Engine Mechanical - 2.0L-GTDI: Removal & Installation Ford Explorer V

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. Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.
2. Position the intake manifold and connect the crankcase ventilation oil separator tube. Attach the 2 KS wiring harness retainers from the intake manifold. Connect the TB electrical connector and attach the wiring harness retainer to the TB.
3. Install the intake manifold and the 5 bolts. Tighten in the sequence shown in illustration to 20 Nm (177 lb-in). Install the vacuum tube into the quick connect coupling.
4. Connect the 2 vacuum hoses to the intake manifold. Connect the vacuum tube quick connect coupling. REFER to «QUICK CONNECT COUPLING»(ref-517564-S07557795332012121200000) . Attach the vacuum hose retainer to the intake manifold.
5. Attach the 2 fuel tube retaining clips to the intake manifold.
6. Install the EVAP canister purge valve and EVAP tube assembly. Install the engine appearance cover mounting stud. Tighten to 5 Nm (44 lb-in). Connect the EVAP canister purge valve electrical connector. Connect the EVAP tube to the EVAP canister purge valve and the ACL outlet pipe. REFER to «QUICK CONNECT COUPLING»(ref-517564-S07557795332012121200000) .
7. Connect the FRP sensor and MAP sensor electrical connectors. Attach the 2 EVAP tube retainers to the intake manifold. Attach the heater hose to the retaining clip.
8. Connect the CAC outlet tube to the TB. Tighten the clamp to 5 Nm (44 lb-in). Connect the EVAP tube to the CAC outlet tube. REFER to «QUICK CONNECT COUPLING»(ref-517564-S07557795332012121200000) .
9. Install the underbody shield and the 4 retainers.
10. Connect the battery ground cable. REFER to «BATTERY DISCONNECT»(ref-517589-S39248827582012121200000) .

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 AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Release the fuel pressure. REFER to «FUEL SYSTEM PRESSURE RELEASE»(ref-517564-S07897741922012121200000) .
3. Disconnect the battery ground cable. REFER to «BATTERY DISCONNECT»(ref-517589-S39248827582012121200000) .
4. Disconnect the EVAP canister purge valve electrical connector and vapor tube. REFER to «QUICK CONNECT COUPLING»(ref-517564-S07557795332012121200000) .
5. Loosen the 4 retainers and remove the underbody shield.
6. Remove the ACL outlet pipe, the turbocharger inlet pipe and the CAC inlet/intermediate inlet tube assembly. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
7. Remove the coil-on-plug assemblies. REFER to «ENGINE IGNITION SYSTEM - 2.0L-GTDI»(ref-517571)
8. Disconnect the fuel supply tube from the fuel jumper tube and the fuel jumper tube from the fuel injection pump. REFER to «QUICK CONNECT COUPLING»(ref-517564-S07557795332012121200000) . Detach the 2 fuel tube retainers from the intake manifold. Remove the bolt and the fuel jumper tube.
9. Remove the oil level indicator. Remove the nut, the bolt and the CAC intermediate tube mounting bracket.
10. Disconnect the FRP sensor and the MAP sensor electrical connectors.
11. Disconnect the 5 engine wiring harness electrical connectors. Detach the 6 wiring harness retainers.
12. Disconnect the 2 vacuum hoses from the vacuum reservoir. Disconnect the vacuum tube quick connect coupling. REFER to «QUICK CONNECT COUPLING»(ref-517564-S07557795332012121200000) . Detach the 3 vacuum hose retainers.
13. Loosen the 14 valve cover retainers and remove the valve cover. Discard the valve cover gasket.
14. NOTE: The VCT solenoid seals should only be replaced if they are damaged. Remove any damaged VCT solenoid seals using the 205-153 (T80T-4000-W) and 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 and inspect the sealing surfaces.
2. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine. Using the 205-153 (T80T-4000-W) and 303-1247/2 , install new VCT solenoid seals.
3. NOTE: The valve cover must be secured within 10 minutes of sealant 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. Apply a 5.5 mm (0.216 in) drop of Silicone Gasket and Sealant to the 6 locations shown in illustration.
4. Using a new gasket install the valve cover. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
5. Connect the 2 vacuum hoses to the vacuum reservoir. Connect the vacuum tube quick connect coupling. REFER to «QUICK CONNECT COUPLING»(ref-517564-S07557795332012121200000) . Attach the 3 vacuum hose retainers.
6. Connect the 5 engine wiring harness electrical connectors. Attach the 6 wiring harness retainers.
7. Connect the FRP sensor and the MAP sensor electrical connectors.
8. Install the CAC intermediate tube mounting bracket, the nut and the bolt. Tighten to 8 Nm (71 lb-in). Install the oil level indicator.
9. Connect the fuel supply tube from the fuel jumper tube and the fuel jumper tube from the fuel injection pump. REFER to «QUICK CONNECT COUPLING»(ref-517564-S07557795332012121200000) . Attach the 2 fuel tube retainers to the intake manifold. Install the fuel jumper tube bolt. Tighten to 8 Nm (71 lb-in).
10. Install the coil-on-plug assemblies. REFER to «ENGINE IGNITION SYSTEM - 2.0L-GTDI»(ref-517571)
11. Install the ACL outlet pipe, the turbocharger inlet pipe and the CAC inlet/intermediate inlet tube assembly. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
12. Install the underbody shield and the 4 retainers.
13. Connect the EVAP canister purge valve electrical connector and vapor tube. REFER to «QUICK CONNECT COUPLING»(ref-517564-S07557795332012121200000) .
14. Connect the battery ground cable. REFER to «BATTERY DISCONNECT»(ref-517589-S39248827582012121200000) .

