Engine

All vehicles

NOTICE: 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: Refer to exploded views in Description and Operation.

1. WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. • Measure the length in two directions.
     
   • Record the smallest measurement for each crankshaft main bearing journal.
     

1. NOTE: The main bearing beam has 2 arrows pointing towards the front of engine for correct orientation for reassembly.

   Mounted flush and finger tight.
   

1. Torque :
     Stage 1:  19 Nm
     Stage 2:  85 °

1. Measure the length in five places.
   

1. Using the chart, select the crankshaft main bearings.
   

1. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

   Use the original connecting rod cap bolts.
   Torque :
     Stage 1:  10 Nm
     Stage 2:  18 Nm
     Stage 3:  24 Nm
     Stage 4:  90 °

1. • Measure the length or distance in two directions.
     
   • Record the smallest measurement for each connecting rod.
     

1. • Measure the length in two directions.
     
   • Record the smallest measurement for each connecting rod journal.
     

1. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal
   

1. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

   NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. Mounted flush.
   

1. NOTE: Lubricate the main bearing beam bolts threads with clean engine oil.

   NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.

   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
   Torque :
     Stage 1:  19 Nm
     Stage 2:  85 °

1. • Position the crankshaft to the rear of the cylinder block.
     
   • Zero the Dial Indicator Gauge with Holding Fixture.
     Special Tool(s) : 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
   • Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
     
   • Acceptable crankshaft end play is 0.12-0.43 mm (0.008-0.017 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
     

1. NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly.

   NOTE: Make sure the dimple faces the front of the engine.

   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. NOTE: The upper and lower compression rings are to be fitted with the identification marks on the upper side.

   NOTE: The upper and lower compression ring end gaps are not controlled for installation.

   1. Upper oil control segment ring gap location.
      
   2. Expander ring gap location.
      
   3. Lower oil control segment ring gap location.
      

1. NOTE: Using a connecting rod installer will unsure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.

   NOTE: Make sure the piston arrow on top is facing toward the front of the engine.

   General Equipment : Piston Ring Compressor
   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

   NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.

   NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.

   Use new connecting rod caps bolts.
   Torque :
     Stage 1:  10 Nm
     Stage 2:  18 Nm
     Stage 3:  24 Nm
     Stage 4:  90 °

1. Install Special Service Tool : 303-748 Locking Tool, Crankshaft

1. NOTE: Only rotate the crankshaft clockwise direction.

   Rotate the crankshaft until the crankshaft balance weight is up against the crankshaft locking tool. The engine is now at TDC .
   

1. NOTE: There are different length of bolts noted in disassembly.

   Torque :
     Stage 1:  6 Nm
     Stage 2:  10 Nm

1. Torque : 10 Nm

1. NOTE: The O-ring seal is to be reused unless damaged.

1. Torque : 10 Nm

1. NOTE: New crankshaft rear seal is supplied with an alignment sleeve which must be removed after installation.

   NOTE: Do not remove the alignment sleeve from the crankshaft rear seal prior to installation on the crankshaft.

   1. Align the crankshaft rear seal and alignment sleeve on the crankshaft and push the crankshaft rear seal off the alignment sleeve onto the crankshaft without stopping until the crankshaft rear seal meets the cylinder block.
      Torque :
        Stage 1:  4 Nm
        Stage 2:  10 Nm
   2. Remove the alignment sleeve.
      

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant.

   Make sure that the mating faces are clean and free of foreign material.
   Material : Motorcraft® Metal Surface Prep / ZC-31-A
   Material : Motorcraft® Silicone Gasket Remover / ZC-30

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant.

   Make sure that the mating faces are clean and free of foreign material.
   Material : Motorcraft® Metal Surface Prep / ZC-31-A
   Material : Motorcraft® Silicone Gasket Remover / ZC-30

1. Install the following items:
   • Two M8x20 studs
     

1. NOTE: The component must be installed within 5 minutes of applying the sealant.

   Material : Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

1. Remove the following items:
   • Two M8x20 studs
     

1. NOTE: Only tighten the bolts finger tight at this stage.

1. Torque :
     Stage 1: 
   1 - 13   10 Nm
     Stage 2: 
   1 - 13   19 Nm

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

   NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

   Material : Motorcraft® Metal Surface Prep / ZC-31-A

1. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

   NOTE: Lubricate the bolts with clean engine oil prior to installation.

   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
   Torque :
     Stage 1:  5 Nm
     Stage 2:  15 Nm
     Stage 3:  35 Nm
     Stage 4:  75 °

1. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. If removed.
   Torque : 21 Nm

1. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. NOTE: The VCT bridge must be installed within 5 minutes of applying the gasket maker.

   Material : Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

1. NOTE: Make sure that the camshafts and the camshaft bearing caps are installed in their original locations or damage to the engine may occur.

   NOTE: Apply clean engine oil to the camshaft bearing caps and the VCT bridge.

   Tighten the bolts evenly, half a turn at a time, until the camshaft bearing caps and the VCT bridge are seated against the cylinder head.
   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
   Torque :
     Stage 1: 
   1 - 16   7 Nm
     Stage 2: 
   17 - 20   10 Nm
     Stage 3: 
   1 - 16   45°
     Stage 4: 
   17 and 19   70°
     Stage 5: 
   18 and 20   53°

1. If the cylinder head, camshafts or valve tappets were replaced, check the valve clearance.
   Refer to: Valve Clearance Adjustment (303-01A Engine - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, General Procedures).
   

1. Special Tool(s) : 303-1532 Installer, Camshaft Seal
   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. NOTE: It may be necessary to use an open-ended wrench to turn the camshafts by the hexagon to align the camshafts.

