303-01A Motor 2.5 Duratec (gasolina)

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-1 303-01A-1 . SECTION 303-01A Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 VEHICLE APPLICATION: 2011.50 Ranger CONTENTS SPECIFICATIONS Specifications...................................................................................................................... Engine oil........................................................................................................................ DESCRIPTION AND OPERATION Engine (Overview).............................................................................................................. General View...................................................................................................................... Variable camshaft timing (VCT).......................................................................................... Power and torque curve .................................................................................................... Valves and valve seats....................................................................................................... Lubrication System............................................................................................................. Engine (Component Location)............................................................................................ GENERAL PROCEDURES Valve Clearance Adjustment............................................................................................... Balance Shaft Backlash...................................................................................................... REMOVAL AND INSTALLATION Camshafts...................................................................................................... Crankshaft Front Seal..................................................................................... Crankshaft Pulley........................................................................................... Crankshaft Rear Seal..................................................................................... Cylinder Head................................................................................................. Engine Front Cover............................................................................................................. Exhaust Manifold............................................................................................ Intake Manifold............................................................................................... Timing Chain................................................................................................... Oil Pan............................................................................................................ Oil Pump......................................................................................................... Valve Cover.................................................................................................... Valve Stem Seals........................................................................................... REMOVAL Engine – Vehicles With: 5-Speed Manual Transmission - MT75.................. Engine Accessories........................................................................................ DISASSEMBLY Engine............................................................................................................ PAGE 303-01A-3 303-01A-3 303-01A-7 303-01A-7 303-01A-9 303-01A-10 303-01A-11 303-01A-11 303-01A-12 303-01A-15 303-01A-21 (21 284 0) 303-01A-27 (21 467 0) 303-01A-32 (21 572 0) 303-01A-33 (21 468 4) 303-01A-38 (21 163 0) 303-01A-40 303-01A-43 (21 187 0) 303-01A-46 (21 183 0) 303-01A-48 (21 314 0) 303-01A-51 (21 154 0) 303-01A-53 (21 714 0) 303-01A-56 (21 141 0) 303-01A-57 (21 238 0) 303-01A-60 (21 132 0; 21 132 6; 21 132 7) 303-01A-61 (21 139 4) 303-01A-68 (21 134 8) 303-01A-75

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-2 303-01A-2 . DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Cylinder Head................................................................................................. ASSEMBLY Engine............................................................................................................ INSTALLATION Engine – Vehicles With: 5-Speed Manual Transmission - MT75.................. Engine Accessories........................................................................................ (21 165 6) 303-01A-83 (21 134 8) 303-01A-85 (21 132 0; 21 132 6; 21 132 7) 303-01A-102 (21 139 4) 303-01A-109

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-3 303-01A-3 SPECIFICATIONS Engine data Description Engine code Firing order Emission level Displacement No. of cylinders Bore Stroke Cubic capacity Compression ratio Number of main bearings Camshaft drive Oil pressure (hot @ 2,000 rpm) Engine weight (without accessory drive components and flexplate or flywheel) Engine oil Viscosity / ambient temper- DWXUH Recommended engine oil SAE 5W-30 / below -20°C to over Castrol Engine Oil +40°C Alternative engine oils (for top- up only) SAE 10W-40 / -20°C to over Ford Formula XR+ +40°C SAE 5W-40 / below -20°C to over Ford Formula S +40°C Cylinder block Description Cylinder bore diameter Cylinder bore maximum out-of-round Main bearing bore diameter Head gasket surface flatness Piston Description Diameter (1) Diameter (2) Diameter (3) Specification GBVAF EV,GBVAL EV,GBVAK EV 1-3-4-2 Stage IV 2.5L 4 89 mm 100 mm 2488.5 cm¹ 9.7 : 1 5 Chain 200-268 kPa (29-39 psi) 203.8 kg Type Specification WSS M2C930-A / WSS M2C929- $ ACEA A3/B3 ACEA A3/B3 mm 89.0 - 89.03 mm 0.008 mm 57.018 - 57.040 mm 0.1 mm/general and 0.05 mm/200 x 200 mm 88.965 - 88.975 mm 88.975 - 88.985 mm 88.985 - 88.995 mm

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-4 303-01A-4 SPECIFICATIONS Description Piston-to-bore clearance Ring groove width - top Ring groove width - 2nd Ring groove width - oil Piston skirt coating thickness Piston pin Description Diameter Length Valve Description Valve head diameter - intake Valve head diameter - exhaust Valve stem diameter - intake Valve stem diameter - exhaust Valve stem-to-guide clearance - intake Valve stem-to-guide clearance - exhaust Valve face runout Valve face angle Valve spring - compression pressure Description Intake and exhaust (installed) Intake (valve open) 8.9 mm of lift Exhaust (valve open) 7.4 mm of lift Free length Assembled height Cylinder head Description Cylinder head flatness Valve lift @ zero lash (exhaust) Valve lift @ zero lash (intake) Valve guide diameter Valve seat width - intake/exhaust Valve seat angle mm 0.025 - 0.045 mm 1.203 - 1.205 mm 1.202 - 1.204 mm 2.501 - 2.503 mm 0.008 - 0.016 mm mm 19.995 - 20.0 mm 54.7 - 55.0 mm mm and degree 34.85 - 35.15 mm 29.85 - 30.15 mm 5.470 - 5.485 mm 5.465 - 5.480 mm 0.0027 mm 0.0029 mm 0.05 mm 45 degrees kg and mm 17.5 kg 44 kg 42 kg 44.92 mm 37.9 mm mm and degree 0.08 maximum overall, a maximum of 0.05 mm within 150 mm 7.7 mm 8.8 mm 5.509 - 5.539 mm 0.99 - 1.84 mm 45 degrees

