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

DISASSEMBLY

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

Note. Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

Note. If the components are to be reinstalled, they must be installed in the same positions. Mark the components removed for locations.

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1. NOTE: Rear shown, front similar.
2. NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
3. NOTE: Use a small screwdriver and multi-purpose grease to remove the valve collets. Remove the valve collets, valve spring retainers and the valve springs. Use Special Service Tool: 303-300 (T87C-6565-A) Set, Valve Spring Compressor , 303-350 (T89P-6565-A) Compressor, Valve Spring , 303-472 (T94P-6565-AH) Adapter, Valve Spring Compressor . Material: Motorcraft® Multi-Purpose Grease Spray/XL-5 (ESB-M1C93-B)
4. Use Special Service Tool: 303-468 (T94P-6510-AH) Remover, Valve Stem Oil Seal , 307-005 (T59L-100-B) Slide Hammer .
5. NOTE: Note the location of the valves if they are to be reused.
6. Inspect the following valve areas: The end of the stem or grooves or scoring. The valve face and the edge for pits, grooves or scores. The valve head for signs of burning, erosion, warping and cracking. The valve margin for wear. Install new parts, as necessary.

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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 clean engine oil. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
2. NOTE: Use the protector provided with the replacement kit to prevent damage to the valve seals. Use Special Service Tool: 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal . Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
3. NOTE: Use a small screwdriver and multi-purpose grease to install the valve collets. NOTE: Check the seating of the valve collets after installation. Install the valve springs, valve spring retainers and the valve collets. Use Special Service Tool: 303-300 (T87C-6565-A) Set, Valve Spring Compressor , 303-350 (T89P-6565-A) Compressor, Valve Spring , 303-472 (T94P-6565-AH) Adapter, Valve Spring Compressor . Material: Motorcraft® Multi-Purpose Grease Spray/XL-5 (ESB-M1C93-B)
4. NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. Torque: 106 lb.in (12 Nm)
5. Torque: 106 lb.in (12 Nm)
6. Torque: 41 lb.ft (55 Nm)
7. Torque: 177 lb.in (20 Nm)
8. Torque: 89 lb.in (10 Nm)
9. NOTE: Rear shown, front similar. Torque: 35 lb.ft (47 Nm)

Note. If the piston and connecting rod are to be reinstalled, they must be assembled in the same orientation. Mark the piston orientation to the connecting rod reassembly.

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1. Using a suitable fixture and press, remove the piston pin.
2. Refer to: «PISTON INSPECTION»(ref-635246-S24520297242014070200000) .

Scheme 184

1. NOTE: Align the piston-to-connecting rod orientation marks made during disassembly.
2. Gradually heat the pin bore side of the connecting rod to approximately 250°C-300°C (482°F-572°F) and immediately install the piston pin.
3. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
4. NOTE: Align the piston rings on the piston. Upper oil control segment ring gap location. Oil control spacer gap location. Lower oil control segment ring gap location.

SPECIAL TOOL DESCRIPTIONS 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge 205-153 (T80T-4000-W) Handle 300-OTC1819E 2, 200# Floor Crane, Fold Away 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 303-1416 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 Round-Ended Steel Rule

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MATERIALS SPECIFICATIONS

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 may occur.

Note. During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and 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. For additional information, refer to the exploded views in DESCRIPTION AND OPERATION .

