Section 5 (Engine - 1.0L ECOBOOST (90KW/120PS)): Assembly: Engine
Special Tool(s) / General Equipment
| 100-002 (TOOL-4201-C)Holding Fixture with Dial Indicator Gauge | |
|---|---|
| 300-OTC1819E2, 200# Floor Crane, Fold Away | |
| 303-1567Sizer, Teflon SealTKIT-2010C-FLM | |
| 303-1602Locking Tool, Crankshaft | |
| 303-1603Installer, Front Cover Seal | |
| 303-1604Timing Peg, Crankshaft TDC | |
| 303-1605Alignment Tool, Camshaft | |
| 303-1606Locking Tool, Variable Camshaft Timing | |
| 303-1611Torque Multiplier | |
| 303-1611-01Adapter for 303-1611 | |
| 303-1611-02Adapter for 303-1611, Torque MultiplierTKIT-2014A-FLTKIT-2014A-ROW | |
| 310-207Installer, Fuel Injector Seal AssemblyTKIT-2009A-FLM | |
| Feeler Gauge | |
| Plastic Scraper | |
| Hose Clamp Remover/Installer | |
| Piston Ring Compressor | |
| Punch | |
| 4 mm Drill Bit |
Materials
| Name | Specification |
|---|---|
| Motorcraft ® SAE 5W-20 Synthetic Blend Motor OilXO-5W20-QSP | WSS-M2C945-A |
| Motorcraft ® Metal Surface Prep WipesZC-31-B | - |
| Motorcraft ® Silicone Gasket and SealantTA-30 | WSE-M4G323-A4 |
| Motorcraft ® Gasket MakerTA-16 | WSK-M2G348-A5 |
- 2.
- Measure the diameter in two directions.
- Record the smallest measurement for each crankshaft main bearing journal.
- 3.
Torque:Stage 1: 89 lb.in (10 Nm)
Stage 2: 18 lb.ft (25 Nm)
Stage 3: 22 lb.ft (30 Nm)
Stage 4: 90 °
- 6.
Original connecting rod cap bolts.Torque:
Stage 1: 71 lb.in (8 Nm)
Stage 2: 106 lb.in (12 Nm)
Stage 3: 159 lb.in (18 Nm)
Stage 4: 35 °
- 9.
- Measure the diameter in two 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.
- 12.NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- 13.NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- 15.
Torque:Stage 1: 89 lb.in (10 Nm)
Stage 2: 18 lb.ft (25 Nm)
Stage 3: 22 lb.ft (30 Nm)
Stage 4: 90 °
- 16.
- 1.
Position the crankshaft to the rear of the cylinder block.
- 2.
Zero the Dial Indicator Gauge with Holding Fixture. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- 3.
Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
- 4.
Acceptable crankshaft end play is 0.220-0.450 mm (0.0087-0.0177 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
- 1.
- 17.NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly.
Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- 18.NOTE: The upper and lower compression rings are to be fitted with the identification marks on the upper side.NOTE: Arrows face the front of the engine.
- 1.
Upper compression ring gap location.
- 2.
Upper oil control segment ring gap location.
- 3.
Expander ring gap location.
- 4.
Lower oil control segment ring gap location.
- 5.
Lower compression ring gap location.
- 1.
- 19.NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
Use the General Equipment: Piston Ring Compressor
Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- 20.NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
Torque:
Stage 1: 71 lb.in (8 Nm)
Stage 2: 106 lb.in (12 Nm)
Stage 3: 159 lb.in (18 Nm)
Stage 4: 35 °
- 22.NOTE: Make sure that the mating faces are clean and free of foreign material.NOTE: New crankshaft rear seal carriers are supplied with an alignment sleeve which must be removed after installation.
Torque: 89 lb.in (10 Nm)
- 23.NOTE: Make sure that new bolts are installed.
- Use Special Service Tool: 303-1602 Locking Tool, Crankshaft.
