Engine System - General Information: Component Locations Ford Flex I

Special Tool(s)

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

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

Note. Refer to the appropriate ENGINE - 3.5L or ENGINE - 3.5L GTDI for the specification.

1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play.
2. Position the camshaft to the rear of the cylinder head.
3. Zero the Dial Indicator Gauge.
4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play.

1. If camshaft end play exceeds specifications, install a new camshaft and recheck end play.
2. If camshaft end play exceeds specification after camshaft installation, install a new cylinder head.

Scheme 862

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

Note. Refer to the appropriate ENGINE - 3.5L or ENGINE - 3.5L GTDI for the specification.

Scheme 863

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

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

Note. Refer to the appropriate ENGINE - 3.5L or ENGINE - 3.5L GTDI for the specification.

Scheme 864

1. NOTE: Camshaft journals must be within specifications before checking runout. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft runout. Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial Indicator Gauge reading.

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

Note. Refer to the appropriate ENGINE - 3.5L or ENGINE - 3.5L GTDI for the specification.

Scheme 865

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

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

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Note. Refer to the appropriate ENGINE - 3.5L or ENGINE - 3.5L GTDI for the specification.

Scheme 867

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

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

Scheme 868

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

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

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

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

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

Note. Refer to the appropriate ENGINE - 3.5L or ENGINE - 3.5L GTDI for the specification.

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

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Scheme 872

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

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

Note. Refer to the appropriate ENGINE - 3.5L or ENGINE - 3.5L GTDI for the specification.

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Scheme 874

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

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

Note. Refer to the appropriate ENGINE - 3.5L or ENGINE - 3.5L GTDI for the specification.

Scheme 875

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

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

Note. Refer to the appropriate ENGINE - 3.5L or ENGINE - 3.5L GTDI for the specification.

Scheme 876

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

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

Note. Refer to the appropriate ENGINE - 3.5L or ENGINE - 3.5L GTDI for the specification.

Scheme 877

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

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

Scheme 878

Note. Refer to the appropriate ENGINE - 3.5L or ENGINE - 3.5L GTDI for the specification.

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

Scheme 879

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

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

Scheme 880

Note. Refer to the appropriate ENGINE - 3.5L or ENGINE - 3.5L GTDI for the specification.

Scheme 881

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

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

Note. Refer to the appropriate ENGINE - 3.5L or ENGINE - 3.5L GTDI for the specification.

Scheme 882

1. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, silicone sealant, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check. NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end. Using a Straightedge and a Feeler Gauge Set, inspect the cylinder head for flatness in the sequence shown in illustration.

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

Note. Refer to the appropriate ENGINE - 3.5L or ENGINE - 3.5L GTDI for the specification.

Scheme 883

1. NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end. Use a Straightedge and a Feeler Gauge Set to inspect the cylinder block for flatness.

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

Scheme 884

1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket sealing surfaces.
2. NOTE: New exhaust manifold gaskets, studs, nuts and/or bolts must be installed when an exhaust manifold is serviced. NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end. Using the Straightedge and a Feeler Gauge Set, check the exhaust manifold sealing surface for warpage. If the warpage is greater than 0.76 mm (0.0299 in), install a new exhaust manifold.

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

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