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-5 303-01A-5 SPECIFICATIONS Description Valve seat runout Valve lash adjuster bore diameter Cam bore diameter Crankshaft Description Main bearing journal diameter Production repair Main bearing clearance Connecting rod journal diameter Production repair End play Rings Description Width - top Width - 2nd Width - oil Ring gap (in bore) - top Ring gap (in bore) - 2nd Ring gap (in bore) - oil Valve tappet Description Diameter Tappet-to-valve clearance -intake Tappet-to-valve clearance -exhaust Tappet-to-bore clearance Camshaft Description Intake camshaft lobe lift Exhaust camshaft lobe lift Runout (1)a Thrust clearance Journal diameter Journal-to-bore clearance a - No. 3 journal - supported by No. 1 and No. 5 journals. mm and degree 0.075 mm 31.00 - 31.03 mm 25.015 - 25.040 mm mm 51.978 - 52.002 mm 51.730 - 51.750 mm 0.016 - 0.047 mm 51.978 - 52.002 mm 51.730 - 51.750 mm 0.220 - 0.450 mm mm 1.17 - 1.185 mm 1.197 - 1.199 mm 2.38 - 2.45 mm 0.16 - 0.31 mm 0.31 - 0.46 mm 0.2 - 0.7 mm mm 30.97 - 30.98 mm 0.22 - 0.28 mm 0.27 - 0.33 mm 0.02 - 0.06 mm mm 8.24999 mm 7.80007 mm 0.03 mm 0.09 - 0.24 mm 24.96 - 24.98 mm 0.035 - 0.080 mm

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-6 303-01A-6 SPECIFICATIONS Connecting rod Description Bearing clearance Bearing thickness Crank bore diameter Pin bore diameter Length (center-to-center) Side clearance Axial clearance mm 0.027 - 0.052 mm 1.496 - 1.520 mm 55.023 - 55.047 mm 20.965 - 20.985 mm 151.8 mm 1.95 - 3.05 mm 0.14 - 0.36 mm

303-01A-7 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-7 DESCRIPTION AND OPERATION Engine œ Overview General View E131455

303-01A-8 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-8 DESCRIPTION AND OPERATION 1 2 3 4 E131999 X X X XXXXX X X XXXX E131457 Item Description 1 Valve cover 2 Cylinder head 3 Cylinder block 4 Oil pan

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A- 303-01A- DESCRIPTION AND OPERATION Item Description 1 Engine code Variable camshaft timing (VCT) 774 63 32 331 E83423 Item Description 1 Control unit - variable camshaft timing 2 Camshaft bearing cap 3 VCT oil control solenoid This system is an electronically controlled camshaft adjuster that allows variable timing for the inlet camshaft. The valves are driven by a timing chain which drives the inlet camshaft timing control unit. This unit drives the associated camshafts. The timing chain is tensioned using a conventional timing chain tensioner. The inlet camshaft is fitted with a sensor ring for the active camshaft position (CMP) sensor. This CMP sensor is mounted inside the valve cover. Timing chain replacement does not require the variable camshaft timing control unit to be disconnected. Item Description 2 Engine serial number 5 6 Item Description 4 Valve cover 5 Camshaft Position Sensor 6 Camshaft sensor ring To ensure trouble-free operation of the variable camshaft timing system and optimum engine performance, it is essential to adhere precisely to the valve timing adjustment procedure. A special tool is needed to fix the camshafts in the adjustment position. Remember that this special tool must not be used to keep the camshaft from rotating when mounting the camshaft sprocket. They may only be kept from rotating by using the hexagon, which has been specially provided for this purpose. Advantages of variable camshaft timing (VCT). ‡ Lower fuel consumption due to improved volumetric efficiency

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-10 303-01A-10 DESCRIPTION AND OPERATION ‡ Enhanced engine power and torque 1 E83476 Item Description 1 Bolts - Balancer shafts 2 Balancer shaft unit Power and torque curve 220 210 200 190 180 170 A 160 150 140 130 120 110 100 1000 1500 2000 2500 3000 B 3500 E68432 ‡ Improved idling characteristics 2 1 120 100 80 C 60 40 20 0 4000 4500 5000 5500 6000 6500

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-11 303-01A-11 DESCRIPTION AND OPERATION Item Description $ Torque (Nm) % Engine speed (rpm) Service note: The valve clearance of the engine only needs to be monitored if the engine is converted to operation using alternative fuel (every 60,000 km). Conversion of the engine to operation with alternative fuel requires no modification to the engine as the valve seats are reinforced as standard. All that is required is an adaptation of the fuel system. Valves and valve seats The engines for petrol operation and gas operation are basically identical. Because gas is a dry fuel and combusts at a higher temperature, the valve train is under higher stress. The adaptations described below are therefore necessary. Because of the higher stress involved in gas operation: ‡ The inlet and exhaust valves are made of a harder material. ‡ The inlet and exhaust valve seats and the valve stems are made of a harder material. ‡ The valve clearances must be checked more frequently and corrected if necessary. Lubrication System The engine lubrication system operates as follows: ‡ Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan. ‡ Oil is pumped through the oil filter on the right front side of the cylinder block. ‡ Oil enters the main gallery where it is distributed to the crankshaft main journals and to the cylinder head. ‡ From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls Item Description & Power output (kW) as well as the entire connecting rod, piston and piston ring assembly.

