Engine Mechanical - 1.6L: Removal & Installation

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.

Note. Do not rotate the camshafts unless instructed to in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves and pistons.

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Scheme 1: Removal

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Refer to: «VARIABLE CAMSHAFT TIMING (VCT) UNIT»(ref-658856-S12316413982014092900000) .
Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal .
NOTE: Use a heat gun to soften the flange sealant, this will aid in the removal of the camshaft mega cap. Failure to follow these directions may result in damage to the camshaft mega cap. NOTE: Note the position of the components before removal. Use the General Equipment: Hot Air Gun
Material : Motorcraft® Metal Surface Prep/ZC-31-B
Material : Motorcraft® Metal Surface Prep/ZC-31-B

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Scheme 5: Installation

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NOTE: If any new parts are being installed (cylinder head, valves, tappets, camshafts) it is necessary to check the valve clearance, follow the next 12 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 13 . Place a paint mark on the crankshaft at the 12 o'clock position.
Remove Special Service Tool: 303-393A Locking Tool, Flywheel , 303-393-02 Adapter for 303-393 .
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: 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: 62 lb.in (7 Nm) Stage 2: Tighten bolts 17 through 20 to: 89 lb.in (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 component must be installed within 5 minutes of applying the sealant. Material : Flange Sealant/CU7Z-19B508-A (WSS-M2G348-A11)
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:: 62 lb.in (7 Nm) Stage 2: Tighten bolts 17 through 20 to:: 89 lb.in (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°
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)
Refer to: «VARIABLE CAMSHAFT TIMING (VCT) UNIT»(ref-658856-S12316413982014092900000) .

Remove the following items: Refer to: «FLEXPLATE»(ref-658856-S35888447722014092900000) . Refer to: «OIL PAN»(ref-658856-S04442427762014092900000) .

Installation

NOTE: Make sure that the mating faces are clean and free of foreign material. NOTE: The 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: Tighten bolts 1 through 6 to:: 35 lb.in (4 Nm) Stage 2: Tighten bolts 1 through 6 to:: 89 lb.in (10 Nm) Remove the alignment sleeve.
Install the following items: Refer to: «OIL PAN»(ref-658856-S04442427762014092900000) . Refer to: «FLEXPLATE»(ref-658856-S35888447722014092900000) .

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.

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Scheme 15: Installation

NOTE: Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.
NOTE: There are different length of bolts noted in removal. Torque : 150 lb.in (17 Nm) Torque : 89 lb.in (10 Nm)
Refer to: «QUICK RELEASE COUPLING»(ref-658885-S17306120802014092900000) . Use the General Equipment: Hose Clamp Remover/Installer
Refer to: «GENERATOR - 1.6L ECOBOOST (132KW/180PS) - SIGMA»(ref-658902-S08678315172014092900000) .
Torque : 89 lb.in (10 Nm) Torque : 44 lb.in (5 Nm)
Torque : 44 lb.in (5 Nm)
Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-658873-S03187421432014092900000) .

Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. 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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Scheme 16: Removal

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Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) .
Remove the following items: Refer to: «DEGAS BOTTLE»(ref-658853-S02503234422014092900000) . Remove the RH front wheel and tire. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
Remove the RH front fender splash shield. Refer to: «FENDER SPLASH SHIELD»(ref-658872-S14314641892014092900000) .
Remove the following items: Refer to: «STARTER MOTOR»(ref-658903-S33481449902014092900000) . Refer to: «GENERATOR - 1.6L ECOBOOST (132KW/180PS) - SIGMA»(ref-658902-S08678315172014092900000) .
Install Special Service Tool: 303-1502 Lifting Device Engine .
Install Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine .
Install Special Service Tool: 303-F072 Support Bar, Engine , 303-290B-18 Adapter for 303-290B .
Remove the following items: Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
NOTE: Only rotate the crankshaft in a clockwise direction. 11 o'clock position.
NOTE: It may be necessary to rotate the halfshaft to remove the front lower bolt.
NOTE: The Crankshaft TDC Timing Pin 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. 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 TDC Timing Pin. The engine is now at TDC .
Install Special Service Tool: 303-393A Locking Tool, Flywheel , 303-393-02 Adapter for 303-393 .
NOTE: It may necessary to rotate the camshafts slightly to install the special tool. Install Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit .
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: Install a holding pin.