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 «FENDER SPLASH SHIELD»(ref-517609-S36660239832012121200000) .
2. Loosen the 4 retainers and remove the underbody shield.
3. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt from the crankshaft pulley.
4. Remove the brake vacuum pump. REFER to «BRAKE VACUUM PUMP»(ref-517556-S14386392052012121200000) .
5. Remove the valve cover. REFER to «Valve Cover»(ref-517530-S21116338972012121200000) .
6. Remove the 2 bolts and the rear intake camshaft cap.
7. Using a wrench on the flats of the intake camshaft to prevent cam rotation, remove the brake vacuum pump adapter.
8. NOTE: Turn the engine in the normal direction of rotation only. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the TDC marked tooth on the crankshaft pulley (located on the 20th tooth counterclockwise from the missing tooth) at the 6 o'clock position.
9. Remove the 2 bolts, the 2 nuts and the RH halfshaft bracket.
10. Remove the engine plug bolt.
11. Install the 303-507 .
12. NOTE: The 303-507 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 shown removed in graphic for clarity. Rotate the crankshaft slowly clockwise until the crankshaft contacts the 303-507 . The TDC marked tooth on the crankshaft pulley will align with the center line of the CKP sensor.
13. NOTE: The 303-1565 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 303-1565 cannot be installed, remove the 303-507 and rotate the crankshaft three-fourths of a revolution clockwise and repeat the previous 2 steps of this procedure. Install the 303-1565 into the rear of the intake camshaft slot as shown in illustration.
14. 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. The diamond washer must be replaced. Remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur. Use the 303-D055 (D85L-6000-A) to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt. Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley. Remove the diamond washer and discard.
15. If the diamond washer did not come off with the crankshaft pulley, remove the washer from the crankshaft and discard.

