Contents Wiring diagrams Section: Mechanical All sections

Engine Mechanical: Other Ford Grand C-MAX II

Mechanical 61 illustrations ~3581 words

Lubricants

ItemSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Oil Pressure

ItemSpecification
Oil pressure (hot @ 2, 000 rpm)200-414 kPa (29-60 psi)

Cylinder Block

ItemSpecification
Cylinder bore diameter87.5-87.53 mm (3.444-3.445 in)
Cylinder bore maximum out-of-round0.008 mm (0.0003 in)
Main bearing bore diameter57.018-57.040 mm (2.244-2.245 in)
Head gasket surface flatness0.1 mm/general 0.05 mm/200 x 200 (0.004 in/general) (0.0019 in/7.87 x 7.87)

Piston

ItemSpecification
Piston Diameter (1)87.470-87.480 mm (3.4437-3.4440 in)
Piston Diameter (2)87.478-87.492 mm (3.4440-3.4445 in)
Piston Diameter (3)87.490-87.500 mm (3.4444-3.4449 in)
Piston-to-bore clearance0.013-0.047 mm (0.0005-0.0018 in) grade 2
Ring groove width - top1.23-1.25 mm (0.0484-0.0492 in)
Ring groove width - 2nd1.23-1.25 mm (0.0484-0.0492 in)
Ring groove width - oil2.03-2.05 mm (0.0799-0.0807 in)
Piston skirt coating thickness (per side)0.007-0.017 mm (0.0002-0.0006 in)

Piston Pin

ItemSpecification
Diameter20.997-21.000 mm (0.8266-0.8268 in)
Length64.7-65.3 mm (2.547-2.570 in)
Pin-to-rod clearancePress fit

Cylinder Head

ItemSpecification
Cylinder head flatness0.08 mm (0.0031 in) maximum overall, a maximum of 0.05 mm (0.0019 in) within 150 mm (5.9 in)
Valve lift @ zero lash (exhaust)8.07 mm (0.317 in)
Valve lift @ zero lash (intake)8.83 mm (0.347 in)
Valve guide diameter5.509-5.539 mm (0.216-0.218 in)
Valve seat width - intake/exhaust0.99-1.84 mm (0.038-0.072 in)
Valve seat angle45 degrees
Valve seat runout0.075 mm (0.0029 in)
Valve tappet bore diameter31.00-31.03 mm (1.220-1.221 in)
Cam bore diameter25.015-25.040 mm (0.984-.0985 in)

Valve

ItemSpecification
Valve head diameter - intake34.85-35.15 mm (1.372-1.383 in)
Valve head diameter - exhaust29.85-30.15 mm (1.175-1.187 in)
Valve stem diameter - intake5.470-5.485 mm (0.2153-0.2159 in)
Valve stem diameter - exhaust5.465-5.480 mm (0.2151-0.2157 in)
Valve stem-to-guide clearance - intake0.0027 mm (0.00010 in)
Valve stem-to-guide clearance - exhaust0.0029 mm (0.00011 in)
Valve face runout0.05 mm (0.0019 in)
Valve face angle45 degrees

Valve Spring - Compression Pressure

ItemSpecification
Intake and exhaust (installed)18 kg (40 lb)
Intake (valve open) 9.2 mm (0.362 in of lift)46 kg (101 lb)
Exhaust (valve open) 9.2 mm (0.362 in of lift)46 kg (101 lb)
Free length47.904 mm (1.8862 in)
Assembled height37.9 mm (1.492 in)

Crankshaft

ItemSpecification
Main bearing journal diameter51.978-52.002 mm (2.046-2.047 in)
Main bearing clearance0.016-0.047 mm (0.0006-0.0015 in)
Connecting rod journal diameter46.980-47.000 mm (1.849-1.850 in)
End play0.220-0.450 mm (0.008-0.018 in)

Rings

ItemSpecification
Width - top1.17-1.185 mm (0.0460-0.0466 in)
Width - 2nd1.197-1.199 mm (0.0471-0.0472 in)
Width - oil2.38-2.45 mm (0.093-0.096 in)
Ring gap (in bore) - top0.16-0.31 mm (0.006-0.012 in)
Ring gap (in bore) - 2nd0.31-0.46 mm (0.012-0.018 in)
Ring gap (in bore) - oil0.2-0.7 mm (0.007-0.027 in)

