Engine Mechanical - 2.0L: Removal & Installation Ford C-MAX II

Removal

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.

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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. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-635208-S40563097982014070200000) .
3. Refer to: «VALVE CLEARANCE CHECK»(ref-635248-S10146238802014070200000)
4. Refer to: «VARIABLE VALVE TIMING (VVT) UNIT»(ref-635248-S23326615702014070200000) .
5. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing .
6. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. NOTE: Mark the location and orientation of each camshaft bearing cap. NOTE: Mark the location of the camshafts prior to removal. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the camshaft bearing caps.

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1. 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 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. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
2. Tighten the camshaft bearing cap bolts one turn at a time, until finger-tight. Torque : Stage 1: 62 lb.in (7 Nm) Stage 2: 142 lb.in (16 Nm)
3. NOTE: The Camshaft Alignment Tool 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 .
4. Torque : 97 lb.in (11 Nm)
5. Torque : 97 lb.in (11 Nm)
6. Refer to: «VARIABLE VALVE TIMING (VVT) UNIT»(ref-635248-S23326615702014070200000) .

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.

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1. Refer to: «CRANKSHAFT PULLEY»(ref-635248-S25993361172014070200000) .
2. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal .

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1. 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)
2. Refer to: «CRANKSHAFT PULLEY»(ref-635248-S25993361172014070200000) .

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

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-635208-S40563097982014070200000) .
2. Remove the following items: RH only. Refer to: «FENDER SPLASH SHIELD»(ref-635237-S25268650062014070200000) . Refer to: «VALVE COVER»(ref-635248-S16129223262014070200000) .
3. Turn the crankshaft clockwise until the No. 1 piston is 45 degrees BTDC using the guide holes on the engine front cover and the crankshaft pulley.
4. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
5. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation. NOTE: The engine front cover is removed from graphic for clarity. Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
6. NOTE: The Camshaft Alignment Timing Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Timing Tool cannot be installed, remove the TDC Timing Peg and rotate the crankshaft three-fourths of a revolution clockwise and repeat the previous 2 steps of this procedure. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing .
7. NOTE: The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool, and the bolt should be removed using an air impact wrench (1/2-in drive minimum). NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. NOTE: Use an air impact wrench to remove the crankshaft pulley bolt. Use Special Service Tool: 303-1416 Tool, Crank Damper Holding .
8. NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur. If the diamond washer did not come off with the crankshaft pulley, remove the diamond washer.

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1. NOTE: Before installation clean and inspected 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.
2. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
3. 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.
4. 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°
5. NOTE: Do not tighten the CKP sensor bolts at this time.
6. 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)
7. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
8. Torque : 177 lb.in (20 Nm)
9. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing .
10. Remove.
11. Install the following items: Refer to: «VALVE COVER»(ref-635248-S16129223262014070200000) . RH only. Refer to: «FENDER SPLASH SHIELD»(ref-635237-S25268650062014070200000) .

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.

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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. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-635208-S40563097982014070200000) . Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-635249-S12376281022014070200000) . Refer to: «HIGH VOLTAGE BATTERY DISCONNECT AND CONNECT - HYBRID ELECTRIC VEHICLE (HEV)»(ref-635195-S17598128122014070200000) . Refer to: «BATTERY DISCONNECT AND CONNECT - HYBRID ELECTRIC VEHICLE (HEV)»(ref-635223-S23523047482014070200000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635217-S18215536912014070200000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635216-S38165086382014070200000) .
3. Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-635215-S24436004202014070200000) .
4. Refer to: «INTAKE MANIFOLD»(ref-635248-S26926123552014070200000) .
5. Refer to: «VALVE TAPPETS»(ref-635248-S21925164002014070200000) .
6. NOTE: Transmission removed from graphic for clarity.
7. Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
8. Remove Special Service Tool: 303-F072 Support Bar, Engine , 303-290-05A Adapter for 303-290A .

