Engine Mechanical - 1.6L: Overhaul — Ford Kuga II (2012-2016)

DISASSEMBLY

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

Note. If the components are to be reinstalled, mark the location of the components removed, they must be installed in the same location.

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Refer to: «EXHAUST MANIFOLD CLEANING AND INSPECTION»(ref-658863-S21216123242014092900000) .
NOTE: Only use hand tools when removing or installing the spark plugs, or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.
NOTE: Use a small screwdriver and multi-purpose grease to remove the valve collets. Use Special Service Tool: 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 , 303-1249 Valve Spring Compressor . Material : Motorcraft® Multi-Purpose Grease Spray/XL-5 (ESB-M1C93-B)
NOTE: Install new parts, as necessary.
Use Special Service Tool: 303-468 (T94P-6510-AH) Remover, Valve Stem Oil Seal , 307-005 (T59L-100-B) Slide Hammer .
NOTE: Note the location of the valves if they are to be reused.
NOTE: Install new parts, as necessary. The end of the stem for grooves or scoring. The valve face and the edge for pits, grooves or scores. The valve head for signs of burning, erosion, warpage and cracking. The valve margin for wear.

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NOTE: If installing the original valves, make sure the valves are installed in the same position from which they were removed. Coat the valve stems with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Use Special Service Tool: 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal . Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: Use a small screwdriver and multi-purpose grease to install the valve collets. Check the seating of the valve collet. Use Special Service Tool: 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 , 303-1249 Valve Spring Compressor . Material : Motorcraft® Multi-Purpose Grease Spray/XL-5 (ESB-M1C93-B)
NOTE: Only use hand tools when removing or installing the spark plugs, or damage can occur to the cylinder head or spark plug. Torque : 133 lb.in (15 Nm)
Torque : 89 lb.in (10 Nm)
Torque : Tighten:: 15 lb.ft (21 Nm) Retighten:: 15 lb.ft (21 Nm)
Torque : 21 lb.ft (29 Nm)
Torque : 168 lb.in (19 Nm) Torque : 44 lb.in (5 Nm) Torque : 159 lb.in (18 Nm)

Refer to: «PISTON INSPECTION»(ref-658863-S05050837942014092900000) .

ASSEMBLY

NOTE: Indicates front of engine.
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: The upper and lower compression rings are to be fitted with the identification marks on the upper side. NOTE: Arrows faces the front of the engine. NOTE: Align the piston rings on the piston. Upper compression ring gap location. Lower compression ring gap location. Upper oil control segment ring gap location. Expander ring gap location. Lower oil control segment ring gap location.

SPECIAL TOOL DESCRIPTION 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge 300-OTC1819E 2, 200# Floor Crane, Fold Away 303-103 (T74P-6375-A) Holding Tool, Flywheel TKIT-2009TC-F T74P-77000-A 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit TKIT-2010B-FLM TKIT-2010B-ROW 303-1502 Lifting Device Engine TKIT-2012A-FL TKIT-2012A-ROW 303-1532 Installer, Camshaft Seal TKIT-2010B-FLM TKIT-2010B-ROW 303-1550 Alignment Tool, Crankshaft Vibration Damper TKIT-2012A-FL TKIT-2012A-ROW 303-1552 Alignment Tool, Camshaft TKIT-2012A-FL TKIT-2012A-ROW 303-1567 Sizer, Teflon Seal TKIT-2010C-FLM TKIT-2010C-FLM 303-175 (T82L-6316-A) Installer, Crankshaft Vibration Damper TKIT-1982-F 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal TKIT-1988-F TKIT-1988-FLM 303-393-02 Adapter for 303-393 TKIT-2012A-FL TKIT-2012A-ROW 303-393A Locking Tool, Flywheel TKIT-2012A-FL TKIT-2012A-ROW 303-420 (T92P-6701-BH) Installer, Crankshaft Front Oil Seal TKIT-1992-FLMH/LMH TKIT-1992-LMH/MH 303-748 Locking Tool, Crankshaft TKIT-2010B-FLM TKIT-2010B-ROW 310-205 Fuel Injector Brush 310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM Feeler Gauge Hose Clamp Remover/Installer Piston Ring Compressor

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Scheme 199: Engine

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Name	Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.) XO-5W20-QSP (U.S.)	WSS-M2C945-A
Thread Sealant with PTFE TA-24-B	WSK-M2G350-A2
Motorcraft® Silicone Gasket Remover ZC-30-A
Flange Sealant CU7Z-19B508-A	WSS-M2G348-A11
Motorcraft® Metal Surface Prep ZC-31-B
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4
Flange Sealant - Anaerobic Loctite® 51031	WSK-M2G348-A7
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A	ESE-M1C171-A

MATERIALS SPECIFICATION

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 exploded views in DESCRIPTION AND OPERATION .