Valve Tappet

ItemSpecification
Diameter30.97-30.98 (1.2192-1.2196 in)
Tappet-to-valve clearance - intake0.20-0.30 mm (0.008-0.012 in)
Tappet-to-valve clearance - exhaust0.31-0.41 mm (0.012-0.016 in)
Tappet-to-bore clearance0.02-0.06 mm (0.0007-0.0023 in)

Camshaft

ItemSpecification
Lobe lift - intake8.83mm (0.347 in)
Lobe lift - exhaust8.07 mm (0.317 in)
Runout (1) (1)0.03 mm (0.001 in)
Thrust clearance0.09-0.24 mm (0.003-0.009 in)
Journal diameter24.96-24.98 mm (0.982-0.983 in)
Journal-to-bore clearance0.035-0.080 mm (0.001-0.003 in)
(1) No. 3 Journal - Supported by No. 1 and No. 5 journals.
(1)No. 3 Journal - Supported by No. 1 and No. 5 journals.

Connecting Rod

ItemSpecification
Bearing clearance0.027-0.052 mm (0.001-0.002 in)
Bearing thickness1.498-1.522 mm (0.058-0.059 in)
Crank bore diameter50.025-50.045 mm (1.969-1.970 in)
Pin bore diameter20.965-20.985 mm (0.825-0.826 in)
Length (center to center)154.8 mm (6.094 in)
Side clearance1.95-3.05 mm (0.076-0.120 in)
Axial clearance0.14-0.36 mm (0.005-0.014 in)

Engine Code Information Label

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

ItemDescription
1Engine part number
2Chihuahua engine plant
3Engine build date (YYMMDD)
4Engine displacement
5Bar code
6Running number
7Plant shift line
8Bar code

Valve Train

The valve train uses direct acting mechanical buckets (DAMB). The camshaft lobes are positioned directly above mechanical buckets which are positioned on top of the valves.

Lower Engine Block (View 1)

ItemPart NumberDescription
16010Cylinder block
26K318Crankshaft rear oil seal and retainer
36K390Flywheel
46675Oil pan
56714Oil filter
66884Oil filter adapter
79278Engine Oil Pressure (EOP) switch
86A636Oil filter adapter gasket
96A785Crankcase vent oil separator
106622Oil pump screen and pickup tube
117550Damper

Scheme 264

Scheme 264: Lower Engine Block (View 2)
ItemPart NumberDescription
1Main bearing beam (part of 6010)
26A338Crankshaft main bearing beam bearing (5 required)
36300Crankshaft assembly
46333Cylinder block crankshaft main bearing (4 required)
56337Cylinder block crankshaft main thrust bearing
66110Piston (4 required)

Scheme 265

Scheme 265: Front Engine Block
ItemPart NumberDescription
16C315Crankshaft Position (CKP) sensor
26K340Crankshaft pulley bolt
36316Crankshaft pulley
46700Crankshaft front seal
56019Engine front cover
66K254Timing chain tensioner
76K255Timing chain tensioner arm
86268Timing chain
96K297Timing chain guide
106C271Oil pump chain tensioner
116A895Oil pump chain
126652Oil pump drive gear
136378Diamond washer
146306Crankshaft sprocket
156378Diamond washer
166600Oil pump
176010Cylinder block

Scheme 266

Scheme 266: Cylinder Head
ItemPart NumberDescription
112A366Coil-on-plug assembly (4 required)
212405Spark plug (4 required)
36766Oil filler cap
412K073Camshaft Position (CMP) sensor
56K271Valve cover
66K260Valve cover gasket
76M280Variable Camshaft Timing (VCT) oil control solenoid
86G004Cylinder Head Temperature (CHT) sensor
9Camshaft front bearing cap (part of 6049)
10Camshaft bearing cap (part of 6049) (8 required)
116A272Camshaft (exhaust)
126A271Camshaft (intake)
136C251Camshaft sprocket
146C525VCT actuator
156500Valve tappet (16 required)
166518Valve collet (16 required)
176514Valve spring retainer (16 required)
186513Valve spring (16 required)
196A517Valve stem seal (16 required)
206049Cylinder head
216505Exhaust valve (8 required)
226507Intake valve (8 required)
236051Head gasket
246010Cylinder block

Scheme 267

Scheme 267: Intake Manifold
ItemPart NumberDescription
19H487Fuel rail
28K556Coolant outlet
39D475Exhaust Gas Recirculation (EGR) valve
49F991Electronic throttle body
56051Cylinder head gasket
66010Cylinder block
79424Intake manifold
89441Intake manifold gasket
96049Cylinder head
109F593Fuel injector (4 required)
119J469Exhaust Gas Recirculation (EGR) gasket
129E936Electronic throttle body gasket
  1. For basic mechanical concerns

REFER to: ENGINE (303-00 Engine System - General Information, Diagnosis and Testing).

