Engine Mechanical - 2.0L Gtdi: Removal & Installation Ford Escape III

Installation

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.

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1. 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.
2. 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.
3. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
4. Tighten in the sequence shown in illustration to 20 Nm (177 lb-in).
5. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
6. Install the TB. Refer to «FUEL CHARGING AND CONTROLS - 2.0L GTDI»(ref-569617) .
7. Connect the battery ground cable. Refer to «BATTERY, MOUNTING AND CABLES»(ref-569582) .

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. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Remove the cowl panel. Refer to «FRONT END BODY PANELS»(ref-569581) .
3. Disconnect the battery ground cable. Refer to «BATTERY, MOUNTING AND CABLES»(ref-569582) .
4. Remove the ACL outlet pipe. Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-569599) .
5. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
6. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
7. Remove the coil-on-plug assemblies. Refer to «ENGINE IGNITION - 2.0L GTDI»(ref-569618) .
8. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
9. Early build vehicles equipped with metal vacuum tubes. Late build vehicles equipped with nylon vacuum tubes.
10. Discard the specified component. Follow local disposal regulations.
11. NOTE: The VCT solenoid seals should only be replaced if they are damaged upon inspection. Visual check. Discard the specified component. Follow local disposal regulations. Special Tool(s): Handle 205-153 and Remover, VCT Spark Plug Tube Seal 303-1247/1.

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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 which make leak paths. Clean the specified component with the specified material. Material: Motorcraft® Metal Surface Prep ZC-31-A.
2. 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.
3. Apply a bead of the specified diameter from the specified tube. Material: Silicone Gasket and Sealant TA-30.
4. 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).
5. Tighten to 25 Nm (18 lb-ft).
6. Early build vehicles equipped with metal vacuum tubes. Late build vehicles equipped with nylon vacuum tubes.
7. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
8. Install the coil-on-plug assemblies. Refer to «ENGINE IGNITION - 2.0L GTDI»(ref-569618) .
9. Tighten to 5 Nm (44 lb-in).
10. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) . Tighten to 5 Nm (44 lb-in).
11. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) . Tighten to 5 Nm (44 lb-in).
12. Install the ACL outlet pipe. Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-569599) .
13. Connect the battery ground cable. Refer to «BATTERY, MOUNTING AND CABLES»(ref-569582) .
14. Install the cowl panel. Refer to «FRONT END BODY PANELS»(ref-569581) .

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. Remove the RH fender splash shield. Refer to «FRONT END BODY PANELS»(ref-569581) .
2. Remove the accessory drive belt. Refer to «ACCESSORY DRIVE»(ref-569614) .
3. Remove the brake vacuum pump. Refer to «POWER BRAKE ACTUATION»(ref-569595) .
4. Remove the valve cover. Refer to «VALVE COVER»(ref-569556-S36973038392013072700000) .
5. 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.
6. Special Tool(s): Timing Peg, Crankshaft TDC 303-507.
7. 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. Special Tool(s): Timing Peg, Crankshaft TDC 303-507.
8. NOTE: The Camshaft Alignment 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 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. Special Tool(s): Camshaft Alignment Tool 303-1565.
9. 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 Strap Wrench 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. Strap Wrench. Discard the specified component. Follow local disposal regulations. General Equipment: Strap Wrench, 1/2-in drive air impact wrench.
10. 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 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.
2. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
3. NOTE: This step will correctly align the crankshaft pulley to the crankshaft. General Equipment: M6 Bolt.
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 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.
5. Remove the General Equipment: M6 Bolt.
6. NOTE: Do not tighten the CKP sensor bolts at this time.
7. 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).
8. Remove the Special Tool(s): Timing Peg, Crankshaft TDC 303-507.
9. Tighten to 20 Nm (177 lb-in).
10. Special Tool(s): Camshaft Alignment Tool 303-1565.
11. Tighten to 63 Nm (46 lb-ft).
12. 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.
13. 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).
14. Install the valve cover. Refer to «VALVE COVER»(ref-569556-S36973038392013072700000) .
15. Install the brake vacuum pump. Refer to «POWER BRAKE ACTUATION»(ref-569595) .
16. Install the accessory drive belt. Refer to «ACCESSORY DRIVE»(ref-569614) .
17. Install the RH fender splash shield. Refer to «FRONT END BODY PANELS»(ref-569581) .
18. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.

