Engine - 2.0L Ecoboost: Removal & Installation Ford Focus III

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.

Scheme 304

1. Visual check.
2. Torque : 20 Nm
3. Refer to: «QUICK RELEASE COUPLING»(ref-516008-S13871488872012120400000) .
4. 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.

Scheme 305

Scheme 306

Scheme 307

Scheme 308

Scheme 309

Scheme 310

Scheme 311

Scheme 312

Scheme 313

Scheme 314

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
2. Refer to: «COWL PANEL GRILLE»(ref-515949-S01491422342012120400000) .
3. Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-515950-S24980559872012120400000) .
4. Refer to: «IGNITION COIL-ON-PLUG»(ref-515989-S16051073622012120400000) .
5. Refer to: «QUICK RELEASE COUPLING»(ref-516008-S13871488872012120400000) .
6. Early build vehicles equipped with metal vacuum tubes. Late build vehicles equipped with nylon vacuum tubes.
7. Discard the specified component. Follow local disposal regulations.
8. NOTE: The VCT solenoid seals should only be replaced if they are damaged. Visual check. Discard the specified component. Follow local disposal regulations. Special Tool(s) : 205-153 (Handle) , 303-1247/1 (Remover, VCT Spark Plug Tube Seal)

Scheme 315

Scheme 316

Scheme 317

Scheme 318

1. Clean the specified component with the specified material. Material : Motorcraft® Metal Surface Prep / ZC-31-A
2. Special Tool(s) : 205-153 (Handle) , 303-1247/2 (Installer, VCT Spark Plug Tube Seal)
3. Apply a bead of the specified diameter from the specified tube. Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
4. Material : Motorcraft® Metal Surface Prep / ZC-31-A Torque : 10 Nm
5. Torque : 1 10 Nm 2 25 Nm
6. Early build vehicles equipped with metal vacuum tubes. Late build vehicles equipped with nylon vacuum tubes.
7. Refer to: «QUICK RELEASE COUPLING»(ref-516008-S13871488872012120400000) .
8. Refer to: «IGNITION COIL-ON-PLUG»(ref-515989-S16051073622012120400000) .
9. Torque : 12 Nm
10. Torque : 5 Nm
11. Torque : 12 Nm
12. Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-515950-S24980559872012120400000) .
13. Refer to: «COWL PANEL GRILLE»(ref-515949-S01491422342012120400000) .

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

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

Scheme 319

Scheme 320

Scheme 321

Scheme 322

Scheme 323

Scheme 324

1. Remove the following items: RH fender splash shield. Refer to: «FENDER SPLASH SHIELD»(ref-515949-S09347435982012120400000) . Refer to: «ACCESSORY DRIVE BELT»(ref-515990-S37682049472012120400000) . Refer to: «BRAKE VACUUM PUMP - 2.0L ECOBOOST»(ref-515961-S28099976842012120400000) . Refer to: «Valve Cover»(ref-515988-S12739680932012120400000) .
2. Turn the crankshaft clockwise until the No. 1 piston is 45 degrees BTDC using the guide holes on the engine front cover and the crankshaft pulley.
3. Install the Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
4. Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
5. Install the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
6. NOTE: The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Strap Wrench and the bolt should be removed using an air impact wrench (1/2-in drive minimum). NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced. Remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur. Strap Wrench. Discard the specified component. Follow local disposal regulations. General Equipment : Strap Wrench
7. Discard the specified component. Follow local disposal regulations.

