Engine - 2.0l Duratec-He Ford Focus ST III

Specifications

ENGINE SPECIFICATIONS

LUBRICANTS SPECIFICATIONS

ENGINE OIL CAPACITY SPECIFICATIONS

OIL PRESSURE SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

PISTON SPECIFICATIONS

PISTON PIN SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

VALVE SPECIFICATIONS

VALVE SPRING - COMPRESSION PRESSURE

CRANKSHAFT SPECIFICATIONS

RINGS SPECIFICATIONS

VALVE TAPPET SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CONNECTING ROD SPECIFICATIONS

Overview

The 2.0L Twin Independent Variable Cam Timing (Ti-VCT) Gasoline Direct Injection (GDI) 4-cylinder engine has the following features

1. Dual overhead camshafts
2. Four valves per cylinder
3. Composite intake manifold
4. Aluminum cylinder head
5. Gasoline Direct Injection (GDI)
6. Twin Independent Variable Cam Timing (Ti-VCT)
7. An electronic ignition system with 4 ignition coil-on-plugs

Engine Identification

Always refer to these labels when installation of new parts is necessary or when checking engine calibrations. The engine parts often differ within a CID family. Verification of the identification codes will make sure the correct parts are obtained. These codes contain all the pertinent information relating to the dates, optional equipment and revisions.

Engine Code Information Label

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

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Valve Train

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

Twin Independent Variable Cam Timing (Ti-VCT) System

The Twin Independent Variable Cam Timing (Ti-VCT) system allows variable control of intake valve closing which optimizes combustion at full load providing improved power and low speed torque (broadening the torque curve) which enables variable valve overlap which provides better fuel economy and emissions and provides optimized cold start operation with improved exhaust emissions.

PCV System

All engines are equipped with a closed-type Positive Crankcase Ventilation (PCV) system recycling the crankcase vapors to the intake manifold.

Lubrication System

The engine lubrication system is of the force-feed type in which oil is supplied under full pressure to the crankshaft, connecting rod bearings, timing chain tensioners, camshaft bearing caps and VCT solenoids. The flow of oil to the valve tappets and valve train is controlled by a restricting orifice located in the cylinder head gasket.

The lubrication system is designed to provide optimum oil flow to critical components of the engine through its entire operating range.

The heart of the system is a positive displacement internal gear oil pump.

Generically, this design is known as a gerotor pump, which operates as follows

1. The oil pump is chain driven off of the crankshaft. The oil pump is chain driven off of the crankshaft.
2. System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump. System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump.
3. Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure both at hot idle and maximum speed. Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure both at hot idle and maximum speed.
4. The relief valve calibration protects the system from excessive pressure during high-viscosity conditions. The relief valve calibration protects the system from excessive pressure during high-viscosity conditions.
5. The relief valve is designed to provide adequate connecting rod bearing lubrication under high temperature and high-speed conditions. The relief valve is designed to provide adequate connecting rod bearing lubrication under high temperature and high-speed conditions.

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For basic engine mechanical concerns.

REFER to: ENGINE .

For driveability symptoms. INTRODUCTION - GASOLINE MODELS

Special Tool(s) / General Equipment

Feeler Gauge

Check

1. Refer to: «Valve Cover»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__valve-cover) .
2. Measure the clearance of each valve and record its location. A midrange clearance is the most desirable. General Equipment : Feeler Gauge
3. NOTE: The number on the valve tappet reflects the thickness of the valve tappet. For example, a tappet with the number 3.310 has the thickness of 3.31 mm (0.1303 in). NOTE: The number on the valve tappet reflects the thickness of the valve tappet. For example, a tappet with the number 3.310 has the thickness of 3.31 mm (0.1303 in). Intake: 0.23 mm (0.0091 in) - 0.33 mm (0.0130 in). Exhaust: 0.31 mm (0.0122 in) - 0.41 mm (0.0161 in).
4. If any of the valve clearances are out of specification, select new tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location.
5. If any tappets do not measure within specifications, install new tappets in these locations. Refer to: «Valve Tappets»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__valve-tappets) .

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
2. Refer to: «BATTERY DISCONNECT AND CONNECT»(/ford/focus-st/iii-2012-2015/remont/charging-system/#battery-mounting-and-cables-except-electric) .
3. Refer to: «AIR CLEANER OUTLET PIPE»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#intake-air-distribution-and-filtering-20l-duratec-he) .
4. Refer to: «QUICK RELEASE COUPLING»(/ford/focus-st/iii-2012-2015/remont/fuel-system/#fuel-system-general-information-20l-duratec-engine__quick-release-coupling) .
5. NOTE: Position back the intake manifold to allow access to disconnect the crankcase ventilation oil separator tube from the intake manifold.

Installation

Note. If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

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1. NOTE: Install new intake manifold gaskets if necessary.
2. Finger tight.
3. Finger tight.
4. Torque : 20 Nm
5. Refer to: «QUICK RELEASE COUPLING»(/ford/focus-st/iii-2012-2015/remont/fuel-system/#fuel-system-general-information-20l-duratec-engine__quick-release-coupling) .
6. Refer to: «AIR CLEANER OUTLET PIPE»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#intake-air-distribution-and-filtering-20l-duratec-he) .
7. Refer to: «BATTERY DISCONNECT AND CONNECT»(/ford/focus-st/iii-2012-2015/remont/charging-system/#battery-mounting-and-cables-except-electric) .

Valve Cover

SPECIAL TOOL(S) / GENERAL EQUIPMENT 205-153 Handle 303-1247/1 Remover, VCT Spark Plug Tube Seal 303-1247/2 Installer, VCT Spark Plug Tube Seal

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MATERIALS SPECIFICATIONS

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. Refer to: «IGNITION COIL-ON-PLUG»(/ford/focus-st/iii-2012-2015/remont/ignition-system/#engine-ignition-20l-duratec-he__ignition-coil-on-plug) .
2. Refer to: «QUICK RELEASE COUPLING»(/ford/focus-st/iii-2012-2015/remont/fuel-system/#fuel-system-general-information-20l-duratec-engine__quick-release-coupling) .
3. If equipped.
4. NOTE: Discard the valve cover gasket.
5. Special Tool(s) : 205-153 (Handle) , 303-1247/1 (Remover, VCT Spark Plug Tube Seal)

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1. Clean and inspect the sealing surfaces.
2. Special Tool(s) : 205-153 (Handle) , 303-1247/2 (Installer, VCT Spark Plug Tube Seal)
3. Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
4. Torque : 10 Nm
5. If equipped. Torque : 3 Nm
6. Torque : 10 Nm
7. Refer to: «QUICK RELEASE COUPLING»(/ford/focus-st/iii-2012-2015/remont/fuel-system/#fuel-system-general-information-20l-duratec-engine__quick-release-coupling) .
8. Refer to: «IGNITION COIL-ON-PLUG»(/ford/focus-st/iii-2012-2015/remont/ignition-system/#engine-ignition-20l-duratec-he__ignition-coil-on-plug) .

Crankshaft Pulley

SPECIAL TOOL(S) / GENERAL EQUIPMENT 303-1521 Alignment Tool, Crankshaft Position Sensor 303-1565 Alignment Tool, Camshaft 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM 303-D055 Strap Wrench

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MATERIALS SPECIFICATIONS

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

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

Note. Early build engines have a 6-rib crankshaft pulley, late build engines have a 4-rib crankshaft pulley. Early built shown in illustration.

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
2. Remove the following items: Remove the RH front fender splash shield. Refer to: «FENDER SPLASH SHIELD»(/ford/focus-st/iii-2012-2015/remont/exterior-body-panels/#body-panel-system-front-end-body-panels-except-electric) . Refer to: «AIR CLEANER OUTLET PIPE»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#intake-air-distribution-and-filtering-20l-duratec-he) . Refer to: «ACCESSORY DRIVE BELT»(/ford/focus-st/iii-2012-2015/remont/accessory-drive-belts/#accessory-drive-system-20l-duratec-he) . Refer to: «Valve Cover»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__valve-cover) .
3. Turn the crankshaft until piston No. 1 is 45 degrees before TDC by using the guide holes on the engine front cover and the crankshaft pulley.
4. Install the special tool and using the crankshaft pulley bolt, turn the crankshaft clockwise slowly until contact is made with the special tool. Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
5. Rotate the special tool so the tool number faces down and install into the rear of the intake camshaft slot as shown in illustration. Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
6. 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. 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 special tool, and the crankshaft pulley bolt should be removed using an air impact wrench (1/2-in drive minimum). Use the special tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt. Special Tool(s) : 303-D055 (Strap Wrench) Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley.
7. Remove the diamond washer and discard.

