Engine - 2.0L Duratec-He: Removal & Installation

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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Scheme 29: Installation

Scheme 30

NOTE: Install new intake manifold gaskets if necessary.
Finger tight.
Finger tight.
Torque : 20 Nm
Refer to: «QUICK RELEASE COUPLING»(ref-515980-S11306190512012120400000) .
Refer to: «AIR CLEANER OUTLET PIPE»(ref-515968-S05863009252012120400000) .
Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-515950-S24980559872012120400000) .

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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Scheme 31: Removal

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Refer to: «IGNITION COIL-ON-PLUG»(ref-515981-S23741769452012120400000) .
Refer to: «QUICK RELEASE COUPLING»(ref-515980-S11306190512012120400000) .
If equipped.
NOTE: Discard the valve cover gasket.
Special Tool(s) : 205-153 (Handle) , 303-1247/1 (Remover, VCT Spark Plug Tube Seal)

Scheme 39

Clean and inspect the sealing surfaces.
Special Tool(s) : 205-153 (Handle) , 303-1247/2 (Installer, VCT Spark Plug Tube Seal)
Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
Torque : 10 Nm
If equipped. Torque : 3 Nm
Torque : 10 Nm
Refer to: «QUICK RELEASE COUPLING»(ref-515980-S11306190512012120400000) .
Refer to: «IGNITION COIL-ON-PLUG»(ref-515981-S23741769452012120400000) .

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. 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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Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
Remove the following items: Remove the RH front fender splash shield. Refer to: «FENDER SPLASH SHIELD»(ref-515949-S09347435982012120400000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-515968-S05863009252012120400000) . Refer to: «ACCESSORY DRIVE BELT»(ref-515982-S08866593742012120400000) . Refer to: «Valve Cover»(ref-515979-S27070655882012120400000) .
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.
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)
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)
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.
Remove the diamond washer and discard.

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Install a new diamond washer onto the crankshaft.
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)
Install a standard bolt through the crankshaft pulley TDC guide hole and into the engine front cover TDC guide hole.
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°
Remove.
Do not tighten the bolts at this time.
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
Torque : 20 Nm
Remove the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
Install the following items: Refer to: «Valve Cover»(ref-515979-S27070655882012120400000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-515968-S05863009252012120400000) . Refer to: «ACCESSORY DRIVE BELT»(ref-515982-S08866593742012120400000) . Install the RH fender splash shield. Refer to: «FENDER SPLASH SHIELD»(ref-515949-S09347435982012120400000) .

Refer to: «Crankshaft Pulley»(ref-515979-S13941580902012120400000) .
Special Tool(s) : 303-409 (Remover, Crankshaft Seal)

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)
Refer to: «Crankshaft Pulley»(ref-515979-S13941580902012120400000) .

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Scheme 50: Removal

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Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
Remove the following items: Refer to: «FUEL INJECTION PUMP»(ref-515983-S06341686522012120400000) . Refer to: «Engine Front Cover»(ref-515979-S10154444992012120400000) .
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)
Using the flats on the exhaust and intake camshaft to prevent camshaft rotation, loosen the exhaust and intake VCT unit bolts.
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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Torque : 10 Nm
NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
Using the edge of a vise, compress the timing chain tensioner plunger.
Using a small pick, push back and hold the ratchet mechanism.
While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
Torque : 10 Nm
Torque : Stage 1: 50 Nm Stage 2: Tighten an additional 90°
Remove the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
Torque : Stage 1: 8 Nm Stage 2: Tighten an additional 60°
Torque : 20 Nm
Install the following items: Refer to: «Engine Front Cover»(ref-515979-S10154444992012120400000) . Refer to: «FUEL INJECTION PUMP»(ref-515983-S06341686522012120400000) .

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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Scheme 61: Removal

Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
Refer to: «Variable Valve Timing (VVT) Unit»(ref-515979-S42939152422012120400000) .
Refer to: «Valve Clearance Check»(ref-515979-S00510071122012120400000) .
Remove the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
Depending on the camshaft being serviced, mark the camshaft lobe orientation onto the camshaft bearing cap.
If servicing the exhaust camshaft, remove the camshaft bearing cap bolts in the sequence shown in illustration and remove the exhaust camshaft.
If servicing the intake camshaft, remove the camshaft bearing cap bolts in the sequence shown in illustration and remove the intake camshaft.
Inspect the camshaft.