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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. 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: 303-393-02 Adapter for 303-393 , 303-393A Locking Tool, Flywheel .
Remove Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit .
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)
Torque : 35 lb.ft (48 Nm)
Torque : 44 lb.in (5 Nm) Torque : 18 lb.ft (25 Nm) Torque : 18 lb.ft (25 Nm)
Install the following items: Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
Remove Special Service Tool: 303-F072 Support Bar, Engine , 303-290B-18 Adapter for 303-290B , 303-050 (T70P-6000) Lifting Bracket, Engine .
Torque : 41 lb.ft (55 Nm)
Torque : 89 lb.in (10 Nm) Finger tight. Finger tight.
Torque : 89 lb.in (10 Nm)
Torque : 35 lb.ft (48 Nm)
Torque : 89 lb.in (10 Nm)
Torque : 59 lb.ft (80 Nm)
Refer to: «GENERATOR - 1.6L ECOBOOST (132KW/180PS) - SIGMA»(ref-658902-S08678315172014092900000) .
Remove the following items: Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
Refer to: «STARTER MOTOR»(ref-658903-S33481449902014092900000) .
Torque : 177 lb.in (20 Nm)
Install the RH front fender splash shield. Refer to: «FENDER SPLASH SHIELD»(ref-658872-S14314641892014092900000) .
Install the RH front wheel and tire. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
Torque : 44 lb.in (5 Nm)
Torque : 44 lb.in (5 Nm)
Refer to: «DEGAS BOTTLE»(ref-658853-S02503234422014092900000) .
Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) .
After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.

Refer to: «VARIABLE CAMSHAFT TIMING (VCT) UNIT»(ref-658856-S12316413982014092900000) .
Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal .

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)
Refer to: «VARIABLE CAMSHAFT TIMING (VCT) UNIT»(ref-658856-S12316413982014092900000) .

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Scheme 47: Removal

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Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
Remove the following items: Refer to: «VALVE COVER»(ref-658856-S37139780532014092900000) . Refer to: «TIMING BELT»(ref-658856-S17915395852014092900000) .
Remove Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit .
NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
Install the following items: Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
Remove.
Remove.

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Scheme 51: Installation

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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 .
12 o'clock position.
NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning. NOTE: The timing marks of the VCT unit must be at the 12 o'clock position. 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°
NOTE: 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.
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 : 168 lb.in (19 Nm)
Install.
Remove the following items: Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
Install the following items: Refer to: «TIMING BELT»(ref-658856-S17915395852014092900000) . Refer to: «VALVE COVER»(ref-658856-S37139780532014092900000) .

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

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Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter. Use the General Equipment: Oil Drain Equipment Use the General Equipment: Strap Wrench Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A) Torque : 128 lb.in (14.5 Nm)
Use the General Equipment: Locking Pliers
NOTE: If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may cause engine failure. To diagnose mechanical concerns. Refer to: «ENGINE»(ref-658863-S16845662912014092900000) . Use the General Equipment: Oil Drain Equipment Torque : 41 lb.ft (55 Nm)

To install, reverse the removal procedure.

Valve Cover Only

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Scheme 57: Removal

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Remove the following items: Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) . Refer to: «FUEL RAIL»(ref-658904-S17328702432014092900000) .
Refer to: «QUICK RELEASE COUPLING»(ref-658885-S17306120802014092900000) . Use the General Equipment: Hose Clamp Remover/Installer
NOTE: Note the position of the components before removal.
NOTE: The O-ring seals are to be reused unless damaged.
NOTE: Do not set the valve cover sealing surface face down on a bench as the check valve and splitter leg is susceptible to breakage.
Fuel Pump and Brake Vacuum Pump Mounting Brackets
Remove the following items: Refer to: «FUEL PUMP»(ref-658904-S01158449112014092900000) . Refer to: «BRAKE VACUUM PUMP - 1.6L ECOBOOST (110KW/150PS) - SIGMA/1.6L ECOBOOST (132KW/180PS) - SIGMA»(ref-658883-S05014508152014092900000) .
NOTE: Use a heat gun to soften the flange sealant, this will aid in the removal of the fuel pump mounting bracket. Failure to follow these directions may result in damage to the fuel pump mounting bracket. Use the General Equipment: Hot Air Gun
NOTE: Use a heat gun to soften the flange sealant, this will aid in the removal of the brake vacuum pump mounting bracket. Failure to follow these directions may result in damage to the brake vacuum pump mounting bracket. Use the General Equipment: Hot Air Gun