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.

1. Remove the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-569556-S15984177222013072700000) .
2. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal. Discard the specified component. Follow local disposal regulations. Special Tool(s): Remover, Oil Seal 303-409.

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1. 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.
2. Install the crankshaft pulley. Refer to «CRANKSHAFT PULLEY»(ref-569556-S15984177222013072700000) .

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. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Remove the accessory drive belt and tensioner. Refer to «ACCESSORY DRIVE»(ref-569614) .
3. Remove the crankshaft front seal. Refer to «CRANKSHAFT FRONT SEAL»(ref-569556-S01545814572013072700000) .
4. Remove the engine mount. Refer to «ENGINE MOUNT»(ref-569556-S27048489932013072700000) .
5. 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. Plastic scraper. General Equipment: Plastic Scraper.

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1. 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.
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. 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.
3. 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).
4. Tighten to 20 Nm (177 lb-in).
5. Install the engine mount. Refer to «ENGINE MOUNT»(ref-569556-S27048489932013072700000) .
6. Install the crankshaft front seal. Refer to «CRANKSHAFT FRONT SEAL»(ref-569556-S01545814572013072700000) .
7. Install the accessory drive belt and tensioner. Refer to «ACCESSORY DRIVE»(ref-569614) .

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. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Remove the fuel injection pump and tappet. Refer to «FUEL CHARGING AND CONTROLS - 2.0L GTDI»(ref-569617) .
3. Remove the RF wheel and tire. Refer to «WHEELS AND TIRES»(ref-569561) .
4. Remove the RH fender splash shield. Refer to «FRONT END BODY PANELS»(ref-569581) .
5. NOTE: The fuel injection cam lobe must be positioned at zero lift before removing the fuel injection pump housing. Turn the component CW.
6. Remove the engine front cover. Refer to «ENGINE FRONT COVER»(ref-569556-S10199030572013072700000) .
7. NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Do not rely on the Camshaft Alignment Tool to prevent camshaft rotation. Damage to the tool or the camshaft can occur. Special Tool(s): Camshaft Alignment Tool 303-1565.
8. General Equipment: 23 mm Wrench.
9. General Equipment: 23 mm Wrench.
10. General Equipment: Small Pick, Holding Pin. Using a small pick, release and hold the ratchet mechanism. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner. Insert a holding pin into the hole to retain the tensioner.

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1. 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.
2. 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.
3. General Equipment: Small Pick. Using a small pick, push back and hold the ratchet mechanism.
4. General Equipment: Small Pick. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
5. 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.
6. General Equipment: Holding Pin. Tighten to 10 Nm (89 lb-in). Remove the holding pin to release the piston.
7. General Equipment: 23 mm Wrench. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 60 degrees.
8. General Equipment: 23 mm Wrench. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 60 degrees.
9. Install the engine front cover. Refer to «ENGINE FRONT COVER»(ref-569556-S10199030572013072700000) .
10. NOTE: The fuel injection cam lobe must be positioned at zero lift before installing the fuel injection pump housing. Turn the component CW.
11. Visual check. Replace as necessary.
12. Tighten to 15 Nm (133 lb-in) plus an additional 60 degrees.
13. Nm (97 lb-in).
14. Install the tappet and fuel injection pump. Refer to «FUEL CHARGING AND CONTROLS - 2.0L GTDI»(ref-569617) .
15. Install the RH fender splash shield. Refer to «FRONT END BODY PANELS»(ref-569581) .
16. Install the RF wheel and tire. Refer to «WHEELS AND TIRES»(ref-569561) .

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. Do not rotate the camshafts unless instructed to in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves and pistons.

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Release the fuel system pressure. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
3. Remove the camshaft phaser and sprockets. Refer to «CAMSHAFT PHASER AND SPROCKET»(ref-569556-S09961418492013072700000) .
4. Remove the Special Tool(s): Camshaft Alignment Tool 303-1565.
5. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. NOTE: Note the location and orientation of each camshaft bearing cap and the position of the camshaft lobes on the No. 1 cylinder for installation reference. Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.

