Engine Mechanical - 2.0l Ford Transit Connect I рестайлинг

Material Specifications

MATERIAL SPECIFICATIONS

General Specifications

GENERAL SPECIFICATIONS

Torque Specifications

TORQUE SPECIFICATIONS

The 2.0L 4-cylinder engine has the following features

1. Dual overhead camshaft
2. Four valves per cylinder
3. Sequential Multi-Port Fuel Injection (SFI)
4. Aluminum cylinder head
5. Aluminum cylinder block
6. Electronic ignition system with coil-on-plug 4 ignition coils

The 2.0L engine is a 4 valve-per-cylinder, dual overhead camshaft engine. The engine uses a coil-on-plug ignition system. The cylinder block is made of aluminum and the bearing caps are integrated into the ladder assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block and to the transmission to provide greater strength. The camshafts are mounted in the cylinder heads and act against valve tappets to open and close the valves. The camshafts are driven off the front of the cylinder head by one timing chain. The chain is driven by a sprocket that is located on the crankshaft. The piston assembly is an aluminum piston with a cast iron connecting rod. The oil pump is driven by the crankshaft via a dedicated chain that is driven by the same sprocket that drives the timing chain.

Engine Identification

Always refer to these labels when installation of new parts is necessary or when checking engine calibrations. The engine parts often differ within a CID family. Verification of the identification codes will make sure the correct parts are obtained. These codes contain all the pertinent information relating to the dates, optional equipment and revisions.

Engine Code Information Label

The engine code information label, located on the front side of the valve cover, contains the following

Scheme 1

ITEM DESCRIPTION

Scheme 2

Exhaust Emission Control System

Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered in the INTRODUCTION article.

Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 4 solenoid-operated fuel injectors

1. are mounted in the cylinder head.
2. meter fuel into the air intake stream in accordance with engine demand.
3. are positioned so that their tips direct fuel just ahead of the engine intake valves.
4. supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.

A constant fuel pressure is maintained across the fuel injectors by the fuel pressure sensor. The fuel pressure sensor is positioned upstream from the fuel injectors on the fuel injection supply manifold.

PCV System

All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the intake manifold.

Lubrication System

The engine lubrication system operates as follows

1. Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan.
2. Oil is pumped through the oil filter on the left front side of the cylinder block.
3. Oil enters the main gallery where it is distributed to the crankshaft main journals and to the cylinder head.
4. From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod, piston and piston ring assembly.

Refer to ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION article for basic mechanical concerns or refer to the INTRODUCTION article for driveability concerns.

Scheme 3

1. Remove the valve cover. For additional information, refer to «VALVE COVER»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
2. Remove the 2 bolts and accessory drive belt splash shield. To install, tighten to 9 Nm (80 lb-in).
3. Use a feeler gauge to measure each valve's clearance and record its location.
4. Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
5. If any tappets do not measure within specifications, install new tappets in these locations. For additional information, refer to «VALVE TRAIN COMPONENTS - EXPLODED VIEW»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) and «VALVE TAPPETS»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.

Scheme 4

ITEM DESCRIPTION

Scheme 5

ITEM DESCRIPTION

Scheme 6

ITEM DESCRIPTION

Scheme 7

Scheme 8

Scheme 9

Scheme 10

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the Air Cleaner (ACL) and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system) article.
3. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
4. Remove the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.0L»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#fuel-charging-and-controls-20l) article.
5. Remove the transaxle fluid indicator.
6. Remove the intake manifold lower bolt.
7. Detach the engine wiring harness pin-type retainer from the intake manifold.
8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wire harness retainer from the starter stud bolt.
9. Disconnect the electronic throttle control electrical connector.
10. Disconnect the fuel vapor return hose.
11. Disconnect the power brake booster vacuum tube. Depress the quick release locking ring. Pull the vacuum tube out of the quick release fitting.
12. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
13. Detach the wiring harness retainer from the intake manifold and disconnect the Knock Sensor (KS) electrical connector.
14. Detach the 4 wiring harness pin-type retainers from the intake manifold.
15. Loosen the 2 intake manifold bolts.
16. Remove the 5 intake manifold bolts.
17. Remove the EGR tube from the cylinder head.
18. Disconnect the PCV hose and remove the intake manifold.

Scheme 11

Scheme 12

Scheme 13

Scheme 14

1. Inspect and install new intake manifold gaskets if necessary.
2. Position the intake manifold and connect the PCV hose.
3. Install the EGR tube. Tighten to 55 Nm (41 lb-ft).
4. Attach the wiring harness retainer to the intake manifold and connect the KS electrical connector.
5. Install the intake manifold and hand-tighten the 2 intake manifold bolts.
6. Install the 5 intake manifold mounting bolts. Tighten all 7 bolts to 18 Nm (159 lb-in).
7. Attach the 4 wiring harness pin-type retainers to the intake manifold.
8. Connect the MAP sensor electrical connector.
9. Connect the power brake booster vacuum tube. Push the vacuum tube into the quick release fitting.
10. Connect the fuel vapor return hose.
11. Connect the electronic throttle control electrical connector.
12. Connect the EOP switch electrical connector and attach the wire harness retainer to the starter stud bolt.
13. Attach the engine wiring harness pin-type retainer to the intake manifold.
14. Install the lower intake manifold bolt. Tighten to 18 Nm (159 lb-in).
15. Install the transaxle fluid indicator.
16. Install the fuel rail. For additional information, refer to «FUEL CHARGING AND CONTROLS - 2.0L»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#fuel-charging-and-controls-20l) article.
17. Install the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
18. Install the Air Cleaner (ACL) and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system) article.

MATERIAL SPECIFICATIONS

Scheme 15

ITEM DESCRIPTION

Scheme 16

ITEM DESCRIPTION

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.

Scheme 17

1. Disconnect the Camshaft Position (CMP) sensor electrical connector.
2. Disconnect the 4 ignition coil-on-plug electrical connectors.
3. Remove the 4 ignition coil-to-valve cover bolts and the ignition coils.
4. Lift up the connector boot and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
5. Disconnect the crankcase breather tube from the valve cover.
6. Detach the 6 wiring harness retainers from the valve cover stud bolts.
7. Disconnect the generator electrical connector.
8. Remove the radio interference capacitor bracket bolt.
9. Remove the radio interference capacitor ground bolt and position the bracket aside.
10. Remove the 14 valve cover retainers, the valve cover and gasket. Discard the valve cover gasket.

Scheme 18

1. Clean and inspect the sealing surfaces.
2. Apply silicone gasket and sealant to the locations shown in illustration
3. Install the valve cover, a new gasket and the 14 retainers. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
4. Position the radio interference capacitor bracket and install the bolt. Tighten to 10 Nm (89 lb-in).
5. Install the radio interference capacitor ground bolt. Tighten to 10 Nm (89 lb-in).
6. Connect the generator electrical connector.
7. Attach the 6 wiring harness retainers to the valve cover stud bolts.
8. Connect the crankcase breather tube on the valve cover.
9. Connect the CHT sensor electrical connector and install the connector boot.
10. Install the ignition coils and the 4 ignition coil-to-valve cover bolts. Tighten to 10 Nm (89 lb-in).
11. Connect the 4 ignition coil-on-plug electrical connectors.
12. Connect the CMP sensor electrical connector.

Scheme 19

ITEM DESCRIPTION

Scheme 20

ITEM DESCRIPTION

1. For additional information, refer to the appropiate procedures in this service information.

Special Tool(s)

SPECIAL TOOLS Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Holding Tool, Crankshaft Damper 303-1416 Timing Peg, Crankshaft TDC 303-507

Scheme 21

Scheme 22

Scheme 23

General Equipment

GENERAL EQUIPMENT REFERENCE

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 24

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the RH wheel and tire. For additional information, refer to «TIRES & WHEELS»(/ford/transit-connect/i-2009-2013/remont/wheel-tire-system/#tires-wheels) article.
3. Remove the accessory drive belt. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(/ford/transit-connect/i-2009-2013/remont/accessory-drive-belts/#accessory-drive-system) article.
4. Remove the valve cover. For additional information, refer to «VALVE COVER»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.
6. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
7. Remove the engine plug bolt.
8. Install the Crankshaft TDC Timing Peg.
9. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt. Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley. Remove the diamond washer and discard.