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1. Install a new diamond washer onto the crankshaft.
2. Position the crankshaft pulley onto the crankshaft with the crankshaft pulley TDC guide hole at the 6 o'clock position. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
3. Install a standard bolt through the crankshaft pulley TDC guide hole and into the engine front cover TDC guide hole.
4. Install a new crankshaft pulley bolt. Use the special tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages: Special Tool(s) : 303-D055 (Strap Wrench) Torque : Stage 1: 100 Nm Stage 2: Tighten an additional 90°
5. Remove.
6. Do not tighten the bolts at this time.
7. Install the special tool to set the CKP sensor position and tighten the 2 bolts. Special Tool(s) : 303-1521 (Alignment Tool, Crankshaft Position Sensor) Torque : 7 Nm
8. Torque : 20 Nm
9. Remove the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
10. Install the following items: Refer to: «Valve Cover»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__valve-cover) . Refer to: «AIR CLEANER OUTLET PIPE»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#intake-air-distribution-and-filtering-20l-duratec-he) . Refer to: «ACCESSORY DRIVE BELT»(/ford/focus-st/iii-2012-2015/remont/accessory-drive-belts/#accessory-drive-system-20l-duratec-he) . Install the RH fender splash shield. Refer to: «FENDER SPLASH SHIELD»(/ford/focus-st/iii-2012-2015/remont/exterior-body-panels/#body-panel-system-front-end-body-panels-except-electric) .

Crankshaft Front Seal

SPECIAL TOOL(S) / GENERAL EQUIPMENT 303-096 Installer, Camshaft Front Oil Seal TKIT-2009TC-F 303-409 Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH

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MATERIALS SPECIFICATIONS

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

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

1. Refer to: «Crankshaft Pulley»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__crankshaft-pulley) .
2. Special Tool(s) : 303-409 (Remover, Crankshaft Seal)

1. Special Tool(s) : 303-096 (Installer, Camshaft Front Oil Seal) Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
2. Refer to: «Crankshaft Pulley»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__crankshaft-pulley) .

Engine Front Cover

SPECIAL TOOL(S) / GENERAL EQUIPMENT 303-F072 Support Bar, Engine

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MATERIALS SPECIFICATIONS

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1. Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(/ford/focus-st/iii-2012-2015/remont/manual-hvac-system/#climate-control-system-general-information-except-electric__air-conditioning-ac-system-recovery-evacuation) .
2. Loosen.
3. Refer to: «COWL PANEL GRILLE»(/ford/focus-st/iii-2012-2015/remont/exterior-body-panels/#body-panel-system-front-end-body-panels-except-electric) .
4. Install the Special Tool(s) : 303-F072 (Support Bar, Engine)
5. Refer to: «Crankshaft Front Seal»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__crankshaft-front-seal) .
6. NOTE: Discard the O-ring seal.

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1. Clean and inspect the mounting surfaces of the engine and the front cover. Material : Motorcraft® Silicone Gasket Remover / ZC-30 Material : Motorcraft® Metal Surface Prep / ZC-31-A
2. Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
3. Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
4. Torque : Tighten bolts 1 through 17 to 10 Nm Torque : Tighten bolts 19 through 21 to 48 Nm Torque : Tighten bolt 22 to 25 Nm Torque : Tighten bolt 18 to 48 Nm
5. Torque : Tighten the 2 bolts to 90 Nm Torque : Tighten the 2 nuts to 80 Nm
6. Torque : 15 Nm
7. Finger tight.
8. Torque : 25 Nm
9. Refer to: «Crankshaft Front Seal»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__crankshaft-front-seal) .
10. Remove the Special Tool(s) : 303-F072 (Support Bar, Engine)
11. Refer to: «COWL PANEL GRILLE»(/ford/focus-st/iii-2012-2015/remont/exterior-body-panels/#body-panel-system-front-end-body-panels-except-electric) .
12. Torque : 20 Nm
13. Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(/ford/focus-st/iii-2012-2015/remont/manual-hvac-system/#climate-control-system-general-information-except-electric__air-conditioning-ac-system-recovery-evacuation) .

Timing Drive Components

SPECIAL TOOL(S) / GENERAL EQUIPMENT 303-1565 Alignment Tool, Camshaft

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. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
2. Remove the following items: Refer to: «FUEL INJECTION PUMP»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#fuel-charging-and-controls-20l-duratec-he) . Refer to: «Engine Front Cover»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__engine-front-cover) .
3. Install the Camshaft Alignment Tool into the rear of both of the camshaft slots as shown in illustration and tighten the retainer. Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
4. Using the flats on the exhaust and intake camshaft to prevent camshaft rotation, loosen the exhaust and intake VCT unit bolts.
5. Using a small pick, release and hold the ratchet mechanism. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner. Insert a holding pin into the hole to retain the tensioner.

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1. Torque : 10 Nm
2. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
3. Using the edge of a vise, compress the timing chain tensioner plunger.
4. Using a small pick, push back and hold the ratchet mechanism.
5. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
6. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
7. Torque : 10 Nm
8. Torque : Stage 1: 50 Nm Stage 2: Tighten an additional 90°
9. Remove the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
10. Torque : Stage 1: 8 Nm Stage 2: Tighten an additional 60°
11. Torque : 20 Nm
12. Install the following items: Refer to: «Engine Front Cover»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__engine-front-cover) . Refer to: «FUEL INJECTION PUMP»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#fuel-charging-and-controls-20l-duratec-he) .

Camshaft

SPECIAL TOOL(S) / GENERAL EQUIPMENT 303-1565 Alignment Tool, Camshaft

MATERIALS SPECIFICATIONS

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.

Note. Failure to position the No. 1 piston at TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only.

Note. The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Note. The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the camshaft removal and installation

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
2. Refer to: «Variable Valve Timing (VVT) Unit»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he) .
3. Refer to: «Valve Clearance Check»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he) .
4. Remove the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
5. Depending on the camshaft being serviced, mark the camshaft lobe orientation onto the camshaft bearing cap.
6. If servicing the exhaust camshaft, remove the camshaft bearing cap bolts in the sequence shown in illustration and remove the exhaust camshaft.
7. If servicing the intake camshaft, remove the camshaft bearing cap bolts in the sequence shown in illustration and remove the intake camshaft.
8. Inspect the camshaft.

1. Lubricate the cylinder head and camshaft journals with clean engine oil and position the camshafts onto the cylinder head in their original location and orientation. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
2. Apply a bead of the specified diameter from the specified tube. Material : flange sealant (WSS-M2G348-A11)
3. If servicing the exhaust camshaft, install the camshaft bearing caps in their original location and orientation and tighten the camshaft bearing cap bolts in pairs in the sequence shown in illustration in 2 stages: Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 7 Nm Stage 2: 16 Nm
4. If servicing the intake camshaft, install the camshaft bearing caps in their original location and orientation and tighten the camshaft bearing cap bolts in pairs in the sequence shown in illustration in 2 stages: Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 7 Nm Stage 2: 16 Nm
5. If exhaust or intake camshafts were replaced, check the valve clearance. Refer to: «Valve Clearance Check»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he) .
6. Install the Camshaft Alignment Tool into the rear of both of the camshaft slots as shown in illustration and tighten the retainer. Install the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
7. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : 10 Nm
8. Refer to: «Variable Valve Timing (VVT) Unit»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he) .

Valve Tappets

MATERIALS SPECIFICATIONS

1. Refer to: «Camshaft»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__camshaft) .
2. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
3. Install new components as necessary.

