Engine Mechanical - 2.5L: Overhaul Ford Kuga II

DISASSEMBLY

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including 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, they must be installed in the same positions. Mark the components removed for locations.

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1. NOTE: Rear shown, front similar.
2. NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
3. NOTE: Use a small screwdriver and multi-purpose grease to remove the valve collets. Remove the valve collets, valve spring retainers and the valve springs. 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 . Material : Motorcraft® Multi-Purpose Grease Spray/XL-5 (ESB-M1C93-B)
4. Install new parts, as necessary.
5. Use Special Service Tool: 303-468 (T94P-6510-AH) Remover, Valve Stem Oil Seal , 307-005 (T59L-100-B) Slide Hammer .
6. NOTE: Note the location of the valves if they are to be reused.
7. Inspect the following valve areas: The end of the stem or 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. Install new parts, as necessary.

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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-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
2. NOTE: Use the protector provided with the replacement kit to prevent damage to the valve seals. Use Special Service Tool: 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal . Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
3. NOTE: Use a small screwdriver and multi-purpose grease to install the valve collets. NOTE: Check the seating of the valve collets after installation. Install the valve springs, valve spring retainers and the valve collets. Use Special Service Tool: 303-300 (T87C-6565-A) Set, Valve Spring Compressor , 303-350 (T89P-6565-A) Compressor, Valve Spring , 303-472 (T94P-6565-AH) Adapter, Valve Spring Compressor . Material : Motorcraft® Multi-Purpose Grease Spray/XL-5 (ESB-M1C93-B)
4. NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. Torque : 106 lb.in (12 Nm)
5. Torque : 106 lb.in (12 Nm)
6. Torque : 177 lb.in (20 Nm)
7. NOTE: Replace gasket, if damaged.
8. Torque : 89 lb.in (10 Nm)
9. NOTE: Rear shown, front similar. Torque : 35 lb.ft (47 Nm)

ASSEMBLY

1. NOTE: Align the piston-to-connecting rod orientation marks made during disassembly. Indicates front of engine.
2. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
3. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
4. NOTE: The piston compression upper and lower rings should be installed with the paint mark on the outside diameter circumference of the ring to be positioned on the right side of the ring gap. The lower compression ring needs to be installed with the undercut side downward. NOTE: The upper and lower compression ring gaps are not controlled for installation. 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 100-010 Remover, O-Ring Seal 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 303-103 (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 303-1416 Tool, Crank Damper Holding TKIT-2008ET-FLM 303-1417 Tool, Crank Sensor Alignment TKIT-2008ET-FLM TKIT-2008ET-ROW 303-328 (T88P-6701-B1) Replacer, Rear Seal TKIT-1988-F TKIT-1988-FLM TKIT-1988-LM 303-465 Tool, Camshaft Align Timing TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW

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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 may 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.

Note. Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

Note. For additional information, refer to the exploded views in DESCRIPTION AND OPERATION .

