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Engine Mechanical - 2.0L: Overhaul Ford Kuga II

Mechanical 30 illustrations ~5356 words

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. Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

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

  1. NOTE: RH shown, LH similar.
  2. NOTE: Use a small screwdriver and multi-purpose grease to remove the valve collets. Remove the valve collet, valve spring retainer and the valve spring. 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)
  3. Install new parts, as necessary.
  4. Use Special Service Tool: 303-468 (T94P-6510-AH) Remover, Valve Stem Oil Seal , 307-005 (T59L-100-B) Slide Hammer .
  5. NOTE: Note the location of the valves if they are to be reused.
  6. 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.

ASSEMBLY

  1. 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-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  2. Use Special Service Tool: 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal . Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  3. 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)
  4. Torque: 97 lb.in (11 Nm)
  5. NOTE: Replace gasket if damaged.
  6. Torque: 89 lb.in (10 Nm)
  7. NOTE: RH shown, LH similar. Torque: 35 lb.ft (47 Nm)

Note. If the piston and connecting rod are to be reinstalled, they must be assembled in the same orientation. Mark the piston orientation to the connecting rod reassembly.

  1. Refer to: «PISTON INSPECTION»(ref-658863-S05050837942014092900000) .
  1. NOTE: Align the piston-to-connecting rod orientation marks made during disassembly.
  2. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  3. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  4. NOTE: Align the piston rings on the piston. Upper oil control segment ring gap location. Oil control spacer gap location. Lower oil control segment ring gap location.

ENGINE SPECIAL TOOLS DESCRIPTION 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge 205-153 (T80T-4000-W) Handle 300-OTC1819E 2, 200# Floor Crane, Fold Away 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal TKIT-2009TC-F 303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW 303-1521 Alignment Tool, Crankshaft Position Sensor TKIT-2010C-FLM TKIT-2010C-FLM 303-1565 Alignment Tool, Camshaft TKIT-2010C-FLM TKIT-2010C-FLM 303-1567 Sizer, Teflon Seal TKIT-2010C-FLM TKIT-2010C-FLM 303-328 (T88P-6701-B1) Replacer, Rear Seal TKIT-1988-F TKIT-1988-FLM TKIT-1988-LM 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW 310-205 Fuel Injector Brush 310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM Feeler Gauge Strap Wrench Round-Ended Steel Rule

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NameSpecification
Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) XO-5W30-QSP (U.S.)WSS-M2C946-A
Motorcraft® Metal Surface Prep ZC-31-B
Silicone Gasket and Sealant TA-30WSE-M4G323-A4
Gasket Maker TA-16WSK-M2G348-A5
Motorcraft® Orange Antifreeze/Coolant Concentrated (U.S.) VC-3-B (U.S.)WSS-M97B44-D

MATERIAL SPECIFICATIONS

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. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