1. To install, reverse the removal procedure.

Valve Springs

SPECIAL TOOL(S) / GENERAL EQUIPMENT 303-1249 Valve Spring Compressor TKIT-2006UF-FLM 303-300 Set, Valve Spring Compressor TKIT-2009TC-F 303-350 Compressor, Valve Spring TKIT-1989-F TKIT-1989-FLM TKIT-1989-FM TKIT-1990-LMH TKIT-2009TC-F 303-472 Adapter, Valve Spring Compressor TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2

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MATERIALS SPECIFICATIONS

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. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
2. Remove the following items: Refer to: «Valve Tappets»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__valve-tappets) . Refer to: «SPARK PLUGS»(/ford/focus-st/iii-2012-2015/remont/ignition-system/#engine-ignition-20l-duratec-he) .
3. Connect a compressed air supply to the cylinder that is being serviced.
4. Apply compressed air to the cylinder and remove the valve spring. Special Tool(s) : 303-300 (Set, Valve Spring Compressor) , 303-350 (Compressor, Valve Spring) , 303-472 (Adapter, Valve Spring Compressor) , 303-1249 (Valve Spring Compressor) Material : Multi-Purpose Grease / Motorcraft® XL-5 (aerosol) and/or CRC® SL3151 (ESB-M1C93-B)
5. Repeat the appropriate removal steps for all of the other cylinders
6. Install new parts, as necessary.

1. Special Tool(s) : 303-300 (Set, Valve Spring Compressor) , 303-350 (Compressor, Valve Spring) , 303-472 (Adapter, Valve Spring Compressor) , 303-1249 (Valve Spring Compressor) Material : Multi-Purpose Grease / Motorcraft® XL-5 (aerosol) and/or CRC® SL3151 (ESB-M1C93-B)
2. Disconnect the compressed air supply.
3. Install the following items: Refer to: «Valve Tappets»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__valve-tappets) . Refer to: «SPARK PLUGS»(/ford/focus-st/iii-2012-2015/remont/ignition-system/#engine-ignition-20l-duratec-he) .

Cylinder Head

Hose Clamp Remover/Installer

MATERIALS SPECIFICATIONS

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 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
2. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(/ford/focus-st/iii-2012-2015/remont/cooling-system-mechanical/#engine-cooling-20l-duratec-he__cooling-system-draining-and-vacuum-filling) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/focus-st/iii-2012-2015/remont/cooling-system-mechanical/#engine-cooling-20l-duratec-he__cooling-system-draining-filling-and-bleeding) .
3. Remove the following items: Refer to: «FUEL INJECTOR»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#fuel-charging-and-controls-20l-duratec-he) . Refer to: «HEATED OXYGEN SENSOR (HO2S)»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#electronic-engine-controls-20l-duratec-he__heated-oxygen-sensor-ho2s) .
4. NOTE: Discard the gasket.
5. NOTE: Discard the nuts and catalytic converter gasket.
6. Refer to: «Camshaft»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__camshaft) .
7. General Equipment : Hose Clamp Remover/Installer
8. NOTE: If the valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.

Scheme 113

Scheme 114

Scheme 115

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. 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. Material : Motorcraft® Silicone Gasket Remover / ZC-30 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. Material : Motorcraft® Silicone Gasket Remover / ZC-30 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. Material : Motorcraft® Metal Surface Prep / ZC-31-A
2. Clean and inspect the catalytic converter flange. Refer to: «EXHAUST MANIFOLD CLEANING AND INSPECTION»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-system-general-information__exhaust-manifold-cleaning-and-inspection) .
3. Refer to: Refer to: «CYLINDER HEAD DISTORTION»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-system-general-information__cylinder-head-distortion) . Refer to: «CYLINDER BLOCK DISTORTION»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-system-general-information__cylinder-block-distortion) .
4. Torque : Stage 1: 7 Nm Stage 2: 15 Nm Stage 3: 45 Nm Stage 4: 90° Stage 5: Tighten an additional 90°
5. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
6. General Equipment : Hose Clamp Remover/Installer
7. Torque : 10 Nm
8. Refer to: «Camshaft»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__camshaft) .
9. Torque : 17 Nm
10. Torque : Stage 1: 55 Nm Stage 2: Re-tighten to 55 Nm
11. Torque : 25 Nm
12. Torque : Tighten the first nut to 48 Nm Torque : Tighten the second nut to 48 Nm Torque : Re-tighten the first nut to 48 Nm
13. Torque : 25 Nm
14. Torque : 10 Nm
15. Drain and install the drain plug. Torque : 27 Nm
16. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 8 Nm Stage 2: 180°
17. Remove the following items: Refer to: «HEATED OXYGEN SENSOR (HO2S)»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#electronic-engine-controls-20l-duratec-he__heated-oxygen-sensor-ho2s) . Refer to: «FUEL INJECTOR»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#fuel-charging-and-controls-20l-duratec-he) .
18. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(/ford/focus-st/iii-2012-2015/remont/cooling-system-mechanical/#engine-cooling-20l-duratec-he__cooling-system-draining-and-vacuum-filling) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/focus-st/iii-2012-2015/remont/cooling-system-mechanical/#engine-cooling-20l-duratec-he__cooling-system-draining-filling-and-bleeding) .
19. Fill the engine with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. The exhaust manifold is an integral part of the catalytic converter and serviced as an assembly. Refer to: «CATALYTIC CONVERTER»(/ford/focus-st/iii-2012-2015/remont/exhaust/#exhaust-system-20l-duratec-he) .

1. The exhaust manifold is an integral part of the catalytic converter and serviced as an assembly. Refer to: «CATALYTIC CONVERTER»(/ford/focus-st/iii-2012-2015/remont/exhaust/#exhaust-system-20l-duratec-he) .

Oil Pan

MATERIALS SPECIFICATIONS

All vehicles

Note. Automatic transmission shown in illustration, manual transmission similar.

Scheme 116

Scheme 117

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Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
2. Refer to: «AIR CLEANER»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#intake-air-distribution-and-filtering-20l-duratec-he) . Refer to: «AIR CLEANER OUTLET PIPE»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#intake-air-distribution-and-filtering-20l-duratec-he) . Vehicles with automatic transmission
3. NOTE: This step does not apply if the engine front cover is removed.
4. NOTE: This step does not apply if the engine front cover is removed. All vehicles
5. Loosen. Distance : 0, 197 in (5 mm)
6. NOTE: This step does not apply if the engine front cover is removed.
7. Loosen. Distance : 0, 197 in (5 mm)
8. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(/ford/focus-st/iii-2012-2015/remont/accessory-drive-belts/#accessory-drive-system-20l-duratec-he__air-conditioning-ac-compressor-belt) .
9. NOTE: Support the A/C compressor. Do not allow the A/C compressor to hang by the A/C lines or damage to the A/C compressor and tubes may occur.
10. Drain and install the drain plug. Torque : 27 Nm
11. Remove.
12. Remove.
13. NOTE: This step does not apply if the engine front cover is removed.
14. Loosen. Distance : 0, 197 in (5 mm)
15. Separate the engine and transaxle. Distance : 0, 197 in (5 mm)
16. Remove.

All vehicles

Scheme 127

1. Clean and inspect all mating surfaces. Material : Motorcraft® Metal Surface Prep / ZC-31-A Material : Motorcraft® Silicone Gasket Remover / ZC-30
2. Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
3. Finger-tight.
4. Torque : 10 Nm
5. Torque : 20 Nm
6. Torque : 48 Nm
7. Torque : 48 Nm
8. Torque : 48 Nm
9. Torque : 86 Nm
10. Torque : 48 Nm
11. Torque : 25 Nm
12. Torque : 18 Nm
13. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 8 Nm Stage 2: 180°
14. Torque : 20 Nm
15. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(/ford/focus-st/iii-2012-2015/remont/accessory-drive-belts/#accessory-drive-system-20l-duratec-he__air-conditioning-ac-compressor-belt) .
16. Torque : 48 Nm Vehicles with automatic transmission
17. Torque : 10 Nm
18. NOTE: This step does not apply if the engine front cover is removed. All vehicles
19. Refer to: «AIR CLEANER»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#intake-air-distribution-and-filtering-20l-duratec-he) . Refer to: «AIR CLEANER OUTLET PIPE»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#intake-air-distribution-and-filtering-20l-duratec-he) .
20. Fill the engine with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

Oil Pump

Round-Ended Steel Rule

MATERIALS SPECIFICATIONS

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. Automatic transmission shown in illustration, manual transmission similar.