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

1. Install a new diamond washer.
2. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
3. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
4. Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (one-fourth turn).
5. Remove the 6 mm x 18 mm bolt.
6. Remove the Crankshaft TDC Timing Peg.
7. Remove the Camshaft Alignment Plate.
8. Turn the crankshaft clockwise one and three-fourths turns.
9. Install the Crankshaft TDC Timing Peg.
10. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
11. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure.
12. Install the Camshaft Alignment Plate to check the position of the camshafts. If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected by repeating this procedure.
13. Remove the Camshaft Alignment Plate.
14. Remove the 6 mm x 18 mm bolt.
15. Remove the Crankshaft TDC Timing Peg.
16. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
17. Install the valve cover. For additional information, refer to «VALVE COVER»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
18. Install the accessory drive belt. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(/ford/transit-connect/i-2009-2013/remont/accessory-drive-belts/#accessory-drive-system) article.
19. Install the RF wheel and tire. For additional information, refer to «TIRES & WHEELS»(/ford/transit-connect/i-2009-2013/remont/wheel-tire-system/#tires-wheels) article.

SPECIAL TOOLS Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Remover, Oil Seal 303-409 (T92C-6700-CH)

Scheme 33

Scheme 34

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.

1. Remove the crankshaft pulley. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) and «CRANKSHAFT PULLEY»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
2. Using the Oil Seal Remover, remove the crankshaft front oil seal.

Installation

1. Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
2. Install the crankshaft pulley. For additional information, refer to «LOWER END COMPONENTS - EXPLODED VIEW»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) and «CRANKSHAFT PULLEY»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.

SPECIAL TOOLS Holding Tool, Flywheel 303-103 (T74P-8375-A)

Scheme 35

Scheme 36

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4F27E»(/ford/transit-connect/i-2009-2013/remont/automatic-trans/#automatic-transaxletransmission-4f27e) article.
3. Install the Flywheel Holding Tool and remove the 6 flexplate bolts and the flexplate. Discard the bolts.

Scheme 37

Scheme 38

1. Install the flexplate.
2. Install the Flywheel Holding Tool.
3. Tighten the new bolts in the sequence shown in illustration in 3 stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (50 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
4. Install the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4F27E»(/ford/transit-connect/i-2009-2013/remont/automatic-trans/#automatic-transaxletransmission-4f27e) article.

SPECIAL TOOS Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1)

Scheme 39

MATERIAL SPECIFICATIONS

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the flexplate. For additional information, refer to «FLEXPLATE»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
3. Drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
4. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
5. Remove the 17 bolts and the oil pan.
6. Remove the 6 bolts and the crankshaft rear seal with retainer plate.

Scheme 40

Scheme 41

Scheme 42

Scheme 43

1. Using the Crankshaft Rear Main Oil Seal Installer, position the crankshaft rear oil seal with retainer plate onto the crankshaft.
2. Install the crankshaft rear seal with retainer plate and 6 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
3. Clean and inspect all the oil pan, cylinder block and front cover flange mating surfaces.
4. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan and the 2 bolts finger-tight.
5. Install the 4 engine front cover-to-oil pan bolts. Tighten to 10 Nm (89 lb-in).
6. Install the remaining oil pan bolts. Tighten in the sequence shown in illustration to 25 Nm (18 lb-ft).
7. Install the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
8. Install the flexplate. For additional information, refer to «FLEXPLATE»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
9. Fill the engine with clean engine oil.

SPECIAL TOOLS Aligner, Crankshaft Sensor 303-1417 Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Remover, Oil Seal 303-409 (T92C-6700-CH)

Scheme 44

Scheme 45

GENERAL EQUIPMENT REFERENCE

MATERIAL SPECIFICATIONS

Scheme 46

ITEM DESCRIPTION

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 47

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Loosen the 3 coolant pump pulley bolts.
3. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
4. Disconnect the Crankshaft Position (CKP) sensor electrical connector. Detach the 2 wiring harness retainers from the engine front cover.
5. Remove the 2 bolts and the CKP sensor.
6. Using the Oil Seal Remover, remove the crankshaft front oil seal.
7. Remove the 3 bolts and the coolant pump pulley.
8. Remove the coolant degas bottle. For additional information, refer to «ENGINE COOLING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) article.
9. Remove the power steering pump. For additional information, refer to «POWER STEERING SYSTEM SERVICING»(/ford/transit-connect/i-2009-2013/remont/manual-power-steering/#power-steering-system-servicing) article.
10. Remove the engine mount. For additional information, refer to «ENGINE MOUNT»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
11. Slightly raise the engine for access to the accessory drive idler pulley.
12. Remove the accessory drive idler pulley. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(/ford/transit-connect/i-2009-2013/remont/accessory-drive-belts/#accessory-drive-system) article.
13. Remove the bolts and the engine front cover.

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

1. Clean and inspect the mounting surfaces of the engine and the front cover.
2. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the front cover.
3. Install the engine front cover. Tighten the bolts in the sequence shown in illustration, to the following specifications: Tighten the 8-mm bolts to 10 Nm (89 lb-in). Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
4. Install the accessory drive idler pulley. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(/ford/transit-connect/i-2009-2013/remont/accessory-drive-belts/#accessory-drive-system) article.
5. Lower the engine to the installed position.
6. Install the engine mount. For additional information, refer to «ENGINE MOUNT»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
7. Install the power steering pump. For additional information, refer to «POWER STEERING SYSTEM SERVICING»(/ford/transit-connect/i-2009-2013/remont/manual-power-steering/#power-steering-system-servicing) article.
8. Install the coolant degas bottle. For additional information, refer to «ENGINE COOLING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) article.
9. Install the coolant pump pulley and the 3 bolts. Do not tighten at this time.
10. Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
11. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
12. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
13. Install the CKP sensor and the 2 bolts. Do not tighten the bolts at this time.
14. Using the Crankshaft Sensor Aligner, adjust the CKP sensor. Tighten the 2 bolts to 7 Nm (62 lb-in).
15. Connect the CKP sensor electrical connector. Attach the 2 wiring harness retainers to the engine front cover.
16. Remove the 6 mm x 18 mm bolt.
17. Tighten the coolant pump pulley bolts. Tighten to 20 Nm (177 lb-in).
18. Fill the power steering system. For additional information, refer to «STEERING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/manual-power-steering/#steering-system) Article.

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 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
3. Compress the timing chain tensioner in the following sequence. 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 paper clip into the hole to retain the tensioner.
4. Remove the 2 bolts and the timing chain tensioner.
5. Remove the RH timing chain guide.
6. Remove the timing chain.
7. Remove the bolts and the LH timing chain guide.
8. Remove the bolts and the camshaft drive gears. Use the flats on the camshaft to prevent camshaft rotation.

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

1. Install the camshaft drive gears and the bolts. Do not tighten the bolts at this time.
2. Install the LH timing chain guide and bolts. Tighten to 10 Nm (89 lb-in).
3. Install the timing chain.
4. Install the RH timing chain guide. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
5. Using the edge of a vise, compress the timing chain tensioner plunger.
6. Using a small pick, push back and hold the ratchet mechanism.
7. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
8. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
9. Install the timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the paper clip to release the piston.
10. Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gear bolts. Tighten to 72 Nm (53 lb-ft).
11. Install the front cover. For additional information, refer to «ENGINE FRONT COVER»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.

SPECIAL TOOLS Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Timing Peg, Crankshaft TDC 303-507

Scheme 66

Scheme 67

GENERAL EQUIPMENT REFERENCE

MATERIAL SPECIFICATIONS

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.

