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Engine - Hybrid Electric Vehicle (HEV)

WARNING: This page is about a different variant/trim than selected.

Special Tool(s) / General Equipment 

GFD197861Courtesy of FORD MOTOR COMPANY
100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
GFD197862Courtesy of FORD MOTOR COMPANY
205-153 (T80T-4000-W) Handle
GFD197863Courtesy of FORD MOTOR COMPANY
300-OTC1819E2, 200# Floor Crane, Fold Away
GFD197864Courtesy of FORD MOTOR COMPANY
303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal TKIT-2009TC-F
GFD197865Courtesy of FORD MOTOR COMPANY
303-1247VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
GFD197866Courtesy of FORD MOTOR COMPANY
303-1416 Tool, Crank Damper Holding TKIT-2008ET-FLM
GFD197867Courtesy of FORD MOTOR COMPANY
303-1521 Alignment Tool, Crankshaft Position Sensor TKIT-2010C-FLM
GFD197868Courtesy of FORD MOTOR COMPANY
303-328 (T88P-6701-B1) Replacer, Rear Seal TKIT-1988-FLM TKIT-1988-F TKIT-1988-LM
GFD197869Courtesy of FORD MOTOR COMPANY
303-465 Tool, Camshaft Align Timing TKIT-1994-LMH/MH2 TKIT-1994-FH/FMH/FLMH
GFD197870Courtesy of FORD MOTOR COMPANY
303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW
Feeler Gauge
Round-Ended Steel Rule
Piston Ring Compressor

Materials 

Name Specification
Motorcraft ® Silicone Gasket Remover ZC-30-A -
Motorcraft ® Metal Surface Prep Wipes ZC-31-B -
Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil XO-0W20-QSP WSS-M2C947-A
Motorcraft ® Silicone Gasket and Sealant TA-30 WSE-M4G323-A4
Motorcraft ® Silicone Brake Caliper Grease and Dielectric Compound XG-3-A ESE-M1C171-A
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. 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: If it is necessary to install a new timing chain tensioner, a cast iron tensioner is to be replaced with an aluminum tensioner (6K254). The existing bolts must be discarded and replaced with new bolts (6K282).
NOTE: For additional information, refer to the exploded views in Description and Operation in this article.
  1. NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly.
    NOTE: The front bulkhead does not have an oil squirter.

    Torque: 35 lb.in (4 Nm)

    GFD197871Courtesy of FORD MOTOR COMPANY
  2. NOTE: Record the smallest diameter for each journal.
    GFD197872Courtesy of FORD MOTOR COMPANY
  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 and install the original main bearing beam bolts finger tight.
    GFD197873Courtesy of FORD MOTOR COMPANY
  4. Torque:

    Stage 1: 44 lb.in (5 Nm)

    Stage 2: 18 lb.ft (25 Nm)

    Stage 3: 90 °

    Fig 1: Main bearing Beam Tightening Sequence (Tighten) (1 of 3) (HEV)
    GFD197874Courtesy of FORD MOTOR COMPANY
  5. Measure each crankshaft block main bearing bore diameter.
    GFD197875Courtesy of FORD MOTOR COMPANY
  6. Using the chart, select the crankshaft main bearings.
    GFD197876Courtesy of FORD MOTOR COMPANY
  7. NOTE: Use the original connecting rod cap bolts; installation must keep the same orientation as marked during disassembly or engine damage may occur.

    Torque:

    Stage 1: 89 lb.in (10 Nm)

    Stage 2: 21 lb.ft (29 Nm)

    Stage 3: 90 °

    GFD197877Courtesy of FORD MOTOR COMPANY
  8. NOTE: Record the smallest measurement for each connecting rod.

    Remove and discard the bolts after measuring.

    GFD197878Courtesy of FORD MOTOR COMPANY
  9. NOTE: Record the smallest measurement for each connecting rod.
    GFD197879Courtesy of FORD MOTOR COMPANY
  10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
    GFD197880Courtesy of FORD MOTOR COMPANY
  11. Fig 2: Main Bearing Beam Tightening Sequence (Loosen) (2 of 3) (HEV)
    GFD197881Courtesy of FORD MOTOR COMPANY
  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.
    NOTE: The center bulkhead is the thrust bearing.

    Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)

    GFD197882Courtesy of FORD MOTOR COMPANY
  13. NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

    Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)

    GFD197883Courtesy of FORD MOTOR COMPANY
  14. NOTE: Lubricate the journals on the crankshaft with clean engine oil.

    Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)

    GFD197884Courtesy of FORD MOTOR COMPANY
  15. Material Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
    GFD197885Courtesy of FORD MOTOR COMPANY
  16. Mounted flush.
    GFD197886Courtesy of FORD MOTOR COMPANY
  17. NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads 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.

    Torque:

    Stage 1: 44 lb.in (5 Nm)

    Stage 2: 18 lb.ft (25 Nm)

    Stage 3: 90 °

    Fig 3: Main Bearing Beam Tightening Sequence (Tighten) (3 of 3) (HEV)
    GFD197874Courtesy of FORD MOTOR COMPANY
    • Position the crankshaft to the rear of the cylinder block.

    • Zero the Dial Indicator Gauge with Holding Fixture. Use Special Service Tool: 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.

    • If the crankshaft end play exceeds the specified range, install new parts as necessary.

      Distance

      : 0.01-0.02in (.22-.45mm)

    GFD197887Courtesy of FORD MOTOR COMPANY
  18. NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly.

    Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)

    GFD197888Courtesy of FORD MOTOR COMPANY
  19. GFD197889Courtesy of FORD MOTOR COMPANY
  20. 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 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)

    GFD197890Courtesy of FORD MOTOR COMPANY
  21. NOTE: 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.

    Torque:

    Stage 1: 89 lb.in (10 Nm)

    Stage 2: 21 lb.ft (29 Nm)

    Stage 3: 90 °

    GFD197891Courtesy of FORD MOTOR COMPANY
    • Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

    • Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Peg. The engine is now at TDC and must remain at the TDC position until the timing drive components and crankshaft pulley are installed.

    GFD197892Courtesy of FORD MOTOR COMPANY
  22. Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
  23. NOTE: Clean the oil pump and cylinder block mating surfaces.

    Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B

    Torque:

    Stage 1: 89 lb.in (10 Nm)

    Stage 2: 177 lb.in (20 Nm)

    Fig 4: Oil Pump Tightening Sequence (HEV)
    GFD197893Courtesy of FORD MOTOR COMPANY
  24. GFD197894Courtesy of FORD MOTOR COMPANY
  25. Torque: 89 lb.in (10 Nm)
    GFD197895Courtesy of FORD MOTOR COMPANY
  26. NOTE: If equipped, the diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.
    NOTE: Early build engines are equipped with a diamond washers on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

    If equipped, install the diamond washer onto the crankshaft.

    GFD197896Courtesy of FORD MOTOR COMPANY
  27. GFD197897Courtesy of FORD MOTOR COMPANY
  28. Use Special Service Tool: 303-328 (T88P-6701-B1) Replacer, Rear Seal.

    Torque: 89 lb.in (10 Nm)

    GFD197898Courtesy of
  29. NOTE: 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.

    Clean and inspect all mating surfaces of the engine and oil pan.

    Material: Motorcraft ® Silicone Gasket Remover / ZC-30-A

    Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B

  30. NOTE: If the oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

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

    GFD197899Courtesy of FORD MOTOR COMPANY
  31. Finger-tight.
    GFD197900Courtesy of FORD MOTOR COMPANY
  32. Use the General Equipment: Round-Ended Steel Rule
    GFD197901Courtesy of FORD MOTOR COMPANY
  33. Torque: 177 lb.in (20 Nm)
    GFD197902Courtesy of FORD MOTOR COMPANY
  34. NOTE: 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.

    Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.

    Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B

  35. NOTE: Dowels must be fully seated in the cylinder block.
    GFD197903Courtesy of FORD MOTOR COMPANY
  36. Material: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
    GFD197904Courtesy of FORD MOTOR COMPANY
  37. GFD197905Courtesy of FORD MOTOR COMPANY
  38. 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 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)

    Torque:

    Stage 1: 62 lb.in (7 Nm)

    Stage 2: 133 lb.in (15 Nm)

    Stage 3: 33 lb.ft (45 Nm)

    Stage 4: 90 °

    Stage 5: 90 °

    GFD197906Courtesy of FORD MOTOR COMPANY
  39. Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
    GFD197907Courtesy of FORD MOTOR COMPANY
  40. NOTE: If any new parts are being installed (cylinder head, valves, tappets, camshafts) it is necessary to check the valve clearance.

    Place a paint mark on the crankshaft at the 12 o'clock position.

    GFD197908Courtesy of FORD MOTOR COMPANY
    • Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
    GFD197909Courtesy of FORD MOTOR COMPANY
  41. NOTE: Rotating the crankshaft will position all of the pistons below the deck of the cylinder block and allow the camshafts to be installed and the valve clearance checked without the possibility of damage to the valves or pistons.

    Using the crankshaft bolt and washer, rotate the crankshaft clockwise 270 degrees until the paint mark is at the 9 o'clock position.