For driveability concerns Refer to ENGINE CONTROLS - INTRODUCTION (HYBRID) .

Materials

NameSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C945-A
NameSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C945-A
NameSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C945-A
NameSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C945-A
Motorcraft® Silicone Gasket Remover ZC-30
Motorcraft® Metal Surface Prep ZC-31-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4
NameSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C945-A
Motorcraft® Silicone Gasket Remover ZC-30
Motorcraft® Metal Surface Prep ZC-31-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4
NameSpecification
Motorcraft® Silicone Gasket Remover ZC-30
Motorcraft® Metal Surface Prep ZC-31-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4
NameSpecification
Motorcraft® Silicone Gasket Remover ZC-30
Motorcraft® Metal Surface Prep ZC-31-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4
NameSpecification
Silicone Gasket and Sealant TA-30WSE-M4G323-A4
NameSpecification
Motorcraft® Metal Surface Prep ZC-31-A

Scheme 268

Scheme 268: Removal

Scheme 269

Scheme 269

Scheme 270

Scheme 270
  1. Refer to: «OIL PUMP SCREEN AND PICKUP TUBE»(ref-539206-S42498503212013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).

Scheme 271

Scheme 271: Installation

Scheme 272

Scheme 272
  1. Material: Motorcraft® Metal Surface Prep / ZC-31-A
  2. Torque: Stage 1: 10 Nm Stage 2: 20 Nm
  3. Torque: 25 Nm
  4. Torque: 10 Nm
  5. Refer to: «OIL PUMP SCREEN AND PICKUP TUBE»(ref-539206-S42498503212013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
NameSpecification
Motorcraft® Metal Surface Prep ZC-31-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4
NameSpecification
Multi-Purpose Grease Motorcraft® XL-5 (aerosol), CRC® SL3151ESB-M1C93-B
NameSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C945-A
NameSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C945-A
Motorcraft® Silicone Gasket Remover ZC-30
Motorcraft® Metal Surface Prep ZC-31-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4
NameSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C945-A
NameSpecification
Thread Sealant with PTFE TA-24WSK-M2G350-A2
NameSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C945-A
NameSpecification
Multi-Purpose Grease Motorcraft® XL-5 (aerosol), CRC® SL3151ESB-M1C93-B
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C945-A
NameSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C945-A
NameSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C945-A
Motorcraft® Silicone Gasket Remover ZC-30
Motorcraft® Metal Surface Prep ZC-31-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4
Silicone Brake Caliper Grease and Dielectric Compound XG-3-AESE-M1C171-A

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 may occur.

Note. During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and 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. For additional information, refer to the exploded views in Description and Operation in this section.