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1. 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. NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the metal surface prep. NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed. Clean all mating surfaces. Material: Motorcraft® Metal Surface Prep/ZC-31-B Material: Motorcraft® Silicone Gasket Remover/ZC-30
2. Refer to: «CYLINDER HEAD DISTORTION»(ref-635246-S29918798922014070200000) . Refer to: «CYLINDER BLOCK DISTORTION»(ref-635246-S18547529522014070200000) .
3. Apply the specified sealant to the specified component. Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
4. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. 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°
5. Install Special Service Tool: 303-F072 Support Bar, Engine , 303-290-05A Adapter for 303-290A .
6. Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
7. NOTE: Transmission removed from graphic for clarity.
8. Refer to: «VALVE TAPPETS»(ref-635248-S21925164002014070200000) .
9. Torque : 150 lb.in (17 Nm)
10. Torque : 41 lb.ft (55 Nm)
11. Torque : 18 lb.ft (25 Nm)
12. Torque : 18 lb.ft (25 Nm)
13. Torque : 35 lb.ft (48 Nm)
14. Refer to: «INTAKE MANIFOLD»(ref-635248-S26926123552014070200000) .
15. Torque : 18 lb.ft (25 Nm)
16. Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-635215-S24436004202014070200000) .
17. Use the General Equipment: Oil Drain Equipment Torque : 20 lb.ft (27 Nm)
18. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A) Torque : Stage 1: 71 lb.in (8 Nm) Stage 2: 180°
19. 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)
20. 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) .

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.

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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. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-635208-S40563097982014070200000) . Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-635249-S12376281022014070200000) . Refer to: «HIGH VOLTAGE BATTERY DISCONNECT AND CONNECT - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-635195-S15098289302014070200000) . Refer to: «BATTERY DISCONNECT AND CONNECT - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-635223-S34077458332014070200000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635217-S18215536912014070200000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635216-S38165086382014070200000) .
3. Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-635215-S24436004202014070200000) .
4. Refer to: «INTAKE MANIFOLD»(ref-635248-S26926123552014070200000) .
5. Refer to: «VALVE TAPPETS»(ref-635248-S21925164002014070200000) .
6. NOTE: Transmission removed from graphic for clarity.
7. Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
8. Remove Special Service Tool: 303-F072 Support Bar, Engine , 303-290-05A Adapter for 303-290A .

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1. 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. NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the metal surface prep. NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed. Clean all mating surfaces. Material: Motorcraft® Metal Surface Prep/ZC-31-B Material: Motorcraft® Silicone Gasket Remover/ZC-30
2. Refer to: «CYLINDER HEAD DISTORTION»(ref-635246-S29918798922014070200000) . Refer to: «CYLINDER BLOCK DISTORTION»(ref-635246-S18547529522014070200000) .
3. Apply the specified sealant to the specified component. Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
4. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. 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°
5. Install Special Service Tool: 303-F072 Support Bar, Engine , 303-290-05A Adapter for 303-290A .
6. Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
7. NOTE: Transmission removed from graphic for clarity.
8. Refer to: «VALVE TAPPETS»(ref-635248-S21925164002014070200000) .
9. Torque : 150 lb.in (17 Nm)
10. Torque : 41 lb.ft (55 Nm)
11. Torque : 89 lb.in (10 Nm)
12. Torque : 18 lb.ft (25 Nm)
13. Torque : 18 lb.ft (25 Nm)
14. Torque : 35 lb.ft (48 Nm)
15. Refer to: «INTAKE MANIFOLD»(ref-635248-S26926123552014070200000) .
16. Torque : 18 lb.ft (25 Nm)
17. Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-635215-S24436004202014070200000) .
18. Use the General Equipment: Oil Drain Equipment Torque : 20 lb.ft (27 Nm)
19. Material: Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A) Torque : Stage 1: 71 lb.in (8 Nm) Stage 2: 180°
20. 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)
21. 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) .

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.

