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Engine Mechanical - 2.0L: Other Ford C-MAX II

Mechanical 22 illustrations ~882 words

Lubricants

ItemSpecification
Motorcraft® SAE 0W-20 Synthetic Blend Motor OilXO-0W20-QSP

Oil Pressure

ItemSpecification
Oil pressure (hot @ 2, 000 RPM)200-414 kPa (29-60 psi)

Cylinder Block

ItemSpecification
Cylinder bore diameter87.5-87.53 mm (3.444-3.445 in)
Cylinder bore maximum out-of-round0.008 mm (0.0003 in)
Main bearing bore diameter57.018-57.040 mm (2.244-2.245 in)
Head gasket surface flatness0.1 mm/general 0.05 mm/200 x 200 (0.004 in/general) (0.0019 in/7.87 x 7.87)

Piston

ItemSpecification
Piston Diameter (1)87.470-87.480 mm (3.4437-3.4440 in)
Piston Diameter (2)87.478-87.492 mm (3.4440-3.4445 in)
Piston Diameter (3)87.490-87.500 mm (3.4444-3.4449 in)
Piston-to-bore clearance0.013-0.047 mm (0.0005-0.0018 in) grade 2
Ring groove width - top1.23-1.25 mm (0.0484-0.0492 in)
Ring groove width - 2nd1.23-1.25 mm (0.0484-0.0492 in)
Ring groove width - oil2.03-2.05 mm (0.0799-0.0807 in)
Piston skirt coating thickness (per side)0.007-0.017 mm (0.0002-0.0006 in)

Piston Pin

ItemSpecification
Diameter20.997-21.000 mm (0.8266-0.8268 in)
Length64.7-65.3 mm (2.547-2.570 in)
Pin-to-rod clearancePress fit

Cylinder Head

ItemSpecification
Cylinder head flatness0.08 mm (0.0031 in) maximum overall, a maximum of 0.05 mm (0.0019 in) within 150 mm (5.9 in)
Valve lift @ zero lash (exhaust)8.07 mm (0.317 in)
Valve lift @ zero lash (intake)8.83mm (0.347 in)
Valve guide diameter5.509-5.539 mm (0.216-0.218 in)
Valve seat width - intake/exhaust0.99-1.84 mm (0.038-0.072 in)
Valve seat angle45 degrees
Valve seat runout0.075 mm (0.0029 in)
Valve tappet bore diameter31.00-31.03 mm (1.220-1.221 in)
Cam bore diameter25.015-25.040 mm (0.984-.0985 in)

Valve

ItemSpecification
Valve head diameter - intake34.85-35.15 mm (1.372-1.383 in)
Valve head diameter - exhaust29.85-30.15 mm (1.175-1.187 in)
Valve stem diameter - intake5.470-5.485 mm (0.2153-0.2159 in)
Valve stem diameter - exhaust5.465-5.480 mm (0.2151-0.2157 in)
Valve stem-to-guide clearance - intake0.0027 mm (0.00010 in)
Valve stem-to-guide clearance - exhaust0.0029 mm (0.00011in)
Valve face runout0.05 mm (0.0019 in)
Valve face angle45 degrees

Valve Spring - Compression Pressure

ItemSpecification
Intake and exhaust (installed)18 kg (40 lb)
Intake (valve open) 9.2 mm (0.362 in of lift)46 kg (101 lb)
Exhaust (valve open) 9.2 mm (0.362 in of lift)46 kg (101 lb)
Free length47.904 mm (1.8862 in)
Assembled height37.9 mm (1.492 in)

Crankshaft

ItemSpecification
Main bearing journal diameter51.978-52.002 mm (2.046-2.047 in)
Main bearing clearance0.016-0.047 mm (0.0006-0.0015 in)
Connecting rod journal diameter46.980-47.000 mm (1.849-1.850 in)
End play0.220-0.450 mm (0.008-0.018 in)

