Engine Mechanical - 2.0L Gtdi: Overhaul Ford Escape III

Disassembly

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. 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, mark the location of the components removed, they must be installed in the same location.

Scheme 397

1. NOTE: RH shown in illustration, LH similar.
2. Discard the specified component. Follow local disposal regulations.
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. Special Tool(s): Compressor, Valve Spring 303-300, Compressor, Valve Spring 303-350, Compressor, Valve Spring 303-472 and Compressor, Valve Spring 303-1249. Materials: Multi-Purpose Grease XG-4 and/or XL-5.
4. Visual check. Install new parts, as necessary.
5. Discard the specified component. Follow local disposal regulations. Special Tool(s): Remover, Valve Stem Oil Seal 303-468, Slide Hammer 307-005.
6. NOTE: Note the location of the valves if they are to be reused.
7. Visual check. 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. Install new parts, as necessary.

Scheme 398

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. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil
2. Apply the specified lubricant to the specified component. Special Tool(s): Installer, Valve Stem Oil Seal 303-470. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil
3. Install the valve springs, valve spring retainers and the valve collets. Special Tool(s): Compressor, Valve Spring 303-300, Compressor, Valve Spring 303-350, Compressor, Valve Spring 303-472 and Compressor, Valve Spring 303-1249. Compress the valve spring and install the valve collet using some multi-purpose grease and a small screwdriver. Check the seating of the valve collets.
4. Tighten to 11 Nm (97 lb-in).
5. NOTE: Replace gasket if damaged. Visual check.
6. Tighten to 10 Nm (89 lb-in).
7. NOTE: RH shown in illustration, LH similar. Tighten to 47 Nm (35 lb-ft).

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.

1. Discard the specified component. Follow local disposal regulations.
2. Discard the specified component. Follow local disposal regulations.
3. Clean and inspect the piston and connecting rod. Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-569567) .

Assembly

1. NOTE: Align the piston-to-connecting rod orientation marks made during disassembly.
2. Apply the specified lubricant to the specified component. Materials: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
3. Apply the specified lubricant to the specified component. Materials: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
4. 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 TOOLS Brush, Fuel Injector 310-205 Camshaft Alignment Tool 303-1565 Crank Sensor Alignment Tool 303-1521 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Handle 205-153 (T80T-4000-W) Holding Tool, Flywheel 303-103 (T74P-8375-A) Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1) Installer, VCT Spark Plug Tube Seal 303-1247/2 Seal Installer, Fuel Injector 310-207 Sizer, Teflon® Seal 303-1567 Timing Peg, Crankshaft TDC 303-507

Scheme 399

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GENERAL EQUIPMENT

MATERIAL SPECIFICATIONS

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Scheme 402

Engine - Lower Block Components

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. 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. Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