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)
Apply a bead of the specified diameter from the specified tube. Material : flange sealant (WSS-M2G348-A11)
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
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
If exhaust or intake camshafts were replaced, check the valve clearance. Refer to: «Valve Clearance Check»(ref-515979-S00510071122012120400000) .
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)
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : 10 Nm
Refer to: «Variable Valve Timing (VVT) Unit»(ref-515979-S42939152422012120400000) .

Refer to: «Camshaft»(ref-515979-S25527374962012120400000) .
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
Install new components as necessary.

To install, reverse the removal procedure.

Scheme 62

Scheme 62: Removal

Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
Remove the following items: Refer to: «Valve Tappets»(ref-515979-S00305267832012120400000) . Refer to: «SPARK PLUGS»(ref-515981-S28839310102012120400000) .
Connect a compressed air supply to the cylinder that is being serviced.
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)
Repeat the appropriate removal steps for all of the other cylinders
Install new parts, as necessary.

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)
Disconnect the compressed air supply.
Install the following items: Refer to: «Valve Tappets»(ref-515979-S00305267832012120400000) . Refer to: «SPARK PLUGS»(ref-515981-S28839310102012120400000) .

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Scheme 63: Removal

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Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-515984-S15674360012012120400000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-515984-S18220348442012120400000) .
Remove the following items: Refer to: «FUEL INJECTOR»(ref-515983-S32664634342012120400000) . Refer to: «HEATED OXYGEN SENSOR (HO2S)»(ref-515938-S11048006112012120400000) .
NOTE: Discard the gasket.
NOTE: Discard the nuts and catalytic converter gasket.
Refer to: «Camshaft»(ref-515979-S25527374962012120400000) .
General Equipment : Hose Clamp Remover/Installer
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 77

Scheme 77: Installation

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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
Clean and inspect the catalytic converter flange. Refer to: «EXHAUST MANIFOLD CLEANING AND INSPECTION»(ref-515962-S00490536562012120400000) .
Refer to: Refer to: «CYLINDER HEAD DISTORTION»(ref-515962-S03531406522012120400000) . Refer to: «CYLINDER BLOCK DISTORTION»(ref-515962-S26744535742012120400000) .
Torque : Stage 1: 7 Nm Stage 2: 15 Nm Stage 3: 45 Nm Stage 4: 90° Stage 5: Tighten an additional 90°
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
General Equipment : Hose Clamp Remover/Installer
Torque : 10 Nm
Refer to: «Camshaft»(ref-515979-S25527374962012120400000) .
Torque : 17 Nm
Torque : Stage 1: 55 Nm Stage 2: Re-tighten to 55 Nm
Torque : 25 Nm
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
Torque : 25 Nm
Torque : 10 Nm
Drain and install the drain plug. Torque : 27 Nm
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 8 Nm Stage 2: 180°
Remove the following items: Refer to: «HEATED OXYGEN SENSOR (HO2S)»(ref-515938-S11048006112012120400000) . Refer to: «FUEL INJECTOR»(ref-515983-S32664634342012120400000) .
Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-515984-S15674360012012120400000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-515984-S18220348442012120400000) .
Fill the engine with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

The exhaust manifold is an integral part of the catalytic converter and serviced as an assembly. Refer to: «CATALYTIC CONVERTER»(ref-515985-S25261672492012120400000) .

The exhaust manifold is an integral part of the catalytic converter and serviced as an assembly. Refer to: «CATALYTIC CONVERTER»(ref-515985-S25261672492012120400000) .

All vehicles

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

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Scheme 80: Removal

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Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
Refer to: «AIR CLEANER»(ref-515968-S10605516232012120400000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-515968-S05863009252012120400000) . Vehicles with automatic transmission
NOTE: This step does not apply if the engine front cover is removed.
NOTE: This step does not apply if the engine front cover is removed. All vehicles
Loosen. Distance : 0, 197 in (5 mm)
NOTE: This step does not apply if the engine front cover is removed.
Loosen. Distance : 0, 197 in (5 mm)
Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-515982-S36573478082012120400000) .
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.
Drain and install the drain plug. Torque : 27 Nm
Remove.
Remove.
NOTE: This step does not apply if the engine front cover is removed.
Loosen. Distance : 0, 197 in (5 mm)
Separate the engine and transaxle. Distance : 0, 197 in (5 mm)
Remove.