    GFD197910Courtesy of FORD MOTOR COMPANY
  42. NOTE: 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.

    Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)

    GFD197911Courtesy of FORD MOTOR COMPANY
  43. Tighten the camshaft bearing cap bolts one at a time until finger-tight

    Torque:

    Stage 1: 62 lb.in (7 Nm)

    Stage 2: 142 lb.in (16 Nm)

    GFD197912Courtesy of FORD MOTOR COMPANY
    1. Using the flats of the camshaft, rotate the camshaft to place the cam lobe at base circle, with the lobe pointed away from the tappet.
    2. Use a feeler gauge to measure the clearance of each valve and record its location. Use the General Equipment: Feeler Gauge
    3. Repeat to measure all of the lobe/tappet clearances.
    GFD197913Courtesy of FORD MOTOR COMPANY
  44. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
    NOTE: Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance.
    NOTE: The nominal clearance is:

    • intake: 0.25 mm (0.0095 in).
    • exhaust: 0.36 mm (0.0142 in).

    NOTE: The acceptable clearances after being fully installed are:

    • intake: 0.19-0.31 mm (0.007-0.012 in).
    • exhaust: 0.30-0.42 mm (0.012-0.017 in).

    Select the closest tappet size to the ideal tappet thickness available and mark the installation location.

  45. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
    NOTE: Mark the location and orientation of each camshaft bearing cap.

    Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the camshaft bearing caps.

    GFD197914Courtesy of FORD MOTOR COMPANY
    • Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
    GFD197909Courtesy of FORD MOTOR COMPANY
  46. NOTE: Rotating the crankshaft will position the engine at TDC and allow you to install the camshafts in the same position as noted during the disassembly.

    Rotate the crankshaft clockwise 90 degrees so the crankshaft contacts the Timing Peg, Crankshaft TDC 303-507.

    GFD197915Courtesy of FORD MOTOR COMPANY
  47. If necessary, replace any tappets with the correct tappets selected during the valve clearance check.

    Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)

    GFD197916Courtesy of FORD MOTOR COMPANY
  48. NOTE: 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.

    Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)

    GFD197911Courtesy of FORD MOTOR COMPANY
  49. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

    Install Special Service Tool: 303-465 Tool, Camshaft Align Timing.

    GFD197917Courtesy of FORD MOTOR COMPANY
  50. Tighten the camshaft bearing cap bolts one at a time until finger-tight

    Torque:

    Stage 1: 62 lb.in (7 Nm)

    Stage 2: 142 lb.in (16 Nm)

    GFD197912Courtesy of FORD MOTOR COMPANY
  51. Torque: 97 lb.in (11 Nm)
    GFD197918Courtesy of FORD MOTOR COMPANY
  52. Torque: 97 lb.in (11 Nm)
    GFD197919Courtesy of FORD MOTOR COMPANY
  53. NOTE: Before installation, clean and inspect the diamond washer for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.
    NOTE: The crankshaft sprocket flange must be facing away from the engine block.

    Install a diamond washer on both sides of the crankshaft sprocket.

    GFD197920Courtesy of FORD MOTOR COMPANY
  54. Torque: 18 lb.ft (25 Nm)
    GFD197921Courtesy of FORD MOTOR COMPANY
    • Torque: 89 lb.in (10 Nm)

    • Hook the tensioner spring around the shoulder bolt.

    GFD197922Courtesy of FORD MOTOR COMPANY
  55. NOTE: Do not tighten the bolts at this time.
    GFD197923Courtesy of FORD MOTOR COMPANY
  56. GFD197924Courtesy of FORD MOTOR COMPANY
  57. GFD197925Courtesy of FORD MOTOR COMPANY
  58. GFD197926Courtesy of FORD MOTOR COMPANY
    NOTE: If equipped with aluminum timing chain tensioner.
    NOTE: If the timing chain tensioner plunger is not pinned in the compressed position, follow the next step.
  59. Reset the timing chain tensioner.

    1. Position the timing chain tensioner in a soft-jawed vise.
    2. Spread the ends of the ratchet wire clip apart.
    3. Using the soft-jawed vise, compress the plunger to the reset position.
    4. Install a locking pin in the 2 holes of the timing chain tensioner body to hold the plunger in place.

    GFD197927Courtesy of FORD MOTOR COMPANY
  60. NOTE: If equipped with aluminum timing chain tensioner.
    NOTE: Do not remove the locking pin until the tensioner bolts are tightened.