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Scheme 431

1. Tighten to 10 Nm (89 lb-in).
2. Measure the length or distance. Two directions. Record the smallest measurement for each crankshaft main bearing journal.
3. Main bearing beam mounted flush. Original bolts finger tight.
4. Tighten in the sequence shown in illustration in 3 stages: Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten an additional 90 degrees.
5. Measure the length or distance. Five places.
6. Using the chart, select the crankshaft main bearings.
7. Tighten original bolts in 3 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 29 Nm (21 lb-ft). Stage 3: Tighten an additional 90 degrees.
8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.
9. Discard the specified component. Follow local disposal regulations.
10. Measure the length or distance. Two directions. Record the smallest measurement for each connecting rod.
11. NOTE: Mixed grade bearing pairs (green/blue, blue/red, red/brown) can be installed in upper or lower positions. It is not necessary to maintain specific position. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
12. Discard the specified component. Follow local disposal regulations.
13. 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. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
14. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
15. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
16. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
17. Mounted flush.
18. NOTE: Lubricate the main bearing beam bolt 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 main bearing beam bolts. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil. Tighten the new bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten an additional 90 degrees.
19. Special Tool(s): Dial Indicator Gauge with Holding Fixture 100-002. Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge with Holding Fixture. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Acceptable crankshaft end play is 0.220-0.450 mm (0.0087-0.0177 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
20. NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
21. 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.
22. 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. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil. General Equipment: Piston Ring Compressor.
23. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation. Tighten the new bolts in 3 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 29 Nm (21 lb-ft). Stage 3: Tighten an additional 90 degrees.
24. Special Tool(s): Timing Peg, Crankshaft TDC 303-507. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Peg. The engine is now at TDC.
25. NOTE: Due to the precision interior construction of the balance shaft assembly, it should not be disassembled. NOTE: The original adjustment shims must be installed in their original positions. NOTE: Confirm by visual inspection that there is no damage to the balance shaft assembly gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balance shaft assembly. Install the adjustment shims in their original positions on the seat faces of the balance shaft assembly. With the balance shaft assembly marks in the TDC position, slowly install the balance shaft assembly onto the cylinder block to avoid interference between the crankshaft drive gear and the balance shaft assembly driven gear.
26. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 42 Nm (31 lb-ft).
27. Remove the Special Tool(s): Timing Peg, Crankshaft TDC 303-507. Rotate the crankshaft to confirm that there are no meshing problems between the balance shaft assembly gear and the crankshaft gear.
28. Install the Special Tool(s): Timing Peg, Crankshaft TDC 303-507. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Peg. The engine is now at TDC. Remove the Special Tool(s): Timing Peg, Crankshaft TDC 303-507.
29. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements. NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown in illustration. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft assembly housing. NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown in illustration into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown in illustration. Position the Dial Indicator Gauge with Holding Fixture as shown in illustration. Measure the gear backlash. Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balance shaft assembly. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in). If the backlash exceeds the specified range, carry out the Balance Shaft Backlash procedure. For additional information, refer to «BALANCE SHAFT BACKLASH»(ref-569556-S26657868272013072700000) .
30. Install the Special Tool(s): Timing Peg, Crankshaft TDC 303-507. 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.
31. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
32. Tighten to 25 Nm (18 lb-ft).