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  1. Torque: 89 lb.in (10 Nm)
  2. Measure the length or distance in two directions. Record the smallest measurement for each crankshaft main bearing journal.
  3. Mounted flush and original main bearing beam bolts finger tight.
  4. Torque : Stage 1: 44 lb.in (5 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 90°
  5. Measure each crankshaft block main bearing bore diameter.
  6. Using the chart, select the crankshaft main bearings.
  7. Original connecting rod cap bolts. Torque : Stage 1: 89 lb.in (10 Nm) Stage 2: 21 lb.ft (29 Nm) Stage 3: 90°
  8. Measure the length or distance in two directions. Record the smallest measurement for each connecting rod.
  9. Measure the length or distance in two directions. Record the smallest measurement for each connecting rod journal.
  10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
  11. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  12. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  13. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  14. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  15. Mounted flush.
  16. NOTE: Lubricate the new main bearing beam bolts threads and under the bolt heads with clean engine oil. NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A) Torque : Stage 1: 44 lb.in (5 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 90°
  17. 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 0.220-0.450 mm (0.0087-0.0177 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
  18. NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  19. Upper oil control segment ring gap location. Oil control spacer gap location. Lower oil control segment ring gap location.
  20. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal. NOTE: Make sure the piston arrow on top is facing toward the front of the engine. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  21. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation. Torque : Stage 1: 89 lb.in (10 Nm) Stage 2: 21 lb.ft (29 Nm) Stage 3: 90°
  22. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC . Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC .
  23. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled. NOTE: The original adjustment shims must be installed in their original positions. NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit. Install the adjustment shims in their original positions on the seat faces of the balancer unit. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
  24. Torque : Stage 1: 18 lb.ft (25 Nm) Stage 2: 31 lb.ft (42 Nm)
  25. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC . Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
  26. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC . Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC . Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
  27. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements. NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown below. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing. NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown below into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown below. NOTE: Position the Dial Indicator Gauge with Holding Fixture as shown below. Measure the gear backlash. Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. Backlash specifications are 0.020 to 0.120 mm (0.00078 to 0.0047 in). If the backlash exceeds the specified range, carry out the BALANCE SHAFT BACKLASH procedure. Refer to: «BALANCE SHAFT BACKLASH»(ref-658858-S28604042692014092900000) .
  28. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Peg. The engine is now at TDC and must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
  29. Torque : Stage 1: 89 lb.in (10 Nm) Stage 2: 177 lb.in (20 Nm)
  30. Torque: 18 lb.ft (25 Nm)
  31. NOTE: Before installation, clean and inspect the diamond washer for any damage. If damaged 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.
  32. Torque: 89 lb.in (10 Nm) Push the tensioner spring down and position the spring under the shoulder bolt.
  33. Use Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal . Torque: 89 lb.in (10 Nm)
  34. NOTE: A new gasket must be installed.
  35. Torque: 89 lb.in (10 Nm)
  36. NOTE: If the oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
  37. Finger-tight.
  38. Front surface of the oil pan flush with the front surface of the engine block. Use the General Equipment: Round-Ended Steel Rule
  39. Torque: 177 lb.in (20 Nm)
  40. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. Torque : Stage 1: 62 lb.in (7 Nm) Stage 2: 133 lb.in (15 Nm) Stage 3: 41 lb.ft (55 Nm) Stage 4: 90° Stage 5: 90°
  41. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  42. 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 59 . Place a paint mark on the crankshaft at the 12 o'clock position.
  43. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
  44. 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.
  45. NOTE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts. NOTE: Lubricate the camshaft journals and camshaft bearing caps with clean engine oil. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A) Tighten 2 turns at a time in the sequence shown below in 2 stages. Torque : Stage 1: 62 lb.in (7 Nm) Stage 2: 142 lb.in (16 Nm)
