Engine Mechanical - 2.5L: Other Ford Escape III

Engine Code Information Label

The engine code information label, located on the front side of the valve cover, contains the following

Scheme 670

Scheme 671

Valve Train

The valve train uses Direct Acting Mechanical Buckets (DAMB). The camshaft lobes are positioned directly above mechanical buckets with are positioned on top of the valves.

Induction System

The iVCT system allows variable control of the intake valve closing which optimizes combustion at full load providing improved power and low speed torque (broadening the torque curve). This also enables variable valve overlap which provides better fuel economy and emissions and provides optimized cold start operation with improved exhaust emissions.

Refer to ENGINE SYSTEM - GENERAL INFORMATION for basic mechanical concerns or refer to the INTRODUCTION - GAS for driveability concerns.

Valve Clearance Check

GENERAL EQUIPMENT

1. Remove the valve cover. Refer to «VALVE COVER»(ref-569568-S18678395122013072700000) .
2. NOTE: Turn the engine clockwise only, and only use the crankshaft bolt. NOTE: Measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. General Equipment: Feeler Gauge. Use a feeler gauge to measure the clearance of each valve and record its location.
3. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: The nominal clearance is: intake: 0.26 mm (0.01 in) exhaust: 0.30 mm (0.0115 in). The acceptable clearances after being fully installed are: intake: 0.23-0.28 mm (0.009-0.011 in). exhaust: 0.27-0.33 mm (0.010-0.013 in). Select tappets using this formula: 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.
4. If any tappets do not measure within specifications, install new tappets in these locations. Refer to «VALVE TAPPETS»(ref-569568-S11062742222013072700000) .

Balance Shaft Backlash

SPECIAL TOOLS Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Timing Peg, Crankshaft TDC 303-507

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Scheme 676

1. Special tool(s): Timing Peg, Crankshaft TDC 303-507. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC.
2. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC.
3. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled. Remove the 4 bolts and the balancer unit.
4. Remove the adjustment shims from the seat faces of the balancer unit.
5. NOTE: Visually inspect the balancer unit gear for damage and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit. Install the master adjustment shims (No. 50) on the seat faces of the balancer unit.
6. With the balancer unit shaft marks at the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
7. Install the balancer unit bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 52 Nm (38 lb-ft).
8. Special tool(s): Timing Peg, Crankshaft TDC 303-507. Remove the Crankshaft TDC Timing Peg. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
9. Special tool(s): Timing Peg, Crankshaft TDC 303-507. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. Remove the Crankshaft TDC Timing Peg.
10. 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 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. Special tool(s): Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C). Position 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 balancer unit. 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.
11. NOTE: If maximum backlash exceeds 0.120 mm (0.0047 in), install a new balancer unit. Using the backlash measurement, select the proper shims from the Adjustment Shim Selection Table. Remove the balancer unit from the cylinder block. Install the selected adjustment shims on the seat faces of the balancer unit.
12. Special tool(s): Timing Peg, Crankshaft TDC 303-507. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC.
13. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
14. Install the balancer unit bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 52 Nm (38 lb-ft).
15. NOTE: Remeasure 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 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. Special tool(s): Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C). Position 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 balancer unit. 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. If the backlash exceeds the specified range of 0.020 to 0.120 mm (0.0008 to 0.0047 in), install a new balancer unit and repeat the procedure.

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1. With vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Remove the ACL outlet pipe. Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-569599) .
3. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .

Valve Cover

SPECIAL TOOLS Adapter for 303-224 (Handle) 205-153 (T80T-4000-W) Installer, VCT Spark Plug Tube Seal 303-1247/2 Remover, VCT Spark Plug Tube Seal 303-1247/1

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Scheme 687

MATERIAL SPECIFICATIONS

Crankshaft Pulley

SPECIAL TOOLS Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Holding Tool, Crankshaft Damper 303-1416 Timing Peg, Crankshaft TDC 303-507

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Scheme 689

GENERAL EQUIPMENT

MATERIAL SPECIFICATIONS

Crankshaft Front Seal

SPECIAL TOOLS Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Remover, Oil Seal 303-409 (T92C-6700-CH)

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Scheme 691

MATERIAL SPECIFICATIONS

Flexplate

SPECIAL TOOLS Holding Tool, Flywheel 303-103 (T74P-8375-A)

Crankshaft Rear Seal

SPECIAL TOOLS Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1)

Scheme 692

MATERIAL SPECIFICATIONS

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1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Remove the flexplate. Refer to «FLEXPLATE»(ref-569568-S30326334392013072700000) .
3. Remove the A/C belt. Refer to «ACCESSORY DRIVE»(ref-569614) .
4. Relocate and support the component.
5. To install, tighten to 28 Nm (21 lb-ft).
6. NOTE: If the oil pan is not removed, damage to the rear oil seal retainer joint may occur.
7. Discard the specified component. Follow local disposal regulations.