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-635208-S40563097982014070200000) Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-635194-S13131673022014070200000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635217-S18215536912014070200000) .
2. Remove the following items: Refer to: «CRANKSHAFT FRONT SEAL»(ref-635248-S26708535042014070200000) . Refer to: «ENGINE MOUNT»(ref-635248-S18719364262014070200000) .
3. NOTE: The engine front cover bolts vary in size, note the location of each bolt for assembly.

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1. 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 all mating surfaces. Material: Motorcraft® Silicone Gasket Remover/ZC-30 Material: Motorcraft® Metal Surface Prep/ZC-31-A
2. 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)
3. 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)
4. Torque : Stage 1: Bolts 1 - 17: 89 lb.in (10 Nm) Stage 2: Bolt 18 - 21: 35 lb.ft (48 Nm)
5. Torque : 89 lb.in (10 Nm)
6. Torque : 89 lb.in (10 Nm) 133 lb.in (15 Nm) 159 lb.in (18 Nm)
7. Install the following items: Refer to: «ENGINE MOUNT»(ref-635248-S18719364262014070200000) . Refer to: «CRANKSHAFT FRONT SEAL»(ref-635248-S26708535042014070200000) .
8. Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635217-S18215536912014070200000) . Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-635194-S13131673022014070200000) .

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.

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Scheme 47

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-635208-S40563097982014070200000) . Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-635194-S13131673022014070200000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635217-S18215536912014070200000) .
2. Remove the following items: Refer to: «CRANKSHAFT FRONT SEAL»(ref-635248-S26708535042014070200000) . Refer to: «ENGINE MOUNT»(ref-635248-S18719364262014070200000)
3. NOTE: The engine front cover bolts vary in size, note the location of each bolt for assembly.

Scheme 48

1. NOTE: Make sure that the mating faces are clean and free of foreign material. NOTE: The component must be installed within 10 minutes of applying the sealant. Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
2. NOTE: The component must be installed within 10 minutes of applying the sealant. Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
3. Torque : Stage 1: Bolts 1 - 17: 89 lb.in (10 Nm) Stage 2: Bolt 18 - 21: 35 lb.ft (48 Nm)
4. Torque : 89 lb.in (10 Nm)
5. Torque : 89 lb.in (10 Nm) 133 lb.in (15 Nm) 159 lb.in (18 Nm)
6. Install the following items: Refer to: «ENGINE MOUNT»(ref-635248-S18719364262014070200000) . Refer to: «CRANKSHAFT FRONT SEAL»(ref-635248-S26708535042014070200000) .
7. Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635217-S18215536912014070200000) . Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-635194-S13131673022014070200000) .

Note. Removal steps in this procedure may contain installation details.

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Scheme 52

1. Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-635249-S12376281022014070200000) . Refer to: «BATTERY DISCONNECT AND CONNECT - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-635223-S34077458332014070200000) .
2. Remove the following items: Refer to: «AIR CLEANER INTAKE PIPE»(ref-635250-S42143401032014070200000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-635250-S38239475042014070200000) . Refer to: «AIR CLEANER»(ref-635250-S37976058432014070200000) . Refer to: «COOLING FAN MOTOR AND SHROUD»(ref-635217-S32768020702014070200000) .
3. Refer to: «QUICK RELEASE COUPLING»(ref-635249-S13757703032014070200000) .
4. Refer to: «FUEL RAIL»(ref-635251-S15626165562014070200000) .
5. NOTE: Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.