303-01A-12 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-12 DESCRIPTION AND OPERATION Engine œ Component Location E131455

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-13 303-01A-13 DESCRIPTION AND OPERATION 4 3 2 1 11 10 8 E131456 Item Description 1 Engine front cover 2 Coolant pump 3 Thermostat 4 Intake manifold 5 Oil level indicator 6 Crankcase ventilation oil separator 7 Oil filter and cooler 8 Oil pan Coolant pump pulley 13 14 12 5 15 6 18 17 7 16 Item Description 10 Cranksahft pulley 11 Accessory drive belt idler pulley 12 Fuel rail 13 Ignition coils 14 Oil filler cap 15 Valve cover 16 Exhaust manifold 17 Flywheel 18 Water outlet connector

303-01A-14 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-14 DESCRIPTION AND OPERATION X X X XXXX X X XXXX E131457 Item Description 1 Engine code 2 Engine serial number

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-15 303-01A-15 GENERAL PROCEDURES Valve Clearance Adjustment Special Tool(s) / General Equipment 303-465 Tool, Camshaft Align Timing E134673 303-507 Timing Peg, Crankshaft TDC PZ21210 2 mm Punch Materials Name Specification Hypoid Oil 85W-90 SQ-M2C9002-AA / A72SX-19K261-CA Thread Locking MS WSK-M2G349-A7 / 2U7J-M2G349-AA 1. Refer to: Accessory Drive Belt (303-05 Accessory Drive - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 2. Refer to: Valve Cover (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 3. CAUTION: Only rotate the crankshaft clockwise. NOTE: Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. NOTE: If the valve clearance is less than 0.2mm, adjust the valves to the maximum clearance. Rotate the crankshaft until the cam pair of the cylinder to be adjusted are pointing upwards. Using a suitable feeler gauge, measure the valve clearance. E70936 4. Make a note of each cylinder number with the corresponding valve clearance. 5. Compare the measured valve clearance(s) with the specifications. Refer to: Specifications (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Specifications). 6. NOTE: Only carry out the following steps when the valve clearance(s) require adjustment. 7. WARNING: Only rotate the crankshaft clockwise. Turn the crankshaft until no. 1 piston is at about 45° before TDC. E131739 8. CAUTION: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed, rotate the crankshaft one complete

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-16 303-01A-16 GENERAL PROCEDURES revolution clockwise to correctly position the camshafts. Special Tool(s): 303-465 303-465 E134694 9. E131754 10.Special Tool(s): 303-507 303-507 E131755 11. NOTE: Only tighten the bolt finger tight at this stage. ‡ Bolt M6 x 18 mm E131758 12. E131840 13.Reposition the camshaft alignment plate to the slot on the rear of the intake camshaft only. Special Tool(s): 303-465 303-465 E134714 14. CAUTION: Releasing the ratcheting mechanism in the timing chain tensioner allows the plunger to collapse and create slack in the timing chain. Installing an M6 x 30 mm bolt into the upper front cover timing hole will hold the tensioner arm in a retracted position

303-01A-17 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-17 GENERAL PROCEDURES and allow enough slack in the timing chain for removal of the exhaust camshaft gear. 1. NOTE: General Equipment: 2 mm Punch 3. Bolt M6 x 25 mm 2 3 1 E80480 15. CAUTION: Counterhold the camshaft at the hexagon with a wrench to prevent the camshaft from rotating. E80478 16.Remove the Special Tool(s): 303-465 303-465 E134714 17.Remove the timing chain from the intake camshaft drive gear. E134715 18.Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference. A0044352 19. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.

303-01A-18 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-18 GENERAL PROCEDURES NOTE: Mark the location and orientation of each camshaft bearing cap. 7 6 4 3 5 1 2 12 11 10 8 E134716 20. ‡ Remove the valve tappet and read the thickness from the underside. 21.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: The nominal clearance is: intake: 0.25 mm (0.0095 in). exhaust: 0.30 mm (0.0115 in). NOTE: The acceptable clearances after being fully installed are: intake: 0.22-0.28 mm (0.008-0.011 in). exhaust: 0.27-0.33 mm (0.010-0.013 in). ‡ Calculate the required thickness of the valve tappet with the following formula: X S + M - V ‡ Required thickness of tappet ; ‡ Thickness of currently fitted tappet 6 ‡ Measurement of existing valve clearance (actual value) 0 ‡ Desired valve clearance 9 22.Install the correct valve tappet. 23. CAUTION: Make sure that the camshafts and camshaft bearing caps are installed in their original locations. NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil. Coat the camshaft bearing caps with oil and install the camshafts approximately at valve overlap position cylinder No. 4. Material: Hypoid Oil 85W-90 (SQ-M2C9002-AA / A72SX-19K261-CA) transmission fluid Torque: ‡ Stage 1: 7 Nm ‡ Stage 2: 16 Nm 6 8 7 10 12 11 4 1 2 3 5 E134721 24.Special Tool(s): 303-465 303-465 E134694 25.Install the timing chain on the intake camshaft drive gear. E134715 26.NOTE: Only tighten the bolt finger tight at this stage.

