Engine Control Components - Exploded View, 3.5L and 3.7L
SPECIAL TOOLS CHART Socket, Exhaust Gas Oxygen Sensor 303-476 (T94P-9472-A) Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool
Scheme 25
| Item | Specification |
|---|---|
| High Temperature Nickel Anti-Seize Lubricant XL-2 | |
| Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada) XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada) | WSS-M2C945-A |
| Motorcraft® Orange Antifreeze/Coolant Concentrated VC-3-B (US); CVC-3-B2 (Canada) | WSS-M97B44-D |
| Penetrating and Lock Lubricant (US); Penetrating Fluid (Canada) XL-1 (US); CXC-51-A (Canada) |
MATERIAL SPECIFICATIONS CHART
Camshaft Position (CMP) Sensor
Note. The Air Cleaner (ACL) outlet tube must be removed to service the RH cylinder head CMP sensors. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
Note. The Air Cleaner (ACL) must be removed to service the LH cylinder head CMP sensors. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
Note. Lubricate the Camshaft Position (CMP) sensor O-ring seal with clean engine oil before Installing the CMP sensor.
Scheme 26
| Item | Part Number | Description |
|---|---|---|
| 1 | LH cylinder head exhaust Camshaft Position (CMP) sensor electrical connector (part of 12A581) | |
| 2 | W503275 | LH cylinder head exhaust CMP sensor bolt |
| 3 | 6B288 | LH cylinder head exhaust CMP sensor |
| 4 | LH cylinder head exhaust CMP sensor O-ring seal (part of 6B288) | |
| 5 | LH cylinder head intake Camshaft Position (CMP) sensor electrical connector (part of 12A581) | |
| 6 | W503275 | LH cylinder head intake CMP sensor bolt |
| 7 | 6B288 | LH cylinder head intake CMP sensor |
| 8 | LH cylinder head intake CMP sensor O-ring seal (part of 6B288) | |
| 9 | RH cylinder head exhaust Camshaft Position (CMP) sensor electrical connector (part of 12A581) | |
| 10 | W503275 | RH cylinder head exhaust CMP sensor bolt |
| 11 | 6B288 | RH cylinder head exhaust CMP sensor |
| 12 | RH cylinder head exhaust CMP sensor O-ring seal (part of 6B288) | |
| 13 | RH cylinder head intake Camshaft Position (CMP) sensor electrical connector (part of 12A581) | |
| 14 | W503275 | RH cylinder head intake CMP sensor bolt |
| 15 | 6B288 | RH cylinder head intake CMP sensor |
| 16 | RH cylinder head intake CMP sensor O-ring seal (part of 6B288) |
Crankshaft Position (CKP) Sensor
Note. The LH catalytic converter must be removed to service the Crankshaft Position (CKP) sensor. For additional information, refer to EXHAUST SYSTEM .
Note. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
Scheme 27
| Item | Part Number | Description |
|---|---|---|
| 1 | W701542 | Heat shield nut |
| 2 | W701669 | Heat shield bolt |
| 3 | 6K342 | Heat shield |
| 4 | 6C070 | Rubber grommet cover |
| 5 | Crankshaft Position (CKP) sensor electrical connector (part of 12A581) | |
| 6 | 6D327 | CKP sensor bolt |
| 7 | 6C315 | CKP sensor |
PCM
Note. The module configuration must be retrieved before the PCM is removed. Carry out the module configuration retrieval steps of the Programmable Module Installation (PMI) procedure.
Note. If the Programmable Module Installation (PMI) procedure was not successful in downloading the data from the vehicles original PCM, then the oil life data of the vehicle is lost. If this occurs, and the oil life cannot be determined through service history or customer interview, it is recommended the vehicle engine oil and filter be changed and the oil change reminder reset.
Note. After the PCM is installed, the module configuration must be restored. Carry out the module configuration restore steps of the Programmable Module Installation (PMI) procedure.
Note. After the PCM is installed, the Passive Anti-Theft System (PATS) must be reprogrammed. Carry out the Parameter Reset procedure. For additional information, refer to ANTI-THEFT - PASSIVE ANTI-THEFT SYSTEM (PATS) .
