Section 1 (Engine Mechanical - 1.0L ECOBOOST): Assembly: Engine

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

SPECIAL TOOL DESCRIPTION

	100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
	300-OTC1819E 2, 200# Floor Crane, Fold Away
	303-1054 Locking Tool, Timing Belt Tensioner
	303-1602 Locking Tool, Crankshaft
	303-1604 Timing Peg, Crankshaft TDC
	303-1605 Alignment Tool, Camshaft
	303-1606 Locking Tool, Variable Camshaft Timing
	303-1611 Torque Multiplier
	303-1611-01 Adapter for 303-1611
	303-1611-02 Adapter for 303-1611, Torque Multiplier TKIT-2014A-FL TKIT-2014A-ROW
	310-128 Installer Set, Teflon Seal
Feeler Gauge
Plastic Scraper
Hose Clamp Remover/Installer
Piston Ring Compressor
Punch
4 mm Drill Bit

MATERIAL SPECIFICATIONS

Name	Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.) XO-5W20-QSP (U.S.)	WSS-M2C945-A
Motorcraft® Metal Surface Prep ZC-31-B	-
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4
Gasket Maker TA-16	WSK-M2G348-A5

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.

Torque : 89 lb.in (10 Nm)
- Measure the diameter in two directions.
- Record the smallest measurement for each crankshaft main bearing journal.
Torque :
Stage 1: 89 lb.in (10 Nm)

Stage 2: 18 lb.ft (25 Nm)

Stage 3: 22 lb.ft (30 Nm)

Stage 4: 15°
Measure each crankshaft block main bearing bore diameter.
Using the chart, select the crankshaft main bearings.
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°
- Measure the diameter in two directions.
- Record the smallest measurement for each connecting rod.
- Measure the diameter in two directions.
- Record the smallest measurement for each connecting rod journal.
Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
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 (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
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 (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Torque :

Stage 1: 89 lb.in (10 Nm)

Stage 2: 18 lb.ft (25 Nm)

Stage 3: 22 lb.ft (30 Nm)

Stage 4: 15°
- 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.
- 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.
NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly.

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
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.
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 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
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°
Torque : 17 lb.ft (23 Nm)
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)
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.
Install Special Service Tool: 303-1604 Timing Peg, Crankshaft TDC.
NOTE: Only rotate the crankshaft clockwise.

Rotate the crankshaft slowly until the crankshaft stops.
Torque : 18 lb.ft (25 Nm)
NOTE: Make sure that the component is installed to the position noted before removal.

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
multimedia:A supplement to the article is available.
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°
NOTE: Install the components in their original position.

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
- Install the camshafts approximately at valve overlap position cylinder No. 1.
  Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
- 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.
- Tighten each bolt 2 turns at a time.
  Torque : 89 lb.in (10 Nm)
- Rotate the camshafts and measure the valve clearances.
  Use the General Equipment: Feeler Gauge
- Note down each cylinder number and the valve clearances measured.
- Compare the measured valve clearances with the specifications.
  Refer to: SPECIFICATIONS .
NOTE: Note the position of the components before removal.
- 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).
- 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
Install the correct valve tappet.
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 : Gasket Maker/TA-16 (WSK-M2G348-A5)
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 : Gasket Maker/TA-16 (WSK-M2G348-A5)
- Install the camshafts approximately at valve overlap position cylinder No. 1.
  Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
- 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.
- Tighten each bolt 2 turns at a time.
  Torque : 89 lb.in (10 Nm)
- 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)
Install Special Service Tool: 303-1606 Locking Tool, Variable Camshaft Timing.
NOTE: Only tighten the bolts finger tight at this stage.
Remove Special Service Tool: 303-1606 Locking Tool, Variable Camshaft Timing.
NOTE: Make sure that the component is installed to the position noted before removal.

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

Torque : 80 lb.in (9 Nm)
Torque : 89 lb.in (10 Nm)
WARNING: Take extra care when handling the compressed spring.

Remove Special Service Tool: 303-1054 Locking Tool, Timing Belt Tensioner.
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/ZC-31-B
NOTE: The component must be installed within 10 minutes of applying the sealant.

Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
NOTE: The component must be installed within 10 minutes of applying the sealant.

Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
- NOTE: Make sure that new components are installed.
  
  Torque :
  
  1-2, M6x60: 44 lb.in (5 Nm)
- NOTE: Make sure that new components are installed.
  
  Torque :
  
  3-6, M10x95: 89 lb.in (10 Nm)
- NOTE: Make sure that new components are installed.
  
  Torque :
  
  7-16 M6x60: 44 lb.in (5 Nm)
- Torque :
  3-6: 30 lb.ft (40 Nm)
- Torque :
  3-4:
  
  Stage 1: 52 lb.ft (70 Nm)
  
  Stage 2: 90°
- Torque :
  5-6:
  
  Stage 1: 52 lb.ft (70 Nm)
  
  Stage 2: 90°
- 1-2
  Torque :
  
  Stage 1: 80 lb.in (9 Nm)
  
  Stage 2: 90°
- 7-16
  Torque :
  
  Stage 1: 133 lb.in (15 Nm)
  
  Stage 2: 90°
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/ZC-31-B
NOTE: The component must be installed within 5 minutes of applying the sealant.

Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
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)
Torque : 89 lb.in (10 Nm)
Torque : 89 lb.in (10 Nm)
Install Special Service Tool: 303-1606 Locking Tool, Variable Camshaft Timing.
Torque : 89 lb.in (10 Nm)
- 1. Turn until resistance is felt.
- 2. Torque : 133 lb.in (15 Nm)
Torque : 22 lb.ft (30 Nm)
Remove Special Service Tool: 303-1605 Alignment Tool, Camshaft.
Torque :
Stage 1: 37 lb.ft (50 Nm)

Stage 2: 70°
NOTE: Only rotate the crankshaft clockwise.

Rotate the crankshaft slowly until the crankshaft stops.
- 1.
  NOTE: Make sure that a new component is installed.
- 2. Install 3/16 inch punch.
  Use the General Equipment: Punch
  
  Torque :
  
  Stage 1: 18 lb.ft (25 Nm)
  
  Stage 2: 52 lb.ft (70 Nm)
Remove 3/16 inch punch.
Use the General Equipment: Punch
- 1. M8x30
- 2. M8x25
  Install Special Service Tool: 303-1611-02 Adapter for 303-1611, Torque Multiplier .
  
  Torque : 18 lb.ft (24 Nm)
Install Special Service Tool: 303-1611-01 Adapter for 303-1611.
Torque : 18 lb.ft (24 Nm)
- Only tighten the nut finger tight at this stage.
  Install Special Service Tool: 303-1611 Torque Multiplier.
multimedia:A supplement to the article is available.
- 1. Torque : 44 lb.ft (60 Nm)
- 2. Torque :
  Stage 1: 90°
  
  Stage 2: 90°
  
  Stage 3: 90°
  
  Stage 4: 90°
  
  Stage 5: 90°
Remove Special Service Tool: 303-1611 Torque Multiplier.
- Install 3/16 inch punch.
  Use the General Equipment: Punch
- Remove 3/16 inch punch.
  Use the General Equipment: Punch
Remove Special Service Tool: 303-1604 Timing Peg, Crankshaft TDC.
Remove Special Service Tool: 303-1606 Locking Tool, Variable Camshaft Timing.
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).
Install Special Service Tool: 303-1604 Timing Peg, Crankshaft TDC.
NOTE: Only rotate the crankshaft clockwise.

Rotate the crankshaft slowly until the crankshaft stops.
- NOTE: The punch can only be installed if the valve timing is correct.
  
  Install 3/16 inch punch.
  