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1. 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 13 . Place a paint mark on the crankshaft at the 12 o'clock position.
2. Remove the Special Tool: Timing Peg, Crankshaft TDC 303-507.
3. 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.
4. 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).
5. 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).
6. 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.
7. 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).
8. 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.
9. Install the Special Tool: Timing Peg, Crankshaft TDC 303-507.
10. 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.
11. If necessary, replace any tappets with the correct tappets selected during the valve clearance check.
12. 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.
13. 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).
14. 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).
15. Tighten to 10 Nm (89 lb-in).
16. NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Special Tool(s): Camshaft Alignment Tool 303-1565.
17. Install the camshaft phaser and sprockets. Refer to «CAMSHAFT PHASER AND SPROCKET»(ref-569556-S09961418492013072700000) .

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.

1. Remove the timing drive components. Refer to «TIMING DRIVE COMPONENTS»(ref-569556-S17795474032013072700000) .
2. NOTE: Washers are not required for installation of the VCT units. If equipped, discard the washers.

1. NOTE: Do not tighten the camshaft phaser and sprocket bolts at this time. The bolts will be tightened during the timing drive component installation procedure. Finger-tight.
2. Install the timing drive components. Refer to «TIMING DRIVE COMPONENTS»(ref-569556-S17795474032013072700000) .

Removal and Installation

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. If the camshafts and valve tappets are to be reused, note the location of the valve tappets to make sure they are assembled in their original positions.

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

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Remove the camshafts. Refer to «CAMSHAFTS»(ref-569556-S24019019442013072700000) .
3. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.
4. 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. Visual check. Install new components as necessary.
5. To install, reverse the removal procedure.

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. If the parts are to be reused, mark the location to make sure they are assembled in their original positions.

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Remove the valve tappets. Refer to «VALVE TAPPETS»(ref-569556-S32985000992013072700000) .
3. Remove the spark plugs. Refer to «ENGINE IGNITION - 2.0L GTDI»(ref-569618) .
4. 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 collet is installed. Any loss of air pressure will allow the valve to fall into the cylinder. Connect a compressed air supply to the cylinder that is being serviced. Special Tool(s): Compressor, Valve Spring 303-300, Compressor, Valve Spring 303-350, Compressor, Valve Spring 303-472 and Compressor, Valve Spring 303-1249. Remove the valve collet, using some multi-purpose grease and a small screwdriver. Remove the valve spring retainer and the valve spring.

1. NOTE: Check the seating of the valve collet. Install the valve spring and the valve spring retainer. 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 grease and a small screwdriver. Disconnect the compressed air supply. Repeat the appropriate removal and installation steps for all of the other cylinders requiring service.
2. Install the spark plugs. Refer to «ENGINE IGNITION - 2.0L GTDI»(ref-569618) .
3. Install the valve tappets. Refer to «VALVE TAPPETS»(ref-569556-S32985000992013072700000) .

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.

1. Remove the valve spring. Refer to «VALVE SPRINGS»(ref-569556-S11735546692013072700000) .
2. Discard the specified component. Follow local disposal regulations. Special Tool(s): Remover, Valve Stem Oil Seal 303-468 and Slide Hammer 307-005.

1. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil. Special Tool(s): Installer, Valve Stem Oil Seal 303-470.
2. Install the valve spring. Refer to «VALVE SPRINGS»(ref-569556-S11735546692013072700000) .

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.

Scheme 322

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Release the fuel system pressure. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
3. Remove the turbocharger. Refer to «FUEL CHARGING AND CONTROLS - TURBOCHARGER, 2.0L GTDI»(ref-569613) .
4. Discard the specified component. Follow local disposal regulations.
5. Remove the fuel injectors. Refer to «FUEL CHARGING AND CONTROLS - 2.0L GTDI»(ref-569617) .
6. Remove the valve tappets. Refer to «VALVE TAPPETS»(ref-569556-S32985000992013072700000) .
7. Discard the specified component. Follow local disposal regulations.
8. Discard the specified component. Follow local disposal regulations.