Scheme 128

Scheme 129

Scheme 130

Scheme 131

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
2. Refer to: «Engine Front Cover»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__engine-front-cover) .
3. NOTE: Support the A/C compressor. Do not allow the A/C compressor to hang by the A/C lines or damage to the A/C compressor and tubes may occur.
4. Drain and install the drain plug. Torque : 27 Nm
5. NOTE: Discard the gasket.
6. Push the tensioner spring down and release the spring from under the shoulder bolt. Remove the 2 shoulder bolts and the tensioner and chain.

Scheme 132

Scheme 133

Scheme 134

1. Clean the oil pump and cylinder block mating surfaces. Material : Motorcraft® Silicone Gasket Remover / ZC-30
2. Torque : Stage 1: 10 Nm Stage 2: 20 Nm
3. Torque : 25 Nm
4. Install the tensioner and the 2 shoulder bolts. Torque : 10 Nm Push the tensioner spring down and position the spring under the shoulder bolt.
5. Torque : 10 Nm
6. Clean and inspect all mating surfaces. Material : Motorcraft® Metal Surface Prep / ZC-31-A Material : Motorcraft® Silicone Gasket Remover / ZC-30
7. Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
8. Finger tight.
9. Align the front surface of the oil pan flush with the front surface of the engine block. General Equipment : Round-Ended Steel Rule
10. Torque : 20 Nm
11. Torque : 48 Nm
12. Torque : 48 Nm
13. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 8 Nm Stage 2: 180°
14. Torque : 25 Nm
15. Torque : 18 Nm
16. Refer to: «Engine Front Cover»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__engine-front-cover) .
17. Fill the engine with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

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

1. Refer to: «Oil Pan»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__oil-pan) .
2. Torque : 10 Nm

1. To install, reverse the removal procedure.

Oil Filter Adapter

MATERIALS SPECIFICATIONS

Scheme 135

Scheme 136

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
2. NOTE: Discard the gasket.

1. Clean and inspect the mating surfaces.
2. Torque : 25 Nm
3. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 8 Nm Stage 2: 180°

Flywheel

SPECIAL TOOL(S) / GENERAL EQUIPMENT 303-103 Holding Tool, Flywheel TKIT-2009TC-F

Scheme 137

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
2. Refer to: «CLUTCH DISC AND PRESSURE PLATE - VEHICLES WITH: 5-SPEED MANUAL TRANSMISSION - MTX75»(/ford/focus-st/iii-2012-2015/remont/clutches-manual-hydraulic/#mt-clutch) .
3. Special Tool(s) : 303-103 (Holding Tool, Flywheel)

Scheme 138

1. Special Tool(s) : 303-103 (Holding Tool, Flywheel)
2. Torque : 50 Nm Torque : 80 Nm Torque : 112 Nm
3. Refer to: «CLUTCH DISC AND PRESSURE PLATE - VEHICLES WITH: 5-SPEED MANUAL TRANSMISSION - MTX75»(/ford/focus-st/iii-2012-2015/remont/clutches-manual-hydraulic/#mt-clutch) .

Flexplate

SPECIAL TOOL(S) / GENERAL EQUIPMENT 303-103 Holding Tool, Flywheel TKIT-2009TC-F

Scheme 139

Scheme 140

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
2. Refer to: Transmission - 2.0L Duratec-HE ( «TRANSMISSION - 2.0L DURATEC-HE»(/ford/focus-st/iii-2012-2015/remont/automatic-trans/#automatic-dual-clutch-transaxle-dct-powershift-dps66dct250__transmission-20l-duratec-he) .
3. Special Tool(s) : 303-103 (Holding Tool, Flywheel)

Scheme 141

1. Special Tool(s) : 303-103 (Holding Tool, Flywheel)
2. Torque : 50 Nm Torque : 80 Nm Torque : 112 Nm
3. Refer to: «TRANSMISSION - 2.0L DURATEC-HE»(/ford/focus-st/iii-2012-2015/remont/automatic-trans/#automatic-dual-clutch-transaxle-dct-powershift-dps66dct250__transmission-20l-duratec-he) .

Crankshaft Rear Seal

SPECIAL TOOL(S) / GENERAL EQUIPMENT 303-328 Replacer, Rear Seal TKIT-1988-F TKIT-1988-FLM TKIT-1988-LM TKIT-2009TC-F

Scheme 142

MATERIALS SPECIFICATIONS

Scheme 143

Scheme 144

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
2. Refer to: «Flexplate»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__flexplate) . Refer to: «Flywheel»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__flywheel) .
3. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(/ford/focus-st/iii-2012-2015/remont/accessory-drive-belts/#accessory-drive-system-20l-duratec-he__air-conditioning-ac-compressor-belt) .
4. NOTE: Support the A/C compressor. Do not allow the A/C compressor to hang by the A/C lines or damage to the A/C compressor and tubes may occur.
5. Drain and install the drain plug. Torque : 27 Nm

Scheme 145

1. Clean and inspect all the oil pan and cylinder block mating surfaces.
2. Using the special tool, position the crankshaft rear oil seal with retainer plate onto the crankshaft. Special Tool(s) : 303-328 (Replacer, Rear Seal) Torque : 10 Nm
3. Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
4. Finger-tight.
5. Torque : 10 Nm
6. Torque : 20 Nm
7. Torque : 25 Nm
8. Torque : 18 Nm
9. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(/ford/focus-st/iii-2012-2015/remont/accessory-drive-belts/#accessory-drive-system-20l-duratec-he__air-conditioning-ac-compressor-belt) .
10. Refer to: «Flexplate»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__flexplate) . Refer to: «Flywheel»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__flywheel) .
11. Fill the engine with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

Engine Mount

Trolley Jack

Wooden Block

Scheme 146

Scheme 147

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
2. Support the engine using the oil pan. General Equipment : Trolley Jack General Equipment : Wooden Block

1. Torque : Tighten the 2 nuts to 80 Nm Torque : Tighten the 2 bolts to 90 Nm
2. Torque : 11 Nm

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

1. Refer to: «Timing Drive Components»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__timing-drive-components) .
2. Using the flats on the exhaust and intake camshaft to prevent camshaft rotation, loosen the exhaust and intake VCT unit bolts.

1. Position the exhaust and intake VCT unit and install the bolts finger tight.
2. Refer to: «Timing Drive Components»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__timing-drive-components) .

Valve Stem Seals

SPECIAL TOOL(S) / GENERAL EQUIPMENT 303-468 Remover, Valve Stem Oil Seal TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-470 Installer, Valve Stem Oil Seal TKIT-2009TC-F 307-005 Slide Hammer

Scheme 148

MATERIALS SPECIFICATIONS

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 149

1. Remove the valve spring from the valve being serviced. Refer to: «Valve Springs»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__valve-springs) .
2. Position the Valve Stem Oil Seal Remover and the Slide Hammer over the seal. Special Tool(s) : 303-468 (Remover, Valve Stem Oil Seal) , 307-005 (Slide Hammer) Pull up on the Slide Hammer and remove the seal.

1. Special Tool(s) : 303-470 (Installer, Valve Stem Oil Seal) Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
2. Install the valve spring onto the valve being serviced. Refer to: «Valve Springs»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he__valve-springs) .
3. Repeat the appropriate removal and installation steps for all of the other cylinders.