Scheme 273

Scheme 273

Scheme 274

Scheme 274

Scheme 275

Scheme 275

Scheme 276

Scheme 276

Scheme 277

Scheme 277

Scheme 278

Scheme 278

Scheme 279

Scheme 279

Scheme 280

Scheme 280

Scheme 281

Scheme 281

Scheme 282

Scheme 282

Scheme 283

Scheme 283

Scheme 284

Scheme 284

Scheme 285

Scheme 285

Scheme 286

Scheme 286

Scheme 287

Scheme 287

Scheme 288

Scheme 288

Scheme 289

Scheme 289

Scheme 290

Scheme 290

Scheme 291

Scheme 291

Scheme 292

Scheme 292

Scheme 293

Scheme 293

Scheme 294

Scheme 294

Scheme 295

Scheme 295

Scheme 296

Scheme 296

Scheme 297

Scheme 297

Scheme 298

Scheme 298

Scheme 299

Scheme 299

Scheme 300

Scheme 300

Scheme 301

Scheme 301

Scheme 302

Scheme 302

Scheme 303

Scheme 303

Scheme 304

Scheme 304

Scheme 305

Scheme 305

Scheme 306

Scheme 306

Scheme 307

Scheme 307

Scheme 308

Scheme 308

Scheme 309

Scheme 309

Scheme 310

Scheme 310

Scheme 311

Scheme 311

Scheme 312

Scheme 312

Scheme 313

Scheme 313

Scheme 314

Scheme 314
  1. NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly. NOTE: The front bulkhead does not have an oil squirter. Torque: 4 Nm
  2. NOTE: Record the smallest diameter for each journal.
  3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block and install the original main bearing beam bolts finger tight.
  4. Torque: Stage 1: 5 Nm Stage 2: 25 Nm Stage 3: Tighten an additional 90°
  5. Measure each crankshaft block main bearing bore diameter.
  6. Using the chart, select the crankshaft main bearings.
  7. NOTE: Use the original connecting rod cap bolts; installation must keep the same orientation as marked during disassembly or engine damage may occur. Torque: Stage 1: 10 Nm Stage 2: 29 Nm Stage 3: Tighten an additional 90°
  8. NOTE: Record the smallest measurement for each connecting rod. Remove and discard the bolts after measuring.
  9. NOTE: Record the smallest measurement for each connecting rod journal.
  10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
  11. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. NOTE: The center bulkhead is the thrust bearing. \ Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
  12. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
  13. NOTE: Lubricate the journals on the crankshaft with clean engine oil. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
  14. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
  15. Mounted flush.
  16. NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil. NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the new main bearing beam bolts. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque: Stage 1: 5 Nm Stage 2: 25 Nm Stage 3: Tighten an additional 90° Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge with Holding Fixture. Special Tool(s): 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Acceptable crankshaft end play is 0.22-0.45 mm (0.008-0.018 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
  17. NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
  18. NOTE: The piston compression upper and lower rings should be installed with the paint mark on the outside diameter circumference of the ring to be postioned on the right side of the ring gap. The lower compression ring needs to be installed with the undercut side downward. NOTE: The upper and lower compression ring end gaps are not controlled for installation. Upper oil control segment ring end gap. Oil control spacer gap location. Lower oil control segment ring gap location.
  19. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal. NOTE: Make sure the piston arrow on top is facing toward the front of the engine. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
  20. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten. NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation. Torque: Stage 1: 10 Nm Stage 2: 29 Nm Stage 3: Tighten an additional 90°
  21. Torque: 25 Nm Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Peg. The engine is now at TDC and must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
  22. Clean the oil pump and cylinder block mating surfaces. Material: Motorcraft® Metal Surface Prep / ZC-31-A Torque: Stage 1: 10 Nm Stage 2: 20 Nm
  23. Torque: 10 Nm
  24. Torque: 10 Nm
  25. 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, which make leak paths. Use a plastic scraping tool to remove traces of sealant. Material: Motorcraft® Silicone Gasket Remover / ZC-30 Material: Motorcraft® Metal Surface Prep / ZC-31-A
  26. NOTE: If the oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Material: Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
  27. Finger-tight.
  28. General Equipment: Round-Ended Steel Rule
  29. Torque: 20 Nm
  30. 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. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block. Material: Motorcraft® Metal Surface Prep / ZC-31-A
  31. NOTE: Dowels must be fully seated in the cylinder block.
  32. Material: Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
  33. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. NOTE: Lubricate the bolts with clean engine oil prior to installation. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque: Stage 1: 7 Nm Stage 2: 15 Nm Stage 3: 45 Nm Stage 4: Turn 90° Stage 5: Turn an additional 90°
  34. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
  35. 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 disassembly 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. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
  36. Tighten the camshaft bearing cap bolts one at a time until finger-tight. Torque: Stage 1: 7 Nm Stage 2: 16 Nm
  37. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing
  38. Torque: 11 Nm
  39. Torque: 11 Nm
  40. NOTE: Before installation, clean and inspect the diamond washer for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur. NOTE: The crankshaft sprocket flange must be facing away from the engine block. Install a diamond washer on both sides of the crankshaft sprocket.
  41. Torque: 25 Nm Torque: 10 Nm
  42. Torque: 10 Nm
  43. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
  44. Torque: 10 Nm
  45. Torque: Stage 1: 40 Nm Stage 2: Tighten an additional 60°
  46. Torque: Stage 1: 40 Nm Stage 2: Tighten an additional 60°
  47. NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Clean and inspect the mounting surfaces of the engine and the front cover. Material: Motorcraft® Silicone Gasket Remover / ZC-30 Material: Motorcraft® Metal Surface Prep / ZC-31-A
  48. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep. Material: Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
  49. NOTE: Apply the 3 mm bead of sealant so half of the bead is on the front cover flange and half is on the chamfer. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep. Material: Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
  50. Torque: 1-17 10 Nm 18-21 48 Nm
  51. NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer. Special Tool(s): 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
  52. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
  53. NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur. NOTE: This step will correctly align the crankshaft pulley to the crankshaft. General Equipment: M6 Bolt.
  54. 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 Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only. NOTE: Install a new crankshaft pulley bolt. Special Tool(s): 303-1416 Tool, Crank Damper Holding Torque: Stage 1: 100 Nm Stage 2: Tighten an additional 90°
  55. Do not tighten the bolts at this time.
  56. 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
  57. Remove.
  58. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC
  59. Torque: 20 Nm
  60. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing
  61. 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 which make leak paths. Clean the valve cover gasket surfaces. Material: Motorcraft® Metal Surface Prep / ZC-31-A
  62. NOTE: Installation of a new VCT solenoid seal is required if a damaged seal was removed during disassembly of the engine. Special Tool(s): 303-1247/2 Installer, VCT Spark Plug Tube Seal, 205-153 (T80T-4000-W) Handle
  63. NOTE: Inspect and if necessary, install new valve cover gaskets.
  64. Apply a continuous bead of the specified diameter from the specified tube. Material: Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
  65. NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Torque: 10 Nm
  66. Material: Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A) Torque: 8 Nm
  67. NOTE: The front KS must be installed in the 6 o'clock position and the rear KS must be installed in the 12 o'clock position. The KS must not touch the crankcase vent oil separator. Torque: 1 9 Nm 2 10 Nm 3 20 Nm
  68. 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. NOTE: Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.
  69. Torque: 18 Nm
  70. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
  71. Torque: 23 Nm
  72. Torque: 10 Nm
  73. Torque: 25 Nm
  74. Torque: 9 Nm
  75. Torque: 48 Nm
  76. Torque: 25 Nm
  77. Torque: 10 Nm
  78. Torque: 1 8 Nm 2 26 Nm 3 48 Nm
  79. Torque: 25 Nm
  80. Torque: 1 10 Nm 2 18 Nm
  81. Torque: Stage 1: 10.5 Nm Stage 2: 90°
  82. Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away
  83. NOTE: Special bolts are used for installation. Do not use standard bolts. Special Tool(s): 303-103 (T74P-6375-A) Holding Tool, Flywheel Torque: Stage 1: 50 Nm Stage 2: 80 Nm Stage 3: 112 Nm
  84. Tighten 2 turns at a time in sequence shown. Special Tool(s): 303-103 (T74P-6375-A) Holding Tool, Flywheel Torque: 29 Nm
NameSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C945-A

