Engine Mechanical: Removal & Installation Ford Grand C-MAX II

Removal

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

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1. 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. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-539167-S37930574612013040100000) (100-02 Jacking and Lifting, Description and Operation).
3. Refer to: «VALVE CLEARANCE CHECK»(ref-539206-S00251424152013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), General Procedures).
4. Refer to: «VARIABLE VALVE TIMING (VVT) UNIT»(ref-539206-S22776505562013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
5. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing
6. 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. NOTE: Mark the location of the camshafts prior to removal. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the camshaft bearing caps.

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1. 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. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
2. Tighten the camshaft bearing cap bolts one turn at a time, until finger-tight. Torque: Stage 1: 7 Nm Stage 2: 16 Nm
3. NOTE: The Camshaft Alignment Tool 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
4. Torque: 11 Nm
5. Torque: 11 Nm
6. Refer to: «VARIABLE VALVE TIMING (VVT) UNIT»(ref-539206-S22776505562013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).

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

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

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1. Refer to: «CRANKSHAFT PULLEY»(ref-539206-S06051281522013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
2. 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

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1. 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)
2. Refer to: «CRANKSHAFT PULLEY»(ref-539206-S06051281522013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).

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

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

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-539167-S37930574612013040100000) (100-02 Jacking and Lifting, Description and Operation).
2. Remove the following items: RH only. Refer to: «FENDER SPLASH SHIELD»(ref-539194-S16570676282013040100000) (501-02 Front End Body Panels, Removal and Installation). Refer to: «VALVE COVER»(ref-539206-S39781920592013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
3. 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.
4. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC
5. 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
6. 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
7. 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
8. 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.

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1. NOTE: Before installation clean and inspected 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. Install the diamond washer.
2. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
3. 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.
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 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: 90°
5. NOTE: Do not tighten the CKP sensor bolts at this time.
6. 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
7. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC
8. Torque: 20 Nm
9. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing
10. Remove.
11. Install 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).

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

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

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1. 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. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-539167-S37930574612013040100000) (100-02 Jacking and Lifting, Description and Operation).
3. Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-539208-S34120100422013040100000) (310-00 Fuel System - General Information, General Procedures).
4. 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).
5. Refer to: «BATTERY DISCONNECT AND CONNECT - HYBRID ELECTRIC VEHICLE (HEV)»(ref-539181-S40970790092013040100000) (414-01 Battery, Mounting and Cables, General Procedures).
6. Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-539176-S25563484902013040100000) (303-03A Engine Cooling - 2.0L Duratec - Hybrid (96kW/130PS), General Procedures).
7. Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-539175-S15417758412013040100000) (303-03B Electric Powertrain Cooling, General Procedures).
8. Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-539174-S17401212522013040100000) (307-01 Automatic Transmission - Vehicles With: Automatic Transmission - HF35, Removal and Installation).
9. Refer to: «INTAKE MANIFOLD»(ref-539206-S32270620492013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
10. Refer to: «VALVE TAPPETS»(ref-539206-S02241869132013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
11. NOTE: Transmission removed from graphic for clarity.
12. General Equipment: Trolley Jack General Equipment: Wooden Block
13. Remove Special Service Tool: 303-F072 Support Bar, Engine, 303-290-05A Adapter for 303-290A

