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Section 4 (Engine - 2.3L - (Hybrid)): Assembly: Engine

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL(S) DESCRIPTION

G03898823
 Heavy Duty Floor Crane 014-00071 or equivalent
G03898617
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
G03898747
 Alignment Plate, Camshaft 303 - 465 (T94P-6256-CH)
G03897953
 Timing Peg, Crankshaft 303 - 507
G03898935
 Holding Fixture, Drive Pinion Flange
205-126 (T78P-4851-A)
G03898936
 Adapter for 205-126 (205-072-02)
G03950442
 Installer, Front Oil Seal 303-096 (T74P-6150-A)
G03898710
 Installer, Crankshaft Rear Main Oil Seal
303 - 328 (T88P-6701-B1)
MATERIALS

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent WSS-M2C930-A
Metal Surface Cleaner ZC-21 WSE-M5B392-A
Silicone Gasket and Sealant TA-30 WSE-M4G323-A4
Motorcraft Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A ESE-M1C171-A
Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color) WSS-M97B51-A1
High-Temp 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A ESA-M1C198-A
Fig 1: Identifying Lower Engine Block Component
G03898939Courtesy of FORD MOTOR CO.
Fig 2: Identifying Front Engine Block Component
G03898940Courtesy of FORD MOTOR CO.
Fig 3: Identifying Cylinder Head Component
G03898941Courtesy of FORD MOTOR CO.
Fig 4: Identifying Intake Manifold Component
G03898942Courtesy of FORD MOTOR CO.
CAUTION: 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.
CAUTION: 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 you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.
    CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
  1. Turn the crankshaft clockwise to position the No. 1 piston at TDC.
  2. Remove the engine plug bolt.
    Fig 5: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    3. NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
    Fig 6: Installing Special Tool
    G03897737Courtesy of FORD MOTOR CO.
  3. Install the special tool.
  4. Install the block-off plate and bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 7: Installing Block-Off Plate And Bolts
      G03898919Courtesy of FORD MOTOR CO.
    5. NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface cleaner.
  5. Install the oil pump assembly. Tighten the bolts in the sequence shown in Fig 8 in the following 2 stages:
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten to 20 Nm (15 lb-ft).
      Fig 8: Installing Oil Pump Assembly Tightening Bolts
      G03898057Courtesy of FORD MOTOR CO.
  6. Install a new oil pump pickup tube gasket and the pickup tube.
    • Tighten to 10 Nm (89 lb-in).
      Fig 9: Installing Oil Pump Bolts
      G03898027Courtesy of FORD MOTOR CO.
  7. Using the special tool, install the crankshaft rear main oil seal.
    Fig 10: Installing Crankshaft Rear Main Oil Seal Using Special Tool
    G03897721Courtesy of FORD MOTOR CO.
  8. Tighten the crankshaft rear main oil seal bolts in the sequence shown in Fig 11.
    • Tighten to 10 Nm (89 lb-in).
      Fig 11: Installing Crankshaft Rear Main Oil Seal Bolts
      G03897722Courtesy of FORD MOTOR CO.
    9. CAUTION: 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 and metal surface cleaner to remove traces of sealant.
  9. Clean and inspect all mating surfaces.
    10. NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
  10. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan.
    • Install the oil pan.
    • Install the 2 oil pan bolts finger-tight.
      Fig 12: Identifying Rear Oil Pan Bolts
      G03897723Courtesy of FORD MOTOR CO.
  11. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown in Fig 13.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 13: Installing Oil Pan Bolts
      G03897725Courtesy of FORD MOTOR CO.
  12. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
    Fig 14: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
    13. CAUTION: 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.
    CAUTION: Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
  13. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    3. 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.
    4. 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.
  14. Apply silicone gasket and sealant to the locations shown Fig 15.
    Fig 15: Identifying Silicone Gasket And Sealant Application Points
    G03897827Courtesy of FORD MOTOR CO.
  15. Install a new head gasket.
    Fig 16: Identifying Head Gasket
    G03898065Courtesy of FORD MOTOR CO.
    16. 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.