    1. Install the timing chain tensioner and the bolts.

      Torque: 89 lb.in (10 Nm)

    2. Remove the locking pin.

    GFD197928Courtesy of FORD MOTOR COMPANY
    NOTE: If equipped with cast iron timing chain tensioner.
    NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
  61. NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

    Using the edge of a vise, compress the timing chain tensioner plunger.

    GFD197929Courtesy of FORD MOTOR COMPANY
  62. Using a small pick, push back and hold the ratchet mechanism.
    GFD197930Courtesy of FORD MOTOR COMPANY
  63. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    GFD197931Courtesy of FORD MOTOR COMPANY
  64. Install a locking pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
    GFD197932Courtesy of FORD MOTOR COMPANY
  65. NOTE: If equipped with cast iron timing chain tensioner.
    NOTE: Do not remove the locking pin until the tensioner bolts are tightened.

    Install the timing chain tensioner and the bolts.

    Torque: 89 lb.in (10 Nm)

    GFD197933Courtesy of FORD MOTOR COMPANY
  66. NOTE: If equipped with cast iron timing chain tensioner.

    Remove the locking pin.

    GFD197934Courtesy of FORD MOTOR COMPANY
  67. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    NOTE: Use the flats on the camshafts to prevent camshaft rotation.

    Torque:

    Stage 1: 30 lb.ft (40 Nm)

    Stage 2: 60 °

    GFD197935Courtesy of FORD MOTOR COMPANY
  68. NOTE: 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.

    Clean and inspect the mounting surfaces of the engine and the front cover.

    Material: Motorcraft ® Silicone Gasket Remover / ZC-30-A

    Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B

  69. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft ® Metal Surface Prep.

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

    GFD197936Courtesy of FORD MOTOR COMPANY
  70. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft ® Metal Surface Prep.

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

    GFD197937Courtesy of FORD MOTOR COMPANY
  71. Torque:

    Bolts 1 - 3: 35 lb.ft (48 Nm)

    Bolts 4 - 13: 89 lb.in (10 Nm)

    Bolt 14: 35 lb.ft (48 Nm)

    Bolts 15 - 21: 89 lb.in (10 Nm)

    GFD197938Courtesy of FORD MOTOR COMPANY
  72. NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.

    Use Special Service Tool: 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal.

    Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)

    GFD197939Courtesy of FORD MOTOR COMPANY
  73. NOTE: If equipped, the diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.
    NOTE: Early build engines are equipped with a diamond washers on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

    If equipped, install the diamond washer onto the crankshaft.

    GFD197940Courtesy of FORD MOTOR COMPANY
  74. Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
    GFD197941Courtesy of FORD MOTOR COMPANY
  75. NOTE: Do not install the crankshaft pulley bolt at this time.
    GFD197942Courtesy of FORD MOTOR COMPANY
  76. NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur.
    NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

    General Equipment: M6 Bolt.

    GFD197943Courtesy of FORD MOTOR COMPANY
  77. NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.
    NOTE: Install a new crankshaft pulley bolt.

    Use Special Service Tool: 303-1416 Tool, Crank Damper Holding.

    Torque:

    Stage 1: 74 lb.ft (100 Nm)

    Stage 2: 90 °

    GFD197944Courtesy of FORD MOTOR COMPANY
  78. Do not tighten the bolts at this time.
    GFD197945Courtesy of FORD MOTOR COMPANY
  79. Install the Special Tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel. Use Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor.

    Torque: 62 lb.in (7 Nm)

    GFD197946Courtesy of FORD MOTOR COMPANY
  80. Remove.
    GFD197943Courtesy of FORD MOTOR COMPANY
  81. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
    GFD197909Courtesy of FORD MOTOR COMPANY
  82. Torque: 177 lb.in (20 Nm)
    GFD197947Courtesy of FORD MOTOR COMPANY
  83. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing.
    GFD197948Courtesy of FORD MOTOR COMPANY
  84. NOTE: 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.

    Clean the valve cover gasket surfaces.

    Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B

  85. NOTE: Installation of a new VCT solenoid seal is required if a damaged seal was removed during disassembly of the engine.

    Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer.205-153 (T80T-4000-W) Handle.

    GFD197949Courtesy of FORD MOTOR COMPANY
  86. NOTE: Inspect and if necessary, install new valve cover gaskets.
    GFD197950Courtesy of FORD MOTOR COMPANY
  87. Material: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
    GFD197951Courtesy of FORD MOTOR COMPANY
  88. NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.

    Torque: 89 lb.in (10 Nm)

    GFD197952Courtesy of FORD MOTOR COMPANY
  89. GFD197953Courtesy of FORD MOTOR COMPANY
  90. Apply dielectric compound to the inside of the coil-on-plug boots.