Scheme 325

Scheme 326

Scheme 327

Scheme 328

Scheme 329

Scheme 330

Scheme 331

Scheme 332

Scheme 333

1. NOTE: Do not reuse the diamond washer, a new diamond washer must be installed.
2. Apply the specified lubricant to the specified component. Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)
3. Install an M6 bolt.
4. NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Strap Wrench and the bolt should be installed using hand tools only. Strap Wrench. Do not use power tools. General Equipment : Strap Wrench Torque : Stage 1: 100 Nm Stage 2: 90°
5. Remove the M6 bolt.
6. NOTE: Do not tighten the CKP sensor bolts at this time.
7. Install the Special Tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel. Special Tool(s) : 303-1521 (Alignment Tool, Crankshaft Position Sensor) Torque : 7 Nm
8. Remove the Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
9. Torque : 20 Nm
10. Remove the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
11. Torque : 63 Nm
12. Apply a continuous bead of the specified diameter from the specified tube. Material : flange sealant (WSS-M2G348-A11) Material : Motorcraft® Metal Surface Prep / ZC-31-A
13. Torque : Stage 1: 7 Nm Stage 2: 16 Nm
14. Install the following items: Refer to: «Valve Cover»(ref-515988-S12739680932012120400000) . Refer to: «BRAKE VACUUM PUMP - 2.0L ECOBOOST»(ref-515961-S28099976842012120400000) . Refer to: «ACCESSORY DRIVE BELT»(ref-515990-S37682049472012120400000) . RH fender splash shield. Refer to: «FENDER SPLASH SHIELD»(ref-515949-S09347435982012120400000) .
15. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.

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»(ref-515988-S12101612652012120400000) .
2. Discard the specified component. Follow local disposal regulations. Special Tool(s) : 303-409 (Remover, Crankshaft Seal)

1. Apply the specified lubricant to the specified component. Special Tool(s) : 303-096 (Installer, Camshaft Front Oil Seal) Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)
2. Refer to: «Crankshaft Pulley»(ref-515988-S12101612652012120400000) .

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

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

Scheme 334

Scheme 335

Scheme 336

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
2. Remove the following items: Refer to: «ACCESSORY DRIVE BELT»(ref-515990-S37682049472012120400000) . Refer to: «ACCESSORY DRIVE BELT TENSIONER»(ref-515990-S34935568932012120400000) . Refer to: «Crankshaft Front Seal»(ref-515988-S28105687912012120400000) . Refer to: «Engine Mount»(ref-515988-S13607198092012120400000) .
3. Plastic Scraper.

Scheme 337

1. Apply a continuous bead of the specified diameter from the specified tube. Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4) Material : Motorcraft® Metal Surface Prep / ZC-31-A
2. Apply beads of silicone gasket and sealant that are 2 mm (0.078 in) in diameter and 5 mm (0.19 in) in length across the cylinder head and cylinder block joint areas. Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4) Material : Motorcraft® Metal Surface Prep / ZC-31-A
3. Torque : Bolts 1 - 19 10 Nm Bolts 20 - 22 48 Nm
4. Torque : 20 Nm
5. Install the following items: Refer to: «Engine Mount»(ref-515988-S13607198092012120400000) . Refer to: «Crankshaft Front Seal»(ref-515988-S28105687912012120400000) . Refer to: «ACCESSORY DRIVE BELT TENSIONER»(ref-515990-S34935568932012120400000) . Refer to: «ACCESSORY DRIVE BELT»(ref-515990-S37682049472012120400000) .

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

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

Scheme 338

Scheme 339

Scheme 340

Scheme 341

Scheme 342

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
2. Remove the following items: Fuel injection pump and tappet. Refer to: «FUEL INJECTION PUMP»(ref-515991-S25529157292012120400000) . RH fender splash shield. Refer to: «FENDER SPLASH SHIELD»(ref-515949-S09347435982012120400000) .
3. Turn the component clockwise.
4. Refer to: «Engine Front Cover»(ref-515988-S20932314772012120400000) .
5. Install the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
6. Loosen bolt.
7. Loosen bolt.
8. 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.

Scheme 343

Scheme 344

Scheme 345

Scheme 346

1. 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.
2. Using the edge of a vise, compress the timing chain tensioner plunger.
3. Using a small pick, push back and hold the ratchet mechanism.
4. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
5. Install a holding pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
6. Torque : 10 Nm
7. Torque : 72 Nm
8. Torque : 72 Nm
9. Refer to: «Engine Front Cover»(ref-515988-S20932314772012120400000) .
10. Turn the component clockwise.
11. Visual check. Replace as necessary.
12. Torque : Stage 1: 15 Nm Stage 2: 60°
13. Torque : 11 Nm
14. Install the following items: Fuel injection pump and tappet. Refer to: «FUEL INJECTION PUMP»(ref-515991-S25529157292012120400000) . RH fender splash shield. Refer to: «FENDER SPLASH SHIELD»(ref-515949-S09347435982012120400000) .