  16. Install new cylinder head bolts. Tighten the bolts in the sequence shown in Fig 17 in the following 5 stages:
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 15 Nm (11 lb-ft).
    • Stage 3: Tighten to 45 Nm (33 lb-ft).
    • Stage 4: Turn 90 degrees.
    • Stage 5: Turn an additional 90 degrees.
      Fig 17: Tightening Cylinder Head Bolts
      G03897828Courtesy of FORD MOTOR CO.
    17. CAUTION: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons.
    NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
  17. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in Fig 18 in the following 3 stages:
    • Stage 1: Tighten 1 turn at a time until tight.
    • Stage 2: Tighten to 7 Nm (62 lb-in).
    • Stage 3: Tighten to 16 Nm (12 lb-ft).
      Fig 18: Installing Camshafts And Bearing Caps
      G03898067Courtesy of FORD MOTOR CO.
    18. NOTE: Install a crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
  18. Install the crankshaft sprocket, crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.
    • The crankshaft sprocket flange must be facing away from the engine block.
      Fig 19: Identifying Crankshaft Sprocket Flange
      G03898068Courtesy of FORD MOTOR CO.
  19. Install the oil pump chain, sprocket and bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 20: Identifying Oil Pump Chain, Sprocket And Bolt
      G03898069Courtesy of FORD MOTOR CO.
  20. Install the oil pump chain guide and the shoulder bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 21: Identifying Oil Pump Chain Guide And Shoulder Bolts
      G03898070Courtesy of FORD MOTOR CO.
  21. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 22: Installing Oil Pump Chain Tensioner
      G03898071Courtesy of FORD MOTOR CO.
    22. CAUTION: The special tool 303 - 465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    Fig 23: Identifying Special Tool
    G03898006Courtesy of FORD MOTOR CO.
  22. Install the special tool in the slots on the rear of both camshafts.
  23. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
    Fig 24: Installing Camshaft Drive Gears Bolts
    G03897782Courtesy of FORD MOTOR CO.
  24. Install the LH timing chain guide and the bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 25: Identifying LH Timing Chain Guide And Bolts
      G03897780Courtesy of FORD MOTOR CO.
  25. Install the timing chain.
    Fig 26: Identifying Timing Chain
    G03897779Courtesy of FORD MOTOR CO.
  26. Install the RH timing chain guide.
    Fig 27: Identifying Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
    27. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
    Fig 28: Compressing Timing Chain Tensioner Plunger
    G03898077Courtesy of FORD MOTOR CO.
  27. Using the edge of a vise, compress the timing chain tensioner plunger.
  28. Using a small pick, push back and hold the ratchet mechanism.
    Fig 29: Holding Ratchet Mechanism Using Small Pick
    G03898078Courtesy of FORD MOTOR CO.
  29. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 30: Pushing Ratchet Arm Back Into Tensioner Housing
    G03898079Courtesy of FORD MOTOR CO.
  30. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
    Fig 31: Installing Paper Clip Into Hole In Tensioner Housing
    G03898080Courtesy of FORD MOTOR CO.
  31. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
    • Tighten to 10 Nm (89 lb-in).
      Fig 32: Identifying Timing Chain Tensioner Bolts
      G03897786Courtesy of FORD MOTOR CO.
    32. CAUTION: The special tool 303 - 465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
  32. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
    • Tighten to 65 Nm (48 lb-ft).
      Fig 33: Installing Camshaft Drive Gears Bolts
      G03897782Courtesy of FORD MOTOR CO.
    33. CAUTION: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
  33. Clean and inspect the mounting surfaces of the engine and the front cover.
    34. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
    Fig 34: Applying Silicone Gasket And Sealant On Engine Front Cover
    G03897744Courtesy of FORD MOTOR CO.
  34. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
  35. Install the engine front cover. Tighten the bolts in the sequence shown in Fig 35, 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).
      Fig 35: Tightening Engine Front Cover Bolts
      G03897745Courtesy of FORD MOTOR CO.
    36. NOTE: Remove the through-bolt from the special tool.
    NOTE: Lubricate the oil seal with clean engine oil.