  Use the General Equipment: Punch
- Remove 3/16 inch punch.
  Use the General Equipment: Punch
Remove Special Service Tool: 303-1604 Timing Peg, Crankshaft TDC.
Torque : 177 lb.in (20 Nm)
Remove Special Service Tool: 303-1611-01 Adapter for 303-1611.
Remove Special Service Tool: 303-1611-02 Adapter for 303-1611, Torque Multiplier .
NOTE: Make sure that the component is clean, free of foreign material and lubricant.
- 1. Material : Silicone Gasket and Sealant/TA-30 (WSE-M4G323-A4)
- 2. Material : Gasket Maker/TA-16 (WSK-M2G348-A5)
NOTE: Only tighten the bolts finger tight at this stage.
Torque : 89 lb.in (10 Nm)
Torque : 17 lb.ft (23 Nm)
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
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)
Torque : 142 lb.in (16 Nm)
Torque : 41 lb.ft (55 Nm)
NOTE: Only tighten the bolts finger tight at this stage.
Torque :
1-10: 89 lb.in (10 Nm)
NOTE: Make sure that the component is clean, free of foreign material and lubricant.

NOTE: Make sure that new components are installed.
NOTE: Take extra care when handling the components.

NOTE: Make sure that the area around the component is clean and free of foreign material.
- 1. Use Special Service Tool: 310-128 Installer Set, Teflon Seal.
- 2.
  NOTE: Make sure that a new component is installed.
- 3. Use Special Service Tool: 310-128 Installer Set, Teflon Seal.
- 4. Use Special Service Tool: 310-128 Installer Set, Teflon Seal.
NOTE: Make sure that new components are installed.
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)
Torque : 89 lb.in (10 Nm)
- 1.
  NOTE: Make sure that a new component is installed.
  
  Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
Tighten each bolt 0.5 turn at a time.
Torque :

Stage 1: 44 lb.in (5 Nm)

Stage 2: 115 lb.in (13 Nm)
- 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°
NOTE: Install all the bolts finger tight before final tightening.

Torque : 89 lb.in (10 Nm)
Torque : 89 lb.in (10 Nm)
Torque : 80 lb.in (9 Nm)
Use the General Equipment: Hose Clamp Remover/Installer
Torque :
- 1. 89 lb.in (10 Nm)
- 2. 89 lb.in (10 Nm)
- 3. 89 lb.in (10 Nm)
Make sure that 4 new turbocharger mounting studs and that a new turbocharger gasket is installed.
Torque : 89 lb.in (10 Nm)
Make sure that a new heat shield and turbocharger gasket are installed.
Torque : 89 lb.in (10 Nm)
- NOTE: Make sure that a new component is installed.
NOTE: Install all the bolts finger tight before final tightening.

Torque :

2-3: 89 lb.in (10 Nm)
Make sure that a new turbocharger oil return hose gasket is installed.
- 1.
  NOTE: Make sure that a new component is installed.
- 2. Torque : 89 lb.in (10 Nm)
NOTE: Only tighten the nuts and bolts finger tight at this stage.

Use the General Equipment: Hose Clamp Remover/Installer
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)
Use the General Equipment: Hose Clamp Remover/Installer
Torque :
- 1. 89 lb.in (10 Nm)
- 2. 89 lb.in (10 Nm)
Torque : 18 lb.ft (24 Nm)
NOTE: Only tighten the bolt finger tight at this stage.
NOTE: Only tighten the nut and bolts finger tight at this stage.
- 1.
  NOTE: Make sure that a new component is installed.
- 2.
  NOTE: Make sure that new components are installed.
Torque : 18 lb.ft (25 Nm)
Torque :
1-2: 18 lb.ft (25 Nm)

3: 97 lb.in (11 Nm)
Torque : 97 lb.in (11 Nm)
NOTE: Use a commercially available socket.

Torque : 35 lb.ft (48 Nm)
NOTE: Use a commercially available socket.

Torque : 35 lb.ft (48 Nm)
Torque : 18 lb.ft (25 Nm)
Torque : 35 lb.ft (48 Nm)
Torque : 18 lb.ft (25 Nm)
Torque : 18 lb.ft (25 Nm)
WARNING: Take extra care when handling the compressed spring.

Use the General Equipment: 4 mm Drill Bit

Torque : 18 lb.ft (25 Nm)
WARNING: Take extra care when handling the compressed spring.

Use the General Equipment: 4 mm Drill Bit
NOTE: Only rotate the crankshaft clockwise.

NOTE: Make sure that the accessory drive belt is correctly located on each pulley.
Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away .