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Torque : 80 lb.in (9 Nm)
Measure the length in two directions. Record the smallest measurement for each crankshaft main bearing journal.
Mounted flush and finger tight.
Torque : Stage 1: 22 lb.ft (30 Nm) Stage 2: 37 lb.ft (50 Nm) Stage 3: 45° Stage 4: 45°
Measure the length in five places.
Using the chart, select the crankshaft main bearings.
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. Use the original connecting rod cap bolts. Torque : Stage 1: 159 lb.in (18 Nm) Stage 2: 45° Stage 3: 45°
Measure the length or distance in two directions. Record the smallest measurement for each connecting rod.
Measure the length in two directions. Record the smallest measurement for each connecting rod journal.
Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal
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. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
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 (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Mounted flush.
NOTE: Lubricate the main bearing beam bolts threads with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A) Torque : Stage 1: 22 lb.ft (30 Nm) Stage 2: 37 lb.ft (50 Nm) Stage 3: 45° Stage 4: 45°
Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge with Holding Fixture. Use Special Service Tool: 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 0.12-0.43 mm (0.008-0.017 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
NOTE: Arrows faces the front of the engine.
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 (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: The upper and lower compression rings are to be fitted with the identification marks on the upper side. NOTE: Arrows faces the front of the engine. Upper compression ring gap location. Lower compression ring gap location. Upper oil control segment ring gap location. Expander ring gap location. Lower oil control segment ring gap location.
NOTE: Using a connecting rod installer will unsure 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 arrows on top is facing toward the front of the engine. Use the General Equipment: Piston Ring Compressor Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
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. Use new connecting rod caps bolts. Torque : Stage 1: 159 lb.in (18 Nm) Stage 2: 45° Stage 3: 45°
Install Special Service Tool: 303-748 Locking Tool, Crankshaft .
NOTE: Only rotate the crankshaft clockwise direction. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the crankshaft locking tool. The engine is now at TDC .
NOTE: There are different length of bolts noted in disassembly. NOTE: Finger tight at this stage.
Torque : Stage 1: 49 lb.in (5.5 Nm) Stage 2: 84 lb.in (9.5 Nm)
Torque : 84 lb.in (9.5 Nm)
NOTE: New crankshaft rear seal is supplied with an alignment sleeve which must be removed after installation. NOTE: Do not remove the alignment sleeve from the crankshaft rear seal prior to installation on the crankshaft. Align the crankshaft rear seal and alignment sleeve on the crankshaft and push the crankshaft rear seal off the alignment sleeve onto the crankshaft without stopping until the crankshaft rear seal meets the cylinder block. Torque : Stage 1: 35 lb.in (4 Nm) Stage 2: 80 lb.in (9 Nm)
Finger tight.
Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .
Torque : Stage 1: 133 lb.in (15 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 22 lb.ft (30 Nm) Stage 4: 90°
Remove Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .
NOTE: Only rotate the crankshaft clockwise direction. Verify the crankshaft balance weight is up against the crankshaft locking tool.
Install Special Service Tool: 303-393-02 Adapter for 303-393 , 303-393A Locking Tool, Flywheel .
NOTE: The O-ring seal is to be reused unless damaged.
Torque : 84 lb.in (9.5 Nm)
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. Make sure that the mating faces are clean and free of foreign material. Material : Motorcraft® Metal Surface Prep/ZC-31-B Material : Motorcraft® Silicone Gasket Remover/ZC-30-A