   Install Special Service Tool : 303-376B Alignment Plate, Camshaft

1. NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

   NOTE: The timing marks of the camshaft phaser and sprocket must be at the 12 o'clock position.

   Install Special Service Tool : 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit
   Torque : 25 Nm

1. Remove Special Service Tool : 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit

1. Remove Special Service Tool : 303-376B Alignment Plate, Camshaft

1. NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

   Torque : Tighten an additional 75°

1. NOTE: The special tool can only be installed if the valve timing is correct.

   Install Special Service Tool : 303-376B Alignment Plate, Camshaft

1. NOTE: The special tool can only be installed if the valve timing is correct.

   If the special tools cannot be installed, repeat the adjustment according to the preceding steps.
   Install Special Service Tool : 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit

1. Remove Special Service Tool : 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit

1. Remove Special Service Tool : 303-376B Alignment Plate, Camshaft

1. NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

   Torque : 16 Nm

1. Install Special Service Tool : 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit

1. Torque : 15 Nm

1. Torque :
     Stage 1:  6 Nm
     Stage 2:  10 Nm

1. WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury.

   Torque : 25 Nm

1. Make sure that the mating faces are clean and free of foreign material.
   Special Tool(s) : 303-175 (T82L-6316-A) Installer, Crankshaft Vibration Damper , 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal , 303-420 (T92P-6701-BH) Installer, Crankshaft Front Oil Seal
   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury.

   Remove the holding pin.
   

1. Torque : 9 Nm

1. The final torque of the crankshaft will be completed in the following steps.
   Torque : 100 Nm

1. Remove Special Service Tool : 303-748 Locking Tool, Crankshaft

1. Remove Special Service Tool : 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit

1. Torque :
     Stage 1:  90 °
     Stage 2:  Wait 2s
     Stage 3:  15°

1. NOTE: Only rotate the crankshaft in a clockwise direction.

   Rotate about 1 3/4 turns.
   

1. Install Special Service Tool : 303-748 Locking Tool, Crankshaft

1. NOTE: Only rotate the crankshaft in a clockwise direction.

   Rotate the crankshaft until the crankshaft balance weight is up against the crankshaft locking tool. The engine is now at TDC .
   

1. NOTE: It may necessary to rotate the camshafts slightly to install the special tool.

   NOTE: The special tool can only be installed if the valve timing is correct.

   If the special tool cannot be installed, repeat the adjustment according to the preceding steps.
   Install Special Service Tool : 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit

1. Remove Special Service Tool : 303-1097 Locking Tool, Variable Camshaft Timing Oil Control Unit

1. Remove Special Service Tool : 303-748 Locking Tool, Crankshaft

1. Torque : 20 Nm

1. NOTE: There are different length of bolts noted in disassembly.

   1. Torque : 55 Nm
   2. Torque : 55 Nm

1. Hand start the bolts in the sequence shown.
   Torque :
     Stage 1: 
   1 & 3-8   10 Nm
     Stage 2: 
   2   10 Nm

1. Torque : 24 Nm

1. Finger tight.
   

1. NOTICE: The 2 engine mount studs must be torqued or damage to the powertrain mount may occur.

   Torque : 8 Nm

1. 1. 3-4 turns
      
   2. Torque :
      2-13   10 Nm

1. Torque : 8 Nm

1. NOTE: The O-ring seals are to be reused unless damaged.

   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. Torque : 8 Nm

1. Torque : 9 Nm

1. Torque : 9 Nm

1. Material : Thread Sealant with PTFE / TA-24 (WSK-M2G350-A2)
   Torque : 18 Nm

1. Torque : 10 Nm

1. NOTE: The head of the KS should not touch any other component.

   NOTE: The LH KS must be at the 11 o'clock position and the RH KS must be at the 2 o'clock position.

   Torque : 18 Nm

1. Torque :
     Stage 1:  6 Nm
     Stage 2:  9 Nm

1. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.

   Torque : 55 Nm

1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

   Inspect and install new intake gaskets if necessary.
   

1. Torque :
     Stage 1:  6 Nm
     Stage 2:  18 Nm

1. NOTE: Use O-rings that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.

   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. Torque : 11 Nm

1. If equipped with block heater.
   Torque : 3 Nm

1. NOTE: Lubricate the O-ring seal with clean engine oil.

   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
   Torque : 4 Nm

1. Torque : 19 Nm

1. Torque : 19 Nm

1. Torque : 6 Nm

1. General Equipment : Hose Clamp Remover/Installer

1. General Equipment : Hose Clamp Remover/Installer

1. Apply silicone dielectric compound to the inside of the spark plug wire boots.
   Material : Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

1. Torque : 9 Nm

1. Install Special Service Tool : 300-OTC1819E 2,200# Floor Crane, Fold Away

1. Remove from engine stand.
   

Vehicles with automatic transmission

1. Finger tight.
   

1. Install Special Service Tool : 303-103 (T74P-6375-A) Holding Tool, Flywheel

1. Torque :
     Stage 1:  30 Nm
     Stage 2:  80 °

1. Remove Special Service Tool : 303-103 (T74P-6375-A) Holding Tool, Flywheel

Vehicles with manual transmission

1. Finger tight.
   

1. Install Special Service Tool : 303-103 (T74P-6375-A) Holding Tool, Flywheel

1. Torque :
     Stage 1:  30 Nm
     Stage 2:  80 °

1. Remove Special Service Tool : 303-103 (T74P-6375-A) Holding Tool, Flywheel

1. NOTICE: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

   Using a clutch aligner, centralize the clutch disc to the clutch pressure plate.
   

1. NOTICE: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

   Torque : 29 Nm

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