Fuel Pump and Brake Vacuum Pump Mounting Brackets

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Scheme 64: Installation

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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. 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. 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. 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)
Install the following items: Refer to: «BRAKE VACUUM PUMP - 1.6L ECOBOOST (110KW/150PS) - SIGMA/1.6L ECOBOOST (132KW/180PS) - SIGMA»(ref-658883-S05014508152014092900000) ). Refer to: «FUEL PUMP»(ref-658904-S01158449112014092900000) . Valve Cover Only
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. NOTE: Clean if replacing the valve cover gasket only. 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)
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: 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)
Refer to: «QUICK RELEASE COUPLING»(ref-658885-S17306120802014092900000) . Use the General Equipment: Hose Clamp Remover/Installer Torque : 80 lb.in (9 Nm)
Install the following items: Refer to: «FUEL RAIL»(ref-658904-S17328702432014092900000) . Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) .

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 310-250 Disconnect Tool, Fuel Line TKIT-2012A-FL TKIT-2012A-ROW Strap Wrench Adjustable Mounting Arm Oil Drain Equipment Hose Clamp Remover/Installer Wooden Block

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Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-658885-S01347622612014092900000) .
Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-658833-S06588196542014092900000) .
Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-658853-S08190757262014092900000) .
Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) .
Refer to: «AIR CLEANER»(ref-658888-S03686657652014092900000) .
NOTE: If equipped with block heater.
Refer to: «BATTERY TRAY»(ref-658873-S33576642202014100900000) .
NOTE: Always wrap the fuel line connection with a towel before disconnecting it. Refer to: «SPRING LOCK COUPLINGS»(ref-658885-S01881263292014092900000) . Use Special Service Tool: 310-250 Disconnect Tool, Fuel Line .
Use the General Equipment: Hose Clamp Remover/Installer
Refer to: «DEGAS BOTTLE»(ref-658853-S02503234422014092900000) .
Use the General Equipment: Hose Clamp Remover/Installer
Remove the front wheels and tires. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
Remove the drain plug and drain the engine oil. Use the General Equipment: Oil Drain Equipment Install the drain plug. Torque : 21 lb.ft (28 Nm)
Use the General Equipment: Strap Wrench Use the General Equipment: Oil Drain Equipment
Vehicles with
All vehicles
NOTE: Discard the O-ring seals and gasket seals.
NOTE: LH shown, RH similar. Both sides.
NOTE: Use the internal or external hex-holding feature to prevent the ball and stud from turning while removing or installing the stabilizer bar link nuts. The link boot seal must not be allowed to twist while tightening the link nuts or damage to the boot seal will occur. NOTE: LH shown, RH similar. Both sides.
Refer to: «BRAKE DISC»(ref-658874-S36417337692014092900000) .
NOTE: The struts will need to slide out of the knuckles when the powertrain and subframe assembly is lowered. NOTE: LH shown, RH similar. Both sides.
NOTE: One of these bolts will be used to mount the Adjustable Mounting Arm to the powertrain.
NOTE: AWD shown, FWD similar. Vehicles with
Loosen the 3 bottom PTU bolts.5 mm (0.019in). All vehicles
NOTE: LH shown, RH similar. Both sides.
NOTE: Front bumper cover removed for clarity. NOTE: There are 2 similar connectors in this area the area behind the PCM case, disconnect the upper connector.
Position a 2 x 6 board, 24 in (609.6 mm) in length and two 2 x 6 boards 30 in (762 mm) in length onto the Powertrain Lift. Install Special Service Tool: 300-OTC1585AE Powertrain Lift . Use the General Equipment: Wooden Block
Position the powertrain lift table with the two long boards under the engine and transmission and the short board under the subframe. Install Special Service Tool: 300-OTC1585AE Powertrain Lift .
Use the General Equipment: Adjustable Mounting Arm
NOTE: Make sure the struts slide out of the knuckles when lowered. Using the powertrain lift, lower the powertrain and subframe assembly.
Use the General Equipment: Hose Clamp Remover/Installer
NOTE: Only rotate the crankshaft in a clockwise direction.
Vehicles with
Loosen the 2 PTU bolts.5 mm (0.019). Position the PTU aside.
NOTE: The bottom transaxle-to-engine bolt will not come all the way out. All vehicles
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. Use the General Equipment: Adjustable Mounting Arm
Vehicles with
All vehicles