Scheme 699

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Scheme 702

1. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant. Clean all mating surfaces with Motorcraft® Metal Surface Prep and Motorcraft® Silicone Gasket Remover.
2. Tighten in the sequence shown in illustration. Special Tool(s): Installer, Crankshaft Rear Main Oil Seal 303-328. Tighten to 10 Nm (89 lb-in).
3. 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.
4. Tighten finger tight.
5. NOTE: The engine front cover-to-oil pan bolts must be tightened first to align the front surface of the oil pan flush with the front surface of the engine block. Tighten to 10 Nm (89 lb-in).
6. Tighten in the sequence shown in illustration. Tighten to 20 Nm (177 lb-in).
7. Tighten to 9 Nm (80 lb-in).
8. Tighten to 25 Nm (18 lb-ft).
9. Install the A/C belt. Refer to «ACCESSORY DRIVE»(ref-569614) .
10. Install the flexplate. Refer to «FLEXPLATE»(ref-569568-S30326334392013072700000) .
11. Fill the engine with clean engine oil. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil.

Engine Front Cover

SPECIAL TOOLS Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Remover, Oil Seal 303-409 (T92C-6700-CH)

GENERAL EQUIPMENT

MATERIAL SPECIFICATIONS

Timing Drive Components

GENERAL EQUIPMENT

Camshafts

SPECIAL TOOLS Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Timing Peg, Crankshaft TDC 303-507

GENERAL EQUIPMENT

MATERIAL SPECIFICATIONS

Valve Springs

SPECIAL TOOLS Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH)

Scheme 703

Scheme 704

Scheme 705

MATERIAL SPECIFICATIONS

Valve Seals

SPECIAL TOOLS Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH) Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH) Slide Hammer 307-005 (T59L-100-B)

Scheme 706

Scheme 707

MATERIAL SPECIFICATIONS

Valve Tappets

MATERIAL SPECIFICATIONS

Cylinder Head

MATERIAL SPECIFICATIONS

Oil Filter Adapter

MATERIAL SPECIFICATIONS

Engine Oil Pressure (EOP) Switch

MATERIAL SPECIFICATIONS

Oil Pan

MATERIAL SPECIFICATIONS

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1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Remove the Air Cleaner (ACL) and the ACL outlet pipe. Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-569599) .
3. Remove the cowl panel. Refer to «FRONT END BODY PANELS»(ref-569581) .
4. Remove the HO2S and CMS. Refer to «ELECTRONIC ENGINE CONTROLS»(ref-569601) .
5. NOTE: To prevent damage to the transmission, do not loosen the transmission-to-engine bolts more than 5 mm (0.19 in). Loosen the 3 upper bellhousing-to-engine bolts 5 mm (0.19 in).
6. Loosen the 2 RH engine-to-bellhousing bolt 5 mm (0.19 in).
7. Remove the A/C belt. Refer to «ACCESSORY DRIVE»(ref-569614) .
8. Relocate and support the component.
9. Loosen the 2 LH bellhousing-to-engine bolts 5 mm (0.19 in).
10. Slide the transaxle rearward 5 mm (0.19 in).
11. To install, tighten to 28 Nm (21 lb-ft).
12. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant. Clean all mating surfaces with Motorcraft® Metal Surface Prep.

Scheme 714

1. 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.
2. Finger tight.
3. NOTE: The engine front cover-to-oil pan bolts must be tightened first to align the front surface of the oil pan flush with the front surface of the engine block. Tighten to 10 Nm (89 lb-in).
4. Tighten to 20 Nm (177 lb-in).
5. Alternate tightening the 1 LH bellhousing-to-engine and 1 RH engine-to-bellhousing bolts to slide the transaxle and engine together.
6. 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 125 Nm (92 lb-ft).
10. Tighten to 9 Nm (80 lb-in).
11. Tighten to 25 Nm (18 lb-ft).
12. Install the A/C belt. Refer to «ACCESSORY DRIVE»(ref-569614) .
13. Tighten to 48 Nm (35 lb-ft).
14. Tighten to 48 Nm (35 lb-ft).
15. Tighten to 11 Nm (97 lb-in).
16. Install the HO2S and the CMS. Refer to «ELECTRONIC ENGINE CONTROLS»(ref-569601) .
17. Install the cowl panel. Refer to «FRONT END BODY PANELS»(ref-569581) .
18. Install the ACL and the ACL outlet pipe. Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-569599) .
19. Fill the engine with clean engine oil. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil.