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the coolant expansion tank. For additional information, refer to «ENGINE COOLING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) article.
3. Remove the RF wheel and tire. For additional information, refer to «TIRES & WHEELS»(/ford/transit-connect/i-2009-2013/remont/wheel-tire-system/#tires-wheels) .
4. Check the valve clearance. For additional information, refer to «VALVE CLEARANCE CHECK»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
5. Remove the accessory drivebelt. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(/ford/transit-connect/i-2009-2013/remont/accessory-drive-belts/#accessory-drive-system) article.
6. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.
7. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
8. Remove the engine plug bolt.
9. Install the Crankshaft TDC Timing Peg.
10. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
11. Remove the front cover lower timing hole plug from the engine front cover.
12. Remove the front cover upper timing hole plug from the engine front cover.
13. Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only.
14. Using a small pick tool, unlock the chain tensioner ratchet through the lower front cover timing hole. Using the flats of the camshaft, have an assistant rotate the exhaust camshaft clockwise to collapse the timing chain tensioner plunger. Insert an M6 x 30 mm bolt into the upper front cover timing hole to hold the tensioner arm in place.
15. Remove the Camshaft Alignment Plate.
16. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft drive gear.
17. Remove the timing chain from the intake camshaft drive gear.
18. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and intake camshaft drive gear.
19. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
20. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time. Repeat the first step until all tension is released from the camshaft bearing caps. Remove the camshaft bearing caps. Remove the camshafts.

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

1. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in illustration in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts one turn at a time until finger-tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
2. Install the Camshaft Alignment Plate.
3. Install the intake camshaft drive gear and hand-tighten the bolt.
4. Install the timing chain on the intake camshaft drive gear.
5. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust camshaft. Hand-tighten the bolt.
6. Remove the M6 x 30 mm bolt from the upper front cover timing hole to unlock the tensioner arm.
7. Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gear bolts. Tighten to 72 Nm (53 lb-ft).
8. Remove the Camshaft Alignment Plate.
9. Remove the 6 mm x 18 mm bolt.
10. Remove the Crankshaft TDC Timing Peg.
11. Install the front cover upper timing hole plug. Tighten to 10 Nm (89 lb-in).
12. Apply silicone gasket and sealant to the threads of the front cover lower timing hole plug. Install the plug and tighten to 12 Nm (106 lb-in).
13. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
14. Install the accessory drivebelt. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(/ford/transit-connect/i-2009-2013/remont/accessory-drive-belts/#accessory-drive-system) article.
15. Install the RF wheel and tire. For additional information, refer to «TIRES & WHEELS»(/ford/transit-connect/i-2009-2013/remont/wheel-tire-system/#tires-wheels) article.
16. Install the valve cover. For additional information, refer to «VALVE COVER»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
17. Install the coolant expansion tank. For additional information, refer to «ENGINE COOLING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) article.

Scheme 86

ITEM DESCRIPTION

1. For additional information, refer to the appropriate procedures in this service information.

SPECIAL TOOLS Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH)

Scheme 87

Scheme 88

Scheme 89

MATERIAL SPECIFICATIONS

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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article.
4. Remove the spark plugs. For additional information, refer to «IGNITION SYSTEM - 2.0L»(ref-440995) article.
5. Connect the compressed air supply to cylinder No. 1.
6. Apply compressed air to the cylinder and remove the valve spring. Using the Valve Spring Compressors, compress the valve spring and remove the valve collet, using some multi-purpose grease and a small screwdriver. Remove the valve spring retainer and the valve spring.

1. Using the Valve Spring Compressors, install the valve spring. Insert the valve spring and the valve spring retainer. Compress the valve spring and install the valve collet using some grease and a small screwdriver.
2. Disconnect the compressed air supply.
3. Repeat the appropriate removal and installation steps for all of the other cylinders.
4. Install the spark plugs. For additional information, refer to «IGNITION SYSTEM - 2.0L»(ref-440995) article.
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. For additional information, refer to «CAMSHAFTS»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.

SPECIAL TOOLS Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH) Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH) Slide Hammer 307-005 (T59L-100-B)

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

MATERIAL SPECIFICATIONS

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 95

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article.
4. Remove the spark plugs. For additional information, refer to «IGNITION SYSTEM - 2.0L»(ref-440995) article.
5. Connect the compressed air supply to the No. 1 cylinder.
6. Apply compressed air to the cylinder and remove the valve spring. Using the Valve Spring Compressors, compress the valve spring and remove the valve collet, using some multi-purpose grease and a small screwdriver. Remove the valve spring retainer and the valve spring.
7. Using the Valve Stem Oil Seal Remover and Slide Hammer, remove and discard the valve seal.

Scheme 96

Scheme 97

1. Install the valve stem seal installation sleeve.
2. Using the Valve Stem Oil Seal Installer, install the valve seal.
3. Using the Valve Spring Compressors, install the valve spring. Insert the valve spring and the valve spring retainer. Compress the valve spring and install the valve collet using some multi-purpose grease and a small screwdriver.
4. Disconnect the compressed air supply.
5. Repeat the appropriate removal and installation steps for all of the other cylinders.
6. Install the spark plugs. For additional information, refer to «IGNITION SYSTEM - 2.0L»(ref-440995) article.
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. For additional information, refer to «CAMSHAFTS»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.

MATERIAL SPECIFICATIONS

Removal and Installation

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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
3. Remove and inspect the valve tappets. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article.
4. To install, reverse the removal procedure. Coat the valve tappets with clean engine oil prior to installation.

SPECIAL TOOLS Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Engine Support Bar 303-F072

Scheme 98

Scheme 99

MATERIAL SPECIFICATIONS

Scheme 100

ITEM DESCRIPTION

Scheme 101

ITEM DESCRIPTION

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 102

Scheme 103

Scheme 104

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/fuel-system/#fuel-system-general-information) article.
3. Remove the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article.
4. Remove the generator. For additional information, refer to «CHARGING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system) article.
5. Remove the exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
6. Clean and inspect the exhaust manifold flange. For additional information, refer to exhaust manifold cleaning and inspection in «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article.
7. Drain the cooling system. For additional information, refer to «ENGINE COOLING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) article.
8. Check the valve clearance. For additional information, refer to «VALVE CLEARANCE CHECK»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
9. Remove the engine oil filter and discard.
10. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
11. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
12. Remove the Camshaft Alignment Plate.
13. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
14. Remove the camshafts from the engine. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time. Repeat the first step until all tension is released from the camshaft bearing caps. Remove the camshaft bearing caps. Remove the camshafts.
15. Remove the valve tappets.
16. Inspect the valve tappets. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article.
17. Remove the 3 bolts and position the wiring harness and bracket aside.
18. Disconnect the EGR valve electrical connector.
19. Disconnect the coolant hoses from the coolant bypass.
20. Disconnect the EGR coolant hose.
21. Lower the engine and remove the Engine Support Bar.
22. Remove the 10 bolts and the cylinder head. Discard the bolts.
23. Remove and discard the head gasket.
24. Inspect the cylinder head mating surfaces. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article.

Scheme 105

Scheme 106

Scheme 107

1. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
2. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
3. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article.
4. Apply silicone gasket and sealant to the locations shown in illustration.
5. Install a new cylinder head gasket.
6. Install the cylinder head and the 10 new bolts. Tighten the bolts in the sequence shown in illustration in 5 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (133 lb-in). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
7. Install the Engine Support Bar and raise the engine.
8. Install the EGR coolant hose.
9. Connect the coolant hoses onto the coolant bypass.
10. Connect the EGR valve electrical connector.
11. Position the wire harness bracket and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
12. Install the valve tappets in their original positions.
13. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in illustration in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts, one turn at a time, until the cam is fully seated. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
14. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
15. Install the valve cover. For additional information, refer to «VALVE COVER»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
16. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
17. Install the exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
18. Install the generator. For additional information, refer to «CHARGING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system) article
19. Install the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article.
20. Drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
21. Install a new engine oil filter. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
22. Fill the engine with clean engine oil.
23. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) article.