Scheme 323

Scheme 324

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 silicone gasket remover and 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. NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces. Clean the specified component with the specified material. Material: Motorcraft® Silicone Gasket Remover ZC-30, Motorcraft® Metal Surface Prep ZC-31-A. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
2. Check the cylinder head distortion and the cylinder block distortion. Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-569567) .
3. 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.
4. Tighten to 20 Nm (177 lb-in).
5. Install the valve tappets. Refer to «VALVE TAPPETS»(ref-569556-S32985000992013072700000) .
6. Install the fuel injectors. Refer to «FUEL CHARGING AND CONTROLS - 2.0L GTDI»(ref-569617) .
7. Tighten to 27 Nm (20 lb-ft).
8. 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.
9. Install the turbocharger. Refer to «FUEL CHARGING AND CONTROLS - TURBOCHARGER, 2.0L GTDI»(ref-569613) .
10. Fill the engine with clean engine oil. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.

All vehicles

Scheme 325

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Scheme 328

Scheme 329

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Remove the engine ACL and ACL outlet pipe assembly. Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-569599) .
3. NOTE: To prevent damage to the transmission, do not loosen the transmission-to-engine fasteners more than 5 mm (0.19 in). Loosen 5 mm (0.19 in).
4. NOTE: To prevent damage to the transmission, do not loosen the transmission-to-engine fasteners more than 5 mm (0.19 in). Loosen 5 mm (0.19 in).
5. Remove the A/C drive belt. Refer to «ACCESSORY DRIVE»(ref-569614) .
6. Relocate and support the component. AWD vehicles
7. Remove the PTU. Refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(ref-569566) . All vehicles
8. Loosen 5 mm (0.19 in).
9. Separate the engine and transaxle 5 mm (0.19 in).
10. Tighten to 27 Nm (20 lb-ft).

All vehicles

Scheme 330

Scheme 331

Scheme 332

Scheme 333

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. Plastic scraper. General Equipment: Plastic Scraper.
2. 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.
3. Finger tight.
4. NOTE: The engine front cover-to-oil pan fasteners must be tightened first to align the front surface of the oil pan flush with the front surface of the engine block. Tighten to 10 Nm (89 lb-in).
5. Tighten in the sequence shown in illustration to 20 Nm (177 lb-in).
6. Alternate tightening the LH bellhousing-to-engine and RH engine-to-bellhousing lower bolts to draw the transaxle and engine together. Tighten to 48 Nm (35 lb-ft).
7. Tighten to 48 Nm (35 lb-ft).
8. Tighten to 48 Nm (35 lb-ft).
9. Tighten to 48 Nm (35 lb-ft).
10. Tighten to 48 Nm (35 lb-ft).
11. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil Tighten to 8 Nm (71 lb-in) plus an additional 180 degrees. AWD vehicles
12. Install the PTU. Refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(ref-569566) . All vehicles
13. Tighten to 25 Nm (18 lb-ft). Tighten to 9 Nm (80 lb-in). Tighten to 25 Nm (18 lb-ft).
14. Tighten to 125 Nm (92 lb-ft).
15. Tighten to 5 Nm (44 lb-in). Tighten to 11 Nm (97 lb-in).
16. Install the A/C drive belt. Refer to «ACCESSORY DRIVE»(ref-569614) .
17. Tighten to 48 Nm (35 lb-ft).
18. Install the engine ACL and ACL outlet pipe assembly. Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-569599) .
19. Fill the engine with clean engine oil. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil.

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

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Remove the oil pan. Refer to «OIL PAN»(ref-569556-S42735890552013072700000) .
3. NOTE: A new gasket must be installed. Discard the specified component. Follow local disposal regulations. To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.

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

Scheme 334

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Discard the specified component. Follow local disposal regulations. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil. To install, tighten the new oil filter to 8 Nm (71 lb-in) plus an additional 180 degrees.
3. Discard the specified component. Follow local disposal regulations. To install, tighten to 25 Nm (18 lb-ft).
4. To install, reverse the removal procedure.

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

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Apply the substance from the specified tube. Material: Thread Sealant with PTFE TA-24. To install, tighten to 15 Nm (133 lb-in).
3. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Remove the transaxle. Refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35»(ref-569558) .
3. NOTE: Do not reuse the flexplate bolts. Discard the specified component. Follow local disposal regulations. Special Tool(s): Holding Tool, Flywheel 303-103.

1. 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).
2. Install the transaxle. Refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35»(ref-569558) .
3. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.

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

Scheme 335

Scheme 336

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. General Equipment: Floor Jack and Wooden Block.
3. To install, tighten to 80 Nm (59 lb-ft). To install, tighten to 90 Nm (66 lb-ft).
4. To install, reverse the removal procedure.