Rings

ItemSpecification
Width - top1.17-1.185 mm (0.0460-0.0466 in)
Width - 2nd1.197-1.199 mm (0.0471-0.0472 in)
Width - oil2.38-2.45 mm (0.093-0.096 in)
Ring gap (in bore) - top0.16-0.31 mm (0.006-0.012 in)
Ring gap (in bore) - 2nd0.31-0.46 mm (0.012-0.018 in)
Ring gap (in bore) - oil0.2-0.7 mm (0.007-0.027 in)

Valve Tappet

ItemSpecification
Diameter30.97-30.98 (1.2192-1.2196 in)
Tappet-to-valve clearance - intake0.20-0.30 mm (0.008-0.012 in)
Tappet-to-valve clearance - exhaust0.31-0.41 mm (0.012-0.016 in)
Tappet-to-bore clearance0.02-0.06 mm (0.0007-0.0023 in)

Camshaft

ItemSpecification
Lobe lift - intake8.83mm (0.347 in)
Lobe lift - exhaust8.07 mm (0.317 in)
Runout (1) (1)0.03 mm (0.001 in)
Thrust clearance0.09-0.24 mm (0.003-0.009 in)
Journal diameter24.96-24.98 mm (0.982-0.983 in)
Journal-to-bore clearance0.035-0.080 mm (0.001-0.003 in)
(1) No. 3 Journal - Supported by No. 1 and No. 5 journals.
(1)No. 3 Journal - Supported by No. 1 and No. 5 journals.

Connecting Rod

ItemSpecification
Bearing clearance0.027-0.052 mm (0.001-0.002 in)
Bearing thickness1.498-1.522 mm (0.058-0.059 in)
Crank bore diameter50.025-50.045 mm (1.969-1.970 in)
Pin bore diameter20.965-20.985 mm (0.825-0.826 in)
Length (center to center)154.8 mm (6.094 in)
Side clearance1.95-3.05 mm (0.076-0.120 in)
Axial clearance0.14-0.36 mm (0.005-0.014 in)

Engine Code Information Label

The engine code information label, located on the front side of the valve cover, contains the following

Scheme 208

Scheme 208: Engine Code Information Label
Scheme 208: Engine Code Information Label
ItemDescription
1Engine part number
2Chihuahua engine plant
3Engine build date (YYMMDD)
4Engine displacement
5Bar code
6Running number
7Plant shift line
8Bar code

Scheme 209

Scheme 209: Engine Cylinder Identification
Scheme 209: Engine Cylinder Identification

Valve Train

The valve train uses direct acting mechanical buckets (DAMB). The camshaft lobes are positioned directly above mechanical buckets which are positioned on top of the valves.

Lower Engine Block (View 1)

ItemPart NumberDescription
16010Cylinder block
26K318Crankshaft rear oil seal and retainer
36K390Flywheel
46675Oil pan
56714Oil filter
66884Oil filter adapter
79278Engine Oil Pressure (EOP) switch
86A636Oil filter adapter gasket
96A785Crankcase vent oil separator
106622Oil pump screen and pickup tube
117550Damper

Scheme 210

Scheme 210: Lower Engine Block (View 2)
Scheme 210: Lower Engine Block (View 2)
ItemPart NumberDescription
1Main bearing beam (part of 6010)
26A338Crankshaft main bearing beam bearing (5 required)
36300Crankshaft assembly
46333Cylinder block crankshaft main bearing (4 required)
56337Cylinder block crankshaft main thrust bearing
66110Piston (4 required)

Scheme 211

Scheme 211: Front Engine Block
Scheme 211: Front Engine Block
ItemPart NumberDescription
16C315Crankshaft Position (CKP) sensor
26K340Crankshaft pulley bolt
36316Crankshaft pulley
46700Crankshaft front seal
56019Engine front cover
66K254Timing chain tensioner
76K255Timing chain tensioner arm
86268Timing chain
96K297Timing chain guide
106C271Oil pump chain tensioner
116A895Oil pump chain
126652Oil pump drive gear
136378Diamond washer
146306Crankshaft sprocket
156378Diamond washer
166600Oil pump
176010Cylinder block