Scheme 108

ITEM DESCRIPTION

Scheme 109

ITEM DESCRIPTION

Scheme 110

ITEM DESCRIPTION

Scheme 111

ITEM DESCRIPTION

1. For additional information, refer to the appropriate procedures in this service information.

MATERIAL SPECIFICATIONS

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article
2. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) article.
3. Disconnect the 2 coolant hoses from the oil cooler.
4. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
5. Remove the EOP switch.
6. Remove and discard the oil filter.
7. Remove the 4 bolts and the oil filter adapter. Discard the gasket.

1. Using a new gasket, install the oil filter adapter and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
2. Install a new oil filter. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
3. Install the EOP switch. Tighten to 15 Nm (133 lb-in).
4. Connect the EOP switch electrical connector.
5. Connect the 2 coolant hoses to the oil cooler.
6. Top off the engine with clean engine oil.
7. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) article.

MATERIAL SPECIFICATIONS

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
3. Remove the EOP switch. To install, tighten to 15 Nm (133 lb-in).
4. To install, reverse the removal procedure.

MATERIAL SPECIFICATIONS

Scheme 112

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article.
3. Loosen the upper bellhousing-to-engine bolt and stud bolt 5 mm (0.19 in).
4. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
5. Loosen the 2 LH bellhousing-to-engine bolts 5 mm (0.19 in).
6. Loosen the RH engine-to-bellhousing bolt and stud bolt 5 mm (0.19 in).
7. Remove the 2 bellhousing-to-oil pan bolts.
8. Remove the 2 oil pan-to-bellhousing bolts.
9. Slide the transaxle rearward 5 mm (0.19 in).
10. Remove the 2 bolts and the accessory drive belt splash shield.
11. Drain the engine oil. Install the drain plug. Tighten to 28 Nm (21 lb-ft).
12. Remove the 4 engine front cover-to-oil pan bolts.
13. Remove the 13 bolts and the oil pan.

Scheme 113

Scheme 114

1. Clean and inspect all mating surfaces.
2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan-to-engine block and to the oil pan-to-engine front cover mating surface.
3. Position the oil pan onto the engine and install the 13 oil pan bolts finger-tight.
4. Install the 4 engine front cover-to-oil pan bolts. Tighten to 10 Nm (89 lb-in).
5. Tighten the oil pan bolts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
6. Install the accessory drive belt splash shield and the 2 bolts. Tighten to 9 Nm (80 lb-in).
7. Alternate tightening the 1 LH bellhousing-to-engine and 1 RH engine-to-bellhousing lower bolts to slide the transaxle and engine together. Tighten to 48 Nm (35 lb-ft).
8. Tighten the remaining LH bellhousing-to-engine bolt and the remaining rear engine-to-bellhousing stud bolt. Tighten to 48 Nm (35 lb-ft).
9. Install the 2 bellhousing-to-oil pan bolts. Tighten to 48 Nm (35 lb-ft).
10. Install the 2 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
11. Install the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
12. Tighten the top bellhousing-to-engine bolt and stud bolt. Tighten to 48 Nm (35 lb-ft).
13. Install the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article.
14. Fill the engine with clean engine oil.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the oil pan. For additional information, refer to «OIL PAN»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
3. Remove the 2 bolts and the oil pump screen and pickup tube. Discard the gasket.

1. Clean and inspect all mating surfaces.
2. Using a new gasket, install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
3. Install the oil pan. For additional information, refer to «OIL PAN»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.

MATERIAL SPECIFICATIONS

Scheme 115

1. With the engine in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
3. Remove the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
4. Drain the engine oil, then install the drain plug. To install, tighten to 28 Nm (21 lb-ft).
5. Remove the 2 oil pan-to-bellhousing bolts.
6. Remove the 2 bellhousing-to-oil pan bolts.
7. Remove the 13 bolts and the oil pan.
8. Remove the 2 bolts and the oil pump screen and pickup tube.
9. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the 2 shoulder bolts.
10. Remove the chain from the oil pump sprocket.
11. Remove the bolt and oil pump sprocket.
12. Remove the 4 bolts and the oil pump.

Scheme 116

Scheme 117

Scheme 118

Scheme 119

1. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
2. Install the oil pump sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
3. Install the chain onto the oil pump sprocket.
4. Install the oil pump drive chain tensioner shoulder bolt. Tighten to 10 Nm (89 lb-in).
5. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
6. Install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
7. Clean all mating surfaces with metal surface prep.
8. Apply a 2.5 mm (0.09 in) bead of sealant gasket and sealant to the oil pan. Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.
9. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
10. Install the remaining oil pan bolts. Tighten in the sequence shown in illustration to 25 Nm (18 lb-ft).
11. Install the 2 bellhousing-to-oil pan bolts. Tighten to 48 Nm (35 lb-ft).
12. Install the 4 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
13. Install the oil level indicator and tube. For additional information, refer to «OIL LEVEL INDICATOR AND TUBE»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
14. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
15. Fill the engine with clean engine oil.

MATERIAL SPECIFICATIONS

Scheme 120

ITEM DESCRIPTION

Scheme 121

1. Remove the oil level indicator.
2. Remove the oil level indicator tube bolt. To install, tighten to 10 Nm (89 lb-in).
3. Detach the wiring harness retainer from the oil level indicator tube.
4. Remove the oil level indicator tube and discard the O-ring seal. To install, lubricate the new O-ring seal with clean engine oil.
5. To install, reverse the removal procedure.

MATERIAL SPECIFICATIONS

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the oil drain plug and drain the engine oil. To install, tighten to 28 Nm (21 lb-ft).
3. Remove and discard the oil filter. To install, tighten three-fourths of a turn after the filter gasket makes contact with the oil filter adapter.
4. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) article.
5. Disconnect the 2 coolant hoses from the oil cooler.
6. Disconnect the Engine Oil Pressure (EOP) electrical connector.
7. Remove the 4 bolts and the oil filter adapter. To install, tighten to 25 Nm (18 lb-ft).
8. Position the oil filter adapter in a vise and remove the oil cooler bolt and oil cooler. Inspect the oil cooler. To install, tighten to 34 Nm (25 lb-ft).
9. To install, reverse the removal procedure.
10. Fill the engine with clean engine oil.
11. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) article.

Scheme 122

ITEM DESCRIPTION

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/ford/transit-connect/i-2009-2013/remont/exhaust/#exhaust-system) article.
3. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. Detach the wiring retainer.
4. Remove the 4 exhaust manifold heat shield bolts and the heat shield.
5. Remove and discard the 7 exhaust manifold nuts.
6. Remove the exhaust manifold and discard the exhaust manifold gasket.
7. Remove and discard the 7 exhaust manifold studs.
8. Clean and inspect the exhaust manifold. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article.

1. Install the 7 new exhaust manifold studs. Tighten to 17 Nm (150 lb-in).
2. Install a new exhaust manifold gasket, the exhaust manifold and 7 new nuts in the sequence shown in illustration in 2 stages: Stage 1: Tighten to 48 Nm (35 lb-ft). Stage 1: Tighten to 48 Nm (35 lb-ft).
3. Install the exhaust manifold heat shield and the 4 bolts. Tighten to 10 Nm (89 lb-in).
4. Connect the HO2S electrical connector. Attach the wiring retainer.
5. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/ford/transit-connect/i-2009-2013/remont/exhaust/#exhaust-system) article.

SPECIAL TOOLS Engine Support Bar 303-F072

Scheme 123

Scheme 124

ITEM DESCRIPTION

Scheme 125

ITEM DESCRIPTION

Scheme 126

1. Remove the degas bottle bolt. To install, tighten to 8 Nm (71 lb-in).
2. Lift the coolant degas bottle off of the shock tower bracket and position it aside.
3. Install the Engine Support Bar.
4. Remove the 2 engine mount nuts. To install, tighten to 90 Nm (66 lb-ft).
5. Remove the 3 bolts and the engine mount. To install, tighten to 48 Nm (35 lb-ft).
6. To install, reverse the removal procedure.