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1. Install a new diamond washer.
2. NOTE: Apply clean engine oil on the seal contact area before installing. Position the crankshaft pulley onto the crankshaft and align the TDC marked tooth on the crankshaft pulley with the center line of the CKP sensor.
3. Install the 303-1521 onto the TDC marked tooth on the crankshaft pulley. Install a new crankshaft pulley bolt and washer. Tighten to 20 Nm (177 lb-in). Remove the 303-1521 .
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 303-D055 (D85L-6000-A) and the bolt should be tightened using hand tools only. Use the 303-D055 (D85L-6000-A) to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (one-fourth turn).
5. Remove the 303-507 .
6. Remove the 303-1565 .
7. NOTE: Only turn the engine in the normal direction of rotation. Turn the crankshaft clockwise one and three-fourths turns. Install the 303-507 .
8. NOTE: The engine front cover is shown removed in graphic for clarity. Rotate the crankshaft slowly clockwise until the crankshaft contacts the 303-507 . The TDC marked tooth on the crankshaft pulley will align with the center line of the CKP sensor.
9. Install the 303-1565 to check the position of the camshaft. If it is not possible to install the 303-1565 , the engine valve timing must be corrected by repeating this procedure.
10. Install the 303-1521 . If the 303-1521 does not align with the TDC marked tooth on the crankshaft pulley, loosen the 2 CKP sensor bolts and adjust the sensor until the tool is installed. Tighten the 2 CKP sensor bolts to 7 Nm (62 lb-in). Remove the 303-1521 .
11. Remove the 303-1565 .
12. Remove the 303-507 .
13. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
14. Install the RH halfshaft bracket, the 2 bolts and the 2 nuts. Tighten to 25 Nm (18 lb-ft).
15. Using a wrench on the flats of the intake camshaft to prevent cam rotation, install the brake vacuum pump adapter. Tighten to 63 Nm (46 lb-ft).
16. 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 1 mm (0.039 in) beads of Gasket Maker to the intake rear camshaft bearing cap mating surface as shown in illustration.
17. NOTE: Wipe off any excess sealer from the vacuum pump sealing surface of the cylinder head and camshaft cap. Install the rear intake camshaft cap and the 2 bolts. Tighten the bolts in 2 stages: Stage 1: Tighten to 7 Nm (62 lb-in). Stage 2: Tighten to 16 Nm (142 lb-in).
18. Install the valve cover. REFER to «Valve Cover»(ref-517530-S21116338972012121200000) .
19. Install the brake vacuum pump. REFER to «BRAKE VACUUM PUMP»(ref-517556-S14386392052012121200000) .
20. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt on the crankshaft pulley.
21. Install the underbody shield and tighten the 4 retainers.
22. Install the RH fender splash shield. REFER to «FENDER SPLASH SHIELD»(ref-517609-S36660239832012121200000) .
23. 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.

Scheme 599

1. Remove the crankshaft pulley. REFER to «Crankshaft Pulley»(ref-517530-S37426306982012121200000) .
2. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal. Using 303-409 (T92C-6700-CH), remove the crankshaft front oil seal.

Scheme 600

1. NOTE: Remove the through-bolt from 303-096 (T74P-6150-A). NOTE: Lubricate the oil seal with clean engine oil. Using 303-096 (T74P-6150-A), install the crankshaft front oil seal.
2. Install the crankshaft pulley. REFER to «Crankshaft Pulley»(ref-517530-S37426306982012121200000) .

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 AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Remove the CAC inlet tube. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
3. Loosen the 3 coolant pump pulley bolts.
4. Remove the crankshaft front seal. REFER to «Crankshaft Front Seal»(ref-517530-S36845517572012121200000) .
5. Disconnect the CKP sensor electrical connector.
6. Remove the 2 bolts and the CKP sensor.
7. Remove the engine mount. REFER to «Engine Mount»(ref-517530-S06674160682012121200000) .
8. Remove the 2 bolts and the accessory drive belt tensioner. Remove the accessory drive belt.
9. Remove the 4 bolts and the idler pulley bracket.
10. Remove the 3 bolts and the coolant pump pulley.
11. Remove the nut and the ground strap. Detach the 2 wiring harness retainers from the engine front cover.
12. 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. Remove the 21 bolts, the stud bolt and the engine front cover. Clean and inspect the mounting surfaces of the engine and the front cover.

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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 3 mm (0.12 in) bead of Silicone Gasket and Sealant to the sealing surface of the front cover. Apply a 2 mm (0.08 in) bead of Silicone Gasket and Sealant to the 5 center sealing surface 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 beads of Silicone Gasket and Sealant that are 2 mm (0.08 in) in diameter and 5 mm (0.20 in) in length across the cylinder head and cylinder block joint areas.
3. Install the engine front cover, the 21 bolts and the stud bolt. 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. Install the ground strap and nut. Tighten to 9 Nm (80 lb-in). Attach the 2 wiring harness retainers to the engine front cover.
5. Install the coolant pump pulley and the 3 bolts.
6. Install the idler pulley bracket and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
7. Position the accessory drive belt and install the accessory drive belt tensioner and 2 bolts. Tighten to 25 Nm (18 lb-ft).
8. Install the engine mount. REFER to «Engine Mount»(ref-517530-S06674160682012121200000) .
9. Install the CKP sensor and the 2 bolts. Align the CKP sensor so the 2 bolts are located in the middle of the adjustment slots. Tighten to 7 Nm (62 lb-in).
10. Connect the CKP sensor electrical connector.
11. Install the crankshaft front seal. REFER to «Crankshaft Front Seal»(ref-517530-S36845517572012121200000) .
12. Tighten the 3 coolant pump pulley bolts.
13. Install the CAC inlet tube. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .