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1. NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly. NOTE: The front bulkhead does not have an oil squirter. Torque : 35 lb.in (4 Nm)
2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.
3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block and install the 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. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. Using the original connecting rod cap bolts, install the 4 connecting caps and the 8 bolts. Torque : Stage 1: 89 lb.in (10 Nm) Stage 2: 21 lb.ft (29 Nm) Stage 3: 90°
8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod. Remove the bolts and the connecting rod cap. Discard the connecting rod cap bolts.
9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 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. Remove the 10 bolts in the sequence shown below and the main bearing beam. Discard the main bearing beam bolts.
12. 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. NOTE: The center bulkhead is the thrust bearing. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
13. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
14. NOTE: Lubricate the journals on the crankshaft with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
15. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
16. Mounted flush.
17. NOTE: Lubricate the 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. Install and tighten the 10 new main bearing beam bolts. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A) Torque : Stage 1: 44 lb.in (5 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 90°
18. 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 0.22-0.45 mm (0.008-0.018 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
19. NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
20. NOTE: The piston compression upper and lower rings should be installed with the paint mark on the outside diameter circumference of the ring to be postioned on the right side of the ring gap. The lower compression ring needs to be installed with the undercut side downward. NOTE: The upper and lower compression ring end gaps are not controlled for installation. Upper oil control segment ring gap location. Oil control spacer gap location. Lower oil control segment ring end gap.
21. 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-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
22. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten. NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation. Torque : Stage 1: 89 lb.in (10 Nm) Stage 2: 21 lb.ft (29 Nm) Stage 3: 90°
23. 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 .
24. 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.
25. Torque : Stage 1: 18 lb.ft (25 Nm) Stage 2: 38 lb.ft (52 Nm)
26. 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.
27. 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. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
28. 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. Position as shown below. Measure the gear backlash. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge . 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 0.005 to 0.101 mm (0.00019 to 0.0039 in). If the backlash exceeds the specified range, carry out the BALANCE SHAFT BACKLASH procedure. Refer to: «BALANCE SHAFT BACKLASH»(ref-658857-S34887329322014092900000) .
29. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC . 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.
30. Clean the oil pump and cylinder block mating surfaces. Material : Motorcraft® Metal Surface Prep/ZC-31-B Torque : Stage 1: 89 lb.in (10 Nm) Stage 2: 177 lb.in (20 Nm)
31. NOTE: A new gasket must be installed. Torque : 89 lb.in (10 Nm)
32. Use Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal . Torque : 89 lb.in (10 Nm)
33. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant. Clean and inspect all mating surfaces of the engine and oil pan. Material : Motorcraft® Silicone Gasket Remover/ZC-30-A Material : Motorcraft® Metal Surface Prep/ZC-31-B
34. 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)
35. Tighten finger-tight.
36. General Equipment: Straight Edge
37. Torque : 177 lb.in (20 Nm)
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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block. Material : Motorcraft® Metal Surface Prep/ZC-31-B
39. Dowels must be fully seated in the cylinder block.
40. Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
41. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed. NOTE: Lubricate the bolts with clean engine oil prior to installation. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A) Torque : Stage 1: 62 lb.in (7 Nm) Stage 2: 133 lb.in (15 Nm) Stage 3: 33 lb.ft (45 Nm) Stage 4: 90° Stage 5: 90°
42. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
43. 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 disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
44. Tighten the camshaft bearing cap bolts one at a time until finger-tight. Torque : Stage 1: 62 lb.in (7 Nm) Stage 2: 142 lb.in (16 Nm)
45. Torque : 97 lb.in (11 Nm)
46. Torque : 97 lb.in (11 Nm)
47. NOTE: Before installation, clean and inspect the diamond washer for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur. NOTE: The crankshaft sprocket flange must be facing away from the engine block. Install a diamond washer on both sides of the crankshaft sprocket.
