Engine System - General Information: Component Locations Ford Escape I facelift 2

Special Tool(s)

SPECIAL TOOL DESCRIPTION CHART 12 Volt Master UV Diagnostic Inspection Kit 164-R0756 or equivalent (Leak Detector) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Engine EAR 107-R2103 or equivalent Engine EAR/Chassis EAR 107-R2102 or equivalent Oil Pressure Gauge 303-088 (T73L-6600-A) Vacuum/Pressure Tester 164-R0253 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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SPECIAL TOOL DESCRIPTION CHART Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

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1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play.
2. Position the camshaft to the rear of the cylinder head.
3. Zero the Dial Indicator Gauge.
4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. If camshaft end play exceeds specifications, install a new camshaft and recheck end play. If camshaft end play exceeds specification after camshaft installation, install a new cylinder head.

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1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside the contact area.

SPECIAL TOOL DESCRIPTION CHART Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

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1. Use the Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift. Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial Indicator Gauge reading to figure the camshaft lobe lift.

SPECIAL TOOL DESCRIPTION CHART Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

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1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft runout. Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial Indicator Gauge reading.

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1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions.

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1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each end of the main bearing journal.

SPECIAL TOOL DESCRIPTION CHART Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

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1. Install the Dial Indicator Gauge with Holding Fixture.
2. Position the crankshaft to the rear of the cylinder block.
3. Zero the Dial Indicator Gauge.
4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.

SPECIAL TOOL DESCRIPTION CHART Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

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1. Using the Feeler Gauge Set, measure the clearance between the connecting rod and the piston. Verify the measurement is within specification.

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1. Measure the cylinder bore at the top, middle and bottom of piston ring travel in 2 directions as indicated. Verify the cylinder bore is within the wear limit. The difference indicates the cylinder bore taper. Bore the cylinder to the next oversize limit.

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1. Measure the cylinder bore in 2 directions. The difference is the out-of-round.

SPECIAL TOOL DESCRIPTION CHART Scraper, Piston Ring Groove 303-D033 (D81L-6002-D) or equivalent

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Note. Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can occur.

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1. Clean and inspect the (1) ring lands, (2) skirts, (3) pin bosses and the (4) tops of the pistons. If wear marks, scores or glazing is found on the piston skirt, check for a bent or twisted connecting rod.
2. Use the Piston Ring Groove Scraper to clean the piston ring grooves. Make sure the oil ring holes are clean.

SPECIAL TOOL DESCRIPTION CHART Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

Note. Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore.

Note. Piston rings should not be transferred from one piston to another.

Note. The cylinder bore must be within specification for taper and out-of-round.

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1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel.
2. Use the Feeler Gauge Set to measure the top piston ring end gap and the second piston ring end gap.

SPECIAL TOOL DESCRIPTION CHART Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

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1. Inspect the piston for ring land damage or accelerated wear.
2. Using the Feeler Gauge Set, measure the piston ring-to-groove clearance.

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1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within specification.

SPECIAL TOOL DESCRIPTION CHART Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

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1. Using the Feeler Gauge Set, measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification.

SPECIAL TOOL DESCRIPTION CHART Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

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1. Using the Feeler Gauge Set, measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the measurement is within specification.

SPECIAL TOOL DESCRIPTION CHART Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

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1. Using the Feeler Gauge Set, measure the clearance between the connecting rod and the crankshaft. Verify the measurement is within specification.

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1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification.

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1. Inspect the following valve areas: The end of the stem for grooves or scoring. The valve face and the edge for pits, grooves or scores. The valve head for signs of burning, erosion, warpage and cracking. The valve margin for wear.

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1. Use a ball gauge to determine the inside diameter of the valve guides in 2 directions at the top, middle and bottom of the valve guide.
2. Measure the ball gauge with a micrometer.
3. If the valve guide is not within specifications, install a new cylinder head assembly.

SPECIAL TOOL DESCRIPTION CHART Clearance Gauge, Valve Guide 303-004 (TOOL-6505-E) or equivalent Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

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Note. The valve stem diameter must be within specifications before checking valve stem-to-valve guide clearance.

1. Install a Valve Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve guide.
2. Move the Valve Guide Clearance Gauge toward the Dial Indicator Gauge with Holding Fixture and zero the Dial Indicator Gauge. Move the Valve Guide Clearance Gauge away from the Dial Indicator Gauge with Holding Fixture and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance.

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1. Measure the installed length of each valve spring.

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1. Measure the free length of each valve spring.

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1. Measure the out-of-square on each valve spring. Turn the valve spring and observe the space between the top of the valve spring and the square.

SPECIAL TOOL DESCRIPTION CHART Pressure Gauge, Valve/Clutch Spring 303-006 (TOOL-6513-DD) or equivalent

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1. Use the Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the specified valve spring length.

SPECIAL TOOL DESCRIPTION CHART Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Holding Tool, Flywheel 303-103 (T74P-6375-A)

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Note. Do not clean the dual mass flywheel with any kind of fluid, use a dry cloth only or damage to the dual mass flywheel may occur.

Note. Do not clean the gap between the primary and secondary mass. Only clean the bolt connection surface and the clutch surface or damage to the flywheel may occur.