Oil Pump

SPECIAL TOOLS Support Bar, Engine 303-F072 Adapter for 303-290-05A Adapter for 303-290-19

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GENERAL EQUIPMENT

MATERIAL SPECIFICATIONS

Scheme 717

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1. With the engine in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-569550) .
2. Remove the engine front cover. Refer to «ENGINE FRONT COVER»(ref-569568-S39208542992013072700000) .
3. Install the Engine Support Bar. Special Tool(s): Support Bar, Engine 303-F072, Adapter for 303-290-19 and Adapter for 303-290-05A.
4. Remove the General Equipment: Floor Jack and Wood Block.
5. Relocate and support the component.
6. To install, tighten to 28 Nm (21 lb-ft).
7. Release the tension on the tensioner spring. Remove the tensioner and the 2 shoulder bolts.

Scheme 719

Scheme 720

1. NOTE: Clean the oil pump and cylinder block mating surfaces with Motorcraft® Metal Surface Prep. Tighten to: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
2. Tighten to 25 Nm (18 lb-ft).
3. Tighten to 10 Nm (89 lb-in).
4. Tighten to 10 Nm (89 lb-in). Hook the tensioner spring around the shoulder bolt.
5. NOTE: A new gasket must be installed. Tighten to 10 Nm (89 lb-in).
6. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant. Clean all mating surfaces with Motorcraft® Metal Surface Prep.
7. 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.
8. Finger tight.
9. General Equipment: Straight Edge.
10. Tighten to 20 Nm (177 lb-in).
11. Tighten to 48 Nm (35 lb-ft).
12. Tighten to 48 Nm (35 lb-ft).
13. Tighten to 9 Nm (80 lb-in).
14. Tighten to 25 Nm (18 lb-ft).
15. NOTE: Failure to position the wood block and floor jack as illustrated can result in damage to the oil pan. Install the General Equipment: Floor Jack and Wood Block.
16. Remove the Engine Support Bar. Special Tool(s): Support Bar, Engine 303-F072, Adapter for 303-290-19 and Adapter for 303-290-05A.
17. Install the engine front cover. Refer to «ENGINE FRONT COVER»(ref-569568-S39208542992013072700000) .
18. Fill the engine with clean engine oil. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil.

Engine Mount

GENERAL EQUIPMENT

SPECIAL TOOLS Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH) Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH) Slide Hammer 307-005 (T59L-100-B)

Scheme 721

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MATERIAL SPECIFICATIONS

Scheme 723

Piston

MATERIAL SPECIFICATIONS

Lower Engine Block (View 1)

Lower Engine Block (View 2)

