Engine Mechanical: Component Locations Ford Grand C-MAX II

Special Tool(s) / General Equipment

Feeler Gauge

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1. Remove the following items: Refer to: «VALVE COVER»(ref-539206-S39781920592013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). RH only. Refer to: «FENDER SPLASH SHIELD»(ref-539194-S16570676282013040100000) (501-02 Front End Body Panels, Removal and Installation).
2. NOTE: Turn the engine clockwise only, and only use the crankshaft bolt. NOTE: Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure the clearance of each valve and record its location. General Equipment: Feeler Gauge
3. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. NOTE: The nominal clearance is: intake: 0.25 mm (0.0095 in). exhaust: 0.36 mm (0.0142 in). NOTE: The acceptable clearances after being fully installed are: intake: 0.20-0.30 mm (0.008-0.012 in). exhaust: 0.31-0.41 mm (0.012-0.016 in). Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
4. If any tappets do not measure within specifications, install new tappets in these locations.

Refer to: VALVE TAPPETS (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).

303-465 Tool, Camshaft Align Timing TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2

303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal TKIT-2009TC-F 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH

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303-1416 Tool, Crank Damper Holding TKIT-2008ET-FLM 303-1521 Alignment Tool, Crankshaft Position Sensor 303-465 Tool, Camshaft Align Timing TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM

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303-290-05A Adapter for 303-290A 303-F072 Support Bar, Engine Oil Drain Equipment Trolley Jack Wooden Block

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303-290-05A Adapter for 303-290A 303-F072 Support Bar, Engine Oil Drain Equipment Trolley Jack Wooden Block

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303-103 (T74P-6375-A) Holding Tool, Flywheel TKIT-2009TC-F T74P-77000-A

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1. WARNING: Before beginning any service procedure in this section, refer to «HEALTH AND SAFETY PRECAUTIONS»(ref-539149-S05516616262013040100000) Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury. Refer to: «HEALTH AND SAFETY PRECAUTIONS»(ref-539149-S05516616262013040100000) (100-00 General Information, Description and Operation).
2. NOTE: If the engine is being removed to access the flywheel, it is not necessary to drain the engine oil or remove the oil filter. Refer to: «ENGINE - HYBRID ELECTRIC VEHICLE (HEV)»(ref-539206-S33459892882013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal). Refer to: «ENGINE - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-539206-S14945134932013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal).
3. Special Tool(s): 303-103 (T74P-6375-A) Holding Tool, Flywheel
4. Special Tool(s): 303-103 (T74P-6375-A) Holding Tool, Flywheel

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1. Special Tool(s): 303-103 (T74P-6375-A) Holding Tool, Flywheel Torque: Stage 1: 50 Nm Stage 2: 80 Nm Stage 3: 112 Nm
2. Tighten 2 turns at a time in sequence shown. Special Tool(s): 303-103 (T74P-6375-A) Holding Tool, Flywheel Torque: 29 Nm Refer to: «ENGINE - HYBRID ELECTRIC VEHICLE (HEV)»(ref-539206-S33459892882013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Installation). Refer to: «ENGINE - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-539206-S14945134932013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Installation).

Vise

205-153 (T80T-4000-W) Handle 303-1247/1 Remover, VCT Spark Plug Tube Seal 303-1247/2 Installer, VCT Spark Plug Tube Seal 303-224 (T83T-6701-A) Installer, Crankshaft Rear Oil Seal

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303-300 (T87C-6565-A) Set, Valve Spring Compressor TKIT-2009TC-F T88C-1000-ST TKIT-1988-FESTIVA TKIT-1988-TRACER 303-350 (T89P-6565-A) Compressor, Valve Spring TKIT-1989-F TKIT-1989-FM TKIT-1989-FLM TKIT-1990-LMH 303-472 (T94P-6565-AH) Adapter, Valve Spring Compressor TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2

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303-468 (T94P-6510-AH) Remover, Valve Stem Oil Seal TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal TKIT-2009TC-F TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 307-005 (T59L-100-B) Slide Hammer

303-328 (T88P-6701-B1) Replacer, Rear Seal TKIT-1988-F TKIT-1988-FLM TKIT-1988-LM Oil Drain Equipment

