaust manifold to the cylinder head.
 Tighten the retaining nuts in the sequence shown in two stages.
 Stage 1: 15 Nm
 Stage 2: 20 Nm

43. Install the exhaust manifold lower retaining bolts.

44. Install the exhaust manifold lower heat shield.