NOTE: Do not use metal scrapers, plastic 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. NOTE: Make sure that the mating faces are clean and free of foreign material. Do not use any type of scrapers. There is a rubber sealing surface on the bottom of the crankshaft rear seal, take extra care when cleaning the specified area by peeling off the old sealant by hand.
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. Make sure that the mating faces are clean and free of foreign material. Material : Motorcraft® Metal Surface Prep/ZC-31-B Material : Motorcraft® Silicone Gasket Remover/ZC-30-A
Install the following items: NOTE: The use of the two studs will aid on the alignment of the oil pan. Two M8x20 studs.
NOTE: The component must be installed within 5 minutes of applying the sealant. Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
Remove the following items: Two M8x20 studs.
NOTE: Only tighten the bolts finger tight at this stage.
Torque : Stage 1: 1 - 13: 89 lb.in (10 Nm) Stage 2: 1 - 13: 168 lb.in (19 Nm)
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: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces. Material : Motorcraft® Metal Surface Prep/ZC-31-B
NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. NOTE: Make sure that no fluids are present in the cylinder head bolt threaded bores. Torque : Stage 1: 44 lb.in (5 Nm) Stage 2: 133 lb.in (15 Nm) Stage 3: 26 lb.ft (35 Nm) Stage 4: 90° Stage 5: 90°
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: If any new parts are being installed (cylinder head, valves, tappets, camshafts) it is necessary to check the valve clearance, follow the next 10 steps exactly or serious damage to the engine may occur. If the original parts are being installed it is not necessary to check the valve clearance so proceed to step 68 . Place a paint mark on the crankshaft at the 12 o'clock position.
Remove Special Service Tool: 303-393-02 Adapter for 303-393 , 303-393A Locking Tool, Flywheel .
Remove Special Service Tool: 303-748 Locking Tool, Crankshaft .
NOTE: Rotating the crankshaft will position all of the pistons below the deck of the cylinder block and allow the camshafts to be installed and the valve clearance checked without the possibility of damage to the valves or pistons. Using the crankshaft bolt and washer, rotate the crankshaft clockwise 270 degrees until the paint mark is at the 9 o'clock position
NOTE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts. NOTE: Make sure that the camshafts and camshaft bearing caps are installed in their original locations or damage to the engine may occur. NOTE: Make sure that the components are installed to the position noted before removal. NOTE: Make sure that new bolts are installed. NOTE: Apply clean engine oil to the bearing surfaces of the camshafts, camshaft bearing caps and the VCT bridge. Tighten the bolts evenly, half a turn at a time, until the camshaft bearing caps and the VCT bridge are seated against the cylinder head. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A) Torque : Stage 1: Tighten bolts 1 through 16 to 7 Nm Stage 2: Tighten bolts 17 through 20 to 10 Nm Stage 3: Tighten bolts 1 through 16 an additional 45° Stage 4: Tighten bolts 17 and 18 an additional 70° Stage 5: Tighten bolts 19 and 20 an additional 53°
Using the flats of the camshaft, rotate the camshaft to place the cam lobe at base circle, with the lobe pointed away from the tappet. Use a feeler gauge to measure the clearance of each valve and record its location. Use the General Equipment: Feeler Gauge Repeat to measure all of the lobe/tappet clearances.
NOTE: Select tappets using this formula: ideal tappet thickness measured clearance + the existing tappet thickness - nominal clearance. Select the closest tappet size to the ideal tappet thickness available and mark the installation location. NOTE: The nominal clearance is 0.0079 in (.2 mm) for intake and 0.0134 in (.34 mm) for exhaust. NOTE: The acceptable clearances after being fully installed is 0.007-0.009 in (.17-.23 mm) for intake and 0.012-0.015 in (.31-.37 mm) for exhaust.
NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. NOTE: Note the location and orientation of each camshaft bearing cap and the position of the camshaft lobes on the No. 1 cylinder for installation reference. Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps in sequence shown below.