303-01A-19 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-19 GENERAL PROCEDURES NOTE: Make sure that the camshaft sprockets can rotate on the camshafts. NOTE: The timing chain must be correctly engaged on the teeth of the crankshaft timing sprocket and the intake camshaft drive gear in order to install the exhaust camshaft drive gear onto the exhaust camshaft. E80478 27.NOTE: Releasing the tensioner arm will remove the slack from the timing chain. Remove the bolt M6 x 30mm. E131842 28. CAUTION: Counterhold the camshaft at the hexagon with a wrench to prevent the camshaft from rotating. Torque: 72 Nm E80478 29.Remove the Special Tool(s): 303-465 303-465 E134694 30.Remove the bolt M6 x 18 mm. E131758 31.Remove the Special Tool(s): 303-507 303-507 E131755

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-20 303-01A-20 GENERAL PROCEDURES 32. ‡ Material: Thread Locking MS (WSK-M2G349-A7 / 2U7J-M2G349-AA) adhesive 1. Torque: 10 Nm 2. Torque: 12 Nm 1 2 E131841 33.Torque: 20 Nm E131754 34. CAUTION: Only rotate the crankshaft clockwise. Check that the valve clearance on all cylinders meets the specified tolerances. 35.If necessary, repeat the steps until the valve clearance on each cylinder meets the specified tolerance. 36.Refer to: Valve Cover (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 37.Refer to: Accessory Drive Belt (303-05 Accessory Drive - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation).

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-21 303-01A-21 GENERAL PROCEDURES Balance Shaft Backlash Special Tool(s) 100-002 Holding Fixture with Dial Indicator Gauge E139373 303-507 Timing Peg, Crankshaft TDC PZ21210 Adjustment 38.Remove the timing peg bolt. E131754 39.Install the crankshaft TDC timing peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the crankshaft TDC timing peg. The engine is now at TDC. Special Tool(s): 303-507 303-507 E131755 40.Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC. E134651 41.NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled. Remove the 4 bolts and the balancer unit. x4 E134652 42.Remove the adjustment shims from the seat faces of the balancer unit.

303-01A-22 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-22 GENERAL PROCEDURES 43.NOTE: Visually inspect the balancer unit gear for damage and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit. Install the master adjustment shims (No. 50) on the seat faces of the balancer unit. 44.With the balancer unit shaft marks at the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear. E134651 45.Install the balancer unit bolts. Torque: ‡ Stage 1: 25 Nm ‡ Stage 2: 50 Nm 3 1 2 4 E134653 46.Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear. Remove the Special Tool(s): 303-507 303-507 E131755 47.Install the crankshaft TDC timing peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the crankshaft TDC timing peg. Remove the Special Tool(s): 303-507 303-507 E131755 48.NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements. NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing. NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-23 303-01A-23 GENERAL PROCEDURES the thrust direction with the screwdriver, using a prying action as shown. ‡ Position the dial indicator gauge with holding fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit. Special Tool(s): 100-002 ‡ Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. 100-002 1 2 E134654 49.NOTE: If maximum backlash exceeds 0.101 mm (0.003 in), install a new balancer unit. ‡ Remove the balancer unit from the cylinder block. ‡ Install the selected adjustment shims on the seat faces of the balancer unit.

303-01A-24 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-24 GENERAL PROCEDURES E134655 50.Install the crankshaft TDC timing peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-25 303-01A-25 GENERAL PROCEDURES crankshaft TDC timing peg. The engine is now at TDC. Special Tool(s): 303-507 303-507 E131755 51.With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear. E134651 52.Install the balancer unit bolts. Torque: ‡ Stage 1: 25 Nm ‡ Stage 2: 50 Nm 3 1 2 4 E134653 53.Remove the Special Tool(s): 303-507 303-507 E131755 54.Install the timing peg bolt. Torque: 20 Nm E131754 55.NOTE: Remeasure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements. NOTE: The measurement must be taken with the dial indicator gauge with holding fixture, a 5-mm allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and allen wrench are not touching the balance shaft housing. NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown. ‡ Position the dial indicator gauge with holding fixture (1) on the allen wrench 80 mm (3.149

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-26 303-01A-26 GENERAL PROCEDURES in) above the driven gear shaft center (2) on the balancer unit. Special Tool(s): 100-002 ‡ Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. ‡ If the backlash exceeds the specified range of 0.005 to 0.101 mm (0.00019 to 0.0039 in), install a new balancer unit and repeat the procedure. 1 100-002 2 E134654