Scheme 315

Scheme 315

Scheme 316

Scheme 316

Scheme 317

Scheme 317

Scheme 318

Scheme 318

Scheme 319

Scheme 319

Scheme 320

Scheme 320

Scheme 321

Scheme 321

Scheme 322

Scheme 322
  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: The transaxle-to-engine bolts differ in length. Note the location of the bolts for correct installation. Torque: 48 Nm
  3. Torque: 48 Nm
  4. Torque: 48 Nm
  5. Special Tool(s): 300-OTC1819E 2, 200# Floor Crane, Fold Away
  6. Install Special Service Tool: 300-OTC1585AE Powertrain Lift , 014-00001 ADJUSTABLE GRIP 1735A
  7. Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away
  8. Torque: 11 Nm
  9. Torque: 10 Nm
  10. Torque: 17 Nm
  11. Special Tool(s): 300-OTC1585AE Powertrain Lift, 014-00001 ADJUSTABLE GRIP 1735A Torque: 115 Nm Torque: 90 Nm Torque: 25 Nm
  12. Torque: 133 Nm
  13. Remove Special Service Tool: 300-OTC1585AE Powertrain Lift , 014-00001 ADJUSTABLE GRIP 1735A
  14. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque: 20 Nm
  15. Torque: 48 Nm
  16. Refer to: «ROLL RESTRICTOR RH»(ref-539174-S03841162042013040100000) (307-01 Automatic Transmission - Vehicles With: Automatic Transmission - HF35, Removal and Installation).
  17. Torque: 55 Nm
  18. Torque: 25 Nm
  19. Torque: 25 Nm
  20. Torque: 48 Nm
  21. Torque: 48 Nm
  22. Torque: 25 Nm
  23. Install the following items: NOTE: LH side only. Refer to: «FENDER SPLASH SHIELD»(ref-539194-S16570676282013040100000) (501-02 Front End Body Panels, Removal and Installation). Refer to: «FRONT HALFSHAFT RH»(ref-539187-S42701564832013040100000) (205-04 Front Drive Halfshafts, Removal and Installation). Refer to: «FRONT HALFSHAFT LH»(ref-539187-S37708466412013040100000) (205-04 Front Drive Halfshafts, Removal and Installation). Refer to: «COOLING MODULE»(ref-539176-S27520719402013040100000) (303-03A Engine Cooling - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
  24. Torque: 15 Nm
  25. Refer to: «QUICK RELEASE COUPLING»(ref-539208-S40562506092013040100000) (310-00 Fuel System - General Information, General Procedures).
  26. Torque: 23 Nm
  27. Install the following items: Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-539174-S17401212522013040100000) (307-01 Automatic Transmission - Vehicles With: Automatic Transmission - HF35, 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: «AIR CLEANER»(ref-539209-S08535137802013040100000) (303-12 Intake Air Distribution and Filtering, Removal and Installation). Refer to: «DEGAS BOTTLE»(ref-539176-S00292322012013040100000) (303-03A Engine Cooling - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
  28. Fill the engine with clean engine oil. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Refer to: «BATTERY DISCONNECT AND CONNECT - HYBRID ELECTRIC VEHICLE (HEV)»(ref-539181-S40970790092013040100000) (414-01 Battery, Mounting and Cables, 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: «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). Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-539154-S30541327322013040100000) (412-00 Climate Control System - General Information, General Procedures).
NameSpecification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C945-A