33. NOTE: Before installation, clean and inspect the diamond washer for any damage. If damaged 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.
34. Tighten to 10 Nm (89 lb-in). Push the tensioner spring down and position the spring under the shoulder bolt.
35. Special Tool(s): Installer, Crankshaft Rear Main Oil Seal 303-328. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
36. NOTE: A new gasket must be installed. Tighten to 10 Nm (89 lb-in).
37. 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. Apply a continuous bead of the specified diameter from the specified tube. Material: Silicone Gasket and Sealant TA-30.
38. Finger tight.
39. Front surface of the oil pan flush with the front surface of the engine block. General Equipment: Straight Edge.
40. Tighten in the sequence shown in illustration to 20 Nm (177 lb-in).
41. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. Tighten in the sequence shown in illustration in 5 stages. Stage 1: Tighten to 7 Nm (62 lb-in). Stage 2: Tighten to 15 Nm (133 lb-in). Stage 3: Tighten to 55 Nm (41 lb-ft). Stage 4: Tighten 90 degrees. Stage 5: Tighten an additional 90 degrees.
42. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
43. NOTE: If any new parts are being installed (cylinder head, valves, tappets, camshafts) it is necessary to check the valve clearance, follow the next 12 steps exactly or serious damage to the engine may occur. If the original parts are being installed it is not necessary to check the valve clearance so proceed to step 58 . Place a paint mark on the crankshaft at the 12 o'clock position.
44. Remove the Special Tool: Timing Peg, Crankshaft TDC 303-507.
45. NOTE: Rotating the crankshaft will position all of the pistons below the deck of the cylinder block and allow the camshafts to be installed and the valve clearance checked without the possibility of damage to the valves or pistons. Using the crankshaft bolt and washer, rotate the crankshaft clockwise 270 degrees until the paint mark is at the 9 o'clock position.
46. NOTE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts. NOTE: Lubricate the camshaft journals and camshaft bearing caps with clean engine oil. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil. Install the camshafts and bearing caps in their original location and orientation. Tighten the camshaft bearing caps 2 turns at a time in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 7 Nm (62 lb-in). Stage 2: Tighten to 16 Nm (142 lb-in).
47. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil. Tighten in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 7 Nm (62 lb-in). Stage 2: Tighten to 16 Nm (142 lb-in).
48. General Equipment: Feeler Gauge. Using the flats of the camshaft, rotate the camshaft to place the cam lobe at base circle, with the lobe pointed away from the tappet. Use a feeler gauge to measure the clearance of each valve and record its location. Repeat to measure all of the lobe/tappet clearances.
49. NOTE: Select tappets using this formula: ideal tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. Select the closest tappet size to the ideal tappet thickness available and mark the installation location. NOTE: The nominal clearance is: intake: 0.25 mm (0.0095 in). exhaust: 0.36 mm (0.0142 in). NOTE: The acceptable clearances after being fully installed are: intake: 0.19-0.31 mm (0.007-0.012 in). exhaust: 0.30-0.42 mm (0.012-0.017 in).
50. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.
51. Install the Special Tool: Timing Peg, Crankshaft TDC 303-507.
52. NOTE: Rotating the crankshaft will position the engine at TDC and allow you to install the camshafts in the same position as noted during the disassembly. Rotate the crankshaft clockwise 90 degrees so the crankshaft contacts the Timing Peg, Crankshaft TDC 303-507.
53. If necessary, replace any tappets with the correct tappets selected during the valve clearance check.
54. NOTE: The exhaust camshaft rear bearing cap must be secured within 10 minutes of Gasket Maker application. If the bearing cap is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep. NOTE: Do not allow Gasket Maker to enter the camshaft bearing journal. If Gasket Maker is applied to the camshaft bearing journal, the journal and sealing area must be cleaned with Motorcraft® Metal Surface Prep. Apply a continuos bead of the specified diameter from the specified tube. Material: Gasket Maker TA-16.
55. 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. NOTE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts. NOTE: Wipe off any excess sealer from the fuel injection pump housing sealing surface of the cylinder head and rear camshaft cap. NOTE: Lubricate the camshaft journals and camshaft bearing caps with clean engine oil. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil. Install the camshafts and bearing caps in their original location and orientation. Tighten the camshaft bearing caps 2 turns at a time in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 7 Nm (62 lb-in). Stage 2: Tighten to 16 Nm (142 lb-in).