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 AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Remove the fuel injection pump and tappet. REFER to «FUEL INJECTION PUMP»(ref-517565-S13776337462012121200000) .
3. Remove the RH fender splash shield. REFER to «FENDER SPLASH SHIELD»(ref-517609-S36660239832012121200000) .
4. Using the crankshaft pulley bolt, rotate the engine clockwise until the fuel injection cam lobe is at zero lift.
5. Remove the 4 stud bolts and the fuel injection pump housing.
6. Remove the engine front cover. REFER to «Engine Front Cover»(ref-517530-S30307900532012121200000) .
7. NOTE: The 303-1565 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Install the 303-1565 into the rear of both of the camshaft slots as shown in illustration. Tighten the retainer.
8. NOTE: Do not rely on the 303-1565 to prevent camshaft rotation. Damage to the tool or the camshaft can occur. Using a wrench on the flats of the exhaust camshaft to prevent camshaft rotation, loosen the exhaust camshaft phaser and sprocket bolt.
9. NOTE: The 303-1565 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Using a wrench on the flats of the intake camshaft to prevent camshaft rotation, loosen the intake camshaft phaser and sprocket bolt.
10. Compress the timing chain tensioner in the following sequence. 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 paper clip into the hole to retain the tensioner.
11. Remove the 2 bolts and the timing chain tensioner.
12. Remove the timing chain tensioner arm. Remove the 2 bolts and the timing chain guide. Remove the timing chain.

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1. Install the timing chain onto the 2 camshaft phaser and sprockets and the crankshaft sprocket. Install the timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in). Install the timing chain arm. 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. Using a small pick, push back and hold the ratchet mechanism.
4. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
5. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
6. Install the timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the paper clip to release the piston.
7. NOTE: Do not rely on the 303-1565 to prevent camshaft rotation. Damage to the tool or the camshaft can occur. Using a wrench on the flats of the exhaust camshaft to prevent camshaft rotation, tighten the exhaust camshaft phaser and sprocket bolt. Tighten to 72 Nm (53 lb-ft).
8. NOTE: The 303-1565 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Using a wrench on the flats of the intake camshaft to prevent camshaft rotation, tighten the intake camshaft phaser and sprocket bolt. Tighten to 72 Nm (53 lb-ft).
9. Install the front cover. REFER to «Engine Front Cover»(ref-517530-S30307900532012121200000) .
10. Using the crankshaft pulley bolt, rotate the engine clockwise until the fuel injection cam lobe is at zero lift.
11. Inspect the fuel injection pump housing gasket and replace as necessary.
12. Install the fuel injection pump housing and the 4 bolts. Tighten to 15 Nm (133 lb-in) plus an additional 60 degrees.
13. Install the RH fender splash shield. REFER to «FENDER SPLASH SHIELD»(ref-517609-S36660239832012121200000) .
14. Install the fuel injection pump. REFER to «FUEL INJECTION PUMP»(ref-517565-S13776337462012121200000) .

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.

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1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Check the valve clearance. REFER to «Valve Clearance Check»(ref-517530-S30478342972012121200000) .
3. Remove the camshaft phaser and sprockets. REFER to «Camshaft Phaser and Sprocket»(ref-517530-S33059749212012121200000) .
4. NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Remove the Camshaft Alignment Tool from the rear of both of the camshaft slots.
5. Remove the 2 bolts and the 2 VCT solenoids.
6. Remove the 3 bolts and the front camshaft bearing cap.
7. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. NOTE: Note the position of the camshaft lobes on the No. 1 cylinder for installation reference. NOTE: Mark the location and orientation of each camshaft bearing cap. Remove the camshafts from the engine. Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps. Remove the camshaft bearing caps. Remove the camshafts.

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1. 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 1 mm (0.039 in) beads of Gasket Maker to the exhaust rear camshaft bearing cap as shown in illustration.
2. NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the 303-465 (T94P-6256-CH) 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. 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).
3. NOTE: Lubricate the camshaft journals and the front camshaft bearing cap with clean engine oil. Install the front camshaft bearing cap and the 3 bolts. 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).
4. Install the 2 VCT solenoids and the 2 bolts. Tighten to 10 Nm (89 lb-in). NOTE: The 303-1565 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Install the 303-1565 into the rear of both of the camshaft slots as shown in illustration. Tighten the retainer. Install the camshaft phaser and sprockets. REFER to «Camshaft Phaser and Sprocket»(ref-517530-S33059749212012121200000) .