SPECIAL TOOLS 2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent Lifting Bracket, Engine 303-050 (T70P-6000) Powertrain Lift 300-OTC1585AE or equivalent Retainer, Torque Converter 307-346 (T97T-7902-A) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Adjustable Grip Arm, 1735A 014-00001 or equivalent

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Remove the 2 bolts, pin-type retainer and the LH front splash shield.
3. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/fuel-system/#fuel-system-general-information) article.
4. Recover the A/C system. For additional information, refer to «HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(/ford/transit-connect/i-2009-2013/remont/manual-hvac-system/#hvac-climate-control-system-general-information-diagnostics) article.
5. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system) article.
6. Disconnect the crankcase vent tube from the valve cover.
7. Remove the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article.
8. Remove the nut and disconnect cable from the positive battery cable terminal.
9. Detach the 3 positive battery cable wire harness retainers.
10. Remove the bolt and the negative battery cable ground.
11. Disconnect the fuel tube quick connect coupling from the fuel tube near the bulkhead. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/fuel-system/#fuel-system-general-information) article.
12. Disconnect the Evaporative Emission (EVAP) tube and position aside. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/fuel-system/#fuel-system-general-information) article.
13. Disconnect the power brake booster vacuum tube. Depress the quick connect locking ring. Pull the vacuum tube out of the quick connect fitting.
14. Detach and disconnect the 2 engine harness electrical connectors.
15. Detach the engine harness from the coolant outlet bracket harness retainer.
16. Remove the nut and the ground wire from the negative battery terminal.
17. Disconnect the 3 PCM electrical connectors.
18. Disconnect the starter wire harness electrical connector.
19. Disconnect the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical connectors and detach the wire harness retainer.
20. Disconnect the transaxle shift cable from the lever and bracket.
21. Remove the transmission fluid cooler tube secondary latches.
22. Disconnect the 2 transaxle fluid cooler tubes from the transaxle. Squeeze the tabs together. Slide the transaxle fluid cooler tube lock up and remove the transaxle fluid cooler tubes from the transaxle.
23. Remove the engine oil level indicator.
24. Remove the 2 front wheels and tires. For additional information, refer to «TIRES & WHEELS»(/ford/transit-connect/i-2009-2013/remont/wheel-tire-system/#tires-wheels) article.
25. Remove the accessory drive belt and tensioner. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(/ford/transit-connect/i-2009-2013/remont/accessory-drive-belts/#accessory-drive-system) article.
26. Remove the generator. For additional information, refer to «CHARGING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system) article.
27. Detach the 2 B+ battery cable wire harness retainers from the valve cover stud bolts and remove the wiring harness.
28. Remove the 2 A/C tube nuts from the A/C compressor.
29. Disconnect the 2 A/C tubes from the compressor. Discard the 2 O-ring seals.
30. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) article.
31. Remove the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) article.
32. Disconnect the lower radiator hose from the radiator.
33. Drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
34. Remove the engine oil filter and discard.
35. Remove the LH and RH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/transit-connect/i-2009-2013/remont/axle-shafts/#front-drive-halfshafts) article.
36. Remove the bolt and the power steering tube clip.
37. Remove the bolt and the power steering tubes from the steering gear. Discard the 2 power steering tube O-ring seals.
38. Disconnect the power steering cooler tube.
39. Remove the exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
40. Remove the power steering pump. For additional information, refer to «POWER STEERING SYSTEM SERVICING»(/ford/transit-connect/i-2009-2013/remont/manual-power-steering/#power-steering-system-servicing) article.
41. Release the retaining clip and disconnect the coolant degas bottle hose.
42. Disconnect the coolant degas bottle vent hose from the coolant bypass and position it aside.
43. Disconnect the upper radiator hose and the heater hose from the coolant bypass.
44. Disconnect the heater hose from the coolant tube.
45. Remove the transaxle fluid level indicator.
46. Remove the 2 bolts and the transaxle roll restrictor.
47. Remove the 2 lower bellhousing-to-oil pan bolts.
48. Remove the 2 oil pan-to-bellhousing bolts.
49. Using the Powertrain Lift and Adjustable Grip Arm, secure the engine to the lift table.
50. Remove the 2 engine mount nuts.
51. Remove the 3 bolts and the engine mount.
52. Remove the 5 transaxle mount nuts and the transaxle mount plate.
53. Lower the engine and transaxle assembly from the vehicle.
54. Remove the nut for the HO2S and CMS wire connector bracket.
55. Remove the nut and position the HO2S and CMS wire connector bracket aside.
56. Disconnect the Output Shaft Speed (OSS) sensor electrical connector.
57. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.
58. Disconnect the 2 transaxle electrical connectors.
59. Disconnect the A/C compressor electrical connector.
60. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
61. Detach the wiring harness pin-type retainer from the intake manifold.
62. Detach the 2 Crankshaft Position (CKP) sensor wire harness retainers.
63. Disconnect the CKP sensor electrical connector.
64. Detach the starter wire harness retainer from the starter motor stud bolt.
65. Remove the nut from the starter motor stud bolt and remove the power steering tube bracket.
66. Remove the bolt and the engine ground wire.
67. Remove the nut from the A/C compressor stud bolt and remove the power steering tube bracket.
68. Remove the 2 power steering tubes and the wiring harness as an assembly.
69. Remove the 2 nuts and disconnect the starter motor electrical terminals.
70. Remove the bolt, stud bolt and the starter.
71. Remove the starter isolator.
72. Remove the 4 torque converter nuts.
73. Using the Floor Crane, Engine Lifting Bracket and Spreader Bar, remove the engine and transaxle assembly from the lift table.
74. Remove the 4 bellhousing-to-engine bolts and the one stud bolt and separate the engine and transmission.
75. Install the Torque Converter Retainer, to prevent damage to the torque converter.

SPECIAL TOOLS Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Engine Stand 014-00232 or equivalent 2,200# Floor Crane, Fold Away 300-OTC1819E Holding Tool, Crankshaft Damper 303-1416 Holding Tool, Flywheel 303-103 (T74P-6375-A) Installer, Connecting Rod 303-462 (T94P-6136-AH) Remover, Oil Seal 303-409 (T92C-6700-CH) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Timing Peg, Crankshaft TDC 303-507

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

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.

Note. Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.

Note. For additional information, refer to the exploded view under the Assembly procedure in this service information.