  46. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A) Torque : Stage 1: 62 lb.in (7 Nm) Stage 2: 142 lb.in (16 Nm)
  47. 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.
  48. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. NOTE: The nominal clearance is: intake: 0.25 mm (0.0095 in). exhaust: 0.36 mm (0.0142 in). NOTE: The acceptable clearances after being fully installed are: intake: 0.19-0.31 mm (0.007-0.012 in). exhaust: 0.30-0.42 mm (0.012-0.017 in). Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
  49. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.
  50. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
  51. 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 303-507.
  52. If necessary, replace any tappets with the correct tappets selected during the valve clearance check. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  53. NOTE: The exhaust camshaft rear bearing cap must be secured within 10 minutes of sealant application. If the bearing cap is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep. NOTE: Do not allow sealant to enter the camshaft bearing journal. If sealant is applied to the camshaft bearing journal, the journal and sealing area must be cleaned with Motorcraft® Metal Surface Prep. Material: Gasket Maker/TA-16 (WSK-M2G348-A5) Material: Motorcraft® Metal Surface Prep/ZC-31-B
  54. 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. NOTE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts. NOTE: Wipe off any excess sealant from the fuel injection pump housing sealing surface of the cylinder head and rear camshaft cap. NOTE: Lubricate the camshaft journals and camshaft bearing caps with clean engine oil. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A) Tighten 2 turns at a time in the sequence shown below in 2 stages. Torque : Stage 1: 62 lb.in (7 Nm) Stage 2: 142 lb.in (16 Nm)
  55. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A) Torque : Stage 1: 62 lb.in (7 Nm) Stage 2: 142 lb.in (16 Nm)
  56. Torque: 89 lb.in (10 Nm)
  57. 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: 303-1565 Alignment Tool, Camshaft .
  58. NOTE: Do not tighten the camshaft phaser and sprocket bolts at this time. Finger-tight.
  59. Torque: 89 lb.in (10 Nm) NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
  60. NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly. Using the edge of a vise, compress the timing chain tensioner plunger.
  61. Using a small pick, push back and hold the ratchet mechanism.
  62. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
  63. Install a holding pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
  64. NOTE: Do not remove the holding pin until the tensioner bolts are tightened. Torque: 89 lb.in (10 Nm)
  65. NOTE: Use an open-ended wrench to prevent the component from turning. Torque : Stage 1: 30 lb.ft (40 Nm) Stage 2: 60°
  66. NOTE: Use an open-ended wrench to prevent the component from turning. Torque : Stage 1: 30 lb.ft (40 Nm) Stage 2: 60°
  67. 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) Material: Motorcraft® Metal Surface Prep/ZC-31-B
  68. 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. Apply beads of silicone gasket and sealant that are 2 mm (0.078 in) in diameter and 5 mm (0.19 in) in length across the cylinder head and cylinder block joint areas. Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4) Material: Motorcraft® Metal Surface Prep/ZC-31-B
  69. Torque : Bolts 1 - 19: 89 lb.in (10 Nm) Bolts 20 - 22: 35 lb.ft (48 Nm)
  70. NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer. Use Special Service Tool: 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal . Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  71. NOTE: Do not reuse the diamond washer, a new diamond washer must be installed.
  72. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  73. NOTE: This step will correctly align the crankshaft pulley to the crankshaft. Install an M6 bolt.
  74. 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 Strap Wrench and the bolt should be installed using hand tools only. Use the General Equipment: Strap Wrench Torque : Stage 1: 74 lb.ft (100 Nm) Stage 2: 90°
  75. Remove the M6 bolt.
  76. NOTE: Do not tighten the CKP sensor bolts at this time.
  77. Install the Special Tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel. Use Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor . Torque: 62 lb.in (7 Nm)
  78. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
  79. Remove Special Service Tool: 303-1565 Alignment Tool, Camshaft .
  80. Torque: 177 lb.in (20 Nm)
  81. Torque: 46 lb.ft (63 Nm)
  82. NOTE: The intake camshaft rear bearing cap must be secured within 10 minutes of sealant application. If the bearing cap is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep. Material: Gasket Maker/TA-16 (WSK-M2G348-A5) Material: Motorcraft® Metal Surface Prep/ZC-31-B
  83. NOTE: Wipe off any excess sealant from the vacuum pump sealing surface of the cylinder head and camshaft cap. Torque : Stage 1: 62 lb.in (7 Nm) Stage 2: 142 lb.in (16 Nm)
  84. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine. Use Special Service Tool: 205-153 (T80T-4000-W) Handle , 303-1247 VCT Spark Plug Tube Seal Remover and Installer.
  85. Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