Scheme 53

1. To install, reverse the removal procedure.
2. Torque : 159 lb.in (18 Nm)

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

Scheme 54

Scheme 55

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. Refer to: «ENGINE FRONT COVER - HYBRID ELECTRIC VEHICLE (HEV)»(ref-635248-S18666474232014070200000) . Refer to: «ENGINE FRONT COVER - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-635248-S22578777252014070200000) .
3. Use the General Equipment: Oil Drain Equipment Torque : 20 lb.ft (27 Nm)

Scheme 56

Scheme 57

Scheme 58

Scheme 59

1. 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.
2. NOTE: The component must be installed within 10 minutes of applying the sealant. Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
3. NOTE: Only tighten the bolts finger tight at this stage.
4. Use the General Equipment: Round-Ended Steel Rule
5. Torque : 177 lb.in (20 Nm)
6. Torque : 35 lb.ft (48 Nm)
7. Refer to: «ENGINE FRONT COVER - HYBRID ELECTRIC VEHICLE (HEV)»(ref-635248-S18666474232014070200000) . Refer to: «ENGINE FRONT COVER - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-635248-S22578777252014070200000) .

1. Refer to: «OIL PUMP SCREEN AND PICKUP TUBE»(ref-635248-S05930193222014070200000) .

Installation

1. Material: Motorcraft® Metal Surface Prep/ZC-31-A
2. Torque : Stage 1: 89 lb.in (10 Nm) Stage 2: 177 lb.in (20 Nm)
3. Torque : 18 lb.ft (25 Nm)
4. Torque : 89 lb.in (10 Nm)
5. Refer to: «OIL PUMP SCREEN AND PICKUP TUBE»(ref-635248-S05930193222014070200000) .

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.

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

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. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-635208-S40563097982014070200000) .
3. Refer to: «ENGINE FRONT COVER - HYBRID ELECTRIC VEHICLE (HEV)»(ref-635248-S18666474232014070200000) . Refer to: «ENGINE FRONT COVER - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-635248-S22578777252014070200000) .

Scheme 66

Scheme 67

Scheme 68

1. Torque : 89 lb.in (10 Nm)
2. NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps. Use the General Equipment: Vise
3. Use the General Equipment: Vise
4. Use the General Equipment: Vise
5. Use the General Equipment: Vise
6. Torque : 89 lb.in (10 Nm)
7. Torque : Stage 1: 30 lb.ft (40 Nm) Stage 2: 60°
8. Torque : Stage 1: 30 lb.ft (40 Nm) Stage 2: 60°
9. Refer to: «ENGINE FRONT COVER - HYBRID ELECTRIC VEHICLE (HEV)»(ref-635248-S18666474232014070200000) . Refer to: «ENGINE FRONT COVER - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-635248-S22578777252014070200000) .

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.

Scheme 69

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Scheme 71

Scheme 72

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Scheme 74

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. Remove the following items: Refer to: «AIR CLEANER INTAKE PIPE»(ref-635250-S42143401032014070200000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-635250-S38239475042014070200000) . Refer to: «AIR CLEANER»(ref-635250-S37976058432014070200000) .
3. Refer to: «QUICK RELEASE COUPLING»(ref-635249-S13757703032014070200000) .
4. Refer to: «IGNITION COIL-ON-PLUG»(ref-635247-S28808521332014070200000) .
5. NOTE: The VCT solenoid seal should only be replaced if it is damaged. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer , 205-153 (T80T-4000-W) Handle .
6. Clean the sealing surfaces. Material : Motorcraft® Metal Surface Prep/ZC-31-B

Scheme 75

Scheme 76

Scheme 77

1. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer , 205-153 (T80T-4000-W) Handle .
2. Inspect and if necessary, install new valve cover gaskets.
3. Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
4. Torque : 89 lb.in (10 Nm)
5. Torque : 80 lb.in (9 Nm)
6. Torque : 80 lb.in (9 Nm)
7. Refer to: «IGNITION COIL-ON-PLUG»(ref-635247-S28808521332014070200000) .
8. Refer to: «QUICK RELEASE COUPLING»(ref-635249-S13757703032014070200000) .
9. Install the following items: Refer to: «AIR CLEANER»(ref-635250-S37976058432014070200000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-635250-S38239475042014070200000) . Refer to: «AIR CLEANER INTAKE PIPE»(ref-635250-S42143401032014070200000) .

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.