48. Torque : 18 lb.ft (25 Nm)
49. Torque : 89 lb.in (10 Nm) Hook the tensioner spring around the shoulder bolt.
50. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing .
51. NOTE: Do not tighten the bolts at this time.
52. Torque : 89 lb.in (10 Nm)
53. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
54. 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.
55. Using a small pick, push back and hold the ratchet mechanism. Use Special Service Tool: 100-010 Remover, O-Ring Seal .
56. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
57. Install a holding pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
58. Torque : 89 lb.in (10 Nm) Remove the holding pin to release the piston.
59. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: Use the flats on the camshafts to prevent camshaft rotation. Torque : Stage 1: 30 lb.ft (40 Nm) Stage 2: 60°
60. NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Clean and inspect the mounting surfaces of the engine and the front cover. Material : Motorcraft® Silicone Gasket Remover/ZC-30-A Material : Motorcraft® Metal Surface Prep/ZC-31-B
61. 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)
62. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep. Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
63. Torque : 1-18: 89 lb.in (10 Nm) 19: 35 lb.ft (48 Nm) 20: 18 lb.ft (25 Nm) 21-23: 35 lb.ft (48 Nm)
64. 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-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS M2C945-A)
65. NOTE: Do not install the crankshaft pulley bolt at this time. 6 o'clock position Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
66. NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur. NOTE: This step will correctly align the crankshaft pulley to the crankshaft. General Equipment: M6 Bolt.
67. NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only. NOTE: Install a new crankshaft pulley bolt. Use Special Service Tool: 303-1416 Tool, Crank Damper Holding . Torque : Stage 1: 74 lb.ft (100 Nm) Stage 2: 90°
68. Remove the General Equipment: M6 Bolt.
69. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
70. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing .
71. NOTE: Only turn the engine in the normal direction of rotation. Turn one and three-fourths turns.
72. NOTE: Only turn the engine in the normal direction of rotation. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC . Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
73. NOTE: Only hand-tighten the bolt or damage to the front cover can occur. Install the General Equipment: M6 Bolt. Check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected.
74. If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing .
75. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing .
76. Do not tighten the bolts at this time.
77. Align the CKP . Use Special Service Tool: 303-1417 Tool, Crank Sensor Alignment . Torque : 62 lb.in (7 Nm)
78. Remove the General Equipment: M6 Bolt.
79. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
80. Torque : 177 lb.in (20 Nm)
81. 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. Clean the valve cover gasket surfaces. Material : Motorcraft® Metal Surface Prep/ZC-31-B
82. NOTE: Installation of a new VCT solenoid seal is required if a damaged seal was removed during disassembly of the engine. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer , 205-153 (T80T-4000-W) Handle .
83. NOTE: Inspect and if necessary, install new valve cover gaskets.
84. Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
85. 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 cleaner. Torque : 89 lb.in (10 Nm)
86. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots. Material : Silicone Brake Caliper Grease and Dielectric Compound/XG-3-A (ESE-M1C171-A) Torque : 71 lb.in (8 Nm)
87. If equipped. Torque : 30 lb.ft (40 Nm)
88. Torque : 89 lb.in (10 Nm)
89. NOTE: The KS must not touch the crankcase vent oil separator. Torque : 177 lb.in (20 Nm)
90. Torque : 41 lb.ft (55 Nm)
91. 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. If necessary, install new intake manifold gaskets.
92. Torque : 159 lb.in (18 Nm)
93. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
94. Torque : 17 lb.ft (23 Nm)
95. Torque : 89 lb.in (10 Nm)
96. Refer to: «QUICK RELEASE COUPLING»(ref-658910-S40667565442014092900000) .
97. Torque : 80 lb.in (9 Nm)
98. Refer to: «QUICK RELEASE COUPLING»(ref-658910-S40667565442014092900000) .
99. Material : Motorcraft® Metal Surface Prep/ZC-31-B
100. Torque : 18 lb.ft (25 Nm)
101. Torque : 89 lb.in (10 Nm)
102. NOTE: Clean the coolant pump mating surfaces. NOTE: Install a new O-ring seal. Material : Motorcraft® Metal Surface Prep/ZC-31-B Material : Motorcraft® Orange Antifreeze/Coolant Concentrated (U.S.)/VC-3-B (U.S.) (WSS-M97B44-D) Torque : 89 lb.in (10 Nm)
103. Torque : 177 lb.in (20 Nm)
104. Torque : 97 lb.in (11 Nm)
105. Torque : 18 lb.ft (25 Nm)
106. Torque : 35 lb.ft (48 Nm)
107. Torque : 18 lb.ft (25 Nm)
108. General Equipment: Spreader Bar Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
109. General Equipment: Engine Stand
110. NOTE: Special bolts are used for installation. Do not use standard bolts. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel . 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 Hose Clamp Remover/Installer Wooden Block