Torque:
2-7:
Stage 1: 18 lb.ft (25 Nm)
Stage 2: 37 lb.ft (50 Nm)
Stage 3: 90 °
- Remove Special Service Tool: 303-1602 Locking Tool, Crankshaft.
- Use Special Service Tool: 303-1602 Locking Tool, Crankshaft.
- 26.NOTE: Only rotate the crankshaft clockwise.
Rotate the crankshaft slowly until the crankshaft stops.
- 27.
Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
- 29.NOTE: Make sure that the component is installed to the position noted before removal.
Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- 32.NOTE: Make sure that new bolts are installed.NOTE: Only tighten the bolts finger tight at this stage.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 30 lb.ft (40 Nm)
Stage 3: Loosen: 45 °
Stage 4: 22 lb.ft (30 Nm)
Stage 5: 90 °
Stage 6: 90 °
- 33.NOTE: Install the components in their original position.
Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- 35.
- 1.
Install the camshafts approximately at valve overlap position cylinder No. 1.Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- 2.NOTE: Make sure that the components are installed to the position noted before removal.NOTE: Make sure that new bolts are installed.
Install all the bolts finger tight before final tightening.
- 3.
Tighten each bolt 2 turns at a time.Torque: 89 lb.in (10 Nm)
- 1.
- 36.
- 1.
Rotate the camshafts and measure the valve clearances. Use the General Equipment: Feeler Gauge
- 2.
Note down each cylinder number and the valve clearances measured.
- 3.
Compare the measured valve clearances with the specifications. Refer to: Specifications .
- 1.
- 38.
- Remove the valve tappet and read the thickness from the underside.
- The number on the valve tappet indicates the thickness of the bottom of the tappet. However, the number only indicates the digits after the decimal point (example: 725 = 2.725).
- 39.
- Calculate the required thickness of the valve tappet with the following formula: X = S + M - V
- Required thickness of tappet = X
- Thickness of currently fitted tappet = S
- Measurement of existing valve clearance (actual value) = M
- Desired valve clearance = V
- 41.NOTE: Make sure that the mating faces are clean and free of foreign material.NOTE: The component must be installed within 5 minutes of applying the sealant.
Material: Motorcraft ® Gasket Maker / TA-16 (WSK-M2G348-A5)
- 42.NOTE: Make sure that the mating faces are clean and free of foreign material.NOTE: The component must be installed within 5 minutes of applying the sealant.
Material: Motorcraft ® Gasket Maker / TA-16 (WSK-M2G348-A5)
- 43.
- 1.
Install the camshafts approximately at valve overlap position cylinder No. 1.Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- 2.NOTE: Make sure that the components are installed to the position noted before removal.NOTE: Make sure that new bolts are installed.
Install all the bolts finger tight before final tightening.
- 3.
Tighten each bolt 2 turns at a time.Torque: 89 lb.in (10 Nm)
- 1.
- 44.
- 1.
Install Special Service Tool: 303-1605 Alignment Tool, Camshaft.
- 2.NOTE: Only tighten the bolts finger tight at this stage.
- 3.
Torque: 89 lb.in (10 Nm)
- 1.
- 49.NOTE: Make sure that the component is installed to the position noted before removal.
Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
Torque: 80 lb.in (9 Nm)
- 53.NOTE: Make sure that the mating faces are clean and free of foreign material.
- 1.
Use the General Equipment: Plastic Scraper
- 2.
Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B
- 1.
- 55.NOTE: The component must be installed within 10 minutes of applying the sealant.
Material: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
- 56.NOTE: The component must be installed within 10 minutes of applying the sealant.
Material: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
- 57.
- 1.NOTE: Make sure that new components are installed.
Torque: 1-2, M6x60: 44 lb.in (5 Nm)
- 2.NOTE: Make sure that new components are installed.
Torque: 3-6, M10x95: 89 lb.in (10 Nm)
- 3.NOTE: Make sure that new components are installed.
Torque: 7-16 M6x60: 44 lb.in (5 Nm)
- 4.