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

Note. During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. 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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1. NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly. NOTE: The front bulkhead does not have an oil squirter. Tighten to 4 Nm (35 lb-in).
2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block and install the original main bearing beam bolts finger tight.
4. 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 each crankshaft block main bearing bore diameter.
6. Using the chart, select the crankshaft main bearings.
7. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. Using the original connecting rod cap bolts, install the 4 connecting caps and the 8 bolts. Tighten the 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. Remove the bolts and the connecting rod cap. Discard the connecting rod cap bolts.
9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.
10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
11. Remove the 10 bolts in the sequence shown in illustration and the main bearing beam. Discard the main bearing beam bolts.
12. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. NOTE: The center bulkhead is the thrust bearing. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-20 Super Premium Motor Oil.
13. 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-20 Super Premium Motor Oil.
14. NOTE: Lubricate the journals on the crankshaft with clean engine oil. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-20 Super Premium Motor Oil.
15. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-20 Super Premium Motor Oil.
16. Mounted flush.
17. NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil. NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts. Install and tighten the 10 new main bearing beam bolts. Tighten the 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.
18. Special Tool(s): Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C). 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 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
19. 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-20 Super Premium Motor Oil.
20. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal. NOTE: Make sure the piston arrow on top is facing toward the front of the engine. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-20 Super Premium Motor Oil. General Equipment: Piston Ring Compressor.
21. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten. NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation. Tighten to: 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.
22. Special Tool(s): Timing Peg, Crankshaft TDC 303-507. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC.
23. NOTE: Due to the precision interior construction of the balancer unit, 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 balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit. Install the adjustment shims in their original positions on the seat faces of the balancer unit. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
24. Tighten to: Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 52 Nm (38 lb-ft).
25. Remove the Special Tool(s): Timing Peg, Crankshaft TDC 303-507. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
26. 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 Crankshaft TDC Timing Peg. Remove the Special Tool(s): Timing Peg, Crankshaft TDC 303-507.
27. 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 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. NOTE: Position the Dial Indicator Gauge with Holding Fixture as shown in illustration. Measure the gear backlash. Special Tool(s): Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C). 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 balancer unit. 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 0.020 to 0.120 mm (0.0008 to 0.0047 in). If the backlash exceeds the specified range, carry out the Balance Shaft Backlash procedure. Refer to «BALANCE SHAFT BACKLASH»(ref-569568-S30672621492013072700000) .
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 and must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
29. NOTE: Clean the oil pump and cylinder block mating surfaces with Motorcraft® Metal Surface Prep. Tighten to: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
30. NOTE: A new gasket must be installed. Tighten to 10 Nm (89 lb-in).
31. Special Tool(s): Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1). Tighten to 10 Nm (89 lb-in).
32. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant. Clean and inspect all mating surfaces.
33. 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.
34. Tighten finger-tight.
35. General Equipment: Straight Edge.
36. Tighten in the sequence shown in illustration. Tighten to 20 Nm (177 lb-in).
37. 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 and cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep. NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence. 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.
38. Dowels must be fully seated in the cylinder block.
39. Apply a continuous bead of the specified diameter from the specified tube. Material: Silicone Gasket and Sealant TA-30.
40. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. NOTE: Lubricate the bolts with clean engine oil prior to installation. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-20 Super Premium Motor Oil. Tighten to: Stage 1: Tighten to 7 Nm (62 lb-in). Stage 2: Tighten to 15 Nm (133 lb-in). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
41. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-20 Super Premium Motor Oil.
42. NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-20 Super Premium Motor Oil.
43. Tighten to: Stage 1: Tighten the camshaft bearing cap bolts one at a time until finger-tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
44. Tighten to 11 Nm (97 lb-in).
45. Tighten to 11 Nm (97 lb-in).