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Scheme 210

Scheme 211

Scheme 212

Scheme 213

Scheme 214

Scheme 215

Scheme 216

Scheme 217

Scheme 218

Scheme 219

Scheme 220

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Scheme 226

Scheme 227

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

Scheme 246

1. Install the Flywheel Holding Tool and remove the flywheel or flexplate.
2. Mount the engine on a suitable engine stand.
3. Loosen the bolt and remove the accessory drivebelt idler pulley.
4. Remove the 3 bolts and the coolant pump pulley.
5. Remove the 3 bolts and the coolant pump.
6. Disconnect the oil cooler hose and lower radiator hose from the thermostat housing.
7. Disconnect the EGR valve coolant hose.
8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
9. Disconnect the oil cooler hoses.
10. Remove the bolt and the oil cooler. Discard the oil cooler.
11. Remove the oil filter, 4 bolts and the oil filter adapter. Discard the oil filter and gasket.
12. Disconnect the 4 coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.
13. Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
14. Detach the generator wiring harness retainer from the valve cover stud.
15. Disconnect the 4 fuel injector electrical connectors and detach the 5 wiring harness retainers from valve cover stud bolts and intake manifold.
16. Remove the 2 bolts and the fuel rail with the fuel injectors.
17. Disconnect the Knock Sensor (KS) electrical connector and pin-type retainer.
18. Disconnect the throttle control electrical connector.
19. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector. Detach the 3 wiring harness retainers from the intake manifold.
20. Disconnect the EGR valve electrical connector.
21. Remove the lower intake manifold bolt.
22. Remove the bolt and the oil level indicator tube. Discard the O-ring seal.
23. Loosen the 2 intake manifold bolts.
24. Remove the 5 intake manifold bolts.
25. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold. Remove the intake manifold.
26. Remove the EGR tube.
27. Remove the radio interference capacitor bracket bolt and position the bracket aside.
28. Disconnect the coolant bypass hose.
29. Remove the 4 bolts and the coolant outlet.
30. Disconnect the coolant bypass hose.
31. Remove the 3 bolts, thermostat housing and thermostat.
32. Remove the 2 bolts, stud bolt and the A/C compressor.
33. Remove the bolt and the KS .
34. Remove the 8 bolts and the crankcase vent oil separator.
35. Remove the 3 bolts and the intermediate shaft bracket.
36. Remove the 4 bolts and the ignition coil-on-plugs.
37. Remove the spark plugs and the CHT sensor.
38. Remove the bolts and the valve cover.
39. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.
40. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
41. Remove the engine plug bolt.
42. Install the Crankshaft TDC Timing Peg.
43. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt. Remove and discard the crankshaft pulley bolt and washer. Remove the crankshaft pulley. Remove the diamond washer and discard.
44. Using the Oil Seal Remover, remove the crankshaft front seal.
45. Remove the 2 bolts and the CKP sensor.
46. Remove the 22 bolts and the engine front cover.
47. Compress the timing chain tensioner in the following sequence. 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 paper clip into the hole to retain the tensioner.
48. Remove the 2 bolts and the timing chain tensioner.
49. Remove the RH timing chain guide.
50. Remove the timing chain.
51. Remove the 2 bolts and the LH timing chain guide.
52. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
53. Remove the oil pump drive chain tensioner. Release the tension on the tensioner spring. Remove the tensioner and the 2 shoulder bolts.
54. Remove the oil pump chain and sprockets. Remove the bolt. Remove the chain and sprockets.
55. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
56. Remove the camshafts from the engine. Loosen the camshaft bearing bolts in the sequence shown in illustration, one turn at a time. Repeat until all the tension is released. Remove the camshaft bearing caps. Remove the camshafts.
57. Remove the valve tappets.
58. Inspect the valve tappets. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article.
59. Remove the cylinder head. Remove and discard the 10 cylinder head bolts. Remove the cylinder head. Remove and discard the cylinder head gasket.
60. Remove the cylinder head alignment dowels.
61. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
62. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article.
63. Remove the 13 bolts and the oil pan.
64. Remove the 6 bolts and the crankshaft rear seal with retainer plate.
65. Remove the 2 bolts, oil pump pickup tube and gasket. Discard the gasket.
66. Remove the 4 bolts and the oil pump.
67. Remove the Crankshaft TDC Timing Peg.
68. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
69. Remove the connecting rod cap bolts and cap.
70. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
71. Remove the bolts in the sequence shown in illustration. Remove the main bearing beam. Discard the bolts.
72. Remove the crankshaft from the engine block.
73. Remove the main bearings from the main bearing beam.
74. Remove the main bearings from the cylinder block.
75. Remove the 4 oil squirters.
76. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article.

SPECIAL TOOLS Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-472 (T94P-6565-AH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH) Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH) Slide Hammer 307-005 (T59L-100-B)

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

Scheme 252

MATERIAL SPECIFICATIONS

Scheme 253

ITEM DESCRIPTION

Disassembly

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

Scheme 254

1. Remove the bolts and the 2 lifting eyes.
2. Remove the 4 bolts and the coolant outlet. Discard the gasket.
3. Remove the 2 bolts and the EGR valve. Discard the gasket.
4. Remove the Cylinder Head Temperature (CHT) sensor.
5. Remove the EGR tube.
6. Remove the spark plugs.
7. Using the Valve Spring Compressors, compress the valve spring and remove the valve spring collets, the valve spring retainers and the valve springs.
8. Inspect the valve spring, valve spring retainer and valve spring retainer key. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article.
9. Remove the valves.
10. Using the Valve Stem Oil Seal Remover and Slide Hammer, remove and discard the valve seals.
11. Inspect the valves. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article. Install new parts, as necessary.

Assembly

1. Install the valves.
2. Lubricate the valve stems and guides with clean engine oil and, using the Valve Stem Oil Seal Installer, install the valve seals onto the cylinder head valve guides.
3. Place the valve spring in position over the valve and install the valve spring retainer.
4. Using the Valve Spring Compressors, compress the valve spring and install the valve collets.
5. Install the spark plugs. Tighten to 12 Nm (106 lb-in).
6. Install the EGR tube. Tighten to 55 Nm (41 lb-ft).
7. Install the CHT sensor. Tighten to 12 Nm (106 lb-in).
8. Using a new gasket, install the EGR valve, and the 2 bolts. Tighten to 20 Nm (177 lb-in).
9. Using a new gasket, install the coolant outlet and the 4 bolts. Tighten to 10 Nm (89 lb-in).
10. Install the 2 lifting eyes and the bolts. Tighten to 45 Nm (33 lb-ft).

MATERIAL SPECIFICATIONS

Scheme 255

ITEM DESCRIPTION

1. Remove the piston rings from the piston. Discard the piston rings.
2. Remove the 2 piston pin retainers and the piston pin.
3. Separate the piston from the connecting rod.
4. Clean and inspect the piston and connecting rod. For additional information, refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article.

1. Align the piston-to-connecting rod orientation marks, and position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the piston pin retaining clips in the piston.
5. Lubricate the piston and the new piston rings with clean engine oil.
6. Install the piston rings onto the piston as shown in illustration. Piston pin Upper oil control ring gap location Lower oil control ring gap location Center line of the piston pin bore and the expander gap

SPECIAL TOOLS Aligner, Crankshaft Sensor 303-1417 Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Compressor, Piston Ring 303-D032 (D81L-6002-C) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) 2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent Holding Tool, Crankshaft Damper 303-1416 Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) Installer, Connecting Rod 303-462 (TOOL-6136-AH) Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Timing Peg, Crankshaft TDC 303-507

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

Scheme 262

Scheme 263

Scheme 264

Scheme 265

Scheme 266

GENERAL EQUIPMENT REFERENCE

Material

MATERIAL SPECIFICATIONS

Scheme 267

ITEM DESCRIPTION

Scheme 268

ITEM DESCRIPTION

Scheme 269

ITEM DESCRIPTION

Scheme 270

ITEM DESCRIPTION

Scheme 271

ITEM DESCRIPTION

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.

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 MECHANICAL SYSTEM - GENERAL INFORMATION article.