Scheme 323

Scheme 323

Scheme 324

Scheme 324
  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: The transaxle-to-engine bolts differ in length. Note the location of the bolts for correct installation. Torque: 48 Nm
  3. Torque: 48 Nm
  4. Torque: 48 Nm
  5. Special Tool(s): 300-OTC1819E 2, 200# Floor Crane, Fold Away
  6. Install Special Service Tool: 300-OTC1585AE Powertrain Lift , 014-00001 ADJUSTABLE GRIP 1735A
  7. Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away
  8. Torque: 11 Nm
  9. Torque: 10 Nm
  10. Torque: 17 Nm
  11. Special Tool(s): 300-OTC1585AE Powertrain Lift , 014-00001 ADJUSTABLE GRIP 1735A Torque: 115 Nm Torque: 90 Nm Torque: 25 Nm
  12. Torque: 133 Nm
  13. Remove Special Service Tool: 300-OTC1585AE Powertrain Lift , 014-00001 ADJUSTABLE GRIP 1735A
  14. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque: 20 Nm
  15. Torque: 48 Nm
  16. Refer to: «ROLL RESTRICTOR RH»(ref-539174-S03841162042013040100000) (307-01 Automatic Transmission - Vehicles With: Automatic Transmission - HF35, Removal and Installation).
  17. Torque: 55 Nm
  18. Torque: 10 Nm
  19. Torque: 25 Nm
  20. Torque: 25 Nm
  21. Torque: 48 Nm
  22. Torque: 48 Nm
  23. Torque: 25 Nm
  24. Install the following items: NOTE: LH side only. Refer to: «FENDER SPLASH SHIELD»(ref-539194-S16570676282013040100000) (501-02 Front End Body Panels, Removal and Installation). Refer to: «FRONT HALFSHAFT RH»(ref-539187-S42701564832013040100000) (205-04 Front Drive Halfshafts, Removal and Installation). Refer to: «FRONT HALFSHAFT LH»(ref-539187-S37708466412013040100000) (205-04 Front Drive Halfshafts, Removal and Installation). Refer to: «COOLING MODULE»(ref-539176-S27520719402013040100000) (303-03A Engine Cooling - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
  25. Torque: 15 Nm
  26. Refer to: «QUICK RELEASE COUPLING»(ref-539208-S40562506092013040100000) (310-00 Fuel System - General Information, General Procedures).
  27. Torque: 23 Nm
  28. Install the following items: Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-539174-S17401212522013040100000) (307-01 Automatic Transmission - Vehicles With: Automatic Transmission - HF35, 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: «AIR CLEANER»(ref-539209-S08535137802013040100000) (303-12 Intake Air Distribution and Filtering, Removal and Installation). Refer to: «DEGAS BOTTLE»(ref-539176-S00292322012013040100000) (303-03A Engine Cooling - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
  29. Fill the engine with clean engine oil. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) 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: «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: «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). Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-539154-S30541327322013040100000) (412-00 Climate Control System - General Information, General Procedures).