56. Apply the specified lubricant to the specified component. Materials: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil. Tighten in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 7 Nm (62 lb-in). Stage 2: Tighten to 16 Nm (142 lb-in).
57. Tighten to 10 Nm (89 lb-in).
58. NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Install the Special Tool(s): Camshaft Alignment Tool 303-1565.
59. NOTE: Do not tighten the camshaft phaser and sprocket bolts at this time. Finger-tight.
60. Tighten to 10 Nm (89 lb-in). NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
61. NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly. Using the edge of a vise, compress the timing chain tensioner plunger.
62. General Equipment: Small Pick. Using a small pick, push back and hold the ratchet mechanism.
63. General Equipment: Small Pick. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
64. General Equipment: Holding Pin. Install a holding pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
65. General Equipment: Holding Pin. Tighten to 10 Nm (89 lb-in). Remove the holding pin to release the piston.
66. General Equipment: 23 mm Wrench. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 60 degrees.
67. General Equipment: 23 mm Wrench. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 60 degrees.
68. 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. Apply a continuous bead of the specified diameter from the specified tube. Material: Silicone Gasket and Sealant TA-30. Apply a 3 mm (0.118 in) bead of Silicone Gasket and Sealant to the sealing surface of the front cover. Apply a 2 mm (0.078 in) bead of Silicone Gasket and Sealant to the 5 center sealing surfaces of the front cover.
69. 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. Apply a continuous bead of the specified diameter from the specified tube. Material: Silicone Gasket and Sealant TA-30. Apply beads of silicone gasket and sealant that are 2 mm (0.078 in) in diameter and 5 mm (0.19 in) in length across the cylinder head and cylinder block joint areas.
70. Tighten in the sequence shown in illustration as follows: Tighten 1 through 19 to 10 Nm (89 lb-in). Tighten 20 through 22 to 48 Nm (35 lb-ft).
71. NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer. Apply the specified lubricant to the specified component. Special Tool(s): Installer, Camshaft Front Oil Seal 303-096. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
72. NOTE: Before installation, clean and inspect the diamond washer for any damage. If damaged 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.
73. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
74. NOTE: This step will correctly align the crankshaft pulley to the crankshaft. General Equipment: M6 Bolt.
75. 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 Strap Wrench and the bolt should be installed using hand tools only. Strap wrench. Do not use power tools. General Equipment: Strap Wrench. Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees.
76. Remove the General Equipment: M6 Bolt.
77. NOTE: Do not tighten the CKP sensor bolts at this time.
78. Special Tool(s): Crank Sensor Alignment Tool. Install the Crankshaft Sensor Alignment Tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel. Tighten to 7 Nm (62 lb-in).
79. Remove the Special Tool(s): Timing Peg, Crankshaft TDC 303-507.
80. Special Tool(s): Camshaft Alignment Tool 303-1565.
81. Tighten to 20 Nm (177 lb-in).
82. Tighten to 63 Nm (46 lb-ft).
83. NOTE: The intake camshaft rear bearing cap must be secured within 10 minutes of Gasket Maker application. If the bearing cap is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep. Apply a continuos bead of the specified diameter from the specified tube. Material: Gasket Maker TA-16.
84. NOTE: Wipe off any excess sealer from the vacuum pump sealing surface of the cylinder head and camshaft cap. Stage 1: Tighten the bolts to 7 Nm (62 lb-in). Stage 2: Tighten the bolts to 16 Nm (142 lb-in).
85. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine. Special Tool(s): Handle 205-153 and Installer, VCT Spark Plug Tube Seal 303-1247/2.
86. Apply a bead of the specified diameter from the specified tube. Material: Silicone Gasket and Sealant TA-30.
87. 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 prep. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
88. Early build vehicles equipped with metal vacuum tubes. Late build vehicles equipped with nylon vacuum tubes.
89. Tighten to 6 Nm (53 lb-in).
90. NOTE: The fuel injection cam lobe must be positioned at zero lift before installing the fuel injection pump housing. Turn the component CW.
91. Visual check. Replace as necessary.
92. Tighten to 15 Nm (133 lb-in) plus an additional 60 degrees.
93. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
94. NOTE: Make sure that a new fuel injection pump O-ring seal is installed. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