SPECIAL TOOLS 2, 200# Floor Crane, Fold Away 300-OTC1819E Adjustable Grip Arm, 1735A 014-00001 Powertrain Lift 300-OTC1585AE Retainer, Torque Converter 307-566

Scheme 337

Scheme 338

GENERAL EQUIPMENT

All vehicles

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Scheme 358

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Release the fuel system pressure. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
3. Drain the cooling system. Refer to «ENGINE COOLING»(ref-569571) .
4. Remove the cowl panel. Refer to «FRONT END BODY PANELS»(ref-569581) .
5. Remove the engine ACL and ACL outlet pipe. Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-569599) .
6. NOTE: If equipped with block heater.
7. Remove the battery tray. Refer to «BATTERY, MOUNTING AND CABLES»(ref-569582) .
8. Remove the degas bottle. Refer to «ENGINE COOLING»(ref-569571) .
9. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
10. NOTE: Note the position of the coolant hoses for installation.
11. Remove the Powertrain Control Module (PCM). Refer to «ELECTRONIC ENGINE CONTROLS»(ref-569601) .
12. Remove or install a cable tie. Discard the specified component. Following local disposal regulations.
13. NOTE: Front bumper cover removed for clarity.
14. Remove the cooling module. Refer to «ENGINE COOLING»(ref-569571) .
15. Tighten to 27 Nm (20 lb-ft).
16. Discard the specified component. Following local disposal regulations.
17. Remove the LH and RH halfshafts. Refer to «FRONT DRIVE HALFSHAFTS»(ref-569562) . Vehicles with AWD
18. Remove the PTU. Refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(ref-569566) . All vehicles
19. Discard the specified component. Follow local disposal regulations.
20. Discard the specified component. Follow local disposal regulations.
21. Discard the specified component. Follow local disposal regulations.
22. Relocate and support the component.
23. Discard the specified component. Follow local disposal regulations.
24. 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.
25. Special Tool(s): Powertrain Lift 300-OTC1585AE and Adjustable Grip Arm, 1735A 014-00001. General Equipment: Wooden Block.
26. NOTE: Only rotate the engine in a clockwise direction or engine damage will occur. Marker. Discard the specified component. Follow local disposal regulations. Index mark one stud and the flexplate for assembly reference.
27. Install the Special Tool(s): 2, 200# Floor Crane, Fold Away 300-OTC1819E. General Equipment: Spreader Bar.
28. Remove the Special Tool(s): Powertrain Lift 300-OTC1585AE and Adjustable Grip Arm, 1735A 014-00001. General Equipment: Wooden Block.
29. Special Tool(s): Retainer, Torque Converter 307-566.

SPECIAL TOOLS Camshaft Alignment Tool 303-1565 Handle 205-153 (T80T-4000-W) Holding Tool, Flywheel 303-103 (T74P-8375-A) Remover, Fuel Injector 310-206 Remover, Oil Seal 303-409 (T92C-6700-CH) Remover, VCT Spark Plug Tube Seal 303-1247/1 Slide Hammer 307-005 (T59L-100-B) or equivalent Timing Peg, Crankshaft TDC 303-507

GENERAL EQUIPMENT

MATERIAL SPECIFICATIONS

Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage 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. For additional information, refer to the exploded view under the ASSEMBLY procedure in this information.