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1. Check the transaxle fluid level and fill to the correct level as necessary.
2. With the engine operating at idle and the transaxle in NEUTRAL, listen and check for unacceptable noise. Determine if any unacceptable noise is reduced when the clutch pedal is depressed.
3. If unacceptable noise is identified, remove the transaxle. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION»(ref-344109) .
4. Inspect the clutch slave cylinder for leaks. If a leak is identified, install a new clutch slave cylinder. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION»(ref-344109) .
5. Inspect the sliding surfaces of the clutch release hub and bearing. Any scoring or burr should be removed with a fine grade of emery paper.
6. Inspect the transaxle input shaft for spline wear, scoring or burrs. Any scoring or burr should be removed with a fine grade of emery paper. If spline wear is identified, install a new transaxle. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION»(ref-344109) .
7. Remove the clutch disc and pressure plate. For additional information, refer to «CLUTCH»(ref-344119) . Discard the clutch disc.
8. Inspect the clutch pressure plate and diaphragm spring segments and discard as necessary. Inspect the clutch pressure plate for scoring, cracks or discoloration. Any minor scoring or discoloration should be removed with a fine grade of emery cloth. Inspect the clutch diaphragm spring segments for damage, uneven height, scoring, cracks or discoloration. Any minor scoring or discoloration should be removed with a fine grade of emery cloth.
9. With the dual mass flywheel installed on the engine, inspect the dual mass flywheel surface for scoring, cracks, discoloration or damage. If any of these conditions exist, install a new flywheel.
10. Using a suitable long screwdriver or bar, firmly rotate the secondary mass clockwise and counterclockwise until the dual mass flywheel friction control plate is centered between the secondary mass notches.
11. Inspect the dual mass flywheel friction control plate for damage or melting and install a new dual mass flywheel if necessary.
12. With the dual mass flywheel installed on the engine, inspect the dual mass flywheel rotational freeplay using the following Steps 13 through 17 .
13. Check that the dual mass flywheel friction control plate is centered between the secondary mass notches.
14. Place a reference mark on the secondary mass of the dual mass flywheel.
15. Using light hand pressure, rotate the secondary mass clockwise to the end of the freeplay. Place a reference mark on the primary mass of the dual mass flywheel, in line with the reference mark on the secondary mass.
16. Using light hand pressure, rotate the secondary mass counterclockwise to the end of the freeplay. Place a second reference mark on the primary mass of the dual mass flywheel, in line with the reference mark on the secondary mass.
17. Measure the rotational freeplay XX between the 2 reference marks on the primary mass of the dual mass flywheel. If the rotational freeplay exceeds 19 mm (0.750 in), install a new dual mass flywheel.
18. With the dual mass flywheel installed on the engine, inspect the dual mass flywheel internal spring operation using the following Steps 19 through 21 .
19. Install the Flywheel Holding Tool.
20. Using a suitable long screwdriver or bar, firmly rotate the secondary mass clockwise. The secondary mass should begin to engage the internal spring past the freeplay movement of 19 mm (0.750 in) maximum. The secondary mass should continue to rotate and engage the internal spring with increasing spring pressure. If the secondary mass does not rotate, install a new dual mass flywheel.
21. Using a suitable long screwdriver or bar, firmly rotate the secondary mass counterclockwise. The secondary mass should begin to engage the internal spring past the freeplay movement of 19 mm (0.750 in) maximum. The secondary mass should continue to rotate and engage the internal spring with increasing spring pressure. If the secondary mass does not rotate, install a new dual mass flywheel.
22. Inspect the dual mass flywheel when removed from the engine and placed on a bench, using the following Steps 23 and 24 .
23. Remove the dual mass flywheel and place it on a firm and level surface. Discard the dual mass flywheel retaining bolts and remove the Flywheel Holding Tool.
24. Using the Dial Indicator Gauge with Holding Fixture, inspect the dual mass flywheel hub bush for wear and install new as necessary. Place a dial indicator gauge at a point on the outer upper surface of the secondary mass. Using light hand pressure, press downward at the opposite point on the outer upper surface of the secondary mass and note the deflection on the dial indicator gauge. Repeat this measurement at 120 degree intervals around the dual mass flywheel and note any deflection. If the deflection exceeds 1.5 mm (0.060 in) at any point, install a new dual mass flywheel.
25. Inspect the rear face of the engine block. Make sure that the 2 engine dowel pins are correctly installed and are not damaged, install new dowel pins as necessary. Inspect the upper and lower engine block rear face plates for damage or warping and install new plates as necessary. Inspect the crankshaft flange for residual thread locking compound or rust, and clean as necessary.
26. Inspect the transaxle mounting face. Make sure that the 2 dowel pin holes are not elongated or damaged.
27. Inspect the dual mass flywheel crankshaft mounting flange for residual thread locking compound or rust and clean as necessary.
28. Loosely install the dual mass flywheel.
29. Install the Flywheel Holding Tool.
30. Tighten the dual mass flywheel retaining bolts in the sequence shown in 3 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
31. Install the clutch disc and pressure plate. For additional information, refer to «CLUTCH»(ref-344119) .
32. Install the transaxle. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION»(ref-344109) .

SPECIAL TOOL DESCRIPTION CHART Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

1. Using a Straightedge and a Feeler Gauge Set, inspect the cylinder head for flatness in the sequence shown.

SPECIAL TOOL DESCRIPTION CHART Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

1. Use a Straightedge and a Feeler Gauge Set to inspect the cylinder block for flatness.

SPECIAL TOOL DESCRIPTION CHART Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket sealing surfaces.
2. Using the Straightedge and a Feeler Gauge Set, check the exhaust manifold sealing surface for warpage. If the warpage is greater than 0.76 mm (0.0299 in), install a new exhaust manifold.

SPECIAL TOOL DESCRIPTION CHART Slide Hammer 100-001 (T50T-100-A)

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