Scheme 212

Scheme 212: Cylinder Head
Scheme 212: Cylinder Head
ItemPart NumberDescription
112A366Coil-on-plug assembly (4 required)
212405Spark plug (4 required)
36766Oil filler cap
412K073Camshaft Position (CMP) sensor
56K271Valve cover
66K260Valve cover gasket
76M280Variable Camshaft Timing (VCT) oil control solenoid
86G004Cylinder Head Temperature (CHT) sensor
9Camshaft front bearing cap (part of 6049)
10Camshaft bearing cap (part of 6049) (8 required)
116A272Camshaft (exhaust)
126A271Camshaft (intake)
136C251Camshaft sprocket
146C525VCT actuator
156500Valve tappet (16 required)
166518Valve collet (16 required)
176514Valve spring retainer (16 required)
186513Valve spring (16 required)
196A517Valve stem seal (16 required)
206049Cylinder head
216505Exhaust valve (8 required)
226507Intake valve (8 required)
236051Head gasket
246010Cylinder block

Scheme 213

Scheme 213: Intake Manifold
Scheme 213: Intake Manifold
ItemPart NumberDescription
19H487Fuel rail
28K556Coolant outlet
39D475Exhaust Gas Recirculation (EGR) valve
49F991Electronic throttle body
56051Cylinder head gasket
66010Cylinder block
79424Intake manifold
89441Intake manifold gasket
96049Cylinder head
109F593Fuel injector (4 required)
119J469Exhaust Gas Recirculation (EGR) gasket
129E936Electronic throttle body gasket
  1. For basic mechanical concerns REFER to: «ENGINE»(ref-635246-S38233782722014070200000) . For driveability concerns Refer to «INTRODUCTION - HYBRID»(ref-608996) .

Check

  1. Remove the following items: Refer to: «VALVE COVER»(ref-635248-S16129223262014070200000) . RH only. Refer to: «FENDER SPLASH SHIELD»(ref-635237-S25268650062014070200000) .
  2. NOTE: Turn the engine clockwise only, and only use the crankshaft bolt. NOTE: Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure the clearance of each valve and record its location. Use the General Equipment: Feeler Gauge
  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 the thickness of 3.650 mm. NOTE: Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. NOTE: The nominal clearance is: intake: 0.25 mm (0.0095 in). exhaust: 0.36 mm (0.0142 in). NOTE: The acceptable clearances after being fully installed are: intake: 0.20-0.30 mm (0.008-0.012 in). exhaust: 0.31-0.41 mm (0.012-0.016 in). Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
  4. If any tappets do not measure within specifications, install new tappets in these locations. Refer to: «VALVE TAPPETS»(ref-635248-S21925164002014070200000) .

Camshafts

SPECIAL TOOL DESCRIPTION 303-465 Tool, Camshaft Align Timing TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2

NameSpecification
Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.) XO-0W20-QSP (U.S.)WSS-M2C947-A

MATERIALS SPECIFICATIONS

Crankshaft Front Seal

SPECIAL TOOL DESCRIPTION 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal TKIT-2009TC-F 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH

Scheme 214

Scheme 214: Crankshaft Front Seal
Scheme 214: Crankshaft Front Seal
NameSpecification
Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.) XO-0W20-QSP (U.S.)WSS-M2C947-A

MATERIALS SPECIFICATIONS

Crankshaft Pulley

SPECIAL TOOL DESCRIPTIONS 303-1416 Tool, Crank Damper Holding TKIT-2008ET-FLM 303-1521 Alignment Tool, Crankshaft Position Sensor 303-465 Tool, Camshaft Align Timing TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM

Scheme 215

Scheme 215: Crankshaft Pulley
Scheme 215: Crankshaft Pulley
NameSpecification
Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.) XO-0W20-QSP (U.S.)WSS-M2C947-A