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1. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the metal surface prep. NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed. Clean all mating surfaces. Material: Motorcraft® Metal Surface Prep / ZC-31-A Material: Motorcraft® Silicone Gasket Remover / ZC-30 Refer to: «CYLINDER HEAD DISTORTION»(ref-539205-S34767596262013040100000) (303-00 Engine System - General Information, General Procedures). Refer to: «CYLINDER BLOCK DISTORTION»(ref-539205-S00542151952013040100000) (303-00 Engine System - General Information, General Procedures).
2. Apply the specified sealant to the specified component. Material: Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
3. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. 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: 90° Stage 5: Turn an additional 90°
4. Install Special Service Tool: 303-F072 Support Bar, Engine, 303-290-05A Adapter for 303-290A
5. General Equipment: Trolley Jack General Equipment: Wooden Block
6. NOTE: Transmission removed from graphic for clarity.
7. Refer to: «VALVE TAPPETS»(ref-539206-S02241869132013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
8. Torque: 17 Nm
9. Torque: 55 Nm
10. Torque: 25 Nm
11. Torque: 25 Nm
12. Torque: 48 Nm
13. Refer to: «INTAKE MANIFOLD»(ref-539206-S32270620492013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
14. Torque: 25 Nm
15. Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-539174-S17401212522013040100000) (307-01 Automatic Transmission - Vehicles With: Automatic Transmission - HF35, Removal and Installation).
16. General Equipment: Oil Drain Equipment Torque: 27 Nm
17. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque: Stage 1: 8 Nm Stage 2: 180°
18. 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).

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

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

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1. 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: «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. Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-539174-S17401212522013040100000) (307-01 Automatic Transmission - Vehicles With: Automatic Transmission - HF35, Removal and Installation).
3. Refer to: «INTAKE MANIFOLD»(ref-539206-S32270620492013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
4. Refer to: «VALVE TAPPETS»(ref-539206-S02241869132013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
5. NOTE: Transmission removed from graphic for clarity.
6. General Equipment: Trolley Jack General Equipment: Wooden Block
7. Remove Special Service Tool: 303-F072 Support Bar, Engine, 303-290-05A Adapter for 303-290A

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1. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the metal surface prep. NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed. Clean all mating surfaces. Material: Motorcraft® Metal Surface Prep / ZC-31-A Material: Motorcraft® Silicone Gasket Remover / ZC-30 Refer to: «CYLINDER HEAD DISTORTION»(ref-539205-S34767596262013040100000) (303-00 Engine System - General Information, General Procedures). Refer to: «CYLINDER BLOCK DISTORTION»(ref-539205-S00542151952013040100000) (303-00 Engine System - General Information, General Procedures).
2. Apply the specified sealant to the specified component. Material: Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
3. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. 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: 90° Stage 5: Turn an additional 90°
4. Install Special Service Tool: 303-F072 Support Bar, Engine , 303-290-05A Adapter for 303-290A
5. General Equipment: Trolley Jack General Equipment: Wooden Block
6. NOTE: Transmission removed from graphic for clarity.
7. Refer to: «VALVE TAPPETS»(ref-539206-S02241869132013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
8. Torque: 17 Nm
9. Torque: 55 Nm
10. Torque: 10 Nm
11. Torque: 25 Nm
12. Torque: 25 Nm
13. Torque: 48 Nm
14. Refer to: «INTAKE MANIFOLD»(ref-539206-S32270620492013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
15. Torque: 25 Nm
16. Refer to: «TRANSMISSION CONTROL MODULE (TCM)»(ref-539174-S17401212522013040100000) (307-01 Automatic Transmission - Vehicles With: Automatic Transmission - HF35, Removal and Installation).
17. General Equipment: Oil Drain Equipment Torque: 27 Nm
18. 21. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque: Stage 1: 8 Nm Stage 2: 180°
19. 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).

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

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

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1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-539167-S37930574612013040100000) (100-02 Jacking and Lifting, Description and Operation).
2. Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-539154-S30541327322013040100000) (412-00 Climate Control System - General Information, General Procedures).
3. Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-539176-S25563484902013040100000) (303-03A Engine Cooling - 2.0L Duratec - Hybrid (96kW/130PS), General Procedures).
4. Remove the following items: Refer to: «CRANKSHAFT FRONT SEAL»(ref-539206-S12274579442013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). Refer to: «ENGINE MOUNT»(ref-539206-S14595819742013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
5. NOTE: The engine front cover bolts vary in size, note the location of each bolt for assembly.