    Material: Motorcraft ® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

    Torque: 71 lb.in (8 Nm)

    GFD197954Courtesy of FORD MOTOR COMPANY
  91. GFD197955Courtesy of FORD MOTOR COMPANY
  92. GFD197956Courtesy of FORD MOTOR COMPANY
  93. NOTE: The front KS must be installed in the 6 o'clock position and the rear KS must be installed in the 12 o'clock position. The KS must not touch the crankcase vent oil separator.

    Torque:

    1: 80 lb.in (9 Nm)

    2: 89 lb.in (10 Nm)

    3: 177 lb.in (20 Nm)

    GFD197957Courtesy of FORD MOTOR COMPANY
  94. NOTE: 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.
    NOTE: Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.
    GFD197958Courtesy of FORD MOTOR COMPANY
  95. Torque: 159 lb.in (18 Nm)
    GFD197959Courtesy of FORD MOTOR COMPANY
  96. GFD197960Courtesy of FORD MOTOR COMPANY
  97. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.

    Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)

    GFD197961Courtesy of FORD MOTOR COMPANY
  98. GFD197962Courtesy of FORD MOTOR COMPANY
  99. Torque: 17 lb.ft (23 Nm)
    GFD197963Courtesy of FORD MOTOR COMPANY
  100. Torque: 89 lb.in (10 Nm)
    GFD197964Courtesy of FORD MOTOR COMPANY
  101. GFD197965Courtesy of FORD MOTOR COMPANY
  102. Torque: 18 lb.ft (25 Nm)
    GFD197966Courtesy of FORD MOTOR COMPANY
  103. Torque: 80 lb.in (9 Nm)
    GFD197967Courtesy of FORD MOTOR COMPANY
  104. GFD197968Courtesy of FORD MOTOR COMPANY
  105. GFD197969Courtesy of FORD MOTOR COMPANY
  106. Torque: 35 lb.ft (48 Nm)
    GFD197970Courtesy of FORD MOTOR COMPANY
  107. GFD197971Courtesy of FORD MOTOR COMPANY
  108. GFD197972Courtesy of FORD MOTOR COMPANY
  109. GFD197973Courtesy of FORD MOTOR COMPANY
  110. GFD197974Courtesy of FORD MOTOR COMPANY
  111. GFD197975Courtesy of FORD MOTOR COMPANY
  112. Torque: 89 lb.in (10 Nm)
    GFD197976Courtesy of FORD MOTOR COMPANY
  113. Torque:

    1: 71 lb.in (8 Nm)

    2: 19 lb.ft (26 Nm)

    3: 35 lb.ft (48 Nm)

    GFD197977Courtesy of FORD MOTOR COMPANY
  114. Torque: 18 lb.ft (25 Nm)
    GFD197978Courtesy of FORD MOTOR COMPANY
  115. GFD197979Courtesy of FORD MOTOR COMPANY
  116. GFD197980Courtesy of FORD MOTOR COMPANY
  117. Torque:

    Stage 1: 93 lb.in (10.5 Nm)

    Stage 2: 90 °

    GFD197981Courtesy of FORD MOTOR COMPANY
  118. GFD197982Courtesy of FORD MOTOR COMPANY
  119. Torque 18 lb.ft (25 Nm)
    GFD197983Courtesy of FORD MOTOR COMPANY
  120. Torque: 150 lb.in (17 Nm)
    GFD197984Courtesy of FORD MOTOR COMPANY
  121. Torque: 41 lb.ft (55 Nm)
    GFD197985Courtesy of FORD MOTOR COMPANY
  122. Torque: 18 lb.ft (25 Nm)
    GFD197986Courtesy of FORD MOTOR COMPANY
  123. GFD197987Courtesy of FORD MOTOR COMPANY
  124. GFD197988Courtesy of FORD MOTOR COMPANY
  125. Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.
    GFD197989Courtesy of FORD MOTOR COMPANY
  126. GFD197990Courtesy of FORD MOTOR COMPANY
  127. NOTE: Use a universal pulley holder (such as an OTC 4754, or equivalent).

    Install the flywheel and new bolts.

    • Using a universal pulley holder, tighten the new crankshaft pulley bolts in sequence shown.

      Torque:

      Stage 1: 37 lb.ft (50 Nm)

      Stage 2: 59 lb.ft (80 Nm)

      Stage 3: 83 lb.ft (112 Nm)

    GFD197646Courtesy of FORD MOTOR COMPANY
  128. Install the damper and the bolts.

    • Using a universal pulley holder, tighten 2 turns at a time in sequence shown.

      Torque: 21 lb.ft (29 Nm)

GFD197647Courtesy of FORD MOTOR COMPANY