Install Special Service Tool: 303-748 Locking Tool, Crankshaft .
NOTE: Rotating the crankshaft will position the engine at TDC and allow you to install the camshafts in the same position as noted during the disassembly. Rotate the crankshaft clockwise 90 degrees so the crankshaft contacts the Timing Peg, Crankshaft TDC 303-748.
If necessary, replace any tappets with the correct tappets selected during the valve clearance check.
NOTE: Verify the crankshaft contacts the Timing Peg and the engine is still at TDC Install Special Service Tool: 303-393A Locking Tool, Flywheel , 303-393-02 Adapter for 303-393 .
NOTE: The VCT bridge must be installed within 5 minutes of applying the flange sealant. Material : Flange Sealant/CU7Z-19B508-A (WSS-M2G348-A11)
Tighten the bolts evenly, half a turn at a time, until the camshaft bearing caps and the VCT bridge are seated against the cylinder head. Torque : Stage 1: 1 - 16: 62 lb.in (7 Nm) Stage 2: 17 - 20: 89 lb.in (10 Nm) Stage 3: 1 - 16: 45° Stage 4: 17 and 19: 70° Stage 5: 18 and 20: 53°
Use Special Service Tool: 303-1532 Installer, Camshaft Seal . Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: It may be necessary to use an open-ended wrench to turn the camshafts by the hexagon to align the camshafts. Install Special Service Tool: 303-1552 Alignment Tool, Camshaft .
NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning. Install Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit . Torque : 18 lb.ft (25 Nm)
Remove Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit .
Remove Special Service Tool: 303-1552 Alignment Tool, Camshaft .
NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning. Tighten an additional: Torque : 75°
The special tool can only be installed if the valve timing is correct. Install Special Service Tool: 303-1552 Alignment Tool, Camshaft .
NOTE: The special tool can only be installed if the valve timing is correct. If the special tools cannot be installed, repeat the adjustment according to the preceding steps. Install Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit .
Remove Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit .
Remove Special Service Tool: 303-1552 Alignment Tool, Camshaft .
NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning. Torque : 142 lb.in (16 Nm)
Install Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit .
Torque : Stage 1: 53 lb.in (6 Nm) Stage 2: 89 lb.in (10 Nm)
WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury. Torque : 18 lb.ft (25 Nm)
Make sure that the mating faces are clean and free of foreign material. Use Special Service Tool: 303-175 (T82L-6316-A) Installer, Crankshaft Vibration Damper , 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal , 303-420 (T92P-6701-BH) Installer, Crankshaft Front Oil Seal . Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: Before installation, clean and inspect the sprocket for any damage. If damage is evident, replace the sprocket. If no damage, the sprocket is to be reused.
WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury. NOTE: Remove the holding pin.
Install Special Service Tool: 303-1550 Alignment Tool, Crankshaft Vibration Damper . Rotate crankshaft pulley to align the Special Tool: Use Special Service Tool: 303-1550 Alignment Tool, Crankshaft Vibration Damper . Finger tight at this stage. Using a new bolt, finger tight at this stage.
Remove Special Service Tool: 303-1550 Alignment Tool, Crankshaft Vibration Damper .
Torque : Stage 1: 74 lb.ft (100 Nm) Stage 2: 90° Stage 3: Wait 2s Stage 4: 15°
Remove Special Service Tool: 303-748 Locking Tool, Crankshaft .
Remove Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit .
Remove Special Service Tool: 303-393-02 Adapter for 303-393 , 303-393A Locking Tool, Flywheel .
NOTE: Only rotate the crankshaft in a clockwise direction. Rotate about 1 3/4 turns.
Install Special Service Tool: 303-748 Locking Tool, Crankshaft .
NOTE: Only rotate the crankshaft in a clockwise direction. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the crankshaft locking tool. The engine is now at TDC .
NOTE: It may necessary to rotate the camshafts slightly to install the special tool. NOTE: The special tool can only be installed if the valve timing is correct. If the special tool cannot be installed, repeat the adjustment according to the preceding steps. Install Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit .
Remove Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit .
Remove Special Service Tool: 303-748 Locking Tool, Crankshaft .
Torque : 177 lb.in (20 Nm)
Torque : 89 lb.in (10 Nm)
NOTE: There are different length of bolts noted in disassembly. Torque : 41 lb.ft (55 Nm)
Torque : 89 lb.in (10 Nm) Finger tight. Finger tight.
Torque : 89 lb.in (10 Nm)
NOTE: If equipped with block heater. Torque : 27 lb.in (3 Nm)
Torque : 89 lb.in (10 Nm)
Torque : Tighten:: 15 lb.ft (21 Nm) Retighten:: 15 lb.ft (21 Nm)
Torque : 177 lb.in (20 Nm)
Torque : 177 lb.in (20 Nm)
Torque : 18 lb.ft (25 Nm)
Torque : Tighten:: 18 lb.ft (25 Nm) Retighten:: 18 lb.ft (25 Nm)
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Torque : 19 lb.ft (26 Nm) Torque : 84 lb.in (9.5 Nm)
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Torque : 84 lb.in (9.5 Nm)
Torque : 159 lb.in (18 Nm) Torque : 18 lb.ft (25 Nm) Torque : 17 lb.ft (23 Nm)
NOTE: Lubricate the spigot with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Push the spigot into the engine block. Tighten bolts 1, 2 and 3 to: Torque : 49 lb.in (5.5 Nm) Tighten bolts 4, 5, 6, 7 and 8 to: Torque : 49 lb.in (5.5 Nm) Tighten all bolts in sequence to: Torque : 84 lb.in (9.5 Nm)
NOTE: The head of the KS should not touch any other component. NOTE: The LH KS must be at the 10 o'clock position and the RH KS must be at the 2 o'clock position. Torque : 159 lb.in (18 Nm)
Material : Thread Sealant with PTFE/TA-24-B (WSK-M2G350-A2) Torque : 159 lb.in (18 Nm)
Torque : 80 lb.in (9 Nm)
Torque : 89 lb.in (10 Nm)
NOTE: A new oil cooler must be installed or severe damage to the engine can occur. Torque : 41 lb.ft (55 Nm)
NOTE: There are different length of bolts noted in disassembly. Torque : 150 lb.in (17 Nm) Torque : 89 lb.in (10 Nm)
Use the General Equipment: Hose Clamp Remover/Installer
Torque : 89 lb.in (10 Nm) Torque : 35 lb.ft (48 Nm) Torque : 35 lb.ft (48 Nm) Torque : 35 lb.ft (48 Nm)
Torque : 18 lb.ft (25 Nm)
Torque : 35 lb.ft (48 Nm)
Torque : 18 lb.ft (24 Nm)
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. Make sure that the mating faces are clean and free of foreign material. Material : Motorcraft® Metal Surface Prep/ZC-31-B
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. Make sure that the mating faces are clean and free of foreign material. Material : Motorcraft® Metal Surface Prep/ZC-31-B
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. Make sure that the mating faces are clean and free of foreign material. Material : Motorcraft® Metal Surface Prep/ZC-31-B
NOTE: The components must be installed within 5 minutes of applying the sealant. Material : Flange Sealant/CU7Z-19B508-A (WSS-M2G348-A11)
Torque : 89 lb.in (10 Nm)
NOTE: Use a new O-ring seal. Tighten bolts 1 through 10 to: Torque : Stage 1: 27 lb.in (3 Nm) Stage 2: 80 lb.in (9 Nm) Stage 3: 97 lb.in (11 Nm) Stage 4: Tighten bolts 1, 2, 5, 6, 7, 8, 9 and 10 to:: 124 lb.in (14 Nm)
Torque : 80 lb.in (9 Nm)
Torque : 80 lb.in (9 Nm)
NOTE: The components must be installed within 5 minutes of applying the sealant. Material : Flange Sealant/CU7Z-19B508-A (WSS-M2G348-A11)
Material : Flange Sealant/CU7Z-19B508-A (WSS-M2G348-A11)
Torque : Stage 1: 44 lb.in (5 Nm) Stage 2: 80 lb.in (9 Nm) Stage 3: 89 lb.in (10 Nm)
NOTE: A clean working environment is essential to prevent dirt or foreign material contamination. NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors. NOTE: Do not use compressed air to clean the tip of the fuel injector. NOTE: Do not use a brush to clean the tip of the fuel injector. Use Special Service Tool: 310-205 Fuel Injector Brush .
NOTE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors. NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur. NOTE: Pull the lower Teflon® seal away from the injector. Carefully cut and discard the lower fuel injector Teflon® seals.
NOTE: Do not lubricate the new lower Teflon® fuel injector seals. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly . NOTE: Once the Teflon® seal is installed on the Teflon® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal. NOTE: Make sure that new lower fuel injector Teflon® seals are installed. Using the Pusher Tool, slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly .
NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion. NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal. Some Teflon® seal massaging with your fingers before the Teflon® seal sizer tool is installed will aid in installing the Teflon® seal sizer tool. Position the Teflon® seal sizer tool with the larger opening towards the Teflon® seal. Push while turning the Teflon® seal sizer tool 180 degrees. Use Special Service Tool: 303-1567 Sizer, Teflon Seal . Once the Teflon® seal sizer tool is installed, check and make sure the Teflon® seal is in the sizing portion of the Teflon® seal sizer tool. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.
NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals. NOTE: Do not lubricate the new lower Teflon® fuel injector seals. NOTE: Do not lubricate the new lower Teflon® fuel injector seals. NOTE: Make sure that new upper fuel injector O-ring seals, upper fuel injector O-ring seal support rings and fuel injector retainer clips are installed. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup. NOTE: The fuel rail pressure sensor must be replaced if it is removed from the fuel rail.
NOTE: Do not lubricate the new lower Teflon® fuel injector seals. NOTE: Take extra care when handling the components. Only use moderate force.
Torque : Stage 1: 44 lb.in (5 Nm) Stage 2: 17 lb.ft (23 Nm)
NOTE: Only rotate the crankshaft Clockwise (CW) or damage to the engine may occur. NOTE: The cam lobe for the fuel injection pump must be at BDC for the fuel injection pump installation.
Material: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
NOTE: Install all the bolts finger tight before final tightening. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A) Install the fuel injection pump and loosely install the 2 fuel injection pump bolts, alternately tighten each bolt one half of a revolution until seated. Torque : 115 lb.in (13 Nm)
NOTE: Make sure that a new component is installed. NOTE: Calculate the correct torque wrench setting for the following torque. Refer to Torque Wrench Adapter Formulas below. Torque : 62 lb.in (7 Nm) Torque : Stage 1: Using a torque adapter, tighten to:: 15 lb.ft (21 Nm) Stage 2: Wait 5min Stage 3: Using a torque adapter, tighten to:: 15 lb.ft (21 Nm)
NOTE: Make sure that a new component is installed. NOTE: Only tighten the 2 high pressure fuel tube flare nuts finger tight at this stage. NOTE: Calculate the correct torque wrench setting for the following torque. Refer to Torque Wrench Adapter Formulas below. Torque : Stage 1: Using a torque adapter, tighten to:: 15 lb.ft (21 Nm) Stage 2: Wait 5min Stage 3: Using a torque adapter, tighten to:: 15 lb.ft (21 Nm)
Torque : 89 lb.in (10 Nm) Torque : 53 lb.in (6 Nm)
Material : Silicone Brake Caliper Grease and Dielectric Compound/XG-3-A (ESE-M1C171-A)
NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage. Torque : 89 lb.in (10 Nm)
NOTE: The O-ring seals are to be reused unless damaged. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Torque : 71 lb.in (8 Nm)
Torque : 159 lb.in (18 Nm)
Material : Flange Sealant - Anaerobic/Loctite® 51031 (WSK-M2G348-A7)
Torque : 89 lb.in (10 Nm) Torque : 168 lb.in (19 Nm)
Torque : 89 lb.in (10 Nm)
Torque : 89 lb.in (10 Nm)
Use the General Equipment: Hose Clamp Remover/Installer
Torque : 150 lb.in (17 Nm)
Use the General Equipment: Hose Clamp Remover/Installer
Use the General Equipment: Hose Clamp Remover/Installer
NOTE: If equipped with block heater.
Use the General Equipment: Hose Clamp Remover/Installer
Install Special Service Tool: 303-1502 Lifting Device Engine .
Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
Remove from engine stand.

SPECIAL TOOL DESCRIPTION 300-OTC1585AE Powertrain Lift 300-OTC1819E 2, 200# Floor Crane, Fold Away 303-1502 Lifting Device Engine TKIT-2012A-FL TKIT-2012A-ROW 502-002 (T94P-2100-AH) Alignment Pins, Subframe TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 Adjustable Mounting Arm Hose Clamp Remover/Installer

Scheme 269

Name	Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.) XO-5W20-QSP (U.S.)	WSS-M2C945-A
Threadlock and Sealer TA-25-B