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1. 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 all mating surfaces. Material: Motorcraft® Silicone Gasket Remover / ZC-30 Material: Motorcraft® Metal Surface Prep / ZC-31-A
2. 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)
3. 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)
4. Torque: Stage 1: Bolts 1 - 17 10 Nm Stage 2: Bolt 18 - 21 48 Nm
5. Torque: 10 Nm
6. Torque: 10 Nm 15 Nm 18 Nm
7. Install the following items: Refer to: «ENGINE MOUNT»(ref-539206-S14595819742013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). Refer to: «CRANKSHAFT FRONT SEAL»(ref-539206-S12274579442013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). 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: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-539154-S30541327322013040100000) (412-00 Climate Control System - General Information, General Procedures).

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 71

Scheme 72

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-539167-S37930574612013040100000) (100-02 Jacking and Lifting, Description and Operation).
2. Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-539154-S30541327322013040100000) (412-00 Climate Control System - General Information, General Procedures).
3. Refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-539176-S25563484902013040100000) (303-03A Engine Cooling - 2.0L Duratec - Hybrid (96kW/130PS), General Procedures).
4. Remove the following items: Refer to: «CRANKSHAFT FRONT SEAL»(ref-539206-S12274579442013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). Refer to: «ENGINE MOUNT»(ref-539206-S14595819742013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
5. NOTE: The engine front cover bolts vary in size, note the location of each bolt for assembly.

Scheme 73

Scheme 74

1. 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 all mating surfaces. Material: Motorcraft® Silicone Gasket Remover / ZC-30 Material: Motorcraft® Metal Surface Prep / ZC-31-A
2. 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)
3. 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)
4. Torque: Stage 1: Bolts 1 - 17 10 Nm Stage 2: Bolt 18 - 21 48 Nm
5. Torque: 10 Nm
6. Torque: 10 Nm 15 Nm 18 Nm
7. Install the following items: Refer to: «ENGINE MOUNT»(ref-539206-S14595819742013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). Refer to: «CRANKSHAFT FRONT SEAL»(ref-539206-S12274579442013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). 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: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-539154-S30541327322013040100000) (412-00 Climate Control System - General Information, General Procedures).

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

Scheme 75

Scheme 76

Scheme 77

Scheme 78

1. Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-539208-S34120100422013040100000) (310-00 Fuel System - General Information, General Procedures).
2. Refer to: «BATTERY DISCONNECT AND CONNECT - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-539181-S17001658892013040100000) (414-01 Battery, Mounting and Cables, General Procedures).
3. Remove the following items: Refer to: «AIR CLEANER INTAKE PIPE»(ref-539209-S04113865942013040100000) (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»(ref-539209-S08535137802013040100000) (303-12 Intake Air Distribution and Filtering, Removal and Installation). Refer to: «COOLING FAN MOTOR AND SHROUD»(ref-539176-S11090945472013040100000) (303-03A Engine Cooling - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
4. Refer to: «QUICK RELEASE COUPLING»(ref-539208-S40562506092013040100000) (310-00 Fuel System - General Information, General Procedures).
5. Refer to: «FUEL RAIL»(ref-539210-S18170714312013040100000) (303-04 Fuel Charging and Controls - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
6. NOTE: Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.

Scheme 79

1. To install, reverse the removal procedure.
2. Torque: 18 Nm

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

Scheme 80

Scheme 81

Scheme 82

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: «ENGINE FRONT COVER - HYBRID ELECTRIC VEHICLE (HEV)»(ref-539206-S25971274172013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). Refer to: «ENGINE FRONT COVER - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-539206-S18780029352013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
2. General Equipment: Oil Drain Equipment Torque: 27 Nm

Scheme 83

Scheme 84

Scheme 85

Scheme 86

1. 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.
2. NOTE: The component must be installed within 10 minutes of applying the sealant. Material: Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
3. NOTE: Only tighten the bolts finger tight at this stage.
4. General Equipment: Round-Ended Steel Rule
5. Torque: 20 Nm
6. Torque: 48 Nm Refer to: «ENGINE FRONT COVER - HYBRID ELECTRIC VEHICLE (HEV)»(ref-539206-S25971274172013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). Refer to: «ENGINE FRONT COVER - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-539206-S18780029352013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).