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.

Scheme 347

Scheme 348

Scheme 349

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
2. Refer to: «Valve Clearance Check»(ref-515988-S05983022222012120400000) .
3. Refer to: «Variable Valve Timing (VVT) Unit»(ref-515988-S16927500372012120400000) .
4. Remove the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
5. Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.

Scheme 350

Scheme 351

1. Apply a continuous bead of the specified diameter from the specified tube. Material : flange sealant (WSS-M2G348-A11)
2. NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons. NOTE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts. NOTE: Wipe off any excess sealer from the fuel injection pump housing sealing surface of the cylinder head and rear camshaft cap. NOTE: Lubricate the camshaft journals and camshaft bearing caps with clean engine oil. Apply the specified lubricant to the specified component. Tighten the camshaft bearing cap bolts one turn at a time, until finger-tight. Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A) Torque : Stage 1: 7 Nm Stage 2: 16 Nm
3. Apply the specified lubricant to the specified component. Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A) Torque : Stage 1: 7 Nm Stage 2: 16 Nm
4. Torque : 10 Nm
5. Install the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
6. Refer to: «Variable Valve Timing (VVT) Unit»(ref-515988-S16927500372012120400000) .

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. If the camshafts and valve tappets are to be reused, note the location of the valve tappets to make sure they are assembled in their original positions.

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

Scheme 352

Scheme 353

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
2. Refer to: «Camshaft»(ref-515988-S34433738912012120400000) .
3. Apply the specified lubricant to the specified component. Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)
4. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. Visual check. Install new components as necessary.

1. To install, reverse the removal procedure.

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

Scheme 354

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
2. Remove the following items: Refer to: «Valve Tappets»(ref-515988-S34817511832012120400000) . Refer to: «SPARK PLUGS»(ref-515989-S04604436632012120400000) .
3. NOTE: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the compressed air from the cylinder until the valve spring, valve spring retainer and valve collet is installed. Any loss of air pressure will allow the valve to fall into the cylinder. NOTE: Using some multi-purpose grease and a small screwdriver will aid in the removal of the valve collet. Apply compressed air to the cylinder. Remove the valve collet, valve spring retainer and 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)

1. NOTE: Using some multi-purpose grease and a small screwdriver will aid in the installation of the valve collet. Check the seating of the valve collet. Install the valve spring, the valve spring retainer and the valve collet. Disconnect the compressed air supply. Repeat the appropriate installation steps for all of the other cylinders. 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. Install the following items: Refer to: «SPARK PLUGS»(ref-515989-S04604436632012120400000) . Refer to: «Valve Tappets»(ref-515988-S34817511832012120400000) .

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

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

Scheme 355

Scheme 356

Scheme 357

Scheme 358

Scheme 359

Scheme 360

Scheme 361

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
2. Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-516008-S01997188052012120400000) .
3. Refer to: «TURBOCHARGER»(ref-515992-S16710360502012120400000) .
4. Discard the specified component. Follow local disposal regulations.
5. Remove the following items: Refer to: «FUEL INJECTOR»(ref-515991-S33290914552012120400000) . Refer to: «Valve Tappets»(ref-515988-S34817511832012120400000) .
6. Discard the specified component. Follow local disposal regulations.
7. Discard the specified component. Follow local disposal regulations.