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-27 303-01A-27 REMOVAL AND INSTALLATION Camshafts(21 284 0) Special Tool(s) / General Equipment 303-465 Tool, Camshaft Align Timing E134673 303-507 Timing Peg, Crankshaft TDC PZ21210 2 mm Punch Materials Name Specification Hypoid Oil 85W-90 SQ-M2C9002-AA / A72SX-19K261-CA Thread Locking MS WSK-M2G349-A7 / 2U7J-M2G349-AA Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Accessory Drive Belt (303-05 Accessory Drive - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 2. CAUTIONS: 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. Do not rotate the camshafts unless instructed to in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves and pistons. Refer to: Valve Cover (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 3. WARNING: Only rotate the crankshaft clockwise. Turn the crankshaft until no. 1 piston is at about 45° before TDC. E131739 4. CAUTION: The camshaft alignment plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: The camshaft timing slots are offset. If the camshaft alignment plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts. Special Tool(s): 303-465 303-465 E134694

303-01A-28 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-28 REMOVAL AND INSTALLATION 5. E131754 6. Special Tool(s): 303-507 303-507 E131755 7. NOTE: Only tighten the bolt finger tight at this stage. ‡ Bolt M6 x 18 mm E131758 8. E131840 9. Reposition the camshaft alignment plate to the slot on the rear of the intake camshaft only. Special Tool(s): 303-465 303-465 E134714 10. CAUTION: Releasing the ratcheting mechanism in the timing chain tensioner allows the plunger to collapse and create slack in the timing chain. Installing an M6 x 30 mm bolt into the upper front cover timing hole will hold the tensioner arm in a retracted position and allow enough slack in the timing

303-01A-29 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-29 REMOVAL AND INSTALLATION chain for removal of the exhaust camshaft gear. 1. General Equipment: 2 mm Punch 3. Bolt M6 x 25 mm 2 3 1 E80480 11. CAUTION: Counterhold the camshaft at the hexagon with a wrench to prevent the camshaft from rotating. E80478 12.Remove the Special Tool(s): 303-465 303-465 E134714 13.Remove the timing chain from the intake camshaft drive gear. E134715 14.Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference. A0044352 15. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-30 303-01A-30 REMOVAL AND INSTALLATION NOTE: Mark the location and orientation of each camshaft bearing cap. 7 6 4 3 5 x2 1 2 12 11 10 8 E134716 Installation 1. CAUTION: Make sure that the camshafts and camshaft bearing caps are installed in their original locations. NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil. Coat the camshaft bearing caps with oil and install the camshafts approximately at valve overlap position cylinder No. 4. Material: Hypoid Oil 85W-90 (SQ-M2C9002-AA / A72SX-19K261-CA) transmission fluid Torque: ‡ Stage 1: 7 Nm ‡ Stage 2: 16 Nm 6 7 10 8 x2 12 11 4 3 2 5 E134721 2. NOTE: This step is only necessary when installing a new component. Adjust the valve clearance. Refer to: Valve Clearance Adjustment (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures). 3. Install the timing chain on the intake camshaft drive gear. E134715 4. NOTE: Only tighten the bolt finger tight at this stage. NOTE: Make sure that the camshaft sprockets can rotate on the camshafts. NOTE: The timing chain must be correctly engaged on the teeth of the crankshaft timing sprocket and the intake camshaft drive gear in order to install the exhaust camshaft drive gear onto the exhaust camshaft. E80478 5. NOTE: Releasing the tensioner arm will remove the slack from the timing chain. Remove the bolt M6 x 30mm. E131842

303-01A-31 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-31 REMOVAL AND INSTALLATION 6. CAUTION: Counterhold the camshaft at the hexagon with a wrench to prevent the camshaft from rotating. Torque: 72 Nm E80478 7. Remove the Special Tool(s): 303-465 303-465 E134694 8. Remove the bolt M6 x 18 mm. E131758 9. Remove the Special Tool(s): 303-507 303-507 E131755 10. ‡ Material: Thread Locking MS (WSK-M2G349-A7 / 2U7J-M2G349-AA) adhesive 1. Torque: 10 Nm 2. Torque: 12 Nm 1 2 E131841 11. Torque: 20 Nm E131754 12.Refer to: Valve Cover (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 13.Refer to: Accessory Drive Belt (303-05 Accessory Drive - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation).

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-32 303-01A-32 REMOVAL AND INSTALLATION Crankshaft Front Seal(21 467 0) Special Tool(s) 303-318 Aligner/Installer, Crankshaft Front Seal 21148 303-409 Remover Crankshaft Seal E134603 Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Crankshaft Pulley (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 2. Special Tool(s): 303-409 303-409 E131775 Installation 1. Special Tool(s): 303-318 303-318 E131777 2. Remove the Special Tool(s): 303-318 303-318 E131776 3. To install, reverse the removal procedure.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-33 303-01A-33 REMOVAL AND INSTALLATION Crankshaft Pulley(21 572 0) Special Tool(s) 303-1416 Tool, Crank Damper Holding E134674 303-465 Tool, Camshaft Align Timing E134673 303-507 Timing Peg, Crankshaft TDC PZ21210 Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Accessory Drive Belt (303-05 Accessory Drive - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 2. 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. Refer to: Valve Cover (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 3. WARNING: Only rotate the crankshaft clockwise. Turn the crankshaft until no. 1 piston is at about 45° before TDC. E131739 4. Special Tool(s): 303-1416 303-1416 E131740 Installation 1. WARNING: Only rotate the camshaft clockwise. Turn the camshafts to cylinder no. 4 valve overlap position. E131740