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1. 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 oil squirter. Torque: 35 lb.in (4 Nm)
2. NOTE: Record the smallest diameter for each journal.
3. 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.
4. Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 90°
5. Measure each crankshaft block main bearing bore diameter.
6. Using the chart, select the crankshaft main bearings.
7. NOTE: Use the original connecting rod cap bolts; installation must keep the same orientation as marked during disassembly or engine damage may occur. Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 21 lb.ft (29 Nm) Stage 3: 90°
8. NOTE: Record the smallest measurement for each connecting rod. Remove and discard the bolts after measuring.
9. NOTE: Record the smallest measurement for each connecting rod journal.
10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
11. 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 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
12. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
13. NOTE: Lubricate the journals on the crankshaft with clean engine oil. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
14. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
15. Mounted flush.
16. NOTE: Lubricate the main bearing beam bolts 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 new main bearing beam bolts. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A) Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 90°
17. Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge with Holding Fixture. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge . Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Acceptable crankshaft end play is 0.22-0.45 mm (0.008-0.018 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
18. NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
19. NOTE: The piston compression upper and lower rings should be installed with the paint mark on the outside diameter circumference of the ring to be positioned on the right side of the ring gap. The lower compression ring needs to be installed with the undercut side downward. NOTE: The upper and lower compression ring end gaps are not controlled for installation. Upper oil control segment ring end gap. Oil control spacer gap location. Lower oil control segment ring gap location.
20. 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: Make sure the piston arrow on top is facing toward the front of the engine. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
21. 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. Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 21 lb.ft (29 Nm) Stage 3: 90°
22. Torque: 18 lb.ft (25 Nm)
23. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC . Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Peg. The engine is now at TDC and must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
24. Clean the oil pump and cylinder block mating surfaces. Material: Motorcraft® Metal Surface Prep/ZC-31-B Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 177 lb.in (20 Nm)
25. Torque: 89 lb.in (10 Nm)
26. Torque: 89 lb.in (10 Nm)
27. 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. Use a plastic scraping tool to remove traces of sealant. Material: Motorcraft® Silicone Gasket Remover/ZC-30 Material: Motorcraft® Metal Surface Prep/ZC-31-B
28. 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)
29. Finger-tight.
30. Use the General Equipment: Round-Ended Steel Rule
31. Torque: 177 lb.in (20 Nm)
32. 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block. Material: Motorcraft® Metal Surface Prep/ZC-31-B
33. NOTE: Dowels must be fully seated in the cylinder block.
34. Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
35. 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. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A) Torque: Stage 1: 62 lb.in (7 Nm) Stage 2: 133 lb.in (15 Nm) Stage 3: 33 lb.ft (45 Nm) Stage 4: 90° Stage 5: 90°
36. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
37. NOTE: 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 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. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
38. Tighten the camshaft bearing cap bolts one at a time until finger-tight. Torque: Stage 1: 62 lb.in (7 Nm) Stage 2: 142 lb.in (16 Nm)
39. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing .
40. Torque: 97 lb.in (11 Nm)
41. Torque: 97 lb.in (11 Nm)
42. 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. NOTE: The crankshaft sprocket flange must be facing away from the engine block. Install a diamond washer on both sides of the crankshaft sprocket.
43. Torque: 18 lb.ft (25 Nm)
44. Torque: 89 lb.in (10 Nm)
45. Torque: 89 lb.in (10 Nm)
46. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
47. Torque: 89 lb.in (10 Nm)
48. Torque: Stage 1: 30 lb.ft (40 Nm) Stage 2: 60°
49. Torque: Stage 1: 30 lb.ft (40 Nm) Stage 2: 60°
50. 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 Material: Motorcraft® Metal Surface Prep/ZC-31-B
51. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant 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. Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
52. NOTE: Apply the 3 mm bead of sealant so half of the bead is on the front cover flange and half is on the chamfer. 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. Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
53. Torque: 1-17: 89 lb.in (10 Nm) 18-21: 35 lb.ft (48 Nm)
54. NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer. Use Special Service Tool: 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal . Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
55. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
56. NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur. NOTE: This step will correctly align the crankshaft pulley to the crankshaft. General Equipment: M6 Bolt.
57. 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 Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only. NOTE: Install a new crankshaft pulley bolt. Use Special Service Tool: 303-1416 Tool, Crank Damper Holding . Torque: Stage 1: 74 lb.ft (100 Nm) Stage 2: 90°
58. Do not tighten the bolts at this time.
59. Install the Special Tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel. Use Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor . Torque: 62 lb.in (7 Nm)
60. Remove.
61. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
62. Torque: 177 lb.in (20 Nm)
63. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing .
64. 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 the valve cover gasket surfaces. Material: Motorcraft® Metal Surface Prep/ZC-31-B
65. NOTE: Installation of a new VCT solenoid seal is required if a damaged seal was 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 .
66. NOTE: Inspect and if necessary, install new valve cover gaskets.
67. Apply a continuous bead of the specified diameter from the specified tube. Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
68. 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 metal surface cleaner. Torque: 89 lb.in (10 Nm)
69. Material: Silicone Brake Caliper Grease and Dielectric Compound/XG-3-A (ESE-M1C171-A) Torque: 71 lb.in (8 Nm)
70. NOTE: The front KS must be installed in the 6 o'clock position and the rear KS must be installed in the 12 o'clock position. The KS must not touch the crankcase vent oil separator. Torque: 80 lb.in (9 Nm) 89 lb.in (10 Nm) 177 lb.in (20 Nm)
71. 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. NOTE: Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.
72. Torque: 159 lb.in (18 Nm)
73. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
74. Torque: 17 lb.ft (23 Nm)
75. Torque: 89 lb.in (10 Nm)
76. Torque: 18 lb.ft (25 Nm)
77. Torque: 80 lb.in (9 Nm)
78. Torque: 35 lb.ft (48 Nm)
79. Torque: 18 lb.ft (25 Nm)
80. Torque: 89 lb.in (10 Nm)
81. Torque: 71 lb.in (8 Nm) 19 lb.ft (26 Nm) 35 lb.ft (48 Nm)
82. Torque: 18 lb.ft (25 Nm)
83. Torque: 89 lb.in (10 Nm) 159 lb.in (18 Nm)
84. Torque: Stage 1: 93 lb.in (10.5 Nm) Stage 2: 90°
85. Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
86. NOTE: Special bolts are used for installation. Do not use standard bolts. 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)
87. 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)