Scheme 78

1. Refer to: «VALVE TAPPETS»(ref-635248-S21925164002014070200000) .
2. Refer to: «SPARK PLUGS»(ref-635247-S37507406972014070200000) .
3. NOTE: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the compressed air from the cylinder until the valve spring, valve spring retainer and valve collets is installed. Any loss of air pressure will allow the valve to fall into the cylinder. Connect the compressed air supply to cylinder No. 1.
4. 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)
5. Install new parts as necessary.

Scheme 79

1. NOTE: Use a small screwdriver and multi-purpose grease to install the valve collets. NOTE: Check the seating of the valve collets. 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) Disconnect the compressed air supply. Repeat the appropriate removal and installation steps for all of the other cylinders.
2. Refer to: «SPARK PLUGS»(ref-635247-S37507406972014070200000) .
3. Refer to: «VALVE TAPPETS»(ref-635248-S21925164002014070200000) .

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.

Scheme 80

1. Refer to: «VALVE SPRINGS»(ref-635248-S32960028282014070200000) .
2. Use Special Service Tool: 303-468 (T94P-6510-AH) Remover, Valve Stem Oil Seal , 307-005 (T59L-100-B) Slide Hammer .

1. 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)
2. Refer to: «VALVE SPRINGS»(ref-635248-S32960028282014070200000) .

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.

Scheme 81

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Scheme 83

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. Refer to: «FLYWHEEL»(ref-635248-S10847941112014070200000) .
3. Use the General Equipment: Oil Drain Equipment Torque: 20 lb.ft (27 Nm)
4. NOTE: If the oil pan is not removed, damage to the rear oil seal retainer joint may occur.

Scheme 84

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Scheme 86

1. 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. Clean all mating surfaces. Material : Motorcraft® Metal Surface Prep/ZC-31-B Material : Motorcraft® Silicone Gasket Remover/ZC-30
2. Tighten in the sequence shown below. Use Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal . Torque: 89 lb.in (10 Nm)
3. NOTE: The component must be installed within 10 minutes of applying the sealant. Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
4. NOTE: The component must be installed within 10 minutes of applying the sealant. Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
5. NOTE: Only tighten the bolts finger tight at this stage.
6. NOTE: The engine front cover-to-oil pan bolts must be tightened first to align the front surface of the oil pan flush with the front surface of the engine block. Torque : 89 lb.in (10 Nm) Torque : 159 lb.in (18 Nm)
7. Torque : 177 lb.in (20 Nm)
8. Refer to: «FLYWHEEL»(ref-635248-S10847941112014070200000) .
9. 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)

Note. Removal steps in this procedure may contain installation details.

Scheme 87

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Scheme 89

Scheme 90

Scheme 91

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-635208-S40563097982014070200000) .
2. Remove the following items: Refer to: «WIPER LINKAGE ASSEMBLY»(ref-635222-S18353421652014070200000) . Refer to: «AIR CLEANER»(ref-635250-S37976058432014070200000) .
3. Install Special Service Tool: 303-290-05A Adapter for 303-290A , 303-F072 Support Bar, Engine .
4. Torque : 18 lb.ft (25 Nm) Torque : 66 lb.ft (90 Nm) Torque : 85 lb.ft (115 Nm)

1. To install, reverse the removal procedure.

Note. Removal steps in this procedure may contain installation details.

Scheme 92

Scheme 93

Scheme 94

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. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-635208-S40563097982014070200000) .
3. Torque : Stage 1: 93 lb.in (10.5 Nm) Stage 2: 90°
4. Material : Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A) Torque : Stage 1: 71 lb.in (8 Nm) Stage 2: 180°
5. Refer to: «OIL PRESSURE SWITCH»(ref-635248-S14696850782014070200000) .
6. Torque : 18 lb.ft (25 Nm)

1. To install, reverse the removal procedure.

Note. Removal steps in this procedure may contain installation details.