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 634

Scheme 635

1. Remove the timing drive components. REFER to «Timing Drive Components»(ref-517530-S21934824052012121200000) .
2. Remove the 2 bolts and the intake and exhaust camshaft phaser and sprockets.
3. Remove and discard the 2 washers.

Scheme 636

1. NOTE: Do not reuse the camshaft phaser and sprocket washers. New washers must be installed. Install 2 new washers.
2. 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. Install the intake and exhaust camshaft phaser and sprockets. Install the 2 bolts finger-tight.
3. Install the timing drive components. REFER to «Timing Drive Components»(ref-517530-S21934824052012121200000) .

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. Removal steps in this procedure may contain installation details.

Scheme 637

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Remove the camshafts. REFER to «Camshafts»(ref-517530-S13083194142012121200000) .
3. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: Lubricate the valve tappets with clean engine oil prior to installing. Remove the 16 valve tappets.
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 (0.144 in). Inspect the valve tappets. REFER to «VALVE TAPPET INSPECTION»(ref-517560-S31217765382012121200000) .

1. 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.

Scheme 638

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Remove the valve tappets. REFER to «Valve Tappets»(ref-517530-S05691237862012121200000) .
3. Remove the spark plugs. REFER to «SPARK PLUGS»(ref-517571-S07718097222012121200000) .
4. NOTE: Use compressed air at 7 bar (101 psi) to 10 bar (145 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.
5. NOTE: Place all parts in order to one side. Apply compressed air to the cylinder and remove the valve spring. Using 303-300 (T87C-6565-A), 303-350 (T89P-6565-A), 303-472 (T94P-6565-AH) and 303-1249 compress the valve spring and 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. Using 303-300 (T87C-6565-A), 303-350 (T89P-6565-A), 303-472 (T94P-6565-AH) and 303-1249 compress the valve spring and install the valve collet using some grease and a small screwdriver.
2. Disconnect the compressed air supply.
3. Repeat the appropriate removal and installation steps for all of the other cylinders.
4. Install the spark plugs. REFER to «SPARK PLUGS»(ref-517571-S07718097222012121200000) .
5. Install the valve tappets. REFER to «Valve Tappets»(ref-517530-S05691237862012121200000) .

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 639

1. Remove the valve spring. REFER to «Valve Springs»(ref-517530-S14382321302012121200000) .
2. Remove and discard the valve seal. Position 303-468 (T94P-6510-AH) and 307-005 (T59L-100-B) over the seal. Pull up on 307-005 (T59L-100-B) and 303-468 (T94P-6510-AH) and remove the seal.

Scheme 640

1. NOTE: Lubricate the valve seal with clean engine oil prior to installing. Using 303-470 (T94P-6510-CH), install the valve seal.
2. Install the valve spring. REFER to «Valve Springs»(ref-517530-S14382321302012121200000) .

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 641

Scheme 642

Scheme 643

Scheme 644

Scheme 645

Scheme 646

Scheme 647

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Release the fuel system pressure. REFER to «FUEL SYSTEM PRESSURE RELEASE»(ref-517564-S07897741922012121200000) .
3. Remove the turbocharger. REFER to «TURBOCHARGER»(ref-517569-S36605769712012121200000) .
4. Remove and discard the engine oil filter.
5. Remove the fuel injectors. REFER to «FUEL INJECTORS»(ref-517565-S19062643532012121200000) .
6. Remove the camshafts. REFER to «Camshafts»(ref-517530-S13083194142012121200000) .
7. Remove the bolt and ground wire from the cylinder head.
8. Disconnect the 4 coolant hoses from the coolant outlet. Disconnect the ECT sensor electrical connector.
9. Slide the insulator up and disconnect the CHT electrical connector.
10. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. Remove the 16 valve tappets.
11. 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 (0.144 in). Inspect the valve tappets. REFER to «VALVE TAPPET INSPECTION»(ref-517560-S31217765382012121200000) .
12. Remove the 10 bolts and the cylinder head. Discard the bolts.
13. Remove and discard the head gasket.

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.