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-34 303-01A-34 REMOVAL AND INSTALLATION 2. Special Tool(s): 303-465 303-465 E134694 3. E131754 4. Special Tool(s): 303-507 303-507 E131755 5. WARNING: Only rotate the crankshaft clockwise. Turn the crankshaft until it stops against the special tool. E131757 6. E131759 7. NOTE: Only tighten the bolt finger tight at this stage. ‡ Install the bolt M6 x 18 mm. E131756

303-01A-35 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-35 REMOVAL AND INSTALLATION 8. CAUTION: Make sure that a new bolt is installed. Special Tool(s): 303-1416 Torque: ‡ Stage 1: 100 Nm ‡ Stage 2: 90° 303-1416 E131740 9. Remove the bolt M6 x 18 mm. E131758 10.Remove the Special Tool(s): 303-465 303-465 E134694 11. Remove the Special Tool(s): 303-507 303-507 E131755 12. WARNING: Only rotate the crankshaft clockwise. Turn the crankshaft one and three quarters of a turn until no. 1 piston is at about 45° before TDC. E131739 13.Install the crankshaft TDC timing peg. Special Tool(s): 303-507 303-507 E131755 14. WARNING: Only rotate the crankshaft clockwise.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-36 303-01A-36 REMOVAL AND INSTALLATION Turn the crankshaft until it stops against the special tool. E131761 15.NOTE: Only tighten the bolt finger tight at this stage. NOTE: The bolt can only be installed if the valve timing is correct. ‡ Install the bolt M6 x 18 mm. E131758 16.NOTE: The special tool may only be installed if the valve timings are correct. Special Tool(s): 303-465 303-465 E134694 17.Remove the Special Tool(s): 303-465 303-465 E134694 18.Remove the Special Tool(s): 303-507 303-507 E131755 19.Remove the bolt M6 x 18 mm. E131758

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-37 303-01A-37 REMOVAL AND INSTALLATION 20.Torque: 20 Nm E131754 21.To install reverse the removal procedure.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-38 303-01A-38 REMOVAL AND INSTALLATION Crankshaft Rear Seal(21 468 4) Special Tool(s) 303-254 Locking Tool, Flywheel 21135 303-328 Replacer, Rear Oil Seal E134675 Materials Name Specification Silicone Sealant LB WSE-M4G323-A4 / 2U7J-M4G323-AA Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Clutch Disc and Pressure Plate (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission - MT75, Removal and Installation). 2. Discard the flywheel bolts. Special Tool(s): 303-254 Torque: ‡ Stage 1: 50 Nm ‡ Stage 2: 80 Nm ‡ Stage 3: 112 Nm 1 3 303-254 6 5 4 2 E131789 3. Refer to: Oil Pan (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 4. x6 E134695 Installation 1. CAUTION: Install the crankshaft rear seal carriers within five minutes of applying the sealer. NOTE: Do not damage the mating faces. NOTE: Mating surface should not have traces of oil to improve the adhesion. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant E131791

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-39 303-01A-39 REMOVAL AND INSTALLATION 2. Using the crankshaft rear main oil seal installer, position the crankshaft rear oil seal with retainer plate onto the crankshaft. Special Tool(s): 303-328 303-328 E139683 3. Special Tool(s): 303-328 Torque: 10 Nm 2 4 303-328 5 6 1 3 E134698 4. Remove the Special Tool(s): 303-328 303-328 E131790 5. To install, reverse the removal procedure.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-40 303-01A-40 REMOVAL AND INSTALLATION Cylinder Head(21 163 0) Materials Name Specification Hypoid Oil 85W-90 SQ-M2C9002-AA / A72SX-19K261-CA Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures). 2. Refer to: Timing Chain (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 3. E133545 4. E133767 5. Torque: 10 Nm x4 E131821 6. CAUTIONS: Over bending the exhaust flexible pipe may cause damage resulting in failure. Make sure that the catalytic converter is supported with suitable retaining straps. NOTE: The gasket is to be reused unless damaged. Torque: 48 Nm x7 E134786

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-41 303-01A-41 REMOVAL AND INSTALLATION 7. Torque: 48 Nm E134782 8. E134783 9. Torque: 23 Nm x2 2 1 E134784 10.Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference. A0044352 11. CAUTIONS: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. Note the position of each component before removal. NOTE: Mark the location and orientation of each camshaft bearing cap. 7 4 5 6 3 x2 2 1 12 11 10 8 E134716 12.Discard the cylinder head bolts. 3 7 10 6 2 4 8 9 5 1 E68059