Torque: 3-6: 30 lb.ft (40 Nm)
- 5.
Torque:3-4:
Stage 1: 52 lb.ft (70 Nm)
Stage 2: 90 °
- 6.
Torque:5-6:
Stage 1: 52 lb.ft (70 Nm)
Stage 2: 90 °
- 7.
1-2Torque:
Stage 1: 80 lb.in (9 Nm)
Stage 2: 90 °
- 8.
7-16Torque:
Stage 1: 133 lb.in (15 Nm)
Stage 2: 90 °
- 1.
- 58.NOTE: Make sure that the mating faces are clean and free of foreign material.
- 1.
Use the General Equipment: Plastic Scraper
- 2.
Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B
- 1.
- 59.NOTE: The component must be installed within 5 minutes of applying the sealant.
Material: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
- 60.
Torque:1-2, M6x20 : 89 lb.in (10 Nm)
3, M6x75: 89 lb.in (10 Nm)
4-6, M6x20,: 89 lb.in (10 Nm)
7, M6x75,: 89 lb.in (10 Nm)
8-11, M6x20,: 89 lb.in (10 Nm)
12-13, M6x105,: 89 lb.in (10 Nm)
14, M6x75,: 89 lb.in (10 Nm)
15, M6x20,: 89 lb.in (10 Nm)
- 63.NOTE: Make sure that a new component is installed.
Using the special tool, install the crankshaft front seal. Use Special Service Tool: 303-1603 Installer, Front Cover Seal.
- 64.
Install Special Service Tool: 303-1606 Locking Tool, Variable Camshaft Timing.Torque: 89 lb.in (10 Nm)
- 68.NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
Tighten the VCT units bolt.
Torque:
Stage 1: 37 lb.ft (50 Nm)
Stage 2: 70 lb.ft (95 Nm)
Stage 3: 45 °
Stage 3: 45 °
- 69.NOTE: Only rotate the crankshaft clockwise.
Rotate the crankshaft slowly until the crankshaft stops.
- 70.
- 1.NOTE: The production engine is not equipped with a friction washer. Whenever the crankshaft pulley is removed, a friction washer (base part number 6378) must be installed.
Install a new friction washer.
- 2.
Install the crankshaft pulley.
- 3.
Install a new crankshaft pulley bolt finger tight.
- 1.
- 71.
- 1.
Install 3/16 inch punch. Use the General Equipment: Punch
- 2.
Tighten the crankshaft pulley bolt.Torque:
Stage 1: 18 lb.ft (25 Nm)
Stage 2: 52 lb.ft (70 Nm)
- 1.
- 73.
- 1.
M8x30
- 2.
M8x25Install Special Service Tool: 303-1611-02 Adapter for 303-1611, Torque Multiplier.Torque: 18 lb.ft (24 Nm)
- 1.
- 75.
- 1.
Install Special Service Tool: 303-1611 Torque Multiplier.
- 2.
Only tighten the nut finger tight at this stage.
- 1.
- 76.
- 1.
Torque: 44 lb.ft (60 Nm)
- 2.
Torque:Stage 1: 90 °
Stage 2: 90 °
Stage 3: 90 °
Stage 4: 90 °
Stage 5: 90 °
- 1.
- 78.
- 1.
Install 3/16 inch punch. Use the General Equipment: Punch
- 2.
Remove 3/16 inch punch. Use the General Equipment: Punch
- 1.
- 81.NOTE: Only rotate the crankshaft clockwise.
Rotate the crankshaft 1 and 3/4 revolutions and continue until piston No. 1 is approximately 45 ° before top dead center (BTDC).
- 83.NOTE: Only rotate the crankshaft clockwise.
Rotate the crankshaft slowly until the crankshaft stops.
- 84.
- 1.NOTE: The punch can only be installed if the valve timing is correct.
Install 3/16 inch punch. Use the General Equipment: Punch
- 2.
Remove 3/16 inch punch. Use the General Equipment: Punch
- 1.