Scheme 272

Scheme 273

Scheme 274

Scheme 275

Scheme 276

Scheme 277

Scheme 278

Scheme 279

Scheme 280

Scheme 281

Scheme 282

Scheme 283

Scheme 284

Scheme 285

Scheme 286

Scheme 287

Scheme 288

Scheme 289

Scheme 290

Scheme 291

Scheme 292

Scheme 293

Scheme 294

Scheme 295

Scheme 296

Scheme 297

Scheme 298

Scheme 299

Scheme 300

Scheme 301

Scheme 302

Scheme 303

Scheme 304

Scheme 305

Scheme 306

Scheme 307

Scheme 308

Scheme 309

Scheme 310

Scheme 311

Scheme 312

Scheme 313

Scheme 314

Scheme 315

Scheme 316

Scheme 317

Scheme 318

Scheme 319

Scheme 320

Scheme 321

Scheme 322

Scheme 323

Scheme 324

Scheme 325

Scheme 326

Scheme 327

Scheme 328

Scheme 329

Scheme 330

Scheme 331

Scheme 332

Scheme 333

Scheme 334

Scheme 335

Scheme 336

Scheme 337

Scheme 338

Scheme 339

Scheme 340

Scheme 341

Scheme 342

1. Install the 4 oil squirters. Tighten to 4 Nm (35 lb-in).
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.
4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts. Tighten the bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten an additional 90 degrees.
5. Measure each crankshaft block housing main bearing bore diameter. Remove the bolts and the main bearing beam. Discard the main bearing beam bolts.
6. Using the chart, select the crankshaft main bearings.
7. Using the original connecting rod cap bolts, install the connecting caps and bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 29 Nm (21 lb-ft). Stage 2: Tighten an additional 90 degrees.
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. Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.
12. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.
13. Lubricate journals on the crankshaft with clean engine oil.
14. Position the crankshaft in the cylinder block.
15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown in illustration) with clean engine oil.
16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.
17. Install and tighten the 10 main bearing beam bolts. Tighten the bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 25 Nm (18 lb-ft). Stage 3: Tighten an additional 90 degrees.
18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play. Position the crankshaft to the rear of the cylinder block. Zero the Dial Indicator Gauge with Holding Fixture. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
19. Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies. When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap. The position of the upper and lower compression ring gaps are not controlled for installation.
20. Install the connecting rod caps and bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 29 Nm (21 lb-ft). Stage 2: Tighten an additional 90 degrees.
21. Turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
22. Install the Crankshaft TDC Timing Peg.
23. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in).
24. Using a new oil pump pickup tube gasket, install the pickup tube and bolts. Tighten to 10 Nm (89 lb-in).
25. Using the Crankshaft Rear Main Oil Seal Installer, install the crankshaft rear seal.
26. Tighten the 6 crankshaft rear seal with retainer plate bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
27. Clean and inspect all mating surfaces.
28. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan-to-engine block and to the oil pan-to-engine front cover mating surface.
29. Install the oil pan. Install the 2 oil pan bolts finger-tight.
30. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
31. Install the remaining 13 oil pan bolts and tighten the oil pan bolts in the sequence shown in illustration to 25 Nm (18 lb-ft).
32. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
33. Apply silicone gasket and sealant to the locations shown in illustration.
34. Install a new cylinder head gasket.
35. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in illustration in 5 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (133 lb-in). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
36. Install the valve tappets.
37. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in illustration in 3 stages: Stage 1: Tighten one turn at a time until tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (142 lb-in).
38. Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket. The crankshaft sprocket flange must be facing away from the engine block.
39. Install the oil pump chain, sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
40. Install the oil pump chain tensioner shoulder bolt. Tighten to 10 Nm (89 lb-in).
41. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
42. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
43. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
44. Install the LH timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
45. Install the timing chain.
46. Install the RH timing chain guide. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
47. Using the edge of a vise, compress the timing chain tensioner plunger.
48. Using a small pick, push back and hold the ratchet mechanism.
49. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
50. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
51. Install the timing chain tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the paper clip to release the piston.
52. Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gear bolts to 72 Nm (53 lb-ft).
53. Clean and inspect the mounting surfaces of the engine and the front cover.
54. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the front cover.
55. Install the engine front cover. Tighten the 22 bolts in the sequence shown in illustration to the following specifications: Tighten the 8-mm bolts to 10 Nm (89 lb-in). Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
56. Using the Camshaft Front Oil Seal Installer, install a new crankshaft front seal.
57. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
58. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
59. Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (one-fourth turn).
60. Remove the 6 mm x 18 mm bolt.
61. Remove the Crankshaft TDC Timing Peg.
62. Remove the Camshaft Alignment Plate.
63. Turn the crankshaft clockwise one and three-fourths turn.
64. Install the Crankshaft TDC Timing Peg.
65. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
66. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, the engine valve timing must be corrected.
67. Install the Camshaft Alignment Plate to check the position of the camshafts. If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected.
68. Remove the Camshaft Alignment Plate.
69. Install the Crankshaft Position (CKP) sensor and the 2 bolts. Do not tighten the bolts at this time.
70. Using the Crankshaft Sensor Aligner, adjust the CKP sensor. Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
71. Remove the 6 mm x 18 mm bolt.
72. Remove the Crankshaft TDC Timing Peg.
73. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
74. Clean the valve cover gasket surface with metal surface prep.
75. Apply silicone gasket and sealant to the locations shown in illustration.
76. Install the valve cover. Tighten the 14 bolts in the sequence shown in illustration to 10 Nm (89 lb-in).
77. Install the Cylinder Head Temperature (CHT) sensor and the spark plugs. Tighten the CHT sensor to 12 Nm (106 lb-in). Tighten the spark plugs to 12 Nm (106 lb-in).
78. Install the 4 ignition coil-on-plugs and the 4 bolts. Tighten to 10 Nm (89 lb-in).
79. Install the intermediate shaft bracket and the 3 bolts. Tighten to 48 Nm (35 lb-ft).
80. Install the crankcase vent oil separator and the 8 bolts. Tighten to 10 Nm (89 lb-in).
81. Install the KS and the bolt. Tighten to 20 Nm (177 lb-in).
82. Install the A/C compressor, 2 bolts and the stud bolt. Tighten to 25 Nm (18 lb-ft).
83. Install the thermostat housing and 3 bolts. Tighten to 10 Nm (89 lb-in).
84. Connect the coolant bypass hose.
85. Using a new gasket, install the coolant outlet and the 4 bolts. Tighten to 10 Nm (89 lb-in).
86. Connect the coolant bypass hose.
87. Install the radio interference capacitor bracket and bolt. Tighten to 10 Nm (89 lb-in).
88. Install the EGR tube. Tighten to 55 Nm (41 lb-ft).
89. Inspect and install new intake manifold gaskets if necessary.
90. Position the intake manifold and connect the PCV hose.
91. Install the intake manifold and hand-tighten the 2 intake manifold bolts.
92. Install the 5 intake manifold mounting bolts. Tighten all 7 bolts to 18 Nm (159 lb-in).
93. Using a new O-ring seal, install the oil level indicator tube assembly and the bolt. Tighten to 10 Nm (89 lb-in).
94. Install the lower intake manifold bolt. Tighten to 18 Nm (159 lb-in).
95. Connect the EGR valve electrical connector.
96. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector. Attach the 3 wiring harness retainers to the intake manifold.
97. Connect the throttle control electrical connector.
98. Connect the KS electrical connector and pin-type retainer.
99. Install new fuel injector O-rings. Separate the fuel injectors from the fuel rail. Remove and discard the fuel injector O-rings. Install new O-rings and lubricate with clean engine oil. Install the fuel injectors onto the fuel rail.
100. Install the fuel rail with the fuel injectors and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
101. Connect the 4 fuel injector electrical connectors and attach the 4 wiring harness retainers to valve cover stud bolts and intake manifold.
102. Attach the wiring harness retainer on the valve cover stud.
103. Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.
104. Connect the 4 coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.
105. Using a new gasket, install the oil filter adapter and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
106. Install a new oil cooler and bolt. Tighten to 34 Nm (25 lb-ft).
107. Install the oil filter. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
108. Connect the oil cooler hoses.
109. Connect the Engine Oil Pressure (EOP) switch electrical connector.
110. Connect the EGR valve coolant hose.
111. Connect the oil cooler hose and lower radiator hose to the thermostat housing.
112. Position the coolant pump and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
113. Install the coolant pump pulley and 3 bolts. Tighten to 20 Nm (177 lb-in).
114. Install the accessory drive belt idler pulley. Tighten to 25 Nm (18 lb-ft).
115. Using the Floor Crane and Spreader Bar, remove the engine from the engine stand.
116. Install the flexplate or flywheel and the 6 bolts. Tighten the bolts in the sequence shown in illustration in 3 stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (50 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).