Engine - Hybrid Electric Vehicle (HEV)

SPECIAL TOOL DESCRIPTIONS 300-OTC1585AE Powertrain Lift 300-OTC1819E 2, 200# Floor Crane, Fold Away Adjustable Mounting Arm

MATERIALS SPECIFICATIONS

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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: The transaxle-to-engine bolts differ in length. Note the location of the bolts for correct installation. Torque: 35 lb.ft (48 Nm)
3. Torque: 35 lb.ft (48 Nm)
4. Torque: 35 lb.ft (48 Nm)
5. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
6. Install Special Service Tool: 300-OTC1585AE Powertrain Lift . Use the General Equipment: Adjustable Mounting Arm
7. Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
8. Torque: 97 lb.in (11 Nm)
9. Torque: 89 lb.in (10 Nm)
10. Torque: 150 lb.in (17 Nm)
11. Use Special Service Tool: 300-OTC1585AE Powertrain Lift . Use the General Equipment: Adjustable Mounting Arm
12. Torque: 85 lb.ft (115 Nm) Torque: 66 lb.ft (90 Nm) Torque: 18 lb.ft (25 Nm)
13. Torque: 98 lb.ft (133 Nm)
14. Remove Special Service Tool: 300-OTC1585AE Powertrain Lift . Use the General Equipment: Adjustable Mounting Arm
15. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A) Torque: 177 lb.in (20 Nm)
16. Torque: 35 lb.ft (48 Nm)
17. Refer to: «ROLL RESTRICTOR RH»(ref-635215-S36523617152014070200000) .
18. Torque: 41 lb.ft (55 Nm)
19. Torque: 18 lb.ft (25 Nm)
20. Torque: 18 lb.ft (25 Nm)
21. Torque: 35 lb.ft (48 Nm)
22. Torque: 35 lb.ft (48 Nm)
23. Torque: 18 lb.ft (25 Nm)
24. Install the following items: NOTE: LH side only. Refer to: «FENDER SPLASH SHIELD»(ref-635237-S25268650062014070200000) . Refer to: «FRONT HALFSHAFT RH»(ref-635230-S23723533852014070200000) . Refer to: «FRONT HALFSHAFT LH»(ref-635230-S42232773372014070200000) . Refer to: «COOLING MODULE»(ref-635217-S07535045472014070200000) .
25. Torque: 133 lb.in (15 Nm)
26. Refer to: «QUICK RELEASE COUPLING»(ref-635249-S13757703032014070200000) .
27. Torque: 17 lb.ft (23 Nm)
28. Install the following items: Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-635215-S24436004202014070200000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-635250-S38239475042014070200000) . Refer to: «AIR CLEANER INTAKE PIPE»(ref-635250-S42143401032014070200000) . Refer to: «AIR CLEANER»(ref-635250-S37976058432014070200000) . Refer to: «DEGAS BOTTLE»(ref-635217-S09999976262014070200000) .
29. Fill the engine with clean engine oil. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
30. Refer to: «BATTERY DISCONNECT AND CONNECT - HYBRID ELECTRIC VEHICLE (HEV)»(ref-635223-S23523047482014070200000) . Refer to: «HIGH VOLTAGE BATTERY DISCONNECT AND CONNECT - HYBRID ELECTRIC VEHICLE (HEV)»(ref-635195-S17598128122014070200000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635217-S18215536912014070200000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635216-S38165086382014070200000) . Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-635194-S13131673022014070200000) .