MATERIALS SPECIFICATIONS

Cylinder Head - Hybrid Electric Vehicle (HEV)

SPECIAL TOOL DESCRIPTIONS 303-290-05A Adapter for 303-290A 303-F072 Support Bar, Engine Oil Drain Equipment Trolley Jack Wooden Block

Scheme 216

Scheme 216: Cylinder Head - Hybrid Electric Vehicle (HEV)
Scheme 216: Cylinder Head - Hybrid Electric Vehicle (HEV)

Scheme 217

Scheme 217
Scheme 217
NameSpecification
Motorcraft® Silicone Gasket Remover ZC-30
Motorcraft® Metal Surface Prep ZC-31-B
Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.) XO-0W20-QSP (U.S.)WSS-M2C947-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4

MATERIALS SPECIFICATIONS

Cylinder Head - Plug-In Hybrid Electric Vehicle (PHEV)

SPECIAL TOOL DESCRIPTIONS 303-290-05A Adapter for 303-290A 303-F072 Support Bar, Engine Oil Drain Equipment Trolley Jack Wooden Block

NameSpecification
Motorcraft® Silicone Gasket Remover ZC-30
Motorcraft® Metal Surface Prep ZC-31-B
Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.) XO-0W20-QSP (U.S.)WSS-M2C947-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4

MATERIALS SPECIFICATIONS

Engine Front Cover - Hybrid Electric Vehicle (HEV)

NameSpecification
Motorcraft® Silicone Gasket Remover ZC-30
Motorcraft® Metal Surface Prep ZC-31-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4

MATERIALS SPECIFICATIONS

Engine Front Cover - Plug-In Hybrid Electric Vehicle (PHEV)

NameSpecification
Silicone Gasket and Sealant TA-30WSE-M4G323-A4

MATERIALS SPECIFICATIONS

Flywheel

SPECIAL TOOL DESCRIPTIONS 303-103 (T74P-6375-A) Holding Tool, Flywheel TKIT-2009TC-F T74P-77000-A

Scheme 218

Scheme 218: Flywheel
Scheme 218: Flywheel

Scheme 219

Scheme 219: Removal
Scheme 219: Removal

Scheme 220

Scheme 220
Scheme 220
  1. WARNING: Before beginning any service procedure in this article, refer to Safety Warnings in «GENERAL INFORMATION»(ref-635189) . Failure to follow this instruction may result in serious personal injury. Refer to: «HEALTH AND SAFETY PRECAUTIONS»(ref-635189-S18367805802014070200000) .
  2. NOTE: If the engine is being removed to access the flywheel, it is not necessary to drain the engine oil or remove the oil filter. Refer to: «ENGINE - HYBRID ELECTRIC VEHICLE (HEV)»(ref-635248-S40509981692014070200000) . Refer to: «ENGINE - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-635248-S21827013642014070200000) .
  3. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .
  4. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .

Scheme 221

Scheme 221: Installation
Scheme 221: Installation

Scheme 222

Scheme 222
Scheme 222
  1. 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)
  2. Tighten 2 turns at a time in sequence shown below. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel . Torque : 21 lb.ft (29 Nm)
  3. Refer to: «ENGINE - HYBRID ELECTRIC VEHICLE (HEV)»(ref-635248-S40509981692014070200000) . Refer to: «ENGINE - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-635248-S21827013642014070200000) .