SPECIAL TOOLS 2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent Lifting Bracket, Engine 303-050 (T70P-6000) Powertrain Lift 300-OTC1585AE or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Adjustable Grip Arm, 1735A 014-00001 or equivalent

Scheme 343

Scheme 344

Scheme 345

Scheme 346

Scheme 347

MATERIAL SPECIFICATIONS

Scheme 348

Scheme 349

Scheme 350

Scheme 351

Scheme 352

Scheme 353

Scheme 354

Scheme 355

Scheme 356

Scheme 357

Scheme 358

Scheme 359

Scheme 360

Scheme 361

Scheme 362

Scheme 363

Scheme 364

Scheme 365

Scheme 366

Scheme 367

Scheme 368

Scheme 369

Scheme 370

Scheme 371

Scheme 372

Scheme 373

Scheme 374

Scheme 375

Scheme 376

Scheme 377

Scheme 378

Scheme 379

Scheme 380

Scheme 381

Scheme 382

Scheme 383

Scheme 384

Scheme 385

Scheme 386

Scheme 387

Scheme 388

Scheme 389

Scheme 390

Scheme 391

Scheme 392

Scheme 393

Scheme 394

Scheme 395

Scheme 396

Scheme 397

Scheme 398

Scheme 399

Scheme 400

Scheme 401

Scheme 402

1. Check the installation depth of the torque converter. Lay a straightedge on the automatic transaxle flange. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
2. Using the Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 bellhousing-to-engine fasteners. Tighten to 48 Nm (35 lb-ft).
3. Using the Floor Crane, Engine Lifting Bracket and Spreader Bar, raise the engine and transaxle assembly onto the lift table.
4. Using the Powertrain Lift and Adjustable Grip Arm, secure the engine and transaxle assembly to the lift table.
5. Install the 4 torque converter nuts. Tighten to 35 Nm (26 lb-ft).
6. Install the starter motor isolator.
7. Install the starter motor, stud bolt and the bolt. Install the upper bolt and lower stud bolt finger-tight. Tighten the upper bolt to 35 Nm (26 lb-ft). Tighten the lower stud bolt to 35 Nm (26 lb-ft).
8. Connect the starter motor electrical terminals and install the 2 nuts. Tighten the small nut to 5 Nm (44 lb-in). Tighten the large nut to 12 Nm (106 lb-in).
9. Position the 2 power steering tubes and the wiring harness as an assembly on the engine.
10. Install the power steering tube bracket on the A/C compressor stud bolt and install the nut. Tighten to 20 Nm (177 lb-in).
11. Install the engine ground wire and the bolt. Tighten to 48 Nm (35 lb-ft).
12. Install the power steering tube bracket on the starter motor stud bolt and install the nut. Tighten to 20 Nm (177 lb-in).
13. Attach the starter wire harness retainer to the starter motor stud bolt.
14. Connect the Crankshaft Position (CKP) sensor electrical connector.
15. Attach the 2 CKP sensor wire harness retainers.
16. Attach the wire harness pin-type retainer to the intake manifold.
17. Connect the Power Steering Pressure (PSP) switch electrical connector.
18. Connect the A/C compressor electrical connector.
19. Connect the 2 transaxle electrical connectors.
20. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.
21. Connect the Output Shaft Speed (OSS) sensor electrical connector.
22. Position the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) wire connector bracket and install the nut. Tighten to 25 Nm (18 lb-ft).
23. Install the nut for the HO2S and CMS wire connector bracket. Tighten to 25 Nm (18 lb-ft).
24. Using the lift table, position the engine and transaxle assembly in the vehicle.
25. Install the transaxle mount plate and the 5 nuts. Tighten the center nut to 150 Nm (111 lb-ft). Tighten the 4 outer nuts to 48 Nm (35 lb-ft).
26. Install the engine mount and the 3 bolts. Tighten to 48 Nm (35 lb-ft).
27. Install the 2 motor mount nuts. Tighten to 90 Nm (66 lb-ft).
28. Install the 2 oil pan-to-bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
29. Install the 2 lower bellhousing-to-oil pan bolts. Tighten to 48 Nm (35 lb-ft).
30. Install the transaxle roll restrictor and the 2 bolts. Install the transaxle roll restrictor. Install the short bolt. Install the long bolt. Tighten to 70 Nm (52 lb-ft).
31. Install the transaxle fluid indicator.
32. Connect the heater hose to the coolant tube.
33. Connect the upper radiator hose and the heater hose to the coolant bypass.
34. Connect the coolant degas bottle vent hose to the coolant bypass.
35. Connect the coolant degas bottle hose and install the retaining clip.
36. Install the power steering pump. For additional information, refer to «POWER STEERING SYSTEM SERVICING»(/ford/transit-connect/i-2009-2013/remont/manual-power-steering/#power-steering-system-servicing) article
37. Clean and inspect the exhaust manifold flange. For additional information, refer to Exhaust Manifold Cleaning and Inspection in «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article
38. Install the exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-20l) in this service information.
39. Connect the power steering cooler tube.
40. Using 2 new O-ring seals, install the power steering tubes to the steering gear and install the bolt. Tighten to 18 Nm (159 lb-in).
41. Install the power steering tube clip and the bolt. Tighten to 10 Nm (89 lb-in).
42. Install the LH and RH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/transit-connect/i-2009-2013/remont/axle-shafts/#front-drive-halfshafts) article
43. Install a new engine oil filter. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
44. Connect the lower radiator hose to the radiator.
45. Install the cooling fan motor and shroud. For additional information, refer to «ENGINE COOLING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) article.
46. Using 2 new O-ring seals, connect the A/C tubes to the compressor.
47. Install the 2 A/C tube-to-compressor nuts. Tighten to 15 Nm (133 lb-in).
48. Position and attach the 2 B+ battery cable wire harness retainers.
49. Install the generator. For additional information, refer to «CHARGING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/charging-system/#charging-system) article
50. Install the accessory drive belt and tensioner. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(/ford/transit-connect/i-2009-2013/remont/accessory-drive-belts/#accessory-drive-system) article.
51. Install the 2 front wheels and tires. For additional information, refer to «TIRES & WHEELS»(/ford/transit-connect/i-2009-2013/remont/wheel-tire-system/#tires-wheels) article.
52. Install the engine oil level indicator.
53. Install the transmission fluid cooler tubes on the transaxle and slide the latches to the locked position.
54. Install the secondary latches.
55. Connect the transaxle shift cable to the lever and bracket.
56. Connect the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical connectors and attach the wire harness retainer.
57. Connect the starter wire harness electrical connector.
58. Connect the 3 PCM electrical connectors.
59. Install the ground wire and nut on the negative battery terminal. Tighten to 10 Nm (89 lb-in).
60. Attach the engine harness to the coolant outlet bracket harness retainer.
61. Connect and attach the 2 engine harness electrical connectors.
62. Install the power brake booster vacuum tube into the quick connect fitting.
63. Position and connect the Evaporative Emission (EVAP) tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/fuel-system/#fuel-system-general-information) article.
64. Connect the fuel tube quick connect coupling to the fuel tube near the bulkhead. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/fuel-system/#fuel-system-general-information) article.
65. Install the negative battery cable ground and the bolt. Tighten to 10 Nm (89 lb-in).
66. Attach the 3 positive battery cable wire harness retainer.
67. Connect the positive battery cable nut. Tighten to 10 Nm (89 lb-in).
68. Install the battery tray. For additional information, refer to «BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES»(/ford/transit-connect/i-2009-2013/remont/charging-system/#battery-battery-mounting-system-battery-cables) article.
69. Connect the crankcase vent tube to the valve cover.
70. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system) article.
71. Fill the engine with clean engine oil.
72. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING SYSTEM»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) article.
73. Evacuate and charge the A/C system. For additional information, refer to «HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(/ford/transit-connect/i-2009-2013/remont/manual-hvac-system/#hvac-climate-control-system-general-information-diagnostics) article.
74. Install the splash shield, pin-type retainer and the 2 bolts.

See also:
• INTRODUCTION
• ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION
• JACKING & LIFTING
• INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM
• FUEL CHARGING AND CONTROLS - 2.0L
• TIRES & WHEELS
• ENGINE ACCESSORY DRIVE BELTS
• AUTOMATIC TRANSAXLE/TRANSMISSION - 4F27E
• ENGINE COOLING SYSTEM
• POWER STEERING SYSTEM SERVICING
• STEERING SYSTEM
• FUEL SYSTEM - GENERAL INFORMATION
• BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES
• CHARGING SYSTEM
• EXHAUST SYSTEM
• HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS
• FRONT DRIVE HALFSHAFTS
• VALVE COVER