Oil Pressure Switch

MATERIALS SPECIFICATIONS

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

Scheme 150

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
2. Material : Thread Sealant with PTFE / TA-24 (WSK-M2G350-A2) Torque : 12 Nm

1. To install, reverse the removal procedure.

SPECIAL TOOL(S) / GENERAL EQUIPMENT 014-00001 ADJUSTABLE GRIP 1735A 300-OTC1585AE Powertrain Lift 300-OTC1819E 2, 200# Floor Crane, Fold Away 303-D089 Spreader Bar Hose Clamp Remover/Installer Wooden Block

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

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Scheme 167

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Scheme 169

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Scheme 177

Scheme 178

1. Refer to: «HEALTH AND SAFETY PRECAUTIONS»(/ford/focus-st/iii-2012-2015/remont/oem-general-information/#service-information-introduction-except-electric) .
2. Refer to: «JACKING AND LIFTING - OVERVIEW»(/ford/focus-st/iii-2012-2015/remont/hoistjack/#jacking-lifting-except-electric) .
3. Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(/ford/focus-st/iii-2012-2015/remont/manual-hvac-system/#climate-control-system-general-information-except-electric__air-conditioning-ac-system-recovery-evacuation) .
4. Refer to: «FUEL SYSTEM PRESSURE RELEASE»(/ford/focus-st/iii-2012-2015/remont/fuel-system/#fuel-system-general-information-20l-duratec-engine__fuel-system-pressure-release) .
5. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(/ford/focus-st/iii-2012-2015/remont/cooling-system-mechanical/#engine-cooling-20l-duratec-he__cooling-system-draining-and-vacuum-filling) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/focus-st/iii-2012-2015/remont/cooling-system-mechanical/#engine-cooling-20l-duratec-he__cooling-system-draining-filling-and-bleeding) .
6. Remove the following items: Refer to: «DEGAS BOTTLE»(/ford/focus-st/iii-2012-2015/remont/cooling-system-mechanical/#engine-cooling-20l-duratec-he__degas-bottle) . Refer to: «BATTERY TRAY»(/ford/focus-st/iii-2012-2015/remont/charging-system/#battery-mounting-and-cables-except-electric) . Refer to: «AIR CLEANER»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#intake-air-distribution-and-filtering-20l-duratec-he) . Refer to: «AIR CLEANER OUTLET PIPE»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#intake-air-distribution-and-filtering-20l-duratec-he) .
7. If equipped with automatic transmission.
8. Refer to: «POWERTRAIN CONTROL MODULE (PCM)»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#electronic-engine-controls-20l-duratec-he__powertrain-control-module-pcm) .
9. NOTE: The electrical connector is located behind the PCM case.
10. General Equipment : Hose Clamp Remover/Installer
11. If equipped.
12. Refer to: «HEATED OXYGEN SENSOR (HO2S)»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#electronic-engine-controls-20l-duratec-he__heated-oxygen-sensor-ho2s) .
13. NOTE: Discard the gasket.
14. NOTE: Discard the catalytic converter nuts and gasket.
15. Refer to: «QUICK RELEASE COUPLING»(/ford/focus-st/iii-2012-2015/remont/fuel-system/#fuel-system-general-information-20l-duratec-engine__quick-release-coupling) .
16. Refer to: «QUICK RELEASE COUPLING»(/ford/focus-st/iii-2012-2015/remont/fuel-system/#fuel-system-general-information-20l-duratec-engine__quick-release-coupling) .
17. If equipped with an automatic transmission.
18. If equipped with an automatic transmission.
19. If equipped with an automatic transmission.
20. If equipped with an automatic transmission.
21. If equipped with a manual transmission.
22. If equipped with a manual transmission.
23. Refer to: «FRONT HALFSHAFT RH»(/ford/focus-st/iii-2012-2015/remont/axle-shafts/#front-drive-halfshafts-except-electric__front-halfshaft-rh) . Refer to: «FRONT HALFSHAFT LH»(/ford/focus-st/iii-2012-2015/remont/axle-shafts/#front-drive-halfshafts-except-electric__front-halfshaft-lh) .
24. NOTE: Discard the O-ring seals.
25. General Equipment : Hose Clamp Remover/Installer
26. Drain and install the drain plug. Torque : 27 Nm
27. Refer to: «COOLING FAN MOTOR AND SHROUD»(/ford/focus-st/iii-2012-2015/remont/cooling-system-mechanical/#engine-cooling-20l-duratec-he) .
28. NOTE: Automatic transmission shown in illustration, manual transmission similar.
29. NOTE: Automatic transmission shown in illustration, manual transmission similar.
30. Special Tool(s) : 300-OTC1585AE (Powertrain Lift) , 014-00001 (ADJUSTABLE GRIP 1735A) General Equipment : Wooden Block
31. Lower the powertrain from the vehicle.
32. Clean and inspect the catalytic converter flange. Refer to: «EXHAUST MANIFOLD CLEANING AND INSPECTION»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-system-general-information__exhaust-manifold-cleaning-and-inspection) .
33. If equipped with automatic transmission.
34. Refer to: «STARTER MOTOR»(/ford/focus-st/iii-2012-2015/remont/starter/#starting-system-20l-duratec-he) .
35. If equipped with automatic transmission.
36. Special Tool(s) : 300-OTC1819E (2, 200# Floor Crane, Fold Away) , 303-D089 (Spreader Bar)
37. NOTE: Automatic transmission shown in illustration, manual transmission similar.
38. NOTE: Automatic transmission shown in illustration, manual transmission similar. If equipped with a automatic transmission, remove the 4 bellhousing-to-engine fasteners. If equipped with a manual transmission, remove the 5 bellhousing-to-engine fasteners.
39. Separate the transaxle from the engine.

SPECIAL TOOL(S) / GENERAL EQUIPMENT 205-153 Handle 303-103 Holding Tool, Flywheel TKIT-2009TC-F 303-1247/1 Remover, VCT Spark Plug Tube Seal 303-1419 Remover, 3.5L / 3.7L Stretchy Belt TKIT-2008SB-FLM 303-1565 Alignment Tool, Camshaft 303-409 Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH 303-462 Installer, Connecting Rod 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM 303-D055 Strap Wrench 307-005 Slide Hammer 310-205 Fuel Injector Brush 310-206 Remover, Fuel Injector TKIT-2009A-FLM Hose Clamp Remover/Installer

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MATERIALS SPECIFICATIONS

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

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. 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. Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

Note. Early build engines have a 6-rib crankshaft pulley, late build engines have a 4-rib crankshaft pulley.

Note. Refer to exploded views in Description and Operation .

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1. If equipped with a manual transmission.
2. If equipped with a manual transmission. Special Tool(s) : 303-103 (Holding Tool, Flywheel)
3. If equipped with a automatic transmission. Special Tool(s) : 303-103 (Holding Tool, Flywheel)
4. Mount the engine on a engine stand.
5. Refer to: «QUICK RELEASE COUPLING»(/ford/focus-st/iii-2012-2015/remont/fuel-system/#fuel-system-general-information-20l-duratec-engine__quick-release-coupling) .
6. Position the special tool between the crankshaft pulley and A/C compressor belt as shown in illustration and rotate the crankshaft clockwise. Special Tool(s) : 303-1419 (Remover, 3.5L / 3.7L Stretchy Belt)
7. Rotate the crankshaft until the special tool is at approximately the 5 o'clock position as shown in illustration. Special Tool(s) : 303-1419 (Remover, 3.5L / 3.7L Stretchy Belt)
8. Fold the special tool around the inside of the A/C compressor belt as shown in illustration. Special Tool(s) : 303-1419 (Remover, 3.5L / 3.7L Stretchy Belt)
9. In one quick motion, firmly pull the special tool and remove the A/C compressor belt. Special Tool(s) : 303-1419 (Remover, 3.5L / 3.7L Stretchy Belt)
10. Loosen.
11. NOTE: Discard the O-ring seal.
12. General Equipment : Hose Clamp Remover/Installer
13. NOTE: Remove the generator stud after generator is removed.
14. NOTE: Discard the thermostat housing gasket.
15. Refer to: «QUICK RELEASE COUPLING»(/ford/focus-st/iii-2012-2015/remont/fuel-system/#fuel-system-general-information-20l-duratec-engine__quick-release-coupling) .
16. 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.
17. General Equipment : Hose Clamp Remover/Installer
18. NOTE: Use care when removing the fuel injection pump noise insulator. Spreading the openings will aid in removing the fuel injection pump noise insulator and reduce the risk of damage.
19. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of fuel injection pump flare nut.
20. NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors. NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors. NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract.
21. Remove any of the fuel injectors that remained in the head. Special Tool(s) : 307-005 (Slide Hammer) , 310-206 (Remover, Fuel Injector)
22. Discard the specified component. Follow local disposal regulations.
23. Clean the 4 fuel injector bores in the cylinder head. Special Tool(s) : 310-205 (Fuel Injector Brush)
24. NOTE: Remove and discard the gasket.
25. NOTE: Remove and discard the gasket.
26. NOTE: The RH KS must be installed in the 6 o'clock position and the LH KS must be installed in the 4 o'clock position. Failure to follow these instructions may result in damage to the engine. NOTE: Mark the location of the RH and LH KS.
27. NOTE: Alternately loosen the 2 fuel injection pump bolts one complete revolution at a time, remove the 2 bolts and fuel injection pump.
28. NOTE: Inspect and replace the gasket, if necessary.
29. NOTE: Inspect and replace the gasket, if necessary.
30. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
31. If equipped.
32. NOTE: Discard the valve cover gasket.
33. Special Tool(s) : 205-153 (Handle) , 303-1247/1 (Remover, VCT Spark Plug Tube Seal)
34. Turn the crankshaft until piston no. 1 is 45 degrees before TDC by using the guide holes on the engine front cover and the crankshaft pulley.
35. Install the special tool and using the crankshaft pulley bolt, turn the crankshaft clockwise slowly until contact is made with the special tool. Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC) , 303-507 (Timing Peg, Crankshaft TDC)
36. Install the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
37. Special Tool(s) : 303-D055 (Strap Wrench)
38. NOTE: Remove the diamond washer and discard.
39. Special Tool(s) : 303-409 (Remover, Crankshaft Seal)
40. Using a wrench on the flats of the exhaust camshaft to prevent camshaft rotation, loosen the exhaust camshaft phaser and sprocket bolt.
41. Using a wrench on the flats of the intake camshaft to prevent camshaft rotation, loosen the intake camshaft phaser and sprocket bolt.
42. Using a small pick, release and hold the ratchet mechanism. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner. Insert a holding pin into the hole to retain the tensioner.
43. NOTE: The phaser and sprocket bolts must be discarded and new installed.
44. Remove the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
45. 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. 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.
46. 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.
47. Install new components as necessary.
48. NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
49. 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. 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. Material : Motorcraft® Silicone Gasket Remover / ZC-30 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. Material : Motorcraft® Silicone Gasket Remover / ZC-30 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. Material : Motorcraft® Metal Surface Prep / ZC-31-A
50. Support the cylinder head on a bench with the head gasket side up. Refer to: «CYLINDER HEAD DISTORTION»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-system-general-information__cylinder-head-distortion) . Refer to: «CYLINDER BLOCK DISTORTION»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-system-general-information__cylinder-block-distortion) .
51. NOTE: Discard the gasket.
52. Push the tensioner spring down and release the spring from under the shoulder bolt. Remove the 2 shoulder bolts and the tensioner and chain.
53. Remove the Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
54. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
55. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
56. Remove the piston/rod assembly from the engine block. Special Tool(s) : 303-462 (Installer, Connecting Rod)
57. Refer to: «PISTON INSPECTION»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-system-general-information__piston-inspection) .
58. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
59. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. NOTE: The center bulkhead has the thrust bearing.
60. NOTE: If the engine piston oil coolers are being reused, mark them in order for correct location during reassembly. NOTE: The front bulkhead does not have an engine piston oil cooler.