Scheme 648

Scheme 649

Scheme 650

Scheme 651

Scheme 652

1. 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 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 Motorcraft® Silicone Gasket Remover following package directions, and allow to set for several minutes. Remove the Motorcraft® Silicone Gasket Remover with a plastic scraper. A second application of Motorcraft® Silicone Gasket Remover may be required if residual traces of silicone or gasket material remain. Apply Motorcraft® 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 «CYLINDER HEAD DISTORTION»(ref-517560-S31172092332012121200000) , and «CYLINDER BLOCK DISTORTION»(ref-517560-S26323227782012121200000) .
3. Install a new cylinder head gasket.
4. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. Install the cylinder head and the 10 new bolts. Tighten the bolts 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.
5. NOTE: Lubricate the valve tappets with clean engine oil prior to installing. Install the 16 valve tappets in their original positions.
6. Connect the CHT electrical connector and slide the insulator down.
7. Connect the 4 coolant hoses to the coolant outlet. Connect the ECT sensor electrical connector.
8. Install the ground wire and bolt on the cylinder head. Tighten to 20 Nm (177 lb-in).
9. Install the camshafts. REFER to «Camshafts»(ref-517530-S13083194142012121200000) .
10. Install the fuel injectors. REFER to «FUEL INJECTORS»(ref-517565-S19062643532012121200000) .
11. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
12. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter. Install a new engine oil filter. Tighten to 8 Nm (71 lb-in) plus an additional 180 degrees.
13. Install the turbocharger. REFER to «TURBOCHARGER»(ref-517569-S36605769712012121200000) .
14. Fill the engine with clean engine 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 AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Remove the oil pan. REFER to «Oil Pan»(ref-517530-S04566033582012121200000) .
3. NOTE: A new gasket must be installed. Remove the 2 bolts and the oil pump screen and pickup tube. Discard the gasket. To install, tighten to 10 Nm (89 lb-in).

1. To install, reverse the removal procedure.

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

Scheme 653

Scheme 654

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Loosen the 4 retainers and remove the underbody shield.
3. NOTE: Lubricate the new engine oil filter gasket with clean engine oil prior to installing the new oil filter. Remove and discard the oil filter and gasket. Disconnect the EOP switch electrical connector. To install, tighten the new oil filter to 8 Nm (71 lb-in) plus an additional 180 degrees.
4. NOTE: Install a new oil filter adapter gasket. Remove the 4 bolts and the oil filter adapter. Discard the gasket. To install, tighten the oil filter adapter bolts to 25 Nm (18 lb-ft). To install, tighten the oil cooler bolt to 23 Nm (17 lb-ft), then tighten an additional 75 degrees, pause, tighten an additional 15 degrees.

1. To install, reverse the removal procedure.

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

Scheme 655

Scheme 656

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Disconnect the battery ground cable. REFER to «BATTERY DISCONNECT»(ref-517589-S39248827582012121200000) .
3. Loosen the 4 retainers and remove the underbody shield.
4. Using hose clamp pliers, clamp off the 2 oil cooler coolant hoses.
5. NOTE: If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may cause engine failure. To diagnose mechanical concerns, REFER to «SYMPTOM CHART(S)»(ref-517560-S28288183012012121200000) . Loosen the 2 clamps and disconnect the 2 coolant hoses. Remove the bolt and the oil cooler. To install, tighten to 23 Nm (17 lb-ft), then tighten an additional 75 degrees, pause, tighten an additional 15 degrees.

1. To install, reverse the removal procedure.

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

Scheme 657

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Loosen the 4 retainers and remove the underbody shield.
3. NOTE: Apply thread sealant to the EOP switch threads. Disconnect the EOP switch electrical connector. Remove the EOP switch. To install, tighten to 15 Nm (133 lb-in).

1. To install, reverse the removal procedure.

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

Scheme 658

Scheme 659

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Loosen the 4 retainers and remove the underbody shield.
3. Using a floor jack and a wooden block, support the engine.
4. Remove the 2 bolts, the A/C tube retaining clip and position the degas bottle aside. To install, tighten to 9 Nm (80 lb-in).
5. Remove the 4 nuts, the 3 bolts and the engine support insulator. To install, tighten bolts to 90 Nm (66 lb-ft). To install, tighten nuts to 125 Nm (92 lb-ft).

1. To install, reverse the removal procedure.