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303-290-05A Adapter for 303-290A 303-F072 Support Bar, Engine

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014-00001 ADJUSTABLE GRIP 1735A 300-OTC1585AE Powertrain Lift 300-OTC1819E 2, 200# Floor Crane, Fold Away

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1. WARNING: Before beginning any service procedure in this section, refer to «HEALTH AND SAFETY PRECAUTIONS»(ref-539149-S05516616262013040100000) Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury. Refer to: «HEALTH AND SAFETY PRECAUTIONS»(ref-539149-S05516616262013040100000) (100-00 General Information, Description and Operation). Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-539167-S37930574612013040100000) (100-02 Jacking and Lifting, Description and Operation). Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-539208-S34120100422013040100000) (310-00 Fuel System - General Information, General Procedures). Refer to: «HIGH VOLTAGE BATTERY DISCONNECT AND CONNECT - HYBRID ELECTRIC VEHICLE (HEV)»(ref-539155-S06915697752013040100000) (414-03A High Voltage Battery, Mounting and Cables, General Procedures). Refer to: «BATTERY DISCONNECT AND CONNECT - HYBRID ELECTRIC VEHICLE (HEV)»(ref-539181-S40970790092013040100000) (414-01 Battery, Mounting and Cables, General Procedures). Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-539154-S30541327322013040100000) (412-00 Climate Control System - General Information, General Procedures). Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-539176-S25563484902013040100000) (303-03A Engine Cooling - 2.0L Duratec - Hybrid (96kW/130PS), General Procedures). Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-539175-S15417758412013040100000) (303-03B Electric Powertrain Cooling, General Procedures).
2. Remove the following items: Refer to: «DEGAS BOTTLE»(ref-539176-S00292322012013040100000) (303-03A Engine Cooling - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). Refer to: «AIR CLEANER»(ref-539209-S08535137802013040100000) (303-12 Intake Air Distribution and Filtering, Removal and Installation). Refer to: «AIR CLEANER OUTLET PIPE»(ref-539209-S33663050852013040100000) (303-12 Intake Air Distribution and Filtering, Removal and Installation). Refer to: «AIR CLEANER INTAKE PIPE»(ref-539209-S04113865942013040100000) (303-12 Intake Air Distribution and Filtering, Removal and Installation). Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-539174-S17401212522013040100000) (307-01 Automatic Transmission - Vehicles With: Automatic Transmission - HF35, Removal and Installation).
3. Refer to: «QUICK RELEASE COUPLING»(ref-539208-S40562506092013040100000) (310-00 Fuel System - General Information, General Procedures).
4. Remove the following items: Refer to: «COOLING MODULE»(ref-539176-S27520719402013040100000) (303-03A Engine Cooling - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). Refer to: «FRONT HALFSHAFT LH»(ref-539187-S37708466412013040100000) (205-04 Front Drive Halfshafts, Removal and Installation). Refer to: «FRONT HALFSHAFT RH»(ref-539187-S42701564832013040100000) (205-04 Front Drive Halfshafts, Removal and Installation). NOTE: LH side only. Refer to: «FENDER SPLASH SHIELD»(ref-539194-S16570676282013040100000) (501-02 Front End Body Panels, Removal and Installation).
5. Refer to: «ROLL RESTRICTOR RH»(ref-539174-S03841162042013040100000) (307-01 Automatic Transmission - Vehicles With: Automatic Transmission - HF35, Removal and Installation).
6. Install Special Service Tool: 300-OTC1585AE Powertrain Lift , 014-00001 ADJUSTABLE GRIP 1735A
7. Special Tool(s): 300-OTC1585AE Powertrain Lift , 014-00001 ADJUSTABLE GRIP 1735A
8. Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away
9. Remove Special Service Tool: 300-OTC1585AE Powertrain Lift , 014-00001 ADJUSTABLE GRIP 1735A
10. Special Tool(s): 300-OTC1819E 2, 200# Floor Crane, Fold Away
11. NOTE: The transaxle-to-engine bolts differ in length. Note the location of the bolts for correct installation.