Note. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
Scheme 28
| Item | Part Number | Description |
|---|---|---|
| 1 | PCM electrical connector (part of 12A581) (3 required) | |
| 2 | N804795 | PCM nut (2 required) |
| 3 | 12A650 | PCM |
| 4 | 12A696 | PCM gasket |
Scheme 29
| Item | Part Number | Description |
|---|---|---|
| 1 | Mass Air Flow (MAF) sensor electrical connector (part of 14290) | |
| 2 | W709287 | MAF sensor screw (2 required) |
| 3 | 12B579 | MAF sensor |
Cylinder Head Temperature (CHT) Sensor
Note. The lower intake manifold must be removed to service the Cylinder Head Temperature (CHT) sensor. For additional information, refer to ENGINE - 3.5L for 3.5L engines or ENGINE MECHANICAL - 3.7L for 3.7L engines.
Scheme 30
| Item | Part Number | Description |
|---|---|---|
| 1 | Cylinder Head Temperature (CHT) sensor electrical connector (part of 12A581) | |
| 2 | 6G004 | CHT sensor |
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) - RH Side
Note. If necessary, lubricate the Heated Oxygen Sensor (HO2S) and/or Catalyst Monitor Sensor (CMS) with penetrating and lock lubricant to assist in removal.
Note. Apply anti-seize to the threads of the HO2S and/or CMS prior to installing.
Note. The correct torque wrench setting must be calculated when using the Exhaust Gas Oxygen Sensor Socket to install the HO2S and/or CMS. (Scheme 30)
Scheme 31
Note. To install, tighten the HO2S and/or CMS to 48 Nm (35 lb-ft).
Scheme 32
| Item | Part Number | Description |
|---|---|---|
| 1 | Heated Oxygen Sensor (HO2S) electrical connector (part of 12A581) | |
| 2 | 9F472 | HO2S |
| 3 | Catalyst Monitor Sensor (CMS) electrical connector (part of 12A581) | |
| 4 | 9G444 | CMS |
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) - LH Side
Note. If necessary, lubricate the Heated Oxygen Sensor (HO2S) and/or Catalyst Monitor Sensor (CMS) with penetrating and lock lubricant to assist in removal.
Note. Apply anti-seize to the threads of the HO2S and/or CMS prior to installing.
Note. The correct torque wrench setting must be calculated when using the Exhaust Gas Oxygen Sensor Socket to install the HO2S and/or CMS. (Scheme 32)
Note. To install, tighten the HO2S and/or CMS to 48 Nm (35 lb-ft).
Scheme 33
| Item | Part Number | Description |
|---|---|---|
| 1 | Heated Oxygen Sensor (HO2S) electrical connector (part of 12A581) | |
| 2 | 9F472 | HO2S |
| 3 | Catalyst Monitor Sensor (CMS) electrical connector (part of 12A581) | |
| 4 | 9G444 | CMS |
Variable Camshaft Timing (VCT) Oil Control Solenoid
Note. The LH and/or RH valve cover must be removed to service the Variable Camshaft Timing (VCT) oil control solenoid. For additional information, refer to ENGINE - 3.5L for 3.5L engines or ENGINE MECHANICAL - 3.7L for 3.7L engines.
Note. The VCT oil control solenoid bolt must be tightened in 2 stages.
Scheme 34
- Stage 1: Tighten to 8 Nm (71 lb-in)
- Stage 2: Tighten an additional 20 degrees.
| Item | Part Number | Description |
|---|---|---|
| 1 | W500215 | RH exhaust Variable Camshaft Timing (VCT) oil control solenoid bolt |
| 2 | 6B280A | RH exhaust VCT oil control solenoid |
| 3 | W500215 | RH intake Variable Camshaft Timing (VCT) oil control solenoid bolt |
| 4 | 6B280A | RH intake VCT oil control solenoid |
| 5 | W500215 | LH exhaust Variable Camshaft Timing (VCT) oil control solenoid bolt |
| 6 | 6B280A | LH exhaust VCT oil control solenoid |
| 7 | W500215 | LH intake Variable Camshaft Timing (VCT) oil control solenoid bolt |
| 8 | 6B280A | LH intake VCT oil control solenoid |
Knock Sensor (KS)
Note. The thermostat housing must be removed to service the Knock Sensor (KS). For additional information, refer to ENGINE COOLING .
Note. The lower intake manifold must be removed to service the Knock Sensor (KS). For additional information, refer to ENGINE - 3.5L for 3.5L engines or ENGINE MECHANICAL - 3.7L for 3.7L engines.
Note. Remove and discard the coolant tube O-ring seal. Install a new O-ring seal and lubricate it with clean engine coolant before installing the coolant tube.