95. Alternately tighten each bolt one complete revolution until seated. Tighten in 2 stages. Stage 1: Tighten each bolt to 5 Nm (44 lb-in). Stage 2: Tighten each bolt an additional 55 degrees.
96. Tighten to 17 Nm (150 lb-in).
97. Visual check. Replace as necessary.
98. Tighten to 10 Nm (89 lb-in).
99. Visual check. Replace as necessary.
100. Tighten to 10 Nm (89 lb-in).
101. NOTE: Do not use compressed air or the Fuel Injector Brush to clean the tip of the fuel injectors. Failure to follow this instruction may result in damage to the fuel injectors. NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors. Special Tool(s): Brush, Fuel Injector 310-205.
102. NOTE: Do not lubricate the new lower Teflon® fuel injector seals. Special Tool(s): Sizer, Teflon® Seal 303-1567 and Seal Installer, Fuel Injector 310-207.
103. NOTE: Install the fuel injectors into the cylinder head within 15 minutes due to Teflon® seal expansion. NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the seal. Special Tool(s): Sizer, Teflon® Seal 303-1567.
104. NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil.
105. NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup. NOTE: The fuel rail pressure sensor must be replaced if it is removed from the fuel rail. Refer to «ELECTRONIC ENGINE CONTROLS»(ref-569601) .
106. NOTE: Push down on the fuel rail face above the injectors. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 8 Nm (71 lb-in). Stage 2: Tighten an additional 26 degrees.
107. Finger-tight.
108. Finger-tight.
109. Tighten in 2 stages. Stage 1: Tighten to 15 Nm (133 lb-in). Stage 2: Tighten an additional 30 degrees.
110. Tighten to 10 Nm (89 lb-in).
111. Visual check. Replace as necessary.
112. Tighten to 10 Nm (89 lb-in).
113. NOTE: The forward KS must be installed in the 6 o'clock position and the rearward KS must be installed in the 3 o'clock position as shown in illustration. Failure to follow these instructions may result in damage to the engine. Tighten to 20 Nm (177 lb-in).
114. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
115. 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. Visual check. Replace as necessary.
116. NOTE: Vehicles built on or before 9/28/2012 have a vacuum port on the side of the intake manifold. These engines are equipped with either a brake aspiration hose or intake manifold plug in the vacuum port. If equipped, inspect the intake manifold plug for correct installation. If the plug is missing, install a new one following the instruction sheet included in the service kit. If the nylon tie strap is missing, install a new 2.5 mm (0.098 in) wide and 1.0 mm (0.039 in) thick tie strap.
117. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
118. NOTE: Vehicles built on or before 9/28/2012 have a vacuum port on the side of the intake manifold. These engines are equipped with either a brake aspiration hose or intake manifold plug in the vacuum port. Tighten in the sequence shown in illustration to 20 Nm (177 lb-in).
119. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
120. Tighten to 11 Nm (97 lb-in).
121. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
122. Tighten to 25 Nm (18 lb-ft).
123. NOTE: Install a new coolant pump O-ring seal and lubricate with clean engine coolant prior to installation. Tighten to 10 Nm (89 lb-in). Tighten to 25 Nm (18 lb-ft).
124. Finger-tight. Tighten to 25 Nm (18 lb-in).
125. Tighten to 15 Nm (133 lb-in).
126. Tighten to 25 Nm (18 lb-ft). Tighten to 9 Nm (80 lb-in). Tighten to 25 Nm (18 lb-ft).
127. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) . Tighten to 5 Nm (44 lb-in).
128. General Equipment: 3/8 in Ratchet.
129. Install the A/C compressor drive belt. Refer to «ACCESSORY DRIVE»(ref-569614) .
130. Tighten to 20 Nm (177 lb-in).
131. Tighten to 25 Nm (18 lb-in).
132. Tighten to 25 Nm (18 lb-in). Tighten to 20 Nm (177 lb-in).
133. Tighten to 17 Nm (150 lb-in).
134. Tighten in the sequence shown in illustration to 50 Nm (37 lb-ft).
135. Tighten to 10 Nm (89 lb-in).
136. NOTE: Do not reuse the turbocharger oil return tube/gaskets, new parts must be installed. Tighten to 10 Nm (89 lb-in).
137. NOTE: Do not reuse the turbocharger oil filter, a new part must be installed.
138. NOTE: Do not reuse the turbocharger oil supply tube/gaskets, new parts must be installed. Tighten to 25 Nm (18 lb-ft).
139. NOTE: Early build engine with metal vacuum tubes shown in illustration, late build engines with nylon vacuum tubes similar.
140. NOTE: Do not reuse the gaskets, new parts must be installed. Tighten to 28 Nm (21 lb-ft).
141. Tighten to 5 Nm (44 lb-in).
142. Tighten to 5 Nm (44 lb-in).
143. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) . Tighten to 5 Nm (44 lb-in).
144. NOTE: Special bolts are used for installation. Do not use standard bolts. Special Tool(s): Holding Tool, Flywheel 303-103. Tighten in the sequence shown in illustration in 3 stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (50 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).