    Fig 36: Installing Crankshaft Front Oil Seal Using Special Tool
    G03897717Courtesy of FORD MOTOR CO.
  36. Using the special tool, install the crankshaft front oil seal.
    37. NOTE: Do not reuse the crankshaft damper bolt.
    NOTE: Apply clean engine oil on the seal area before installing.
  37. Install the crankshaft pulley and hand-tighten the bolt.
    38. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
    NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
  38. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
    • Rotate the pulley as necessary to align the bolt holes.
      Fig 37: Aligning Crankshaft Pulley Hole With Engine Front Cover Holes
      G03898086Courtesy of FORD MOTOR CO.
    39. CAUTION: Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover.
  39. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
    • Stage 1: Tighten to 100 Nm (74 lb-ft).
    • Stage 2: Tighten an additional 90 degrees (1/4 turn).
      Fig 38: Holding Crankshaft Pulley Using Special Tool
      G03898087Courtesy of FORD MOTOR CO.
  40. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 39: Aligning Crankshaft Pulley Hole With Engine Front Cover Holes
    G03898086Courtesy of FORD MOTOR CO.
  41. Remove the special tool.
    Fig 40: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  42. Remove the special tool.
    Fig 41: Identifying Special Tool
    G03898006Courtesy of FORD MOTOR CO.
    43. NOTE: Only turn the engine in the normal direction of rotation.
  43. Turn the engine 2 complete revolutions.
    44. NOTE: Only turn the engine in the normal direction of rotation.
  44. Turn the crankshaft until the No. 1 piston is at TDC.
  45. Install the special tool.
    Fig 42: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
    46. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
  46. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
    • If it is not possible to install the bolt, correct the engine timing.
      Fig 43: Aligning Crankshaft Pulley Hole With Engine Front Cover Holes
      G03898086Courtesy of FORD MOTOR CO.
  47. Using the special tool, check the position of the camshafts.
    • If it is not possible to install the special tool, correct the engine timing.
      Fig 44: Identifying Special Tool
      G03898006Courtesy of FORD MOTOR CO.
  48. Install the crankshaft position (CKP) sensor.
    • Do not tighten the bolts at this time.
      Fig 45: Installing Crankshaft Position (CKP) Sensor
      G03898012Courtesy of FORD MOTOR CO.
  49. Adjust the CKP sensor alignment jig and tighten the bolts.
    • Tighten to 7 Nm (62 lb-in).
      Fig 46: Locating CKP Sensor Adjusting Bolts
      G03897758Courtesy of FORD MOTOR CO.
  50. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 47: Aligning Crankshaft Pulley Hole With Engine Front Cover Holes
    G03898086Courtesy of FORD MOTOR CO.
  51. Install the engine plug bolt.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 48: Locating Engine Plug Bolt
      G04319319Courtesy of FORD MOTOR CO.
    52. CAUTION: 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.
  52. Clean the valve cover gasket surface with metal surface cleaner.
  53. Apply silicone gasket and sealant to the locations shown in Fig 49.
    Fig 49: Cleaning Valve Cover Gasket Surface Applying Silicone Gasket And Sealant
    G03898098Courtesy of FORD MOTOR CO.
    54. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
  54. Install the valve cover.
    • Tighten the bolts in the sequence shown in Fig 50 to 10 Nm (89 lb-in).
      Fig 50: Installing Valve Cover Tightening Bolts
      G03897691Courtesy of FORD MOTOR CO.
  55. Install a new cylinder head temperature (CHT) sensor and the spark plugs.
    • Tighten the CHT sensor to 12 Nm (9 lb-ft).
    • Tighten the spark plugs to 15 Nm (11 lb-ft).
      Fig 51: Installing Spark Plugs
      G03898004Courtesy of FORD MOTOR CO.
    56. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
  56. Install the coil-on-plugs, bolts and the crankcase vent tube.
    • Tighten to 10 Nm (89 lb-in).
      Fig 52: Installing Coil-On-Plugs
      G03898003Courtesy of FORD MOTOR CO.