46. NOTE: Before installation, clean and inspect the diamond washer for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur NOTE: The crankshaft sprocket flange must be facing away from the engine block. Install a diamond washer on both sides of the crankshaft sprocket.
47. Tighten to 25 Nm (18 lb-ft).
48. Tighten to 10 Nm (89 lb-in).
49. Tighten to 10 Nm (89 lb-in). Hook the tensioner spring around the shoulder bolt.
50. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Special Tool(s): Alignment Plate, Camshaft 303-465(T94P-6256-CH).
51. NOTE: Do not tighten the bolts at this time.
52. Tighten to 10 Nm (89 lb-in).
53. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
54. 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.
55. General Equipment: Small Pick. Using a small pick, push back and hold the ratchet mechanism.
56. General Equipment: Small Pick. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
57. 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.
58. General Equipment: Holding Pin. Tighten to 10 Nm (89 lb-in). Remove the holding pin to release the piston.
59. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: Using the flats on the camshafts to prevent camshaft rotation. Tighten to: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 60 degrees.
60. NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Clean and inspect the mounting surfaces of the engine and the front cover.
61. 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.
62. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep. Apply a continuous bead of the specified diameter from the specified tube. Material: Silicone Gasket and Sealant TA-30.
63. Tighten to: Stage 1: Tighten bolts 1 - 18 to 10 Nm (89 lb-in). Stage 2: Tighten bolt 19 to 48 Nm (35 lb-ft). Stage 3: Tighten bolt 20 to 25 Nm (18 lb-ft). Stage 4: Tighten bolts 21-23 to 48 Nm (35 lb-ft).
64. 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-20 Super Premium Motor Oil.
65. NOTE: Do not install the crankshaft pulley bolt at this time. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-20 Super Premium Motor Oil. 6 o'clock position.
66. NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur. NOTE: This step will correctly align the crankshaft pulley to the crankshaft. General Equipment: M6 Bolt.
67. NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only. NOTE: Install a new crankshaft pulley bolt. Special Tool(s): Holding Tool, Crankshaft Damper 303-1416. Tighten to: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn).
68. Remove the General Equipment: M6 Bolt.
69. Remove the Special Tool(s): Timing Peg, Crankshaft TDC 303-507.
70. Remove the Special Tool(s): Alignment Plate, Camshaft 303-465 (T94P-6256-CH).
71. NOTE: Only turn the engine in the normal direction of rotation. Turn one and three-fourths turns.
72. NOTE: Only turn the engine in the normal direction of rotation. Install the Special Tool(s): Timing Peg, Crankshaft TDC 303-507. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
73. NOTE: Only hand-tighten the bolt or damage to the front cover can occur. Install the General Equipment: M6 Bolt. Check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected.
74. Install the Special Tool(s): Alignment Plate, Camshaft 303-465 (T94P-6256-CH). If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected.
75. Remove the Special Tool(s): Alignment Plate, Camshaft 303-465 (T94P-6256-CH).
76. Do not tighten the bolts at this time.
77. Special Tool(s): Crank Sensor Alignment Tool 303-1417. Align the CKP sensor. Tighten to 7 Nm (62 lb-in).
78. Remove the General Equipment: M6 Bolt.
79. Remove the Special Tool(s): Timing Peg, Crankshaft TDC 303-507.
80. Tighten to 20 Nm (177 lb-in).
81. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Clean the valve cover gasket surface with Motorcraft® Metal Surface Prep.
82. NOTE: Installation of a new VCT solenoid seal is required if a damaged seal was removed during disassembly of the engine. Special Tool(s): Handle 205-153 and Installer, VCT Spark Plug Tube Seal 303-1247/2.
83. Visual check.
84. Apply a continuous bead of the specified diameter from the specified tube. Material: Silicone Gasket and Sealant TA-30.
85. NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Tighten to 10 Nm (89 lb-in).
86. Visual check.
87. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots. Tighten to 8 Nm (71 lb-in).
88. If equipped. Tighten to 40 Nm (30 lb-ft).
89. Visual check. Clean the specified component.
90. Tighten to 10 Nm (89 lb-in).
91. NOTE: The KS must not touch the crankcase vent oil separator. Tighten to 20 Nm (177 lb-in).
92. Tighten to 55 Nm (41 lb-ft).
93. 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. Visual check. If necessary, install new intake manifold gaskets.
94. Tighten to 18 Nm (159 lb-in).
95. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals. Install new fuel injector O-rings. Separate the fuel injectors from the fuel rail. Remove and discard the fuel injector O-rings. Install new O-rings and lubricate with clean engine oil. Install the fuel injectors onto the fuel rail.
96. Tighten to 23 Nm (17 lb-ft).
97. Tighten to 10 Nm (89 lb-in).
98. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
99. Tighten to 9 Nm (80 lb-in).
100. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
101. NOTE: Clean the gasket mating surfaces with Motorcraft® Metal Surface Prep. NOTE: Install a new gasket. Tighten to 25 Nm (18 lb-ft).
102. Visual check.
103. Tighten to 10 Nm (89 lb-in).
104. NOTE: Clean the coolant pump mating surface with Motorcraft® Metal Surface Prep. NOTE: Install a new O-ring seal. Apply the specified lubricant to the specified component. Material: Motorcraft® Orange Antifreeze/Coolant Prediluted Tighten to 10 Nm (89 lb-in).
105. Tighten to 20 Nm (177 lb-in).
106. Tighten to 11 Nm (97 lb-ft).
107. Tighten to 25 Nm (18 lb-ft).
108. Tighten to 48 Nm (35 lb-ft).
109. Tighten to 25 Nm (18 lb-ft).
110. Install the Special Tool(s): 2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent. General Equipment: Spreader Bar.
111. General Equipment: Engine Stand.
112. NOTE: Special bolts are used for installation. Do not use standard bolts. Special Tool(s): Holding Tool, Flywheel 303-103 Tighten to: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).