Scheme 362

Scheme 363

Scheme 364

Scheme 365

Scheme 366

1. Clean the specified component with the specified material. Material : Motorcraft® Metal Surface Prep / ZC-31-A
2. Refer to: «CYLINDER HEAD DISTORTION»(ref-515962-S03531406522012120400000) .
3. Torque : Stage 1: 7 Nm Stage 2: 15 Nm Stage 3: 55 Nm Stage 4: 90° Stage 5: Tighten an additional 90°
4. Torque : 20 Nm
5. Install the following items: Refer to: «Valve Tappets»(ref-515988-S34817511832012120400000) . Refer to: «FUEL INJECTOR»(ref-515991-S33290914552012120400000) .
6. Torque : 27 Nm
7. Apply the specified lubricant to the specified component. Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A) Torque : Stage 1: 8 Nm Stage 2: 180°
8. Refer to: «TURBOCHARGER»(ref-515992-S16710360502012120400000) .
9. Fill the engine with clean engine oil. Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

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

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
2. Refer to: «Oil Pan»(ref-515988-S27710273132012120400000) .
3. Discard the specified component. Follow local disposal regulations. Torque : 10 Nm

1. To install, reverse the removal procedure.

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

Scheme 367

Scheme 368

Scheme 369

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
2. Discard the specified component. Follow local disposal regulations. Apply the specified lubricant to the specified component. Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A) Torque : Stage 1: 8 Nm Stage 2: 180°
3. Discard the specified component. Follow local disposal regulations. Torque : 25 Nm
4. General Equipment : Vise General Equipment : Vise Jaw Protectors Torque : Stage 1: 23 Nm Stage 2: 75° Stage 3: Wait 5s Stage 4: 15°
5. Refer to: «ENGINE»(ref-515962-S16937650842012120400000)

1. To install, reverse the removal procedure.

Removal and Installation

1. The engine oil cooler is removed from the engine with the engine oil filter adapter. Refer to: «Oil Filter Adapter»(ref-515988-S04000538312012120400000) .

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
2. Refer to: «CLUTCH DISC AND PRESSURE PLATE - VEHICLES WITH: 5-SPEED MANUAL TRANSMISSION - MTX75»(ref-516004-S22221404632012120400000) .
3. Discard the specified component. Follow local disposal regulations. Special Tool(s) : 303-103 (Holding Tool, Flywheel)

1. Special Tool(s) : 303-103 (Holding Tool, Flywheel) Torque : Stage 1: 50 Nm Stage 2: 80 Nm Stage 3: 112 Nm
2. Refer to: «CLUTCH DISC AND PRESSURE PLATE - VEHICLES WITH: 5-SPEED MANUAL TRANSMISSION - MTX75»(ref-516004-S22221404632012120400000) .
3. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.

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

Scheme 370

Scheme 371

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
2. General Equipment : Trolley Jack General Equipment : Wooden Block
3. Torque : 80 Nm Torque : 90 Nm

1. To install, reverse the removal procedure.

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

Scheme 372

Scheme 373

1. Refer to: «Timing Drive Components»(ref-515988-S33381027292012120400000) .
2. Discard the specified component. Follow local disposal regulations.

Scheme 374

1. NOTE: Do not reuse the washers, new washers must be installed.
2. NOTE: Do not tighten the bolts at this time. The bolts will be tightened during the timing drive component installation procedure.
3. Refer to: «Timing Drive Components»(ref-515988-S33381027292012120400000) .

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 375

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
2. Refer to: «Valve Springs»(ref-515988-S19807627312012120400000) .
3. Discard the specified component. Follow local disposal regulations. Special Tool(s) : 303-468 (Remover, Valve Stem Oil Seal) , 307-005 (Slide Hammer)

Scheme 376

1. Apply the specified lubricant to the specified component. Special Tool(s) : 303-470 (Installer, Valve Stem Oil Seal) Material : Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)
2. Refer to: «Valve Springs»(ref-515988-S19807627312012120400000) .

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

Scheme 377

Scheme 378

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
2. Torque : 10 Nm
3. Apply the substance from the specified tube. Material : Thread Sealant with ATF / TA-24 (WSK-M2G350-A2) Torque : 15 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 Hose Clamp Remover/Installer Wooden Block