- 89.NOTE: Make sure that the component is clean, free of foreign material and lubricant.
- 1.
Material: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
- 2.
Material: Motorcraft ® Gasket Maker / TA-16 (WSK-M2G348-A5)
- 1.
- 90.NOTE: If necessary, install a new valve cover gasket.NOTE: Only tighten the bolts finger tight at this stage.
- 95.NOTE: Make sure that the components are installed to the position noted before removal.
Torque:
1: 89 lb.in (10 Nm)
2: 177 lb.in (20 Nm)
- 100.NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.
- 1.
Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
- 2.NOTE: Once the Teflon ® seal is installed on the Teflon ® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon ® seal.NOTE: Make sure that new lower fuel injector Teflon ® seals are installed.
- 3.
Using the Pusher Tool, slide the Teflon ® seals off of the Teflon ® Seal Guide and into the groove on the fuel injectors. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
- 1.
- 101.NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon ® seal expansion.NOTE: Make sure the Teflon ® seal is fully seated in the groove on the fuel injector before sizing the Teflon ® seal.
- 1.
Some Teflon ® seal massaging with your fingers before the Teflon ® seal sizer tool is installed will aid in installing the Teflon ® seal sizer tool.
- 2.
Position the Teflon ® seal sizer tool with the larger opening towards the Teflon ® seal. Push while turning the Teflon ® seal sizer tool 180 degrees. Use Special Service Tool: 303-1567 Sizer, Teflon Seal.
- 3.
Once the Teflon ® seal sizer tool is installed, check and make sure the Teflon ® seal is in the sizing portion of the Teflon ® seal sizer tool. After one minute, turn the Teflon ® seal sizer tool back 180 degrees and remove.
- 1.
- 102.NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.NOTE: Do not lubricate the new lower Teflon ® fuel injector seals.
Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- 104.NOTE: Only use moderate force.NOTE: Install all the bolts finger tight before final tightening.
Tighten each bolt 1 turn at a time.
Torque: 17 lb.ft (23 Nm)
- 106.
- 1.NOTE: Make sure that a new component is installed.
Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
- 1.
- 107.
Tighten each bolt 0.5 turn at a time.Torque:
Stage 1: 44 lb.in (5 Nm)
Stage 2: 115 lb.in (13 Nm)
- 108.
- 1.NOTE: Make sure that a new component is installed.
- 2.NOTE: Tighten both fittings finger tight prior to final tightening.
Torque:
Stage 1: 124 lb.in (14 Nm)
Stage 2: 177 lb.in (20 Nm)
Stage 3: 20 °
- 1.
- 113.
Use the General Equipment: Hose Clamp Remover/InstallerTorque:
1: 89 lb.in (10 Nm)
2: 89 lb.in (10 Nm)
3: 89 lb.in (10 Nm)
- 120.NOTE: Only tighten the nuts and bolts finger tight at this stage.
Use the General Equipment: Hose Clamp Remover/Installer
- 121.
Torque:1-4:
Stage 1: 168 lb.in (19 Nm)
Stage 2: 18 lb.ft (24 Nm)
Stage 3: Wait 30 s
Stage 4: 18 lb.ft (24 Nm)
5: 89 lb.in (10 Nm)
6: 22 lb.ft (30 Nm)
- 122.
Use the General Equipment: Hose Clamp Remover/InstallerTorque:
1: 89 lb.in (10 Nm)
2: 89 lb.in (10 Nm)
- 125.NOTE: Make sure that new components are installed.
Only tighten the nut and bolts finger tight at this stage.
- 143.WARNING: Take extra care when handling the compressed spring.
Use the General Equipment: 4 mm Drill Bit
Torque: 18 lb.ft (25 Nm)
- 144.WARNING: Take extra care when handling the compressed spring.
Use the General Equipment: 4 mm Drill Bit
- 145.NOTE: Only rotate the crankshaft clockwise.NOTE: Make sure that the accessory drive belt is correctly located on each pulley.