014-00001 ADJUSTABLE GRIP 1735A 300-OTC1585AE Powertrain Lift 300-OTC1819E 2, 200# Floor Crane, Fold Away

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1. WARNING: Before beginning any service procedure in this section, refer to «HEALTH AND SAFETY PRECAUTIONS»(ref-539149-S05516616262013040100000) Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury. Refer to: «HEALTH AND SAFETY PRECAUTIONS»(ref-539149-S05516616262013040100000) (100-00 General Information, Description and Operation). Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-539167-S37930574612013040100000) (100-02 Jacking and Lifting, Description and Operation). Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-539208-S34120100422013040100000) (310-00 Fuel System - General Information, General Procedures). Refer to: «HIGH VOLTAGE BATTERY DISCONNECT AND CONNECT - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-539155-S42228152672013040100000) (414-03A High Voltage Battery, Mounting and Cables, General Procedures). Refer to: «BATTERY DISCONNECT AND CONNECT - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-539181-S17001658892013040100000) (414-01 Battery, Mounting and Cables, General Procedures). Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-539154-S30541327322013040100000) (412-00 Climate Control System - General Information, General Procedures). Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-539176-S25563484902013040100000) (303-03A Engine Cooling - 2.0L Duratec - Hybrid (96kW/130PS), General Procedures). Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-539175-S15417758412013040100000) (303-03B Electric Powertrain Cooling, General Procedures).
2. Remove the following items: Refer to: «DEGAS BOTTLE»(ref-539176-S00292322012013040100000) (303-03A Engine Cooling - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). Refer to: «AIR CLEANER»(ref-539209-S08535137802013040100000) (303-12 Intake Air Distribution and Filtering, Removal and Installation). Refer to: «AIR CLEANER OUTLET PIPE»(ref-539209-S33663050852013040100000) (303-12 Intake Air Distribution and Filtering, Removal and Installation). Refer to: «AIR CLEANER INTAKE PIPE»(ref-539209-S04113865942013040100000) (303-12 Intake Air Distribution and Filtering, Removal and Installation). Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-539174-S17401212522013040100000) (307-01 Automatic Transmission - Vehicles With: Automatic Transmission - HF35, Removal and Installation).
3. Refer to: «QUICK RELEASE COUPLING»(ref-539208-S40562506092013040100000) (310-00 Fuel System - General Information, General Procedures).
4. Remove the following items: Refer to: «COOLING MODULE»(ref-539176-S27520719402013040100000) (303-03A Engine Cooling - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). Refer to: «FRONT HALFSHAFT LH»(ref-539187-S37708466412013040100000) (205-04 Front Drive Halfshafts, Removal and Installation). Refer to: «FRONT HALFSHAFT RH»(ref-539187-S42701564832013040100000) (205-04 Front Drive Halfshafts, Removal and Installation). NOTE: LH side only. Refer to: «FENDER SPLASH SHIELD»(ref-539194-S16570676282013040100000) (501-02 Front End Body Panels, Removal and Installation).
5. Refer to: «ROLL RESTRICTOR RH»(ref-539174-S03841162042013040100000) (307-01 Automatic Transmission - Vehicles With: Automatic Transmission - HF35, Removal and Installation).
6. Install Special Service Tool: 300-OTC1585AE Powertrain Lift , 014-00001 ADJUSTABLE GRIP 1735A
7. Special Tool(s): 300-OTC1585AE Powertrain Lift , 014-00001 ADJUSTABLE GRIP 1735A
8. Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away
9. Remove Special Service Tool: 300-OTC1585AE Powertrain Lift , 014-00001 ADJUSTABLE GRIP 1735A
10. Special Tool(s): 300-OTC1819E 2, 200# Floor Crane, Fold Away
11. NOTE: The transaxle-to-engine bolts differ in length. Note the location of the bolts for correct installation.

205-153 (T80T-4000-W) Handle 300-OTC1819E 2, 200# Floor Crane, Fold Away 303-103 (T74P-6375-A) Holding Tool, Flywheel TKIT-2009TC-F T74P-77000-A 303-1247/1 Remover, VCT Spark Plug Tube Seal 303-1416 Tool, Crank Damper Holding TKIT-2008ET-FLM 303-224 (T83T-6701-A) Installer, Crankshaft Rear Oil Seal 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH 303-465 Tool, Camshaft Align Timing TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM

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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. Refer to the exploded views in Description and Operation.