Scheme 379

Scheme 380

Scheme 381

Scheme 382

Scheme 383

Scheme 384

Scheme 385

Scheme 386

Scheme 387

Scheme 388

Scheme 389

Scheme 390

Scheme 391

Scheme 392

Scheme 393

Scheme 394

Scheme 395

Scheme 396

Scheme 397

Scheme 398

Scheme 399

Scheme 400

Scheme 401

Scheme 402

Scheme 403

Scheme 404

Scheme 405

Scheme 406

Scheme 407

Scheme 408

Scheme 409

Scheme 410

Scheme 411

Scheme 412

Scheme 413

1. Refer to: «HEALTH AND SAFETY PRECAUTIONS»(ref-515929-S17418754162012120400000) .
2. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-515942-S20089493392012120400000) .
3. Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-515934-S32792027622012120400000) .
4. Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-516008-S01997188052012120400000) .
5. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-515994-S34655776092012120400000) .
6. Remove the following items: Refer to: «DEGAS BOTTLE»(ref-515994-S32469301152012120400000) . Refer to: «AIR CLEANER»(ref-515993-S21705096842012120400000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-515993-S20287828312012120400000) . Refer to: «COOLING MODULE»(ref-515994-S26133429952012120400000) .
7. Refer to: «BATTERY TRAY»(ref-515950-S24858593422012120400000) .
8. Refer to: «POWERTRAIN CONTROL MODULE (PCM)»(ref-515939-S40216328422012120400000) .
9. Refer to: «QUICK RELEASE COUPLING»(ref-516008-S13871488872012120400000) . General Equipment : Hose Clamp Remover/Installer
10. Remove the following items: Refer to: «FRONT HALFSHAFT LH»(ref-515957-S22611759492012120400000) . Refer to: «FRONT HALFSHAFT RH»(ref-515957-S40462304762012120400000) .
11. Discard the specified component. Follow local disposal regulations.
12. Discard the specified component. Follow local disposal regulations.
13. 3. If equipped.
14. Discard the specified component. Follow local disposal regulations.
15. Relocate and support the component.
16. Discard the specified component. Follow local disposal regulations.
17. Discard the specified component. Follow local disposal regulations.
18. Install the Special Tool(s) : 300-OTC1585AE (Powertrain Lift) , 014-00001 (ADJUSTABLE GRIP 1735A) General Equipment : Wooden Block
19. Special Tool(s) : 300-OTC1585AE (Powertrain Lift) , 014-00001 (ADJUSTABLE GRIP 1735A) General Equipment : Wooden Block
20. Install the Special Tool(s) : 300-OTC1819E (2, 200# Floor Crane, Fold Away)
21. Remove the Special Tool(s) : 300-OTC1585AE (Powertrain Lift) , 014-00001 (ADJUSTABLE GRIP 1735A) General Equipment : Wooden Block
22. Two people required.

SPECIAL TOOL(S) / GENERAL EQUIPMENT 205-153 Handle 300-OTC1819E 2, 200# Floor Crane, Fold Away 303-103 Holding Tool, Flywheel TKIT-2009TC-F 303-1247/1 Remover, VCT Spark Plug Tube Seal 303-1565 Alignment Tool, Camshaft 303-409 Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM 307-005 Slide Hammer 310-206 Remover, Fuel Injector TKIT-2009A-FLM Strap Wrench

Scheme 414

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.