Oil Pan

Oil Drain Equipment
Round-Ended Steel Rule

SPECIAL TOOL DESCRIPTIONS

NameSpecification
Silicone Gasket and Sealant TA-30WSE-M4G323-A4

MATERIALS SPECIFICATIONS

Oil Pump

NameSpecification
Motorcraft® Metal Surface Prep ZC-31-A

MATERIALS SPECIFICATIONS

Valve Cover

SPECIAL TOOL DESCRIPTIONS 205-153 (T80T-4000-W) Handle 303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW

Scheme 223

Scheme 223: Valve Cover
Scheme 223: Valve Cover
NameSpecification
Motorcraft® Metal Surface Prep ZC-31-B
Silicone Gasket and Sealant TA-30WSE-M4G323-A4

MATERIALS SPECIFICATIONS

Valve Springs

SPECIAL TOOL DESCRIPTIONS 303-300 (T87C-6565-A) Set, Valve Spring Compressor TKIT-2009TC-F T88C-1000-ST TKIT-1988-FESTIVA TKIT-1988-TRACER 303-350 (T89P-6565-A) Compressor, Valve Spring TKIT-1989-F TKIT-1989-FM TKIT-1989-FLM TKIT-1990-LMH 303-472 (T94P-6565-AH) Adapter, Valve Spring Compressor TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2

Scheme 224

Scheme 224: Valve Springs
Scheme 224: Valve Springs

Scheme 225

Scheme 225
Scheme 225
NameSpecification
Motorcraft® Multi-Purpose Grease Spray XL-5ESB-M1C93-B

MATERIALS SPECIFICATIONS

Valve Stem Seals

SPECIAL TOOL DESCRIPTIONS 303-468 (T94P-6510-AH) Remover, Valve Stem Oil Seal TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal TKIT-2009TC-F TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 307-005 (T59L-100-B) Slide Hammer

Scheme 226

Scheme 226: Valve Stem Seals
Scheme 226: Valve Stem Seals

Scheme 227

Scheme 227
Scheme 227
NameSpecification
Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.) XO-0W20-QSP (U.S.)WSS-M2C947-A

MATERIALS SPECIFICATIONS

Crankshaft Rear Seal

SPECIAL TOOL DESCRIPTIONS 303-328 (T88P-6701-B1) Replacer, Rear Seal TKIT-1988-F TKIT-1988-FLM TKIT-1988-LM Oil Drain Equipment

Scheme 228

Scheme 228: Crankshaft Rear Seal
Scheme 228: Crankshaft Rear Seal
NameSpecification
Motorcraft® Silicone Gasket Remover ZC-30
Motorcraft® Metal Surface Prep ZC-31-B
Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.) XO-0W20-QSP (U.S.)WSS-M2C947-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4

MATERIALS SPECIFICATIONS

Engine Mount

SPECIAL TOOL DESCRIPTIONS 303-290-05A Adapter for 303-290A 303-F072 Support Bar, Engine

Oil Filter Adapter

NameSpecification
Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.) XO-0W20-QSP (U.S.)WSS-M2C947-A

MATERIALS SPECIFICATIONS

Oil Pressure Switch

NameSpecification
Thread Sealant with PTFE TA-24-BWSK-M2G350-A2

MATERIALS SPECIFICATIONS

Valve Tappets

NameSpecification
Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.) XO-0W20-QSP (U.S.)WSS-M2C947-A

MATERIALS SPECIFICATIONS

SPECIAL TOOL DESCRIPTIONS 303-300 (T87C-6565-A) Set, Valve Spring Compressor TKIT-2009TC-F T88C-1000-ST TKIT-1988-FESTIVA TKIT-1988-TRACER 303-350 (T89P-6565-A) Compressor, Valve Spring TKIT-1989-F TKIT-1989-FM TKIT-1989-FLM TKIT-1990-LMH 303-468 (T94P-6510-AH) Remover, Valve Stem Oil Seal TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal TKIT-2009TC-F TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-472 (T94P-6565-AH) Adapter, Valve Spring Compressor TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 307-005 (T59L-100-B) Slide Hammer

Scheme 229

Scheme 229
Scheme 229
NameSpecification
Motorcraft® Multi-Purpose Grease Spray XL-5ESB-M1C93-B
Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.) XO-0W20-QSP (U.S.)WSS-M2C947-A

MATERIALS SPECIFICATIONS

NameSpecification
Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.) XO-0W20-QSP (U.S.)WSS-M2C947-A

MATERIALS SPECIFICATIONS

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