  57. Install the 3 engine cover studs.
    Fig 53: Installing Engine Cover Studs
    G03898892Courtesy of FORD MOTOR CO.
  58. If equipped, install the block heater.
    • Tighten to 21 Nm (15 lb-ft).
      Fig 54: Identifying Block Heater
      G03898002Courtesy of FORD MOTOR CO.
  59. Install the coolant hoses.
    Fig 55: Installing Coolant Hoses
    G03898890Courtesy of FORD MOTOR CO.
    60. NOTE: Clean the gasket mating surfaces with metal surface cleaner.
  60. Install the oil filter adapter with a new gasket.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 56: Installing Oil Filter Adapter
      G03898889Courtesy of FORD MOTOR CO.
    61. NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.
  61. Install the crankcase vent oil separator and the KS.
    • Tighten the oil separator bolts to 10 Nm (89 lb-in).
    • Tighten the KS to 20 Nm (15 lb-ft).
      Fig 57: Installing Crankcase Vent Oil Separator
      G03898103Courtesy of FORD MOTOR CO.
  62. Install the coolant hose.
    Fig 58: Installing Coolant Hose
    G03897997Courtesy of FORD MOTOR CO.
    63. NOTE: Clean and inspect the thermostat housing gasket. Replace if necessary.
  63. Install the thermostat housing.
    • Tighten to 10 Nm (89 lb-in).
      Fig 59: Installing Thermostat Housing
      G03898885Courtesy of FORD MOTOR CO.
  64. Install the coolant hose.
    Fig 60: Installing Coolant Hose
    G03898884Courtesy of FORD MOTOR CO.
    65. NOTE: Clean the coolant pump mating surface with metal surface cleaner.
    NOTE: Lubricate the coolant pump O-ring with clean engine coolant.
  65. Install the coolant pump and bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 61: Installing Coolant Pump And Bolts
      G03897970Courtesy of FORD MOTOR CO.
  66. Install the coolant pump pulley and bolts.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 62: Installing Coolant Pump Pulley And Bolts
      G03897969Courtesy of FORD MOTOR CO.
  67. Position the engine control wiring harness on the engine and connect the exhaust gas recirculation (EGR) valve electrical connector.
    Fig 63: Connecting (EGR) Valve Electrical Connector
    G03898881Courtesy of FORD MOTOR CO.
  68. Connect the radio ignition interference capacitor electrical connector.
    Fig 64: Connecting Radio Ignition Interference Capacitor Electrical Connector
    G03898880Courtesy of FORD MOTOR CO.
  69. If equipped, connect the block heater electrical connector.
    Fig 65: Locating Block Heater Electrical Connector
    G03897864Courtesy of FORD MOTOR CO.
  70. Connect the CHT sensor and install the rubber boot.
  71. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
    Fig 66: Connecting Coil-On-Plug
    G03897994Courtesy of FORD MOTOR CO.
  72. Install the accessory drive belt tensioner.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 67: Installing Drive Belt Tensioner And Bolts
      G03898876Courtesy of FORD MOTOR CO.
  73. Attach the engine wiring harness pin-type retainer.
    Fig 68: Installing Engine Wiring Harness Pin-Type Retainer
    G03898875Courtesy of FORD MOTOR CO.
  74. Install the engine wiring harness connector bracket.
    • Tighten to 15 Nm (11 lb-ft).
      Fig 69: Installing Engine Wiring Harness Connector Bracket
      G03898874Courtesy of FORD MOTOR CO.
  75. Connect the CKP sensor electrical connector.
    Fig 70: Connecting CKP Sensor Electrical Connector
    G03897961Courtesy of FORD MOTOR CO.
  76. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
    77. NOTE: Special bolts are used for installation. Do not use standard bolts.
  77. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in Fig 71 in the following 3 stages:
    • Stage 1: Tighten to 50 Nm (37 lb-ft).
    • Stage 2: Tighten to 80 Nm (59 lb-ft).
    • Stage 3: Tighten to 112 Nm (83 lb-ft).
      Fig 71: Installing Flywheel And Bolts Tightening Bolts
      G03897718Courtesy of FORD MOTOR CO.
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