All vehicles

Scheme 91

Clean and inspect all mating surfaces. Material : Motorcraft® Metal Surface Prep / ZC-31-A Material : Motorcraft® Silicone Gasket Remover / ZC-30
Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
Finger-tight.
Torque : 10 Nm
Torque : 20 Nm
Torque : 48 Nm
Torque : 48 Nm
Torque : 48 Nm
Torque : 86 Nm
Torque : 48 Nm
Torque : 25 Nm
Torque : 18 Nm
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 8 Nm Stage 2: 180°
Torque : 20 Nm
Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-515982-S36573478082012120400000) .
Torque : 48 Nm Vehicles with automatic transmission
Torque : 10 Nm
NOTE: This step does not apply if the engine front cover is removed. All vehicles
Refer to: «AIR CLEANER»(ref-515968-S10605516232012120400000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-515968-S05863009252012120400000) .
Fill the engine with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

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

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Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
Refer to: «Engine Front Cover»(ref-515979-S10154444992012120400000) .
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.
Drain and install the drain plug. Torque : 27 Nm
NOTE: Discard the gasket.
Push the tensioner spring down and release the spring from under the shoulder bolt. Remove the 2 shoulder bolts and the tensioner and chain.

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Scheme 96: Installation

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Scheme 98

Clean the oil pump and cylinder block mating surfaces. Material : Motorcraft® Silicone Gasket Remover / ZC-30
Torque : Stage 1: 10 Nm Stage 2: 20 Nm
Torque : 25 Nm
Install the tensioner and the 2 shoulder bolts. Torque : 10 Nm Push the tensioner spring down and position the spring under the shoulder bolt.
Torque : 10 Nm
Clean and inspect all mating surfaces. Material : Motorcraft® Metal Surface Prep / ZC-31-A Material : Motorcraft® Silicone Gasket Remover / ZC-30
Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
Finger tight.
Align the front surface of the oil pan flush with the front surface of the engine block. General Equipment : Round-Ended Steel Rule
Torque : 20 Nm
Torque : 48 Nm
Torque : 48 Nm
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque : Stage 1: 8 Nm Stage 2: 180°
Torque : 25 Nm
Torque : 18 Nm
Refer to: «Engine Front Cover»(ref-515979-S10154444992012120400000) .
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.

Refer to: «Oil Pan»(ref-515979-S16132401172012120400000) .
Torque : 10 Nm

To install, reverse the removal procedure.

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

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

Refer to: «Timing Drive Components»(ref-515979-S16145562092012120400000) .
Using the flats on the exhaust and intake camshaft to prevent camshaft rotation, loosen the exhaust and intake VCT unit bolts.

Position the exhaust and intake VCT unit and install the bolts finger tight.
Refer to: «Timing Drive Components»(ref-515979-S16145562092012120400000) .

Scheme 99

Scheme 99: Removal

Remove the valve spring from the valve being serviced. Refer to: «Valve Springs»(ref-515979-S34256156682012120400000) .
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.

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)
Install the valve spring onto the valve being serviced. Refer to: «Valve Springs»(ref-515979-S34256156682012120400000) .
Repeat the appropriate removal and installation steps for all of the other cylinders.

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

Scheme 100

Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
Material : Thread Sealant with PTFE / TA-24 (WSK-M2G350-A2) Torque : 12 Nm

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

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Scheme 101: Engine

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Refer to: «HEALTH AND SAFETY PRECAUTIONS»(ref-515929-S17418754162012120400000) .
Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-515934-S32792027622012120400000) .
Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-515980-S25956436352012120400000) .
Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-515984-S15674360012012120400000) . Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-515984-S18220348442012120400000) .
Remove the following items: Refer to: «DEGAS BOTTLE»(ref-515984-S37240734712012120400000) . Refer to: «BATTERY TRAY»(ref-515950-S24858593422012120400000) . Refer to: «AIR CLEANER»(ref-515968-S10605516232012120400000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-515968-S05863009252012120400000) .
If equipped with automatic transmission.
Refer to: «POWERTRAIN CONTROL MODULE (PCM)»(ref-515938-S13817209062012120400000) .
NOTE: The electrical connector is located behind the PCM case.
General Equipment : Hose Clamp Remover/Installer
If equipped.
Refer to: «HEATED OXYGEN SENSOR (HO2S)»(ref-515938-S11048006112012120400000) .
NOTE: Discard the gasket.
NOTE: Discard the catalytic converter nuts and gasket.
Refer to: «QUICK RELEASE COUPLING»(ref-515980-S11306190512012120400000) .
Refer to: «QUICK RELEASE COUPLING»(ref-515980-S11306190512012120400000) .
If equipped with an automatic transmission.
If equipped with an automatic transmission.
If equipped with an automatic transmission.
If equipped with an automatic transmission.
If equipped with a manual transmission.
If equipped with a manual transmission.
Refer to: «FRONT HALFSHAFT RH»(ref-515957-S40462304762012120400000) . Refer to: «FRONT HALFSHAFT LH»(ref-515957-S22611759492012120400000) .
NOTE: Discard the O-ring seals.
General Equipment : Hose Clamp Remover/Installer
Drain and install the drain plug. Torque : 27 Nm
Refer to: «COOLING FAN MOTOR AND SHROUD»(ref-515984-S02312130842012120400000) .
NOTE: Automatic transmission shown in illustration, manual transmission similar.
NOTE: Automatic transmission shown in illustration, manual transmission similar.
Special Tool(s) : 300-OTC1585AE (Powertrain Lift) , 014-00001 (ADJUSTABLE GRIP 1735A) General Equipment : Wooden Block
Lower the powertrain from the vehicle.
Clean and inspect the catalytic converter flange. Refer to: «EXHAUST MANIFOLD CLEANING AND INSPECTION»(ref-515962-S00490536562012120400000) .
If equipped with automatic transmission.
Refer to: «STARTER MOTOR»(ref-515986-S31532406002012120400000) .
If equipped with automatic transmission.
Special Tool(s) : 300-OTC1819E (2, 200# Floor Crane, Fold Away) , 303-D089 (Spreader Bar)
NOTE: Automatic transmission shown in illustration, manual transmission similar.
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.
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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Name	Specification
Motorcraft® Silicone Gasket Remover ZC-30
Motorcraft® Metal Surface Prep ZC-31-A