  86. NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep. Material: Motorcraft® Metal Surface Prep/ZC-31-B Torque: 89 lb.in (10 Nm)
  87. Early build vehicles equipped with metal vacuum tubes. Late build vehicles equipped with nylon vacuum tubes.
  88. Torque: 53 lb.in (6 Nm)
  89. NOTE: The fuel injection cam lobe must be positioned at zero lift before installing the fuel injection pump housing. Turn the component clockwise.
  90. Replace as necessary.
  91. Torque : Stage 1: 133 lb.in (15 Nm) Stage 2: 60°
  92. Inspect the fuel injection pump tappet for flat spots or scoring, especially in the indicated areas. If any damage is found, inspect the fuel injection pump and the fuel injection pump tappet drive lobe. Install new components as necessary.
  93. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  94. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  95. Alternately tighten each bolt one complete revolution until seated. Torque : Stage 1: 44 lb.in (5 Nm) Stage 2: 55°
  96. Torque: 150 lb.in (17 Nm)
  97. Replace as necessary.
  98. Torque: 89 lb.in (10 Nm)
  99. Replace as necessary.
  100. Torque: 89 lb.in (10 Nm)
  101. NOTE: Do not use compressed air or the Fuel Injector Brush to clean the tip of the fuel injectors. Failure to follow this instruction may result in damage to the fuel injectors. 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. Use Special Service Tool: 310-205 Fuel Injector Brush .
  102. NOTE: Place the Teflon® Seal Sizer, knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed. Use Special Service Tool: 303-1567 Sizer, Teflon Seal . Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly . NOTE: Make sure that new lower fuel injector Teflon® seals are installed. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly .
  103. NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the seal. NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion. Use Special Service Tool: 303-1567 Sizer, Teflon Seal .
  104. 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. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  105. NOTE: The FRP sensor must be replaced if it is removed from the fuel rail. NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.
  106. NOTE: Do not lubricate the new lower Teflon® fuel injector seals. NOTE: Make sure that new fuel rail bolts are installed. Push down on the fuel rail above the injectors. Torque : Stage 1: 71 lb.in (8 Nm) Stage 2: 26°
  107. Finger-tight.
  108. Finger-tight.
  109. Torque : Stage 1: 133 lb.in (15 Nm) Stage 2: 30°
  110. Torque: 89 lb.in (10 Nm)
  111. Replace as necessary.
  112. Torque: 89 lb.in (10 Nm)
  113. NOTE: The forward KS must be installed in the 6 o'clock position and the rearward KS must be installed in the 3 o'clock position as shown in the graphic. Failure to follow these instructions may result in damage to the engine. Torque: 177 lb.in (20 Nm)
  114. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
  115. 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. Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be reused.
  116. NOTE: Vehicles built on or before 9/28/2012 have a vacuum port on the side of the intake manifold. These engines are equipped with an intake manifold plug in the vacuum port. If the plug is missing, install a new one following the instruction sheet included in the service kit. If the nylon strap is missing, install a new 2.5 mm (0.098 in) wide and 1.0 mm (0.039) thick tie strap.
  117. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
  118. Torque: 177 lb.in (20 Nm)
  119. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
  120. Torque: 97 lb.in (11 Nm)
  121. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
  122. Torque: 18 lb.ft (25 Nm)
  123. NOTE: Install a new coolant pump O-ring seal and lubricate with clean engine coolant prior to installation. Material: Motorcraft® Orange Antifreeze/Coolant Concentrated (U.S.)/VC-3-B (U.S.) (WSS-M97B44-D) Torque: 89 lb.in (10 Nm) Torque: 18 lb.ft (25 Nm)
  124. Finger-tight. Torque: 18 lb.ft (25 Nm)
  125. Torque: 133 lb.in (15 Nm)
  126. Torque: 18 lb.ft (25 Nm) Torque: 80 lb.in (9 Nm) Torque: 18 lb.ft (25 Nm)
  127. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
  128. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-658865-S23768654432014092900000) .
  129. Torque: 177 lb.in (20 Nm)
  130. Torque: 18 lb.ft (25 Nm) Torque: 177 lb.in (20 Nm)
  131. Torque: 150 lb.in (17 Nm)
  132. Torque: 37 lb.ft (50 Nm)
  133. Torque: 89 lb.in (10 Nm)
  134. NOTE: Do not reuse the turbocharger oil return tube/gaskets, new parts must be installed. Torque: 89 lb.in (10 Nm)
  135. NOTE: Do not reuse the turbocharger oil filter, a new part must be installed.
  136. NOTE: Do not reuse the turbocharger oil supply tube gaskets, new parts must be installed. Torque: 18 lb.ft (25 Nm)
  137. NOTE: Do not reuse the gaskets, new parts must be installed. Torque: 21 lb.ft (28 Nm)
  138. Torque: 106 lb.in (12 Nm)
  139. Torque: 44 lb.in (5 Nm)
  140. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) . Torque: 44 lb.in (5 Nm)
  141. Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
  142. NOTE: Special bolts are used for installation. Do not use standard bolts. Torque : Stage 1: 37 lb.ft (50 Nm) Stage 2: 59 lb.ft (80 Nm) Stage 3: 83 lb.ft (112 Nm)