SPECIAL TOOL(S) / GENERAL EQUIPMENT 303-1249 Valve Spring Compressor TKIT-2006UF-FLM 303-300 Set, Valve Spring Compressor TKIT-2009TC-F 303-350 Compressor, Valve Spring TKIT-1989-F TKIT-1989-FLM TKIT-1989-FM TKIT-1990-LMH TKIT-2009TC-F 303-468 Remover, Valve Stem Oil Seal TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-470 Installer, Valve Stem Oil Seal TKIT-2009TC-F 303-472 Adapter, Valve Spring Compressor TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 307-005 Slide Hammer

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MATERIALS SPECIFICATIONS

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1. Remove the 2 bolts and the LH and RH engine lift eyes.
2. Inspect and replace the gasket, if necessary.
3. Remove the 4 spark plugs.
4. Apply compressed air to the cylinder and remove the valve spring. Special Tool(s) : 303-300 (Set, Valve Spring Compressor) , 303-350 (Compressor, Valve Spring) , 303-472 (Adapter, Valve Spring Compressor) , 303-1249 (Valve Spring Compressor) Material : Multi-Purpose Grease / Motorcraft® XL-5 (aerosol) and/or CRC® SL3151 (ESB-M1C93-B)
5. Repeat the appropriate removal steps for all of the other cylinders.
6. Install new parts, as necessary.
7. Position the Valve Stem Oil Seal Remover and the Slide Hammer over the seal. Special Tool(s) : 303-468 (Remover, Valve Stem Oil Seal) , 307-005 (Slide Hammer) Pull up on the Slide Hammer and remove the seal.
8. Remove the valves.
9. NOTE: Install new parts, as necessary. The end of the stem for grooves or scoring. The valve face and the edge for pits, grooves or scores. The valve head for signs of burning, erosion, warpage and cracking. The valve margin for wear.

Scheme 245

1. Coat the valve stems with clean engine oil and install the valves. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
2. Special Tool(s) : 303-470 (Installer, Valve Stem Oil Seal) Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
3. Special Tool(s) : 303-300 (Set, Valve Spring Compressor) , 303-350 (Compressor, Valve Spring) , 303-472 (Adapter, Valve Spring Compressor) , 303-1249 (Valve Spring Compressor) Material : Multi-Purpose Grease / Motorcraft® XL-5 (aerosol) and/or CRC® SL3151 (ESB-M1C93-B)
4. Install the 4 spark plugs. Torque : 15 Nm
5. Torque : 10 Nm
6. Install the LH and RH engine lift eyes and the 2 bolts. Torque : 53 Nm

Piston

MATERIALS SPECIFICATIONS

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1. Refer to: «PISTON INSPECTION»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-system-general-information__piston-inspection) .

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1. Indicates front of engine.
2. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
3. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
4. NOTE: The upper and lower compression rings are to be fitted with the identification marks on the upper side. NOTE: Arrows faces the front of the engine. NOTE: Align the piston rings on the piston. Upper compression ring gap location. Lower compression ring gap location. Upper oil control segment ring gap location. Expander ring gap location. Lower oil control segment ring gap location.

SPECIAL TOOL(S) / GENERAL EQUIPMENT 100-002 Holding Fixture with Dial Indicator Gauge 205-153 Handle 303-096 Installer, Camshaft Front Oil Seal TKIT-2009TC-F 303-103 Holding Tool, Flywheel TKIT-2009TC-F 303-1247/2 Installer, VCT Spark Plug Tube Seal 303-1252/2 Tool, Stretchy Belt Installer 303-1521 Alignment Tool, Crankshaft Position Sensor 303-1565 Alignment Tool, Camshaft 303-1567 Sizer, Teflon Seal 303-328 Replacer, Rear Seal TKIT-1988-F TKIT-1988-FLM TKIT-1988-LM TKIT-2009TC-F 303-462 Installer, Connecting Rod 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM 303-D032 Compressor, Piston Ring 303-D055 Strap Wrench 310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM Hose Clamp Remover/Installer Round-Ended Steel Rule

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MATERIALS SPECIFICATIONS

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

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Note. 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.

Note. Refer to exploded views in Description and Operation .

