Engine Mechanical - 2.0L: Removal & Installation Ford Kuga II

Removal

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

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.

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-658885-S01347622612014092900000) .
3. Refer to: «VARIABLE CAMSHAFT TIMING (VCT) UNIT»(ref-658858-S15526865102014092900000) .
4. Remove Special Service Tool: 303-1565 Alignment Tool, Camshaft .
5. 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. NOTE: Inspect the camshaft bores for any scratches that can be felt by hand. Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.

Scheme 531

Scheme 532

Scheme 533

1. 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.
2. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
3. 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.
4. 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)
5. 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)
6. 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.
7. 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.
8. 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.
9. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
10. 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.
11. 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)
12. 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)
13. 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 sealer 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. Tighten the camshaft bearing cap bolts one turn at a time, until finger-tight. 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)
14. 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)
15. Torque: 89 lb.in (10 Nm)
16. 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 .
17. Refer to: «VARIABLE CAMSHAFT TIMING (VCT) UNIT»(ref-658858-S15526865102014092900000) .

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

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

1. RH side only. Refer to: «FENDER SPLASH SHIELD»(ref-658872-S14314641892014092900000) .
2. Remove the following items: Refer to: «ACCESSORY DRIVE BELT»(ref-658865-S22645921542014092900000) . Refer to: «BRAKE VACUUM PUMP - 2.0L ECOBOOST (177KW/240PS) - MI4»(ref-658883-S27503463812014092900000) . Refer to: «VALVE COVER»(ref-658858-S15803108392014092900000) .
3. Turn the crankshaft clockwise until the No. 1 piston is 45 degrees BTDC using the guide holes on the engine front cover and the crankshaft pulley.
4. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
5. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation. NOTE: The engine front cover is removed from graphic for clarity. Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
6. NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Tool cannot be installed, remove the TDC Timing Peg and rotate the crankshaft three-fourths of a revolution clockwise and repeat the previous 2 steps of this procedure. Install Special Service Tool: 303-1565 Alignment Tool, Camshaft .
7. NOTE: The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Strap Wrench and the bolt should be removed using an air impact wrench (1/2-in drive minimum). NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. Use the General Equipment: Strap Wrench
8. If the diamond washer did not come off with the crankshaft pulley, remove the diamond washer.
9. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal .

Installation

1. 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)
2. NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur. Install the diamond washer onto the crankshaft.
3. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
4. NOTE: This step will correctly align the crankshaft pulley to the crankshaft. Install an M6 bolt.
5. 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°
6. Remove the M6 bolt.
7. NOTE: Do not tighten the CKP sensor bolts at this time.
8. 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)
9. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
10. Torque: 177 lb.in (20 Nm)
11. Remove Special Service Tool: 303-1565 Alignment Tool, Camshaft .
12. Torque: 46 lb.ft (63 Nm)
13. 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-A
14. 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)
15. Install the following items: Refer to: «VALVE COVER»(ref-658858-S15803108392014092900000) . Refer to: «BRAKE VACUUM PUMP - 2.0L ECOBOOST (177KW/240PS) - MI4»(ref-658883-S27503463812014092900000) . Refer to: «ACCESSORY DRIVE BELT»(ref-658865-S22645921542014092900000) .
16. RH side only. Refer to: «FENDER SPLASH SHIELD»(ref-658872-S14314641892014092900000) .
17. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.

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

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

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-658885-S01347622612014092900000) .
3. Refer to: «TURBOCHARGER»(ref-658900-S06434340782014092900000) .
4. Remove the following items: Refer to: «FUEL INJECTORS»(ref-658905-S20832033792014092900000) . Refer to: «CAMSHAFTS»(ref-658858-S04021588492014092900000) .
5. NOTE: If the valve tappets are to be reused, note the location of the valve tappets to make sure they are assembled in their original positions.

1. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep. NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed. NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces. Material: Motorcraft® Silicone Gasket Remover/ZC-30-A Material: Motorcraft® Metal Surface Prep/ZC-31-B
2. Refer to: «CYLINDER HEAD DISTORTION»(ref-658863-S16405846182014092900000) .
3. 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°
4. Torque: 177 lb.in (20 Nm)
5. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
6. Install the following items: Refer to: «CAMSHAFTS»(ref-658858-S04021588492014092900000) . Refer to: «FUEL INJECTORS»(ref-658905-S20832033792014092900000) .
7. Torque: 20 lb.ft (27 Nm)
8. 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°
9. Refer to: «TURBOCHARGER»(ref-658900-S06434340782014092900000) .
10. 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)

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

Scheme 534

Scheme 535

Scheme 536

Scheme 537

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-658873-S03187421432014092900000) .
3. Refer to: «THROTTLE BODY»(ref-658905-S19854831122014092900000) .
4. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
5. 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 either a brake aspiration hose or intake manifold plug in the vacuum port.
6. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
7. 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.
8. 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.

Scheme 538

1. To install, reverse the removal procedure.
2. Torque: 177 lb.in (20 Nm)

All vehicles

Scheme 539

Scheme 540

Scheme 541

Scheme 542

Scheme 543

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Remove the following items: Refer to: «AIR CLEANER OUTLET PIPE»(ref-658889-S34519501002014092900000) . Refer to: «AIR CLEANER»(ref-658889-S29103318952014092900000) .
3. NOTE: To prevent damage to the transmission, do not loosen the transmission-to-engine fasteners more than 5 mm (0.19 in). Loosen 5 mm (0.19 in).
4. NOTE: To prevent damage to the transmission, do not loosen the transmission-to-engine fasteners more than 5 mm (0.19 in). Loosen 5 mm (0.19 in).
5. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-658865-S23768654432014092900000) .
6. 4x4
7. Refer to: «TRANSFER CASE»(ref-658881-S12849398172014092900000) . All vehicles
8. NOTE: To prevent damage to the transmission, do not loosen the engine-to-transmission fasteners more than 5 mm (0.19 in). Loosen 5 mm (0.19 in).
9. Torque: 20 lb.ft (27 Nm)

All vehicles

Scheme 544

Scheme 545

Scheme 546

Scheme 547

1. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant. Plastic scraper.
2. 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) Material: Motorcraft® Metal Surface Prep/ZC-31-B
3. Finger tight.
4. NOTE: The engine front cover-to-oil pan fasteners must be tightened first to align the front surface of the oil pan flush with the front surface of the engine block. Torque: 89 lb.in (10 Nm)
5. Torque: 177 lb.in (20 Nm)
6. Alternate tightening the LH bellhousing-to-engine and RH engine-to-bellhousing lower bolts to draw the transaxle and engine together. Torque: 35 lb.ft (48 Nm)
7. Torque: 35 lb.ft (48 Nm)
8. Torque: 35 lb.ft (48 Nm)
9. Torque: 35 lb.ft (48 Nm)
10. Torque: 35 lb.ft (48 Nm)
11. 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° 4x4
12. Refer to: «TRANSFER CASE»(ref-658881-S27519633852014092900000) . All vehicles
13. Torque: 18 lb.ft (25 Nm) Torque: 80 lb.in (9 Nm) Torque: 18 lb.ft (25 Nm)
14. Torque: 92 lb.ft (125 Nm)
15. Torque : 44 lb.in (5 Nm) 97 lb.in (11 Nm)
16. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-658865-S23768654432014092900000) .
17. Torque: 35 lb.ft (48 Nm)
18. Remove the following items: Refer to: «AIR CLEANER»(ref-658889-S29103318952014092900000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-658889-S34519501002014092900000) .
19. 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)

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

Scheme 548

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) .
3. Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-658873-S03187421432014092900000) .
4. Refer to: «AIR CLEANER OUTLET PIPE»(ref-658889-S34519501002014092900000) .
5. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
6. Refer to: «IGNITION COIL-ON-PLUG»(ref-658907-S27857495202014092900000) .
7. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
8. Early build vehicles equipped with metal vacuum tubes. Late build vehicles equipped with nylon vacuum tubes.
9. NOTE: The VCT solenoid seals should only be replaced if they are damaged. Use Special Service Tool: 205-153 (T80T-4000-W) Handle , 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

1. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Material: Motorcraft® Metal Surface Prep/ZC-31-B
2. 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.
3. Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
4. 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)
5. Torque: 18 lb.ft (25 Nm)
6. Early build vehicles equipped with metal vacuum tubes. Late build vehicles equipped with nylon vacuum tubes.
7. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
8. cop
9. Torque: 106 lb.in (12 Nm)
10. Torque: 44 lb.in (5 Nm)
11. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) . Torque: 44 lb.in (5 Nm)
12. Refer to: «AIR CLEANER OUTLET PIPE»(ref-658889-S34519501002014092900000) .
13. Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-658873-S03187421432014092900000) .
14. Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) .