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 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

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. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-539167-S37930574612013040100000) (100-02 Jacking and Lifting, Description and Operation). Refer to: «ENGINE FRONT COVER - HYBRID ELECTRIC VEHICLE (HEV)»(ref-539206-S25971274172013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). Refer to: «ENGINE FRONT COVER - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-539206-S18780029352013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

1. Torque: 10 Nm
2. NOTE: If the timing chain plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps. General Equipment: Vise
3. General Equipment: Vise
4. General Equipment: Vise
5. General Equipment: Vise
6. Torque: 10 Nm
7. Torque: Stage 1: 40 Nm Stage 2: 60°
8. Torque: Stage 1: 40 Nm Stage 2: 60° Refer to: «ENGINE FRONT COVER - HYBRID ELECTRIC VEHICLE (HEV)»(ref-539206-S25971274172013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation). Refer to: «ENGINE FRONT COVER - PLUG-IN HYBRID ELECTRIC VEHICLE (PHEV)»(ref-539206-S18780029352013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).

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 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

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. Remove the following items: Refer to: «AIR CLEANER INTAKE PIPE»(ref-539209-S04113865942013040100000) (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»(ref-539209-S08535137802013040100000) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
3. Refer to: «QUICK RELEASE COUPLING»(ref-539208-S40562506092013040100000) (310-00 Fuel System - General Information, General Procedures).
4. Refer to: «IGNITION COIL-ON-PLUG»(ref-539207-S16462178942013040100000) (303-07 Engine Ignition - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
5. 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
6. Clean the sealing surfaces.

Material: Motorcraft® Metal Surface Prep / ZC-31-A

Scheme 107

Scheme 108

Scheme 109

1. Special Tool(s): 303-1247/2 Installer, VCT Spark Plug Tube Seal, 303-224 (T83T-6701-A) Installer, Crankshaft Rear Oil Seal, 205-153 (T80T-4000-W) Handle
2. Inspect and if necessary, install new valve cover gaskets.
3. Material: Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
4. Torque: 10 Nm
5. Torque: 9 Nm
6. Torque: 9 Nm
7. Refer to: «IGNITION COIL-ON-PLUG»(ref-539207-S16462178942013040100000) (303-07 Engine Ignition - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
8. Refer to: «QUICK RELEASE COUPLING»(ref-539208-S40562506092013040100000) (310-00 Fuel System - General Information, General Procedures).
9. Install the following items: 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).

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 110

Scheme 111

1. Refer to: «VALVE TAPPETS»(ref-539206-S02241869132013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
2. Refer to: «SPARK PLUGS»(ref-539207-S29131089192013040100000) (303-07 Engine Ignition - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
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 collets is installed. Any loss of air pressure will allow the valve to fall into the cylinder. Connect the compressed air supply to cylinder No. 1.
4. NOTE: Use a small screwdriver and multi-purpose grease to remove the valve collets. Remove the valve collets, valve spring retainers and the valve springs. Special Tool(s): 303-300 (T87C-6565-A) Set, Valve Spring Compressor, 303-350 (T89P-6565-A) Compressor, Valve Spring , 303-472 (T94P-6565-AH) Adapter, Valve Spring Compressor Material: Multi-Purpose Grease / Motorcraft® XL-5 (aerosol), CRC® SL3151 (ESB-M1C93-B)
5. Install new parts as necessary.

Scheme 112

1. NOTE: Use a small screwdriver and multi-purpose grease to install the valve collets. NOTE: Check the seating of the valve collets. Install the valve springs, valve spring retainers and the valve collets. Special Tool(s): 303-300 (T87C-6565-A) Set, Valve Spring Compressor , 303-350 (T89P-6565-A) Compressor, Valve Spring, 303-472 (T94P-6565-AH) Adapter, Valve Spring Compressor Material: Multi-Purpose Grease / Motorcraft® XL-5 (aerosol), CRC® SL3151 (ESB-M1C93-B) Disconnect the compressed air supply. Repeat the appropriate removal and installation steps for all of the other cylinders.
2. Refer to: «SPARK PLUGS»(ref-539207-S29131089192013040100000) (303-07 Engine Ignition - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
3. Refer to: «VALVE TAPPETS»(ref-539206-S02241869132013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).