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1. Torque : 4 Nm
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. Torque : Stage 1: 5 Nm Stage 2: 25 Nm Stage 3: Tighten an additional 90°
5. Measure each crankshaft block main bearing bore diameter.
6. Using the chart, select the crankshaft main bearings.
7. Using the original connecting rod cap bolts, install the connecting caps and bolts and tighten the bolts in 2 stages: Torque : Stage 1: 29 Nm Stage 2: Tighten an additional 90°
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.
12. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
13. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
14. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
15. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
16. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
17. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 5 Nm Stage 2: 25 Nm Stage 3: Tighten an additional 90°
18. Measure crankshaft end play. Special Tool(s) : 100-002 (Holding Fixture with Dial Indicator Gauge) 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 0.2-0.43 mm (0.008-0.017 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
19. Piston to be assembled with the arrow pointing to the front of the engine.
20. Connecting rod to be assembled with the front marks pointing to the front of the engine.
21. Install the piston and connecting rod assemblies. Special Tool(s) : 303-D032 (Compressor, Piston Ring) , 303-462 (Installer, Connecting Rod) Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
22. Install the connecting rod caps and the new bolts and tighten the bolts in 2 stages: Torque : Stage 1: 29 Nm Stage 2: Tighten an additional 90°
23. Install the special tool and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the special tool. The engine is now at TDC. Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
24. Material : Motorcraft® Metal Surface Prep / ZC-31-A Torque : Stage 1: 10 Nm Stage 2: 20 Nm
25. Torque : 25 Nm
26. Install the diamond washer and the crankshaft sprocket.
27. Install the chain on the oil pump sprocket and install the tensioner and the 2 shoulder bolts. Torque : 10 Nm Push the tensioner spring down and position the spring under the shoulder bolt.
28. Position the crankshaft rear oil seal with retainer plate onto the crankshaft. Special Tool(s) : 303-328 (Replacer, Rear Seal) Torque : 10 Nm
29. Torque : 10 Nm
30. Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
31. Finger-tight.
32. Align the front surface of the oil pan flush with the front surface of the engine block. General Equipment : Round-Ended Steel Rule
33. Torque : 20 Nm
34. Torque : Stage 1: 7 Nm Stage 2: 15 Nm Stage 3: 45 Nm Stage 4: 90° Stage 5: Tighten an additional 90°
35. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
36. Material : flange sealant (WSS-M2G348-A11)
37. Install the camshaft bearing caps in their original location and orientation and tighten the camshaft bearing cap bolts in pairs in the sequence shown in illustration in 2 stages: Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 7 Nm Stage 2: 16 Nm
38. If camshafts were replaced, check that the camshaft end play is within specification.
39. If camshafts were replaced, check the valve clearance. Refer to: «Valve Clearance Check»(/ford/focus-st/iii-2012-2015/remont/mechanical/#engine-20l-duratec-he) .
40. Install the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
41. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : 10 Nm
42. Finger tight.
43. Torque : 10 Nm
44. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
45. Using the edge of a vise, compress the timing chain tensioner plunger.
46. Using a small pick, push back and hold the ratchet mechanism.
47. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
48. Install a holding pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
49. Install the timing chain tensioner and the 2 bolts, then remove the holding pin to release the piston. Torque : 10 Nm
50. Torque : Stage 1: 50 Nm Stage 2: Tighten an additional 90°
51. Clean and inspect the mounting surfaces of the engine and the front cover. Material : Motorcraft® Silicone Gasket Remover / ZC-30
52. 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.
53. 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.
54. Install engine front cover. Torque : Stage 1: Tighten bolts 1 through 17 to 10 Nm Stage 2: Tighten bolts 19 through 21 to 48 Nm Stage 3: Tighten bolt 22 to 25 Nm Stage 4: Tighten bolt 18 to 48 Nm
55. Special Tool(s) : 303-096 (Installer, Camshaft Front Oil Seal) Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
56. NOTE: Install a new diamond washer.
57. Position the crankshaft pulley onto the crankshaft with the crankshaft pulley TDC guide hole at the 6 o'clock position. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
58. Install a standard bolt through the crankshaft pulley TDC guide hole and into the engine front cover.
59. Special Tool(s) : 303-D055 (Strap Wrench) Torque : Stage 1: 100 Nm Stage 2: Tighten an additional 90°
60. Finger tight.
61. Install the special tool to set the CKP sensor position and tighten the 2 bolts. Special Tool(s) : 303-1521 (Alignment Tool, Crankshaft Position Sensor) Torque : 7 Nm
62. Clean and inspect the sealing surfaces of the valve cover.
63. Special Tool(s) : 205-153 (Handle) , 303-1247/2 (Installer, VCT Spark Plug Tube Seal)
64. 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 Motorcraft Metal Surface Prep.
65. Torque : 10 Nm
66. If equipped. Torque : 3 Nm
67. NOTE: Inspect the ignition coil boot for rips, nicks or tears. Remove and discard the damaged ignition coil boots.
68. Material : Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A) Torque : 10 Nm
69. Torque : 10 Nm
70. Torque : Stage 1: 8 Nm Stage 2: Tighten an additional 60°
71. Torque : 20 Nm
72. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
73. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
74. Turn the crankshaft clockwise until the fuel injection pump cam lobe is at BDC.
75. Install the fuel injection pump and loosely install 2 new fuel injection pump bolts, alternately tighten each bolt one complete revolution until seated. Torque : Stage 1: 20 Nm Stage 2: Tighten an additional 45°
76. Torque : 48 Nm
77. Torque : 25 Nm
78. Torque : 20 Nm
79. Torque : 25 Nm
80. Torque : 10 Nm
81. Pull the lower Teflon® seal away from the injector with narrow tip pliers.
82. Carefully cut and discard the lower fuel injector Teflon® seals.
83. Place the special tool, knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed. Special Tool(s) : 303-1567 (Sizer, Teflon Seal)
84. Install the new lower Teflon® seals on the narrow end of the Arbor (part of the special tool), then install the Arbor on the fuel injector tips. Special Tool(s) : 310-207 (Installer, Fuel Injector Seal Assembly) , 303-1567 (Sizer, Teflon Seal)
85. Using the Pusher Tool (part of the special tool), slide the Teflon® seals off of the Arbor and into the groove on the fuel injectors. Special Tool(s) : 310-207 (Installer, Fuel Injector Seal Assembly) , 303-1567 (Sizer, Teflon Seal)
86. Slide the special tool off the end of the fuel injector to size the seal. Special Tool(s) : 303-1567 (Sizer, Teflon Seal)
87. Install the new upper fuel injector O-ring seal support rings and the new upper fuel injector O-ring seals. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
88. NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup. NOTE: The fuel rail pressure sensor must be replaced if it is removed from the fuel rail.
89. Install the fuel rail by pushing down on the fuel rail face above the injectors and install the 4 bolts. Torque : 25 Nm
90. Hand tighten the high pressure fuel tube-to-fuel rail flare nut. Hand tighten the high pressure fuel tube-to-fuel injection pump flare nut.
91. Finger tight.
92. Torque : Stage 1: 15 Nm Stage 2: 45°
93. Tighten the high pressure fuel tube-to-fuel injection pump flare nut in the following 2 stages: Torque : Stage 1: 15 Nm Stage 2: 45°
94. Torque : 10 Nm
95. NOTE: Use care when installing the fuel injection pump noise insulator. Spreading the openings will aid in installing the fuel injection pump noise insulator and reduce the risk of damage.
96. General Equipment : Hose Clamp Remover/Installer
97. NOTE: Inspect and install new intake manifold gaskets if necessary.
98. Finger tight.
99. Torque : 20 Nm
100. Refer to: «QUICK RELEASE COUPLING»(/ford/focus-st/iii-2012-2015/remont/fuel-system/#fuel-system-general-information-20l-duratec-engine__quick-release-coupling) .
101. Torque : 10 Nm
102. NOTE: Install the generator stud before the generator is installed. Torque : Tighten the generator stud to 8 Nm Torque : Tighten the nut and 2 bolts to 25 Nm
103. General Equipment : Hose Clamp Remover/Installer
104. Torque : 25 Nm
105. Torque : 10 Nm
106. Finger tight.
107. Torque : 25 Nm
108. NOTE: Under no circumstances should the A/C compressor belt, accessory drive belt, tensioner or pulleys be lubricated as potential damage to the belt material and tensioner damping mechanism will occur. Do not apply any fluids or belt dressing to the A/C compressor belt, accessory drive belt or pulleys.
109. Tighten. Torque : 20 Nm
110. Position the A/C compressor belt onto the A/C compressor pulley and around the special tool on the crankshaft pulley. Make sure that the belt is engaged with the crankshaft pulley and rotate the crankshaft clockwise to install the A/C compressor belt. Special Tool(s) : 303-1252/2 (Tool, Stretchy Belt Installer)
111. Torque : 17 Nm
112. Torque : 10 Nm
113. Refer to: «QUICK RELEASE COUPLING»(/ford/focus-st/iii-2012-2015/remont/fuel-system/#fuel-system-general-information-20l-duratec-engine__quick-release-coupling) .
114. Remove the engine from the engine stand.
115. If equipped with a automatic transmission. Special Tool(s) : 303-103 (Holding Tool, Flywheel) Torque : Stage 1: 50 Nm Stage 2: 80 Nm Stage 3: 112 Nm
116. If equipped with a manual transmission. Special Tool(s) : 303-103 (Holding Tool, Flywheel) Torque : Stage 1: 50 Nm Stage 2: 80 Nm Stage 3: 112 Nm
117. Position the clutch disc on the clutch pressure plate. Using a clutch aligner, centralize the clutch disc to the clutch pressure plate.
118. Using a clutch aligner, position the clutch disc and clutch pressure plate on the flywheel. Torque : 29 Nm