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Remove the following items: Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-658865-S23768654432014092900000) . Refer to: «FLEXPLATE»(ref-658858-S06032226572014092900000) .
3. Torque: 20 lb.ft (27 Nm)

1. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant. Plastic scraper.
2. Use Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal . Torque: 89 lb.in (10 Nm)
3. 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: Motorcraft® Metal Surface Prep/ZC-31-B Material: Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
4. Finger tight.
5. NOTE: The engine front cover-to-oil pan bolts must be tightened first to align the front surface of the oil pan flush with the front surface of the engine block. Torque: 89 lb.in (10 Nm)
6. Torque: 177 lb.in (20 Nm)
7. Torque: 18 lb.ft (25 Nm) Torque: 80 lb.in (9 Nm) Torque: 18 lb.ft (25 Nm)
8. Install the following items: Refer to: «FLEXPLATE»(ref-658858-S06032226572014092900000) . Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-658865-S23768654432014092900000) .
9. 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)

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

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
3. Torque: 59 lb.ft (80 Nm) Torque: 66 lb.ft (90 Nm)

1. To install, reverse the removal procedure.

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

Scheme 549

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Material: Thread Sealant with PTFE/TA-24-B (WSK-M2G350-A2) Torque: 133 lb.in (15 Nm)

1. To install, reverse the removal procedure.

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

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

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «FUEL PUMP»(ref-658905-S11279493172014092900000) .
3. Refer to: «FENDER SPLASH SHIELD»(ref-658872-S14314641892014092900000) .
4. NOTE: The fuel injection cam lobe must be positioned at zero lift before removing the fuel injection pump housing.
5. Refer to: «ENGINE FRONT COVER»(ref-658858-S33310742882014092900000) .
6. NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Do not rely on the Camshaft Alignment Tool to prevent camshaft rotation. Damage to the tool or the camshaft can occur. Install Special Service Tool: 303-1565 Alignment Tool, Camshaft .
7. NOTE: Use an open-ended wrench to prevent the component from turning. Loosen bolt.
8. NOTE: Use an open-ended wrench to prevent the component from turning. Loosen bolt.
9. Using a small pick, release and hold the ratchet mechanism. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner. Insert a holding pin into the hole to retain the tensioner.

1. 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.
2. 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.
3. Using a small pick, push back and hold the ratchet mechanism.
4. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
5. Install a holding pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
6. NOTE: Do not remove the holding pin until the tensioner bolts are tightened. Torque: 89 lb.in (10 Nm)
7. NOTE: Use an open-ended wrench to prevent the component from turning. Torque : Stage 1: 30 lb.ft (40 Nm) Stage 2: 60°
8. NOTE: Use an open-ended wrench to prevent the component from turning. Torque : Stage 1: 30 lb.ft (40 Nm) Stage 2: 60°
9. Refer to: «ENGINE FRONT COVER»(ref-658858-S33310742882014092900000) .
10. NOTE: The fuel injection cam lobe must be positioned at zero lift before installing the fuel injection pump housing.
11. Replace as necessary.
12. Torque : Stage 1: 133 lb.in (15 Nm) Stage 2: 60°
13. If any flat spots or scoring are found, especially in the indicated areas, inspect the fuel injection pump and the fuel injection pump tappet drive lobe. Install new components as necessary.
14. Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W30-QSP (U.S.) (WSS-M2C946-A)
15. Torque: 97 lb.in (11 Nm)
16. Install the following items: Refer to: «FENDER SPLASH SHIELD»(ref-658872-S14314641892014092900000) . Refer to: «FUEL PUMP»(ref-658905-S11279493172014092900000) .

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.

1. Refer to: «TIMING CHAIN»(ref-658858-S30629012912014092900000) .
2. NOTE: Washers are not required for installation of the VCT units. If equipped, discard the washers.