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1. Special Tool(s): 303-103 (T74P-6375-A) Holding Tool, Flywheel
2. Special Tool(s): 303-103 (T74P-6375-A) Holding Tool, Flywheel
3. Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away
4. 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.
5. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
6. NOTE: The VCT solenoid seal should only be replaced if it is damaged. Special Tool(s): 303-1247/1 Remover, VCT Spark Plug Tube Seal , 303-224 (T83T-6701-A) Installer, Crankshaft Rear Oil Seal , 205-153 (T80T-4000-W) Handle
7. 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.
8. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC
9. 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 crankshaft pulley removal and installation. NOTE: The engine front cover is removed from graphic for clarity. Special Tool(s) : 303-507 Timing Peg, Crankshaft TDC
10. NOTE: The Camshaft Alignment Timing Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Timing Tool cannot be installed, remove the TDC Timing Peg and rotate the crankshaft three-fourths of a revolution clockwise and repeat the previous 2 steps of this procedure. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing
11. 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 Crankshaft Damper Holding Tool, 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. NOTE: Use an air impact wrench to remove the crankshaft pulley bolt. Special Tool(s): 303-1416 Tool, Crank Damper Holding
12. NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur. If the diamond washer did not come off with the crankshaft pulley, remove the diamond washer.
13. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal. Special Tool(s): 303-409 (T92C-6700-CH) Remover, Crankshaft Seal
14. NOTE: The engine front cover bolts vary in size, note the location of each bolt for assembly.
15. NOTE
16. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing
17. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. NOTE: Mark the location and orientation of each camshaft bearing cap. Loosen one turn at a time. Repeat until all the tension is released.
18. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: 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.
19. Install new parts as necessary.
20. Refer to: «CYLINDER HEAD DISTORTION»(ref-539205-S34767596262013040100000) (303-00 Engine System - General Information, General Procedures).
21. Refer to: «CYLINDER BLOCK DISTORTION»(ref-539205-S00542151952013040100000) (303-00 Engine System - General Information, General Procedures).
22. NOTE: The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur. Remove the diamond washer.
23. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC
24. General Equipment: Abrasive pad.
25. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
26. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
27. NOTE: Mark the position of the parts, so they can be installed in their original positions. Refer to: «PISTON INSPECTION»(ref-539205-S16389223552013040100000) (303-00 Engine System - General Information, General Procedures).
28. Remove in the sequence shown.
29. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
30. 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.
31. NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly. NOTE: The front bulkhead does not have an oil squirter.

303-300 (T87C-6565-A) Set, Valve Spring Compressor TKIT-2009TC-F T88C-1000-ST TKIT-1988-FESTIVA TKIT-1988-TRACER 303-350 (T89P-6565-A) Compressor, Valve Spring TKIT-1989-F TKIT-1989-FM TKIT-1989-FLM TKIT-1990-LMH 303-468 (T94P-6510-AH) Remover, Valve Stem Oil Seal TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal TKIT-2009TC-F TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-472 (T94P-6565-AH) Adapter, Valve Spring Compressor TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 307-005 (T59L-100-B) Slide Hammer

100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge 205-153 (T80T-4000-W) Handle 300-OTC1819E 2, 200# Floor Crane, Fold Away 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal TKIT-2009TC-F 303-103 (T74P-6375-A) Holding Tool, Flywheel TKIT-2009TC-F T74P-77000-A 303-1247/2 Installer, VCT Spark Plug Tube Seal 303-1416 Tool, Crank Damper Holding TKIT-2008ET-FLM 303-1521 Alignment Tool, Crankshaft Position Sensor 303-465 Tool, Camshaft Align Timing TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM Round-Ended Steel Rule

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014-00001 ADJUSTABLE GRIP 1735A 300-OTC1585AE Powertrain Lift 300-OTC1819E 2, 200# Floor Crane, Fold Away

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014-00001 ADJUSTABLE GRIP 1735A 300-OTC1585AE Powertrain Lift 300-OTC1819E 2, 200# Floor Crane, Fold Away

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