Engine - Plug-In Hybrid Electric Vehicle (PHEV)

SPECIAL TOOL DESCRIPTIONS 300-OTC1585AE Powertrain Lift 300-OTC1819E 2, 200# Floor Crane, Fold Away Adjustable Mounting Arm

MATERIALS SPECIFICATIONS

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: The transaxle-to-engine bolts differ in length. Note the location of the bolts for correct installation. Torque: 35 lb.ft (48 Nm)
3. Torque: 35 lb.ft (48 Nm)
4. Torque: 35 lb.ft (48 Nm)
5. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
6. Install Special Service Tool: 300-OTC1585AE Powertrain Lift . Use the General Equipment: Adjustable Mounting Arm
7. Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
8. Torque: 97 lb.in (11 Nm)
9. Torque: 89 lb.in (10 Nm)
10. Torque: 150 lb.in (17 Nm)
11. Use Special Service Tool: 300-OTC1585AE Powertrain Lift . Use the General Equipment: Adjustable Mounting Arm
12. Torque: 85 lb.ft (115 Nm) Torque: 66 lb.ft (90 Nm) Torque: 18 lb.ft (25 Nm)
13. Torque: 98 lb.ft (133 Nm)
14. Remove Special Service Tool: 300-OTC1585AE Powertrain Lift . Use the General Equipment: Adjustable Mounting Arm
15. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A) Torque: 177 lb.in (20 Nm)
16. Torque: 35 lb.ft (48 Nm)
17. Refer to: «ROLL RESTRICTOR RH»(ref-635215-S36523617152014070200000) .
18. Torque: 41 lb.ft (55 Nm)
19. Torque: 89 lb.in (10 Nm)
20. Torque: 18 lb.ft (25 Nm)
21. Torque: 18 lb.ft (25 Nm)
22. Torque: 35 lb.ft (48 Nm)
23. Torque: 35 lb.ft (48 Nm)
24. Torque: 18 lb.ft (25 Nm)
25. Install the following items: NOTE: LH side only. Refer to: «FENDER SPLASH SHIELD»(ref-635237-S25268650062014070200000) . Refer to: «FRONT HALFSHAFT RH»(ref-635230-S23723533852014070200000) . Refer to: «FRONT HALFSHAFT LH»(ref-635230-S42232773372014070200000) . Refer to: «COOLING MODULE»(ref-635217-S07535045472014070200000) .
26. Torque: 133 lb.in (15 Nm)
27. Refer to: «QUICK RELEASE COUPLING»(ref-635249-S13757703032014070200000) .
28. Torque: 17 lb.ft (23 Nm)
29. Install the following items: Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-635215-S24436004202014070200000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-635250-S38239475042014070200000) . Refer to: «AIR CLEANER INTAKE PIPE»(ref-635250-S42143401032014070200000) . Refer to: «AIR CLEANER»(ref-635250-S37976058432014070200000) . Refer to: «DEGAS BOTTLE»(ref-635217-S09999976262014070200000) .
30. Fill the engine with clean engine oil. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
31. Refer to: «BATTERY DISCONNECT AND CONNECT - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-635223-S34077458332014070200000) . Refer to: «HIGH VOLTAGE BATTERY DISCONNECT AND CONNECT - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-635195-S15098289302014070200000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635217-S18215536912014070200000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635216-S38165086382014070200000) . Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-635194-S13131673022014070200000) .