MATERIAL SPECIFICATIONS

All vehicles

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1. Remove Special Service Tool: 307-566 Retainer, Torque Converter . Material : Motorcraft® Multi-Purpose Grease Spray/XL-5 (ESB-M1C93-B)
2. NOTE: If the transmission is not positioned on the dowel pins, damage to the transmission may occur. If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.
3. Torque : 35 lb.ft (48 Nm)
4. Torque : 35 lb.ft (48 Nm)
5. General Equipment: Adjustable Grip Arm Use Special Service Tool: 300-OTC1585AE Powertrain Lift . Use the General Equipment: Wooden Block
6. General Equipment: Spreader Bar Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .
7. NOTE: Only rotate the engine in a clockwise rotation direction or engine damage may occur. Turn component clockwise 90 degrees. Torque : 30 lb.ft (40 Nm)
8. Torque : 26 lb.ft (35 Nm)
9. Torque : 159 lb.in (18 Nm)
10. Use the General Equipment: Hose Clamp Remover/Installer
11. Use the General Equipment: Hose Clamp Remover/Installer
12. Use the General Equipment: Hose Clamp Remover/Installer
13. Torque : 106 lb.in (12 Nm) Torque : 44 lb.in (5 Nm)
14. Torque : 35 lb.ft (48 Nm)
15. Torque : 150 lb.in (17 Nm)
16. General Equipment: Adjustable Grip Arm Use Special Service Tool: 300-OTC1585AE Powertrain Lift .
17. Torque : 109 lb.ft (148 Nm)
18. Torque : Engine mount nuts: 59 lb.ft (80 Nm) Engine mount bolts: 66 lb.ft (90 Nm)
19. Torque : 92 lb.ft (125 Nm)
20. General Equipment: Adjustable Grip Arm Use Special Service Tool: 300-OTC1585AE Powertrain Lift . Use the General Equipment: Wooden Block Vehicles with auxiliary transmission cooling
21. Torque : 80 lb.in (9 Nm)
22. Torque : 22 lb.ft (30 Nm)
23. Material : Motorcraft® MERCON® LV Automatic Transmission Fluid (U.S.)/XT-10-QLVC (U.S.) (WSS-M2C938-A) (MERCON® LV) Torque : 80 lb.in (9 Nm)
24. Material : Motorcraft® MERCON® LV Automatic Transmission Fluid (U.S.)/XT-10-QLVC (U.S.) (WSS-M2C938-A) (MERCON® LV) Torque : 80 lb.in (9 Nm) Vehicles without auxiliary transmission cooling
25. NOTE: If removed, inspect the transmission mounted cooler tube backing rings and seals for damage and install new backing rings or seals as necessary. Lubricate the transmission mounted cooler tube backing rings and seals with clean transmission fluid and install on the transmission cooler tube. Seals (7D258) Backing rings (7J324) Material : Motorcraft® MERCON® LV Automatic Transmission Fluid (U.S.)/XT-10-QLVC (U.S.) (WSS M2C938-A) (MERCON® LV)
26. Torque : 80 lb.in (9 Nm) All vehicles
27. Both sides. Torque : 177 lb.in (20 Nm)
28. Both sides. Torque : 177 lb.in (20 Nm)
29. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
30. Torque : 35 lb.ft (48 Nm)
31. Torque : 35 lb.ft (48 Nm)
32. Install the following items: Refer to: «GENERATOR - 2.5L DURATEC (125KW/170PS)»(ref-658902-S38254099442014092900000) . Refer to: «AIR CONDITIONING (A/C) COMPRESSOR BELT»(ref-658866-S22879634802014092900000) . Refer to: «WINDSHIELD WASHER RESERVOIR»(ref-658896-S41686352032014092900000) .
33. Torque : 41 lb.ft (55 Nm)
34. Torque : 18 lb.ft (25 Nm)
35. Torque : 35 lb.ft (48 Nm)
36. NOTE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.
37. Torque : 18 lb.ft (25 Nm)
38. Torque : 97 lb.in (11 Nm)
39. Refer to: «HEATED OXYGEN SENSOR (HO2S)»(ref-658892-S19334192602014092900000) .
40. Use the General Equipment: Hose Clamp Remover/Installer
41. Use the General Equipment: Hose Clamp Remover/Installer
42. Refer to: «SPRING LOCK COUPLINGS»(ref-658910-S29296078092014092900000) . Refer to: «QUICK RELEASE COUPLING»(ref-658910-S40667565442014092900000) .
43. Torque : 18 lb.ft (25 Nm)
44. Torque : 106 lb.in (12 Nm)
45. Torque : 17 lb.ft (23 Nm)
46. Install the following items: Refer to: «POWERTRAIN CONTROL MODULE (PCM)»(ref-658892-S16540857232014092900000) . Refer to: «FRONT HALFSHAFT RH»(ref-658849-S24244205442014092900000) . Refer to: «FRONT HALFSHAFT LH»(ref-658849-S20048807802014092900000) . Refer to: «DEGAS BOTTLE»(ref-658855-S19546079632014092900000) . Refer to: «BATTERY TRAY»(ref-658873-S33576642202014100900000) . Refer to: «AIR CLEANER OUTLET PIPE»(ref-658908-S39359363192014092900000) . Refer to: «AIR CLEANER»(ref-658908-S40071574252014092900000) . Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) .
47. Refer to: «B-PILLAR TRIM PANEL»(ref-658897-S24050434132014092900000) .
48. Fill the engine with clean engine oil. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
49. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-658855-S14452308552014092900000) .
50. Refer to: «TRANSMISSION FLUID DRAIN AND REFILL»(ref-658852-S20903781302014092900000) .
51. If the engine was disassembled, preform the Misfire Monitor Neutral Profile Correction procedure.