SPECIAL TOOL(S) / GENERAL EQUIPMENT 014-00001 ADJUSTABLE GRIP 1735A 300-OTC1585AE Powertrain Lift 300-OTC1819E 2, 200# Floor Crane, Fold Away 303-D089 Spreader Bar Hose Clamp Remover/Installer Wooden Block

Scheme 294

Scheme 295

Scheme 296

MATERIALS SPECIFICATIONS

Scheme 297

1. Lift the engine and position the engine and transaxle together. Special Tool(s) : 300-OTC1819E (2, 200# Floor Crane, Fold Away) , 303-D089 (Spreader Bar)
2. NOTE: Use caution not to damage the transmission wiring harness or sensors. NOTE: If using the existing automatic transmission clutch assembly, align the index marks on the flexplate and the clutch stud made during removal. NOTE: Automatic transmission shown in illustration, manual transmission similar. If equipped with automatic transmission, install the 4 bellhousing-to-engine fasteners. Torque : 45 Nm If equipped with manual transmission, install the 5 bellhousing-to-engine fasteners. Torque : 45 Nm
3. Torque : 20 Nm
4. Torque : 45 Nm
5. Raise the engine and transaxle assembly onto the lift table. Special Tool(s) : 300-OTC1819E (2, 200# Floor Crane, Fold Away) , 303-D089 (Spreader Bar)
6. Attach the powertrain to the powertrain lift. Special Tool(s) : 014-00001 (ADJUSTABLE GRIP 1735A) , 300-OTC1585AE (Powertrain Lift) General Equipment : Wooden Block
7. If equipped with an automatic transmission.
8. Torque : Stage 1: Tighten nuts 1, 5 and 3 to 12 Nm Stage 2: Tighten all nuts to 25 Nm
9. Refer to: «STARTER MOTOR»(/ford/focus-st/iii-2012-2015/remont/starter/#starting-system-20l-duratec-he) .
10. If equipped with automatic transmission.
11. Position the powertrain into the vehicle.
12. Torque : 150 Nm
13. Torque : Stage 1: Tighten the 2 nuts to 80 Nm Stage 2: Tighten the 2 bolts to 90 Nm
14. Torque : 86 Nm
15. Torque : 48 Nm
16. Torque : 48 Nm
17. Refer to: «COOLING FAN MOTOR AND SHROUD»(/ford/focus-st/iii-2012-2015/remont/cooling-system-mechanical/#engine-cooling-20l-duratec-he) .
18. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 8 Nm Stage 2: 180°
19. General Equipment : Hose Clamp Remover/Installer
20. NOTE: Install 2 new O-ring seals. Torque : Tighten the nuts to 20 Nm Torque : Tighten the bolt to 25 Nm
21. Torque : 18 Nm
22. Refer to: «FRONT HALFSHAFT RH»(/ford/focus-st/iii-2012-2015/remont/axle-shafts/#front-drive-halfshafts-except-electric__front-halfshaft-rh) . Refer to: «FRONT HALFSHAFT LH»(/ford/focus-st/iii-2012-2015/remont/axle-shafts/#front-drive-halfshafts-except-electric__front-halfshaft-lh) .
23. If equipped with a manual transmission. Torque : 48 Nm
24. If equipped with a manual transmission.
25. If equipped with an automatic transmission. Torque : 10 Nm
26. If equipped with an automatic transmission.
27. If equipped with an automatic transmission.
28. If equipped with an automatic transmission.
29. Refer to: «QUICK RELEASE COUPLING»(/ford/focus-st/iii-2012-2015/remont/fuel-system/#fuel-system-general-information-20l-duratec-engine__quick-release-coupling) .
30. Refer to: «QUICK RELEASE COUPLING»(/ford/focus-st/iii-2012-2015/remont/fuel-system/#fuel-system-general-information-20l-duratec-engine__quick-release-coupling) .
31. Torque : 17 Nm
32. Using a new gasket, position the catalytic converter and install the 5 new catalytic converter manifold-to-cylinder head nuts and tighten in 2 stages in the sequence shown in illustration. Torque : Stage 1: 55 Nm Stage 2: Re-tighten to 55 Nm
33. Torque : 25 Nm
34. Torque : Tighten the first nut to 48 Nm Torque : Tighten the second nut to 48 Nm Torque : Re-tighten the first nut to 48 Nm
35. Torque : 25 Nm
36. Torque : 10 Nm
37. Refer to: «HEATED OXYGEN SENSOR (HO2S)»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#electronic-engine-controls-20l-duratec-he__heated-oxygen-sensor-ho2s) .
38. If equipped.
39. General Equipment : Hose Clamp Remover/Installer
40. Torque : 20 Nm
41. NOTE: The electrical connector is located behind the PCM case.
42. Refer to: «POWERTRAIN CONTROL MODULE (PCM)»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#electronic-engine-controls-20l-duratec-he__powertrain-control-module-pcm) .
43. If equipped with automatic transmission.
44. Install the following items: Refer to: «AIR CLEANER»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#intake-air-distribution-and-filtering-20l-duratec-he) . Refer to: «AIR CLEANER OUTLET PIPE»(/ford/focus-st/iii-2012-2015/remont/removal-installation/#intake-air-distribution-and-filtering-20l-duratec-he) . Refer to: «BATTERY TRAY»(/ford/focus-st/iii-2012-2015/remont/charging-system/#battery-mounting-and-cables-except-electric) . Refer to: «DEGAS BOTTLE»(/ford/focus-st/iii-2012-2015/remont/cooling-system-mechanical/#engine-cooling-20l-duratec-he__degas-bottle) .
45. If equipped with manual transmission, fill and bleed the clutch system. Refer to: «CLUTCH SYSTEM BLEEDING»(/ford/focus-st/iii-2012-2015/remont/clutches-manual-hydraulic/#manual-transmission-and-clutch-general-information__clutch-system-bleeding) .
46. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(/ford/focus-st/iii-2012-2015/remont/cooling-system-mechanical/#engine-cooling-20l-duratec-he__cooling-system-draining-and-vacuum-filling) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/focus-st/iii-2012-2015/remont/cooling-system-mechanical/#engine-cooling-20l-duratec-he__cooling-system-draining-filling-and-bleeding) .
47. Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(/ford/focus-st/iii-2012-2015/remont/manual-hvac-system/#climate-control-system-general-information-except-electric__air-conditioning-ac-system-recovery-evacuation) .
48. Fill the engine with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

See also:
• ENGINE
• JACKING AND LIFTING - OVERVIEW
• BATTERY DISCONNECT AND CONNECT
• AIR CLEANER OUTLET PIPE
• QUICK RELEASE COUPLING
• IGNITION COIL-ON-PLUG
• FENDER SPLASH SHIELD
• ACCESSORY DRIVE BELT
• AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING
• FUEL INJECTION PUMP
• SPARK PLUGS
• COOLING SYSTEM DRAINING AND VACUUM FILLING
• COOLING SYSTEM DRAINING, FILLING AND BLEEDING
• HEATED OXYGEN SENSOR (HO2S)
• EXHAUST MANIFOLD CLEANING AND INSPECTION
• CYLINDER HEAD DISTORTION
• CYLINDER BLOCK DISTORTION
• CATALYTIC CONVERTER
• AIR CONDITIONING (A/C) COMPRESSOR BELT
• CLUTCH DISC AND PRESSURE PLATE - VEHICLES WITH: 5-SPEED MANUAL TRANSMISSION - MTX75
• TRANSMISSION - 2.0L DURATEC-HE
• SERVICE INFORMATION
• FUEL SYSTEM PRESSURE RELEASE
• DEGAS BOTTLE
• POWERTRAIN CONTROL MODULE (PCM)
• FRONT HALFSHAFT RH
• FRONT HALFSHAFT LH
• COOLING FAN MOTOR AND SHROUD
• STARTER MOTOR
• PISTON INSPECTION
• CLUTCH SYSTEM BLEEDING
• Valve Cover
• Valve Tappets
• Crankshaft Pulley
• Crankshaft Front Seal
• Engine Front Cover
• Variable Valve Timing (VVT) Unit
• Camshaft
• Oil Pan
• Flexplate
• Flywheel
• Timing Drive Components
• Valve Springs