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-42 303-01A-42 REMOVAL AND INSTALLATION Installation 1. Install new cylinder head bolts. Torque: ‡ Stage 1: 5 Nm ‡ Stage 2: 15 Nm ‡ Stage 3: 45 Nm ‡ Stage 4: 90° ‡ Stage 5: 90° 8 4 1 5 9 7 3 2 6 10 E68060 2. CAUTION: Make sure that the camshafts and camshaft bearing caps are installed in their original locations. Apply hypoid gear oil to the camshaft bearing caps. Install the camshafts approximately at valve overlap position cylinder No. 4. Material: Hypoid Oil 85W-90 (SQ-M2C9002-AA / A72SX-19K261-CA) transmission fluid Torque: ‡ Stage 1: 7 Nm ‡ Stage 2: 16 Nm 6 7 10 8 x2 12 11 4 3 1 2 5 E134721 3. To install reverse the removal procedure.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-43 303-01A-43 REMOVAL AND INSTALLATION Engine Front Cover Special Tool(s) 303-1417 Tool, Crank Sensor Alignment E134676 Removal NOTE: Removal steps in this procedure may contain installation details. 1. Loosen: 3 turn(s) x3 E129498 2. x2 E131781 Materials Name Specification Silicone Sealant LB WSE-M4G323-A4 / 2U7J-M4G323-AA 3. Refer to: Crankshaft Pulley (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 4. Torque: 20 Nm x3 E131780 5. 1. Torque: 25 Nm 2. Torque: 20 Nm 2 1 x3 E131782

303-01A-44 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-44 REMOVAL AND INSTALLATION 6. E131783 Installation 1. CAUTION: Install the engine front cover within five minutes of applying the sealer. NOTE: Do not damage the mating faces. NOTE: Mating surface should not have traces of oil to improve the adhesion. Apply sealant to the engine front cover (bead diameter: 3 mm). Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant 3MM 3mm 3mm E131784

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-45 303-01A-45 REMOVAL AND INSTALLATION 2. Torque: ‡ 1 - 8 10 Nm ‡ 9 48 Nm ‡ 10 - 19 10 Nm ‡ 20 - 22 48 Nm 18 19 12 20 22 8 11 21 4 7 1 5 3 2 13 6 10 14 17 16 15 E131787 3. To install, reverse the removal procedure. 4. Special Tool(s): 303-1417 303-1417 E135214 5. Torque: 7 Nm x2 E131781

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-46 303-01A-46 REMOVAL AND INSTALLATION Exhaust Manifold(21 187 0) Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 2. Torque: 10 Nm x4 E131821 3. CAUTION: Over bending the exhaust flexible pipe may cause damage resulting in failure. NOTE: Securely strap the exhaust flexible pipe to the frame. 1. Remove the exhaust pipe flange nuts. Torque: 48 Nm 2. Remove the exhaust pipe flange studs. Torque: 25 Nm 1 x2 x2 2 E131818 4. x7 E133758 5. 2 x7 1 E133759 Installation 1. Torque: 17 Nm 1 x7 2 E139024

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-47 303-01A-47 REMOVAL AND INSTALLATION 2. NOTE: Make sure that a new exhaust manifold gasket is installed. Torque: 55 Nm 4 1 6 3 7 5 2 E139020 3. To install, reverse the removal procedure.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-48 303-01A-48 REMOVAL AND INSTALLATION Intake Manifold(21 183 0) Removal NOTE: Removal steps in this procedure may contain installation details. 1. WARNINGS: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 2. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 3. Refer to: Throttle Body (303-04 Fuel Charging and Controls - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 4. Refer to: Fuel System Pressure Release (310-00 Fuel System - General Information - 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures). 5. Torque: 10 Nm E131662

303-01A-49 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-49 REMOVAL AND INSTALLATION 6. NOTE: Securely strap the fuel and breather tubes. Torque: 8 Nm E131663 7. E131664 8. E131665 9. Torque: 11 Nm 1 2 x2 E131666 10.NOTE: The gasket is to be reused unless damage. Torque: 19 Nm x5 E131667 Installation 1. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools can cause scratches and gouges which can make leak paths. Use a plastic scraping tool to remove all traces of the old intake manifold gaskets. 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. Clean the sealing surfaces and inspect the gaskets. Install new gaskets if necessary.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-50 303-01A-50 REMOVAL AND INSTALLATION 2. To install, reverse the removal procedure. 3. NOTE: Make sure that the pedals remain in the rest position. Turn the ignition key to position II and then wait one minute in order to initialise the throttle valve. 4. Turn the ignition key to the OFF position.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-51 303-01A-51 REMOVAL AND INSTALLATION Timing Chain(21 314 0) Special Tool(s) / General Equipment 100-010 Remover, O-Ring Seal 17063 303-465 Tool, Camshaft Align Timing E134673 2 mm Punch Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Engine Front Cover (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 2. 2. Special Tool(s): 100-010 3. General Equipment: 2 mm Punch 2 100-010 1 3 E66041 3. x2 E134744 4. Remove the timing chain tensioner arm. A0032596 5. x2 1 2 E134745 Installation 1. CAUTION: Only rotate the camshaft clockwise.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-52 303-01A-52 REMOVAL AND INSTALLATION Turn the camshafts to cylinder no. 4 valve overlap position. Special Tool(s): 303-465 303-465 E134694 2. Torque: 10 Nm 1 x2 2 E134748 3. A0032596 4. Torque: 10 Nm 1 x2 2 E134747 5. Refer to: Engine Front Cover (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation).