SPECIAL TOOLS 2, 200# Floor Crane, Fold Away 300-OTC1819E Adjustable Grip Arm, 1735A 014-00001 Powertrain Lift 014-00765 or equivalent Retainer, Torque Converter 307-566

Scheme 432

GENERAL EQUIPMENT

MATERIAL SPECIFICATIONS

All vehicles

Scheme 433

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Scheme 437

Scheme 438

Scheme 439

Scheme 440

Scheme 441

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Scheme 445

Scheme 446

1. Apply the substance from the specified tube. Material: Multi-Purpose Grease XG-4 and/or XL-5. Special Tool(s): Retainer, Torque Converter 307-566.
2. Visual check.
3. NOTE: Align the torque converter stud marked during removal with the flexplate. Tighten to 48 Nm (35 lb-ft).
4. NOTE: Position a wooden block under the transmission. Special Tool(s): Powertrain Lift 300-OTC1585AE and Adjustable Grip Arm, 1735A 014-00001. General Equipment: Wooden Block.
5. Remove the Special Tool(s): 2, 200# Floor Crane, Fold Away 300-OTC1819E. General Equipment: Spreader Bar.
6. Connect the Positive Crankcase Ventilation (PCV) tube to the turbocharger inlet pipe.
7. NOTE: Only rotate the engine in a clockwise direction or engine damage will occur. Turn the component CW through 90 degrees. Tighten to 40 Nm (30 lb-ft).
8. Tighten to 12 Nm (106 lb-in). Tighten to 5 Nm (44 lb-in).
9. Tighten to 35 Nm (26 lb-ft).
10. Tighten to 18 Nm (159 lb-in).
11. Special Tool(s): Powertrain Lift 300-OTC1585AE and Adjustable Grip Arm, 1735A 014-00001. General Equipment: Wooden Block.
12. Tighten to 148 Nm (109 lb-ft).
13. Tighten to 80 Nm (59 lb-ft). Tighten to 90 Nm (66 lb-ft).
14. Remove the Special Tool(s): Powertrain Lift 300-OTC1585AE and Adjustable Grip Arm, 1735A 014-00001. General Equipment: Wooden Block.
15. Tighten to 125 Nm (92 lb-ft).
16. NOTE: Install a new O-ring seal and gasket. Tighten to 15 Nm (133 lb-in).
17. Tighten to 8 Nm (71 lb-in). Finger tight. Finger tight.
18. Tighten to 15 Nm (133 lb-in).
19. Tighten to 25 Nm (18 lb-ft).
20. Tighten to 25 Nm (18 lb-ft).
21. Discard the specified component. Follow local disposal regulations.
22. Tighten to 48 Nm (35 lb-ft). Vehicles with AWD
23. Install the PTU. Refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(ref-569566) . All vehicles
24. Install the LH and RH halfshafts. Refer to «FRONT DRIVE HALFSHAFTS»(ref-569562) .
25. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil. Tighten to 8 Nm (71 lb-in) plus an additional 180 degrees.
26. Install the 2 transaxle-to-oil pan bolts. Tighten to 48 Nm (35 lb-ft).
27. Tighten to 5 Nm (44 lb-in). Tighten to 11 Nm (97 lb-in).
28. Install the cooling module. Refer to «ENGINE COOLING»(ref-569571) .
29. NOTE: Front bumper cover removed for clarity.
30. Remove or install a cable tie.
31. Install the PCM. Refer to «ELECTRONIC ENGINE CONTROLS»(ref-569601) .
32. Tighten to 25 Nm (18 lb-ft).
33. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
34. Install the degas bottle. Refer to «ENGINE COOLING»(ref-569571) .
35. Install the battery tray. Refer to «BATTERY, MOUNTING AND CABLES»(ref-569582) .
36. Tighten to 23 Nm (17 lb-ft).
37. Tighten to 12 Nm (106 lb-in).
38. NOTE: If equipped with block heater.
39. Install the engine ACL and ACL outlet pipe. Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-569599) .
40. Install the cowl panel. Refer to «FRONT END BODY PANELS»(ref-569581) .
41. Fill the engine with clean engine oil. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
42. Fill and bleed the engine cooling system. Refer to «ENGINE COOLING»(ref-569571) .
43. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.