1. NOTE: Do not tighten the bolts at this time. The bolts will be tightened during the timing drive component installation procedure.
2. Refer to: «TIMING CHAIN»(ref-658858-S30629012912014092900000) .

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

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

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Remove the following items: Refer to: «ACCESSORY DRIVE BELT»(ref-658865-S22645921542014092900000) . Refer to: «ACCESSORY DRIVE BELT TENSIONER»(ref-658865-S00497658932014092900000) . Refer to: «CRANKSHAFT FRONT SEAL»(ref-658858-S25018298792014092900000) . Refer to: «ENGINE MOUNT»(ref-658858-S19637541062014092900000) .
3. 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. Plastic Scraper.

1. 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
2. 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
3. Torque : Bolts 1 - 19: 89 lb.in (10 Nm) Bolts 20 - 22: 35 lb.ft (48 Nm)
4. Torque: 177 lb.in (20 Nm)
5. Install the following items: Refer to: «ENGINE MOUNT»(ref-658858-S19637541062014092900000) . Refer to: «CRANKSHAFT FRONT SEAL»(ref-658858-S25018298792014092900000) . Refer to: «ACCESSORY DRIVE BELT TENSIONER»(ref-658865-S00497658932014092900000) . Refer to: «ACCESSORY DRIVE BELT»(ref-658865-S22645921542014092900000) .

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 Adjustable Mounting Arm Wooden Block

Scheme 550

Scheme 551

All vehicles

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Scheme 556

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Scheme 558

Scheme 559

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Scheme 562

Scheme 563

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Scheme 581

1. Refer to: «JACKING AND LIFTING - OVERVIEW»(ref-658843-S31152527922014092900000) .
2. Refer to: «FUEL SYSTEM PRESSURE RELEASE»(ref-658885-S01347622612014092900000) .
3. Refer to: «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-658833-S06588196542014092900000) .
4. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-658854-S21377632492014092900000) .
5. Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) .
6. Remove the following items: Refer to: «AIR CLEANER»(ref-658889-S29103318952014092900000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-658889-S34519501002014092900000) .
7. NOTE: If equipped with block heater.
8. Refer to: «BATTERY TRAY»(ref-658873-S33576642202014100900000) .
9. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
10. Refer to: «DEGAS BOTTLE»(ref-658854-S10734265502014092900000) .
11. Remove the front wheels and tires. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
12. NOTE: Discard the O-ring seals and gaskets.
13. Drain fluid and install drain plug. Torque: 20 lb.ft (27 Nm)
14. All wheel drive (AWD)
15. Loosen 5 mm (0.197). All vehicles
16. NOTE: LH shown, RH similar. Both sides.
17. 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.
18. Remove the front brake discs. Refer to: «BRAKE DISC»(ref-658874-S36417337692014092900000) .
19. 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.
20. NOTE: One of these bolts will be used to mount the Adjustable Mounting Arm to the powertrain.
21. NOTE: AWD shown, FWD similar.
22. NOTE: LH shown, RH similar. Both sides.
23. NOTE: Front bumper cover removed for clarity.
24. Position a 2 x 6 board, 30 in (762 mm) in length and one 1 x 6 board 30 in (762 mm) in length onto the Powertrain Lift. Install Special Service Tool: 300-OTC1585AE Powertrain Lift . Use the General Equipment: Wooden Block
25. Position the powertrain lift table with the boards under the engine and transmission.
26. Use the General Equipment: Adjustable Mounting Arm
27. NOTE: Make sure the struts slide out of the knuckles when lowered. Using the powertrain lift, lower the powertrain and subframe assembly.
28. NOTE: Only rotate the crankshaft in a clockwise direction. Index mark one stud and the flexplate for assembly reference.
29. All wheel drive (AWD)
30. Loosen the 2 PTU bolts.5 mm (0.019). Position the PTU aside.
31. Vehicles with front wheel drive (FWD)
32. All vehicles
33. General Equipment: Spreader Bar. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
34. Remove Use the General Equipment: Adjustable Mounting Arm
35. Install Special Service Tool: 307-566 Retainer, Torque Converter .