Scheme 359

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Scheme 396

1. Discard the specified component. Follow local disposal regulations. Special Tool(s): Holding Tool, Flywheel 303-103.
2. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
3. Loosen.
4. Discard the specified component. Follow local disposal regulations.
5. NOTE: Early build engine with metal vacuum tubes shown in illustration, late build engines with nylon vacuum tubes similar.
6. Discard the specified component. Follow local disposal regulations.
7. Discard the specified component. Follow local disposal regulations.
8. Discard the specified component. Follow local disposal regulations.
9. Discard the specified component. Follow local disposal regulations.
10. Discard the specified component. Follow local disposal regulations.
11. Loosen.
12. Remove the A/C compressor drive belt. Refer to «ACCESSORY DRIVE»(ref-569614) .
13. General Equipment: 3/8 in drive ratchet.
14. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
15. Discard the specified component. Follow local disposal regulations.
16. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
17. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
18. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
19. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
20. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of the fuel injection pump flare nut. Discard the specified component. Follow local disposal regulations.
21. NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors. NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors. NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain in the cylinder head and require the use of a Fuel Injector Remover tool to extract. Discard the specified component. Follow local disposal regulations.
22. Remove any of the fuel injectors that remained in the fuel rail.
23. Special Tool(s): Slide Hammer 307-005 and Remover, Fuel Injector 310-206.
24. Discard the specified component. Follow local disposal regulations.
25. Discard the specified component. Follow local disposal regulations.
26. NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur. NOTE: Be very careful when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors. Pull the lower Teflon® seal away from the injector. Long-nosed pliers. Carefully cut and discard the lower fuel injector Teflon® seals. Cutting knife. Discard the specified component. Follow local disposal regulations.
27. Alternately loosen one complete revolution at a time.
28. Discard the specified component. Follow local disposal regulations.
29. NOTE: The fuel injection cam lobe must be positioned at zero lift before removing the fuel injection pump housing. Turn the component CW.
30. Early build vehicles equipped with metal vacuum tubes. Late build vehicles equipped with nylon vacuum tubes.
31. Discard the specified component. Follow local disposal regulations.
32. NOTE: The VCT solenoid seals should only be replaced if they are damaged upon inspection. Visual check. Discard the specified component. Follow local disposal regulations. Special Tool(s): Handle 205-153 and Remover, VCT Spark Plug Tube Seal 303-1247/1.
33. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Clean the specified component with the specified material. Material: Motorcraft® Metal Surface Prep ZC-31-A.
34. 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.
35. Special Tool(s): Timing Peg, Crankshaft TDC 303-507.
36. 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. Special Tool(s): Timing Peg, Crankshaft TDC 303-507.
37. NOTE: The Camshaft Alignment 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 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. Special Tool(s): Camshaft Alignment Tool 303-1565. Tighten the retainer.
38. 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 Strap Wrench 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. Strap Wrench. Discard the specified component. Follow local disposal regulations. General Equipment: Strap Wrench and 1/2-in Drive Air Impact Wrench.
39. 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.
40. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal. Discard the specified component. Follow local disposal regulations. Special Tool(s): Remover, Oil Seal 303-409.
41. General Equipment: 23 mm Wrench.
42. General Equipment: 23 mm Wrench.
43. General Equipment: Small Pick, Holding Pin. Using a small pick, release and hold the ratchet mechanism. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner. Insert a holding pin into the hole to retain the tensioner.
44. NOTE: Washers are not required for installation of the VCT units. If equipped, discard the washers.
45. Remove the Special Tool(s): Camshaft Alignment Tool 303-1565.
46. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. NOTE: Note the location and orientation of each camshaft bearing cap and the position of the camshaft lobes on the No. 1 cylinder for installation reference. Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.
47. NOTE: If the camshafts and valve tappets are to be reused, note the location of the valve tappets to make sure they are assembled in their original positions.
48. 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. Visual check.
49. Discard the specified component. Follow local disposal regulations.
50. Discard the specified component. Follow local disposal regulations.
51. 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 silicone gasket remover and 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. NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces. Clean the specified component with the specified material. Materials: Motorcraft® Silicone Gasket Remover ZC-30, Motorcraft® Metal Surface Prep ZC-31-A. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
52. Check the cylinder head distortion and the cylinder block distortion. Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-569567) .
53. 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. Plastic scraper.
54. Discard the specified component. Follow local disposal regulations.
55. Discard the specified component. Follow local disposal regulations.
56. 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.
57. Clean the specified component with the specified material. Material: Motorcraft® Metal Surface Prep ZC-31-A.
58. Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at TDC. Visual check.
59. NOTE: Mark the balance shaft assembly front shafts on the top for reference that the balance shaft assembly is at TDC. Marker. General Equipment: Marker.
60. NOTE: Due to the precision interior construction of the balance shaft assembly, it should not be disassembled.
61. Remove the Special Tool(s): Timing Peg, Crankshaft TDC 303-507.
62. General Equipment: Abrasive pad. Visual check. Clean the specified component with the specified material.
63. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
64. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
65. NOTE: Mark the position of the parts, so they can be installed in their original positions.
66. Inspect the pistons. Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-569567) .
67. Remove in sequence shown in illustration.
68. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
69. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. The center bulkhead has the thrust bearing.