SPECIAL TOOL DESCRIPTION 100-001 (T50T-100-A) Slide Hammer 300-OTC1819E 2, 200# Floor Crane, Fold Away 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 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH 303-748 Locking Tool, Crankshaft TKIT-2010B-FLM TKIT-2010B-ROW 307-005 (T59L-100-B) Slide Hammer 308-375 Remover, Input Shaft Seal TKIT-1999-F/FLM/LT TKIT-2005U-M 310-206 Remover, Fuel Injector TKIT-2009A-FLM Hot Air Gun Hose Clamp Remover/Installer

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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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Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
Remove Special Service Tool: 303-1502 Lifting Device Engine .
Use the General Equipment: Hose Clamp Remover/Installer
NOTE: If equipped with block heater.
Use the General Equipment: Hose Clamp Remover/Installer
Use the General Equipment: Hose Clamp Remover/Installer
Use the General Equipment: Hose Clamp Remover/Installer
NOTE: Note the position of the component before removal.
NOTE: The O-ring seals are to be reused unless damaged.
NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
NOTE: Replace any damaged coil-on-plug assemblies.
NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors. NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors. NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract.
NOTE: Take extra care when handling the components. Remove any of the fuel injectors that remained in the fuel rail.
NOTE: Remove the fuel injectors that remained in the head. Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer . Use Special Service Tool: 310-206 Remover, Fuel Injector .
NOTE: Do not set the valve cover sealing surface face down on a bench as the check valve and splitter leg is susceptible to breakage.
NOTE: Use a heat gun to soften the flange sealant, this will aid in the removal of the fuel pump mounting bracket. Failure to follow these directions may result in damage to the fuel pump mounting bracket. Use the General Equipment: Hot Air Gun
NOTE: Use a heat gun to soften the flange sealant, this will aid in the removal of the brake vacuum pump mounting bracket. Failure to follow these directions may result in damage to the brake vacuum pump mounting bracket. Use the General Equipment: Hot Air Gun
Use the General Equipment: Hose Clamp Remover/Installer
NOTE: Note the different lengths of the bolts.
NOTE: Note the position for installation.
Refer to: «EXHAUST MANIFOLD CLEANING AND INSPECTION»(ref-658863-S21216123242014092900000) .
NOTE: Note the position for installation. NOTE: If equipped with block heater.
NOTE: Note the different lengths of the bolts.
NOTE: Only rotate the crankshaft in a clockwise direction. 11 o'clock position.
NOTE: The Crankshaft TDC Timing Pin 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. 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 TDC Timing Peg. The engine is now at TDC .
Install Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit .
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: Install a holding pin.
NOTE: Inspect the sprocket for damage. If damage is evident, replace the sprocket. If no damage, the sprocket is to be reused.
Use Special Service Tool: 308-375 Remover, Input Shaft Seal , 100-001 (T50T-100-A) Slide Hammer .
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.
Remove Special Service Tool: 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit .
NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal .
NOTE: Use a heat gun to soften the flange sealant, this will aid in the removal of the camshaft mega cap. Failure to follow these directions may result in damage to the camshaft mega cap. NOTE: Do not pry on camshafts when removing or damage to the camshafts may occur. NOTE: Mark the position of each component before removal. Use the General Equipment: Hot Air Gun
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.
NOTE: Install new components as necessary.
NOTE: Make sure that the cylinder head is at ambient air temperature before removing the cylinder head bolts.
Refer to: «CYLINDER HEAD DISTORTION»(ref-658863-S16405846182014092900000) . Refer to: «CYLINDER BLOCK DISTORTION»(ref-658863-S42792501642014092900000) .
Remove Special Service Tool: 303-748 Locking Tool, Crankshaft .
NOTE: Pry pads.
NOTE: Mark the location of the 3 different length bolts.
NOTE: Clean the specified component with a abrasive pad.
NOTE: The connecting rod cap bolts are a torque-to-yield design. The original connecting rod cap bolts will be used when measuring the connecting rod large end bore during assembly. The connecting rod cap bolts will be discarded after measurement. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Using a connecting rod installer, repeat until all the piston/rod assemblies are removed from the engine block.
NOTE: Mark the position of the parts, so they can be installed in their original positions. NOTE: Refer to: «PISTON INSPECTION»(ref-658863-S05050837942014092900000) .
NOTE: The main bearing beam has 2 arrows pointing towards the front of engine for correct orientation for reassembly.
NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. NOTE: The center bulkhead has the thrust bearing.

Engine Mechanical - 1.6L: Removal & Installation Ford Kuga II