ENGINE SPECIAL TOOLS DESCRIPTION 205-153 (T80T-4000-W) Handle 300-OTC1819E 2, 200# Floor Crane, Fold Away 303-103 (T74P-6375-A) Holding Tool, Flywheel TKIT-2009TC-F T74P-77000-A 303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW 303-1565 Alignment Tool, Camshaft TKIT-2010C-FLM TKIT-2010C-FLM 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW 307-005 (T59L-100-B) Slide Hammer 310-206 Remover, Fuel Injector TKIT-2009A-FLM Strap Wrench

Scheme 582

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. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

Scheme 583

Scheme 584

Scheme 585

Scheme 586

Scheme 587

1. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .
2. Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
3. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
4. Loosen.
5. Loosen.
6. Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-658865-S23768654432014092900000) .
7. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
8. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
9. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
10. 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 either a brake aspiration hose or intake manifold plug in the vacuum port.
11. Refer to: «QUICK RELEASE COUPLING»(ref-658906-S19526040892014092900000) .
12. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of the fuel injection pump flare nut.
13. 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 head and require the use of a Fuel Injector Remover tool to extract.
14. Remove any of the fuel injectors that remained in the fuel rail.
15. Remove any of the fuel injectors that remained in the cylinder head. Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer , 310-206 Remover, Fuel Injector .
16. 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: Be very careful when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors. Pull the lower Teflon® seal away from the injector. Carefully cut and discard the lower fuel injector Teflon® seals.
17. NOTE: The fuel injection cam lobe must be positioned at zero lift before removing the fuel injection pump housing.
18. Early build vehicles equipped with metal vacuum tubes. Late build vehicles equipped with nylon vacuum tubes.
19. NOTE: The VCT solenoid seals should only be replaced if they are damaged upon inspection. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer 205-153 (T80T-4000-W) Handle .
20. 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
21. Turn the crankshaft clockwise until the No. 1 piston is 45 degrees BTDC using the guide holes on the engine front cover and the crankshaft pulley.
22. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
23. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation. NOTE: The engine front cover is removed from graphic for clarity. Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
24. NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Tool cannot be installed, remove the TDC Timing Peg and rotate the crankshaft three-fourths of a revolution clockwise and repeat the previous 2 steps of this procedure. Tighten the retainer. Install Special Service Tool: 303-1565 Alignment Tool, Camshaft .
25. NOTE: The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Strap Wrench and the bolt should be removed using an air impact wrench (1/2-in drive minimum). NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. Use the General Equipment: Strap Wrench
26. NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur. If the diamond washer did not come off with the crankshaft pulley, remove the diamond washer.
27. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal .
28. Loosen.
29. Loosen.
30. Using a small pick, release and hold the ratchet mechanism. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner. Insert a holding pin into the hole to retain the tensioner.
31. NOTE: Washers are not required for installation of the VCT units. If equipped, discard the washers.
32. Remove Special Service Tool: 303-1565 Alignment Tool, Camshaft .
33. 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. NOTE: Inspect the camshaft bores for any scratches that can be felt by hand. Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.
34. 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.
35. 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.
36. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the metal surface prep. NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed. Material: Motorcraft® Metal Surface Prep/ZC-31-B
37. Refer to: «CYLINDER BLOCK DISTORTION»(ref-658863-S42792501642014092900000) . Refer to: «CYLINDER HEAD DISTORTION»(ref-658863-S16405846182014092900000) .
38. 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. Plastic scraper.
39. NOTE: The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur. Remove the diamond washer.
40. Material: Motorcraft® Metal Surface Prep/ZC-31-B
41. NOTE: Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at TDC .
42. NOTE: Mark the balance shaft assembly front shafts on the top for reference that the balance shaft assembly is at TDC .
43. NOTE: Due to the precision interior construction of the balance shaft assembly, it should not be disassembled.
44. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
45. Inspect ridge. NOTE: Remove the carbon buildup, do not scratch the cylinder wall. Remove all debris from the cylinder. Abrasive pad.
46. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
47. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
48. NOTE: Mark the position of the parts, so they can be installed in their original positions. Refer to: «PISTON INSPECTION»(ref-658863-S05050837942014092900000) .
49. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
50. 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.