SPECIAL TOOLS 2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent Powertrain Lift 300-OTC1585AE or equivalent Adjustable Grip Arm, 1735A 014-00001 or equivalent

Scheme 747

Scheme 748

GENERAL EQUIPMENT

MATERIAL SPECIFICATIONS

All vehicles

Scheme 749

Scheme 750

Scheme 751

Scheme 752

Scheme 753

Scheme 754

Scheme 755

Scheme 756

Scheme 757

1. Material: Multi-Purpose Grease XL-5 (aerosol) and/or CRC® SL3151
2. NOTE: If the transmission is not positioned on the dowel pins, damage to the transmission may occur. If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.
3. Tighten to 48 Nm (35 lb-ft).
4. Tighten to 48 Nm (35 lb-ft).
5. Special Tool(s): Powertrain Lift 300-OTC1585AE or equivalent and Adjustable Grip Arm, 1735A 014-00001 or equivalent. Secure the engine to the lift table.
6. Remove the Special Tool(s): 2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent. General Equipment: Spreader Bar.
7. NOTE: Only rotate the engine in a clockwise direction only or engine damage will occur. Visual check. Turn the component CW 90 degrees. Tighten to 40 Nm (30 lb-ft).
8. Tighten to 35 Nm (26 lb-ft).
9. Tighten to 18 Nm (159 lb-in).
10. Tighten to 12 Nm (106 lb-in). Tighten to 5 Nm (44 lb-in).
11. Tighten to 48 Nm (35 lb-ft).
12. Tighten to 17 Nm (150 lb-in).
13. Special Tool(s): Powertrain Lift 300-OTC1585AE or equivalent and Adjustable Grip Arm, 1735A 014-00001 or equivalent.
14. Tighten to 148 Nm (109 lb-ft).
15. Tighten the nuts to 80 Nm (59 lb-ft). Tighten the bolts to 90 Nm (66 lb-ft).
16. Tighten to 125 Nm (92 lb-ft).
17. Remove the Special Tool(s): Powertrain Lift 300-OTC1585AE or equivalent and Adjustable Grip Arm, 1735A 014-00001 or equivalent. Vehicles with auxiliary transmission cooling
18. Tighten to 9 Nm (80 lb-in).
19. Tighten to 30 Nm (22 lb-ft).
20. Material: Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC Tighten to 9 Nm (80 lb-in).
21. Material: Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC Tighten to 9 Nm (80 lb-in). Vehicles without auxiliary transmission cooling
22. If removed, inspect the transmission mounted cooler tube backing rings and seals for damage and install new backing rings or seals as necessary. Lubricate the transmission mounted cooler tube backing rings and seals with clean transmission fluid and install on the transmission cooler tube. Seals (7D258). Backing rings (7J324).
23. Tighten to 9 Nm (80 lb-in). All vehicles
24. Both sides. Tighten to 20 Nm (177 lb-in).
25. Both sides. Tighten to 20 Nm (177 lb-in).
26. Apply the specified lubricant to the specified component. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
27. Tighten to 48 Nm (35 lb-ft).
28. Tighten to 48 Nm (35 lb-ft).
29. Install the generator. Refer to «CHARGING SYSTEM»(ref-569572) .
30. Install the accessory drive belt and the A/C belt. Refer to «ACCESSORY DRIVE»(ref-569614) .
31. Install the windshield washer bottle. Refer to «WIPERS AND WASHERS»(ref-569606) .
32. Tighten to 55 Nm (41 lb-ft).
33. Tighten to 25 Nm (18 lb-ft).
34. Tighten to 48 Nm (35 lb-ft).
35. Tighten to 25 Nm (18 lb-ft).
36. Tighten to 11 Nm (97 lb-in).
37. Install the HO2S. Refer to «ELECTRONIC ENGINE CONTROLS»(ref-569601) .
38. NOTE: Radiator and shroud removed for clarity.
39. Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-569597) .
40. Tighten to 25 Nm (18 lb-ft).
41. Tighten to 12 Nm (106 lb-in).
42. Tighten to 23 Nm (17 lb-ft).
43. Install the PCM. Refer to «ELECTRONIC ENGINE CONTROLS»(ref-569601) .
44. Install the RH and LH halfshafts. Refer to «FRONT DRIVE HALFSHAFTS»(ref-569562) .
45. Install the degas bottle. Refer to «ENGINE COOLING»(ref-569571) .
46. Install the battery tray. Refer to «BATTERY, MOUNTING AND CABLES»(ref-569582) .
47. Install the engine ACL and ACL outlet pipe. Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-569599) .
48. Install the cowl panel. Refer to «FRONT END BODY PANELS»(ref-569581) .
49. Install the RR door scuff plate trim panel. Refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-569621) .
50. Fill the engine with clean engine oil. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil.
51. Fill and bleed the cooling system. Refer to «ENGINE COOLING»(ref-569571) .
52. Fill the transmission fluid. Refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35»(ref-569558) .
53. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.