Scheme 35
| Item | Part Number | Description |
|---|---|---|
| 1 | 9N271 | Coolant tube |
| 2 | 8565 | Coolant tube O-ring seal |
| 3 | Knock Sensor (KS) electrical connector (part of 12A581) | |
| 4 | W704749 | KS bolt (2 required) |
| 5 | 12A699 | KS |
Crankshaft Position (CKP) Sensor - 2.0L GTDI
SPECIAL TOOLS CHART Crank Sensor Alignment Tool 303-1521 Timing Peg, Crankshaft TDC 303-507
Heated Oxygen Sensor (HO2S) - 2.0L GTDI
SPECIAL TOOLS CHART Socket, Exhaust Gas Oxygen Sensor 303-476 (T94P-9472-A)
| Item | Specification |
|---|---|
| High Temperature Nickel Anti-Seize Lubricant XL-2 | |
| Penetrating and Lock Lubricant (US); Penetrating Fluid (Canada) XL-1 (US); CXC-51-A (Canada) |
MATERIAL SPECIFICATIONS CHART
Scheme 36
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560).
- Loosen the 4 retainers and remove the underbody shield.
- Detach and disconnect the Heated Oxygen Sensor (HO2S) electrical connector. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S. Calculate the correct torque wrench setting for the following torque. see scheme 38 To install, tighten to 48 Nm (35 lb-ft).
- To install, reverse the removal procedure. Apply a light coat of anti-seize lubricant to the threads of the HO2S.
Catalyst Monitor Sensor - 2.0L GTDI
SPECIAL TOOLS CHART Socket, Exhaust Gas Oxygen Sensor 303-476 (T94P-9472-A)
| Item | Specification |
|---|---|
| High Temperature Nickel Anti-Seize Lubricant XL-2 | |
| Penetrating and Lock Lubricant (US); Penetrating Fluid (Canada) XL-1 (US); CXC-51-A (Canada) |
MATERIAL SPECIFICATIONS CHART
Scheme 37
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560).
- Loosen the 4 retainers and remove the underbody shield.
- Detach and disconnect the Catalyst Monitor Sensor (CMS) electrical connector. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS. Calculate the correct torque wrench setting for the following torque. see scheme 41 To install, tighten to 48 Nm (35 lb-ft).
- To install, reverse the removal procedure. Apply a light coat of anti-seize lubricant to the threads of the CMS.
Fuel Rail Pressure (FRP) Sensor - 2.0L GTDI
| Item | Specification |
|---|---|
| Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil (Canada) XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada); or equivalent | WSS-M2C946-A, 5W30 |
MATERIAL SPECIFICATIONS CHART
Scheme 38
Scheme 39
Scheme 40
Scheme 41
- Remove the upper Charge Air Cooler (CAC) inlet tube and intermediate CAC inlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
- Rotate the accessory drive belt tensioner counterclockwise and position the accessory drive belt aside.
- Remove the 3 bolts and position the power steering pump aside. To install, tighten to 4 Nm (35 lb-in).
- Disconnect the Fuel Rail Pressure (FRP) sensor electrical connector.
- Remove the FRP sensor.
Scheme 42
Scheme 43
Scheme 44
- Install the FRP sensor and tighten in the following 5 stages: Stage 1: Tighten to 6 Nm (53 lb-in). Stage 2: Tighten an additional 5 degrees. Stage 3: Loosen 90 degrees. Stage 4: Tighten to 6 Nm (53 lb-in). Stage 5: Tighten an additional 21 degrees.
- Connect the Fuel Rail Pressure (FRP) sensor electrical connector.
- Position the power steering pump and install the 3 bolts. Tighten to 25 Nm (18 lb-in).
- Rotate the accessory drive belt tensioner counterclockwise and position the accessory drive belt.
- Install the upper CAC inlet tube and intermediate CAC inlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
Scheme 45
- Remove the valve cover. For additional information, refer to «ENGINE - 2.0L GTDI»(ref-494556) .
- Remove the 2 bolts and the Variable Camshaft Timing (VCT) oil control solenoids. To install, tighten to 10 Nm (89 lb-in).
- To install, reverse the removal procedure.
Scheme 46
- Remove the intake manifold. For additional information, refer to «ENGINE - 2.0L GTDI»(ref-494556) .
- Disconnect the 2 KS electrical connectors and remove the 2 bolts and the 2 KS. To install, tighten to 20 Nm (177 lb-in).
- To install, reverse the removal procedure.