ENGINE SPECIAL TOOLS DESCRIPTION 300-OTC1585AE Powertrain Lift 300-OTC1819E 2, 200# Floor Crane, Fold Away 307-566 Retainer, Torque Converter TKIT-2006C-FFMFLM TKIT-2006C-LM TKIT-2006C-ROW 502-002 (T94P-2100-AH) Alignment Pins, Subframe TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 Adjustable Mounting Arm

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NameSpecification
Motorcraft® Multi-Purpose Grease Spray XL-5ESB-M1C93-B
Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.) XO-5W30-QSP (U.S.)WSS-M2C946-A
Threadlock and Sealer TA-25-B

MATERIAL SPECIFICATIONS

All vehicles

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  1. Use Special Service Tool: 307-566 Retainer, Torque Converter . Material: Motorcraft® Multi-Purpose Grease Spray/XL-5 (ESB-M1C93-B)
  2. NOTE: Align the torque converter stud marked during removal with the flexplate.
  3. Torque: 35 lb.ft (48 Nm)
  4. Use the General Equipment: Adjustable Mounting Arm
  5. Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
  6. Vehicles with
  7. Torque: 35 lb.ft (48 Nm) Vehicles with
  8. Torque: 35 lb.ft (48 Nm)
  9. Torque: 46 lb.ft (63 Nm)
  10. Torque: 18 lb.ft (25 Nm) Torque: 46 lb.ft (63 Nm)
  11. Torque: 97 lb.in (11 Nm) All vehicles
  12. Torque: 35 lb.ft (48 Nm)
  13. NOTE: Only rotate the crankshaft in a clockwise direction. Torque: 30 lb.ft (40 Nm)
  14. Torque: 106 lb.in (12 Nm) Torque: 44 lb.in (5 Nm)
  15. Torque: 26 lb.ft (35 Nm)
  16. Torque: 159 lb.in (18 Nm)
  17. NOTE: Make sure the new catalytic converter-to-turbocharger clamp is positioned over both the catalytic converter inlet flange and the turbocharger outlet flange.
  18. Torque: 18 lb.ft (25 Nm)
  19. Torque: 177 lb.in (20 Nm)
  20. Install Special Service Tool: 502-002 (T94P-2100-AH) Alignment Pins, Subframe .
  21. NOTE: Make sure the struts go into the knuckles when the powertrain and subframe assembly is raised. Using the powertrain lift, raise the powertrain and subframe assembly.
  22. Torque: 59 lb.ft (80 Nm) Torque: 66 lb.ft (90 Nm)
  23. Material: Threadlock and Sealer/TA-25-B Torque: 109 lb.ft (148 Nm)
  24. NOTE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. Torque: 85 lb.ft (115 Nm)
  25. Tighten in 2 stages. Torque : Stage 1: 103 lb.ft (140 Nm) Stage 2: 180° Torque: 177 lb.in (20 Nm)
  26. Remove Special Service Tool: 502-002 (T94P-2100-AH) Alignment Pins, Subframe .
  27. Remove Special Service Tool: 300-OTC1585AE Powertrain Lift . Use the General Equipment: Adjustable Mounting Arm
  28. NOTE: Front bumper cover removed for clarity.
  29. NOTE: Front bumper cover removed for clarity.
  30. NOTE: LH shown, RH similar. Both sides. Torque: 18 lb.ft (25 Nm)
  31. Torque: 18 lb.ft (25 Nm)
  32. Torque: 35 lb.ft (48 Nm)
  33. Torque: 35 lb.ft (48 Nm)
  34. NOTE: Make sure the struts are seated into the knuckles. NOTE: LH shown, RH similar. NOTE: Install new bolts on both sides. Torque : Stage 1: 59 lb.ft (80 Nm) Stage 2: 180°
  35. Refer to: «BRAKE DISC»(ref-658874-S36417337692014092900000) .
  36. 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. NOTE: Install new nuts on both sides. Torque: 35 lb.ft (48 Nm)
  37. NOTE: LH shown, RH similar. Vehicles with
  38. Torque: 46 lb.ft (63 Nm)
  39. NOTE: Install new bolts. Torque: 26 lb.ft (35 Nm) All vehicles
  40. Torque: 35 lb.ft (48 Nm)
  41. Torque: 177 lb.in (20 Nm)
  42. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A) Torque : Stage 1: 71 lb.in (8 Nm) Stage 2: 180°
  43. NOTE: Install new O-ring seals and gaskets. Torque: 133 lb.in (15 Nm)
  44. Torque: 44 lb.in (5 Nm) Torque: 97 lb.in (11 Nm)
  45. Install the front wheels and tires. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
  46. Torque: 18 lb.ft (25 Nm)
  47. Refer to: «DEGAS BOTTLE»(ref-658854-S10734265502014092900000) .
  48. Refer to: «SPRING LOCK COUPLINGS»(ref-658906-S26603282432014092900000) .
  49. Torque: 106 lb.in (12 Nm)
  50. Torque: 106 lb.in (12 Nm)
  51. Torque: 35 lb.ft (48 Nm)
  52. Refer to: «BATTERY TRAY»(ref-658873-S33576642202014100900000) .
  53. Torque: 44 lb.in (5 Nm) Torque: 106 lb.in (12 Nm)
  54. NOTE: If equipped with block heater.
  55. Install the following items: Refer to: «AIR CLEANER OUTLET PIPE»(ref-658889-S34519501002014092900000) . Refer to: «AIR CLEANER»(ref-658889-S29103318952014092900000) .
  56. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of vehicle control. Failure to follow this instruction may result in serious injury to vehicle occupant(s). Torque: 21 lb.ft (28 Nm)
  57. Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) .
  58. Fill the engine with clean engine oil. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
  59. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-658854-S21377632492014092900000) .
  60. Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-658833-S06588196542014092900000) .
  61. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.

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