Scheme 95

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-635208-S40563097982014070200000) .
2. Material : Thread Sealant with PTFE/TA-24-B (WSK-M2G350-A2)

1. To install, reverse the removal procedure.

Scheme 96

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. Refer to: «OIL PAN»(ref-635248-S29883795932014070200000) .

1. Torque : 89 lb.in (10 Nm)
2. Refer to: «OIL PAN»(ref-635248-S29883795932014070200000) .

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.

Scheme 97

1. Refer to: «CAMSHAFTS»(ref-635248-S05501122872014070200000) .
2. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
3. Install new parts as necessary.

Scheme 98

1. Material : Motorcraft® SAE 0W-20 Synthetic Blend Motor Oil (U.S.)/XO-0W20-QSP (U.S.) (WSS-M2C947-A)
2. Refer to: «CAMSHAFTS»(ref-635248-S05501122872014070200000) .

Note. Removal steps in this procedure may contain installation details.

Scheme 99

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. Refer to: «TIMING DRIVE COMPONENTS»(ref-635248-S25360655642014070200000) .

1. To install, reverse the removal procedure.

Engine - Hybrid Electric Vehicle (HEV)

SPECIAL TOOL DESCRIPTIONS 014-00001 300-OTC1585AE Powertrain Lift 300-OTC1819E 2, 200# Floor Crane, Fold Away

Scheme 100

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Scheme 121

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. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-635208-S40563097982014070200000) . Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-635249-S12376281022014070200000) . Refer to: «HIGH VOLTAGE BATTERY DISCONNECT AND CONNECT - HYBRID ELECTRIC VEHICLE (HEV)»(ref-635195-S17598128122014070200000) . Refer to: «BATTERY DISCONNECT AND CONNECT - HYBRID ELECTRIC VEHICLE (HEV)»(ref-635223-S23523047482014070200000) . Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-635194-S13131673022014070200000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635217-S18215536912014070200000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635216-S38165086382014070200000) .
3. Remove the following items: Refer to: «DEGAS BOTTLE»(ref-635217-S09999976262014070200000) . Refer to: «AIR CLEANER»(ref-635250-S37976058432014070200000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-635250-S38239475042014070200000) . Refer to: «AIR CLEANER INTAKE PIPE»(ref-635250-S42143401032014070200000) . Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-635215-S24436004202014070200000) .
4. Refer to: «QUICK RELEASE COUPLING»(ref-635249-S13757703032014070200000) .
5. Remove the following items: Refer to: «COOLING MODULE»(ref-635217-S07535045472014070200000) . Refer to: «FRONT HALFSHAFT LH»(ref-635230-S42232773372014070200000) . Refer to: «FRONT HALFSHAFT RH»(ref-635230-S23723533852014070200000) . NOTE: LH side only. Refer to: «FENDER SPLASH SHIELD»(ref-635237-S25268650062014070200000) .
6. Refer to: «ROLL RESTRICTOR RH»(ref-635215-S36523617152014070200000) .
7. Install Special Service Tool: 300-OTC1585AE Powertrain Lift , 014-00001.
8. Use Special Service Tool: 300-OTC1585AE Powertrain Lift , 014-00001.
9. Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
10. Remove Special Service Tool: 300-OTC1585AE Powertrain Lift , 014-00001.
11. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
12. NOTE: The transaxle-to-engine bolts differ in length. Note the location of the bolts for correct installation.