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 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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If equipped with a manual transmission.
If equipped with a manual transmission. Special Tool(s) : 303-103 (Holding Tool, Flywheel)
If equipped with a automatic transmission. Special Tool(s) : 303-103 (Holding Tool, Flywheel)
Mount the engine on a engine stand.
Refer to: «QUICK RELEASE COUPLING»(ref-515980-S11306190512012120400000) .
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)
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)
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)
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)
Loosen.
NOTE: Discard the O-ring seal.
General Equipment : Hose Clamp Remover/Installer
NOTE: Remove the generator stud after generator is removed.
NOTE: Discard the thermostat housing gasket.
Refer to: «QUICK RELEASE COUPLING»(ref-515980-S11306190512012120400000) .
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.
General Equipment : Hose Clamp Remover/Installer
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.
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.
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.
Remove any of the fuel injectors that remained in the head. Special Tool(s) : 307-005 (Slide Hammer) , 310-206 (Remover, Fuel Injector)
Discard the specified component. Follow local disposal regulations.
Clean the 4 fuel injector bores in the cylinder head. Special Tool(s) : 310-205 (Fuel Injector Brush)
NOTE: Remove and discard the gasket.
NOTE: Remove and discard the gasket.
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.
NOTE: Alternately loosen the 2 fuel injection pump bolts one complete revolution at a time, remove the 2 bolts and fuel injection pump.
NOTE: Inspect and replace the gasket, if necessary.
NOTE: Inspect and replace the gasket, if necessary.
NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
If equipped.
NOTE: Discard the valve cover gasket.
Special Tool(s) : 205-153 (Handle) , 303-1247/1 (Remover, VCT Spark Plug Tube Seal)
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.
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)
Install the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
Special Tool(s) : 303-D055 (Strap Wrench)
NOTE: Remove the diamond washer and discard.
Special Tool(s) : 303-409 (Remover, Crankshaft Seal)
Using a wrench on the flats of the exhaust camshaft to prevent camshaft rotation, loosen the exhaust camshaft phaser and sprocket bolt.
Using a wrench on the flats of the intake camshaft to prevent camshaft rotation, loosen the intake camshaft phaser and sprocket bolt.
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.
NOTE: The phaser and sprocket bolts must be discarded and new installed.
Remove the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
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.
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.
Install new components as necessary.
NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
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
Support the cylinder head on a bench with the head gasket side up. Refer to: «CYLINDER HEAD DISTORTION»(ref-515962-S03531406522012120400000) . Refer to: «CYLINDER BLOCK DISTORTION»(ref-515962-S26744535742012120400000) .
NOTE: Discard the gasket.
Push the tensioner spring down and release the spring from under the shoulder bolt. Remove the 2 shoulder bolts and the tensioner and chain.
Remove the Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
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.
NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
Remove the piston/rod assembly from the engine block. Special Tool(s) : 303-462 (Installer, Connecting Rod)
Refer to: «PISTON INSPECTION»(ref-515962-S40286710892012120400000) .
NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
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.
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.

Engine - 2.0L Duratec-He: Removal & Installation Ford Focus III