Scheme 415

Scheme 416

Scheme 417

Scheme 418

Scheme 419

Scheme 420

Scheme 421

Scheme 422

Scheme 423

Scheme 424

Scheme 425

Scheme 426

Scheme 427

Scheme 428

Scheme 429

Scheme 430

Scheme 431

Scheme 432

Scheme 433

Scheme 434

Scheme 435

Scheme 436

Scheme 437

Scheme 438

Scheme 439

Scheme 440

Scheme 441

Scheme 442

Scheme 443

Scheme 444

Scheme 445

Scheme 446

Scheme 447

Scheme 448

Scheme 449

Scheme 450

Scheme 451

Scheme 452

Scheme 453

Scheme 454

Scheme 455

Scheme 456

Scheme 457

Scheme 458

Scheme 459

Scheme 460

Scheme 461

Scheme 462

Scheme 463

Scheme 464

Scheme 465

Scheme 466

Scheme 467

Scheme 468

Scheme 469

Scheme 470

Scheme 471

Scheme 472

Scheme 473

Scheme 474

Scheme 475

Scheme 476

Scheme 477

Scheme 478

Scheme 479

Scheme 480

Scheme 481

1. Loosen each bolt 2 turns at a time until all bolts are removed.
2. Discard the specified component. Follow local disposal regulations. Special Tool(s) : 303-103 (Holding Tool, Flywheel)
3. Install.
4. Remove the Special Tool(s) : 300-OTC1819E (2, 200# Floor Crane, Fold Away)
5. Loosen.
6. Discard the specified component. Follow local disposal regulations.
7. Discard the specified component. Follow local disposal regulations.
8. Discard the specified component. Follow local disposal regulations.
9. Discard the specified component. Follow local disposal regulations.
10. Discard the specified component. Follow local disposal regulations.
11. Discard the specified component. Follow local disposal regulations.
12. Loosen.
13. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-515990-S16586212852012120400000) .
14. Discard the specified component. Follow local disposal regulations.
15. Discard the specified component. Follow local disposal regulations.
16. Refer to: «QUICK RELEASE COUPLING»(ref-516008-S13871488872012120400000) .
17. Discard the specified component. Follow local disposal regulations.
18. Discard the specified component. Follow local disposal regulations.
19. Remove any of the fuel injectors that remained in the fuel rail.
20. Remove any of the fuel injectors that remained in the fuel rail. Special Tool(s) : 307-005 (Slide Hammer) , 310-206 (Remover, Fuel Injector)
21. Discard the specified component. Follow local disposal regulations.
22. Discard the specified component. Follow local disposal regulations.
23. NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur. NOTE: Be very careful when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors. Pull the lower Teflon® seal away from the injector. Long-nosed pliers. Carefully cut and discard the lower fuel injector Teflon® seals. Cutting knife. Discard the specified component. Follow local disposal regulations.
24. Discard the specified component. Follow local disposal regulations.
25. Turn the component clockwise.
26. Early build vehicles equipped with metal vacuum tubes. Late build vehicles equipped with nylon vacuum tubes.
27. Discard the specified component. Follow local disposal regulations.
28. Visual check. Discard the specified component. Follow local disposal regulations. Special Tool(s) : 303-1247/1 (Remover, VCT Spark Plug Tube Seal) , 205-153 (Handle)
29. Clean the specified component with the specified material. Material : Motorcraft® Metal Surface Prep / ZC-31-A
30. Turn the crankshaft clockwise until the No. 1 piston is 45 degrees BTDC using the guide holes on the engine front cover and the crankshaft pulley.
31. Install the Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
32. Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
33. Tighten the retainer. Install the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
34. Discard the specified component. Follow local disposal regulations. General Equipment : Strap Wrench
35. Discard the specified component. Follow local disposal regulations.
36. Discard the specified component. Follow local disposal regulations. Special Tool(s) : 303-409 (Remover, Crankshaft Seal)
37. Loosen.
38. Loosen.
39. 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.
40. Discard the specified component. Follow local disposal regulations.
41. Discard the specified component. Follow local disposal regulations.
42. Remove the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)
43. Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.
44. 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.
45. Visual check.
46. Discard the specified component. Follow local disposal regulations.
47. Discard the specified component. Follow local disposal regulations.
48. Clean the specified component with the specified material. Material : Motorcraft® Metal Surface Prep / ZC-31-A
49. Refer to: «CYLINDER BLOCK DISTORTION»(ref-515962-S26744535742012120400000) . Refer to: «CYLINDER HEAD DISTORTION»(ref-515962-S03531406522012120400000) .
50. Plastic scraper.
51. Discard the specified component. Follow local disposal regulations.
52. Discard the specified component. Follow local disposal regulations.
53. Discard the specified component. Follow local disposal regulations.
54. Clean the specified component with the specified material. Material : Motorcraft® Metal Surface Prep / ZC-31-A
55. Visual check.
56. Marker.
57. NOTE: Due to the precision interior construction of the balance shaft assembly, it should not be disassembled.
58. Remove the Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)
59. Visual check. Abrasive pad.
60. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
61. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
62. Refer to: «PISTON INSPECTION»(ref-515962-S40286710892012120400000) .
63. Remove in the sequence shown in illustration.
64. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
65. 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.