Engine - Plug-In Hybrid Electric Vehicle (PHEV)

SPECIAL TOOL DESCRIPTIONS 014-00001 300-OTC1585AE Powertrain Lift 300-OTC1819E 2, 200# Floor Crane, Fold Away

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

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. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-635208-S40563097982014070200000) . Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-635249-S12376281022014070200000) . Refer to: «HIGH VOLTAGE BATTERY DISCONNECT AND CONNECT - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-635195-S15098289302014070200000) . Refer to: «BATTERY DISCONNECT AND CONNECT - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-635223-S34077458332014070200000) . Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-635194-S13131673022014070200000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635217-S18215536912014070200000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-635216-S38165086382014070200000) .
3. Remove the following items: Refer to: «DEGAS BOTTLE»(ref-635217-S09999976262014070200000) . Refer to: «AIR CLEANER»(ref-635250-S37976058432014070200000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-635250-S38239475042014070200000) . Refer to: «AIR CLEANER INTAKE PIPE»(ref-635250-S42143401032014070200000) . Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-635215-S24436004202014070200000) .
4. Refer to: «QUICK RELEASE COUPLING»(ref-635249-S13757703032014070200000) .
5. Remove the following items: Refer to: «COOLING MODULE»(ref-635217-S07535045472014070200000) . Refer to: «FRONT HALFSHAFT LH»(ref-635230-S42232773372014070200000) . Refer to: «FRONT HALFSHAFT RH»(ref-635230-S23723533852014070200000) . NOTE: LH side only. Refer to: «FENDER SPLASH SHIELD»(ref-635237-S25268650062014070200000) .
6. Refer to: «ROLL RESTRICTOR RH»(ref-635215-S36523617152014070200000) .
7. Install Special Service Tool: 300-OTC1585AE Powertrain Lift , 014-00001.
8. Use Special Service Tool: 300-OTC1585AE Powertrain Lift , 014-00001.
9. Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
10. Remove Special Service Tool: 300-OTC1585AE Powertrain Lift , 014-00001.
11. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
12. NOTE: The transaxle-to-engine bolts differ in length. Note the location of the bolts for correct installation.

SPECIAL TOOL DESCRIPTIONS 205-153 (T80T-4000-W) Handle 300-OTC1819E 2, 200# Floor Crane, Fold Away 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 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH 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 134

Scheme 135

Scheme 136

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. Refer to the exploded views in DESCRIPTION AND OPERATION .

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Scheme 170

1. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .
2. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .
3. Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
4. 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.
5. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
6. NOTE: The VCT solenoid seal should only be replaced if it is damaged. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer , 205-153 (T80T-4000-W) Handle .
7. Turn the crankshaft clockwise until the No. 1 piston is 45 degrees BTDC using the guide holes on the engine front cover and the crankshaft pulley.
8. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
9. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation. NOTE: The engine front cover is removed from graphic for clarity. Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
10. NOTE: The Camshaft Alignment Timing Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Timing Tool cannot be installed, remove the TDC Timing Peg and rotate the crankshaft three-fourths of a revolution clockwise and repeat the previous 2 steps of this procedure. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing .
11. NOTE: The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool, and the bolt should be removed using an air impact wrench (1/2-in drive minimum). NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. NOTE: Use an air impact wrench to remove the crankshaft pulley bolt. Use Special Service Tool: 303-1416 Tool, Crank Damper Holding .
12. NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur. If the diamond washer did not come off with the crankshaft pulley, remove the diamond washer.
13. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal .
14. NOTE: The engine front cover bolts vary in size, note the location of each bolt for assembly.
15. NOTE
16. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing .
17. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. NOTE: Mark the location and orientation of each camshaft bearing cap. Loosen one turn at a time. Repeat until all the tension is released.
18. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
19. Install new parts as necessary.
20. Refer to: «CYLINDER HEAD DISTORTION»(ref-635246-S29918798922014070200000) .
21. Refer to: «CYLINDER BLOCK DISTORTION»(ref-635246-S18547529522014070200000) .
22. NOTE: The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur. Remove the diamond washer.
23. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
24. General Equipment: Abrasive pad.
25. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
26. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
27. NOTE: Mark the position of the parts, so they can be installed in their original positions. Refer to: «PISTON INSPECTION»(ref-635246-S24520297242014070200000) .
28. Remove in the sequence shown below.
29. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
30. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. NOTE: The center bulkhead has the thrust bearing.
31. NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly. NOTE: The front bulkhead does not have an oil squirter.