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 113

1. Refer to: «VALVE SPRINGS»(ref-539206-S04378621282013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
2. Special Tool(s): 303-468 (T94P-6510-AH) Remover, Valve Stem Oil Seal , 307-005 (T59L-100-B) Slide Hammer

Installation

1. NOTE: Use the protector provided with the replacement kit to prevent damage to the valve seals. Special Tool(s): 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
2. Refer to: «VALVE SPRINGS»(ref-539206-S04378621282013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).

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 114

Scheme 115

Scheme 116

Scheme 117

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. Refer to: «FLYWHEEL»(ref-539206-S14349955352013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
3. General Equipment: Oil Drain Equipment Torque: 27 Nm
4. NOTE: If the oil pan is not removed, damage to the rear oil seal retainer joint may occur.

Scheme 118

Scheme 119

Scheme 120

Scheme 121

1. 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. Clean all mating surfaces. Material: Motorcraft® Metal Surface Prep / ZC-31-A Material: Motorcraft® Silicone Gasket Remover / ZC-30
2. Tighten in the sequence shown. Special Tool(s): 303-328 (T88P-6701-B1) Replacer, Rear Seal Torque: 10 Nm
3. NOTE: The component must be installed within 10 minutes of applying the sealant. Material: Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
4. NOTE: The component must be installed within 10 minutes of applying the sealant. Material: Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
5. NOTE: Only tighten the bolts finger tight at this stage.
6. NOTE: The engine front cover-to-oil pan bolts must be tightened first to align the front surface of the oil pan flush with the front surface of the engine block. Torque: 10 Nm Torque: 18 Nm
7. Torque: 20 Nm
8. Refer to: «FLYWHEEL»(ref-539206-S14349955352013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
9. Fill the engine with clean engine oil. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

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

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-539167-S37930574612013040100000) (100-01 Jacking and Lifting, Description and Operation).
2. Remove the following items: Refer to: «WIPER LINKAGE ASSEMBLY»(ref-539180-S15421428082013040100000) (501 - 16 Wipers and Washers, Removal and Installation). Refer to: «AIR CLEANER»(ref-539209-S08535137802013040100000) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
3. Install Special Service Tool: 303-290-05A Adapter for 303-290A, 303-F072 Support Bar, Engine Torque: 25 Nm Torque: 90 Nm Torque: 115 Nm

1. To install, reverse the removal procedure.

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

Scheme 127

Scheme 128

Scheme 129

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. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-539167-S37930574612013040100000) (100-02 Jacking and Lifting, Description and Operation).
3. Torque: Stage 1: 10.5 Nm Stage 2: 90°
4. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A) Torque: Stage 1: 8 Nm Stage 2: 180°
5. Refer to: «OIL PRESSURE SWITCH»(ref-539206-S10900742842013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
6. Torque: 25 Nm

1. To install, reverse the removal procedure.

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

Scheme 130

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-539167-S37930574612013040100000) (100-02 Jacking and Lifting, Description and Operation).
2. Material: Thread Sealant with PTFE / TA-24 (WSK-M2G350-A2)

1. To install, reverse the removal procedure.

Scheme 131

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. Refer to: «OIL PAN»(ref-539206-S11603488722013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).

Scheme 132

1. Torque: 10 Nm
2. Refer to: «OIL PAN»(ref-539206-S11603488722013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).

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 133

1. Refer to: «CAMSHAFTS»(ref-539206-S31252697782013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).
2. 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.
3. Install new parts as necessary.

Scheme 134

1. Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
2. Refer to: «CAMSHAFTS»(ref-539206-S31252697782013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).

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

Scheme 135

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. Refer to: «TIMING DRIVE COMPONENTS»(ref-539206-S42221684042013040100000) (303-01 Engine - 2.0L Duratec - Hybrid (96kW/130PS), Removal and Installation).

1. To install, reverse the removal procedure.