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-53 303-01A-53 REMOVAL AND INSTALLATION Oil Pan(21 154 0) Special Tool(s) 303-428 Separator, Oil Pan 21179 Materials Name Specification Silicone Sealant LB WSE-M4G323-A4 / 2U7J-M4G323-AA Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation). 2. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 3. Torque: 30 Nm 1 x4 2 E128859 4. Torque: 90 Nm x4 x4 E131668 5. WARNING: Be prepared to collect escaping fluids. NOTE: The seal is to be reused unless damaged. Drain the oil into a suitable container. Torque: 28 Nm E131609

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-54 303-01A-54 REMOVAL AND INSTALLATION 6. Torque: 10 Nm E131608 7. Refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation). 8. 1. Torque: 70 Nm 2. Torque: 40 Nm 2 x3 1 E133100 9. Torque: 48 Nm x3 E131612 10.Torque: 10 Nm x4 E131613 11. Special Tool(s): 303-428 1 303-428 x11 2 E131614 Installation 1. CAUTION: Install the oil pan within five minutes of applying the sealer. NOTE: Do not damage the mating faces. NOTE: Mating surface should not have traces of oil to improve the adhesion. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant 3mm E131617 2. CAUTION: Install the oil pan within five minutes of applying the sealer.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-55 303-01A-55 REMOVAL AND INSTALLATION NOTE: Do not damage the mating faces. NOTE: Mating surface should not have traces of oil to improve the adhesion. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant 3mm E131616 3. To install, reverse the removal procedure. 4. Install the oil pan. Torque: 25 Nm 7 12 3 2 6 11 13 4 8 10 1 5 E131625 5. Fill the oil pan with clean engine oil. Refer to: Specifications (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Specifications).

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-56 303-01A-56 REMOVAL AND INSTALLATION Oil Pump(21 714 0) Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Timing Chain (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 2. Refer to: Oil Pan (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 3. CAUTION: Make sure that a new friction washer is installed. 1. Torque: 10 Nm 2. Torque: 25 Nm 1 2 E134760 4. Remove the 2 bolts and the oil pump screen and pickup tube. Torque: 10 Nm 5. Torque: ‡ Stage 1: 10 Nm ‡ Stage 2: 20 Nm 2 4 3 1 E134761 Installation 1. To install, reverse removal procedure.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-57 303-01A-57 REMOVAL AND INSTALLATION Valve Cover(21 141 0) Materials Name Specification Silicone Sealant LB WSE-M4G323-A4 / 2U7J-M4G323-AA Removal NOTE: Removal steps in this procedure may contain installation details. 1. WARNINGS: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 2. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 3. Refer to: Fuel System Pressure Release (310-00 Fuel System - General Information - 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures). 4. Torque: 10 Nm E131932

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-58 303-01A-58 REMOVAL AND INSTALLATION 5. Torque: 10 Nm E131662 6. NOTE: Securely strap the fuel and breather tubes. Torque: 8 Nm E131663 7. E131664 8. E131665 9. Torque: 1 Nm 1 1 2 x2 E131666

303-01A-59 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-59 REMOVAL AND INSTALLATION 10.Torque: 19 Nm 2 1 x5 E131735 11. x4 x4 x3 E131736 12.Torque: 8 Nm x4 E131738 13. x11 x3 E131737 Installation 1. 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 prep. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant E80569 2. NOTE: The gasket is to be reused unless damaged. Torque: 10 Nm 11 6 3 7 12 10 2 13 1 14 5 4 8 E131760 3. To install, reverse the removal procedure.

303-01A-60 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-60 REMOVAL AND INSTALLATION Valve Stem Seals(21 238 0) Special Tool(s) 303-361B Compressor, Valve Spring E62757 303-361B-06 Adapter for 303-361B E62041 303-362 Installer, Valve Stem Collets 21156 303-508 Pliers, Valve Stem Seal 21211 Removal NOTE: Removal steps in this procedure may contain installation details. 1. Refer to: Camshafts (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 2. E66111 3. Special Tool(s): 303-361B, 303-361B-06, 303-362 303-361B-06 303-362 303-361B E134799 4. Special Tool(s): 303-508 303-508 E134800 Installation 1. To install, reverse the removal procedure.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-61 303-01A-61 REMOVAL Engine – Vehicles With: 5-Speed Manual Transmission - MT75(21 132 0; 21 132 6; 21 132 7) Removal Special Tool(s) / General Equipment 303-122 Lifting Bracket, Engine 21068A Hydraulic Jib Crane Transmission Jack 1. Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures). 2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 3. Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 4. Refer to: Starter Motor (303-06 Starting System - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 5. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 6. Refer to: Brake System Health and Safety Precautions (100-00 General Information, Description and Operation). 7. Refer to: Fuel System Pressure Release (310-00 Fuel System - General Information - 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures). 8. 1 x4 2 E128859

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-62 303-01A-62 REMOVAL 9. x9 E131903 10. x7 E131904 11. x4 E131940 12.Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation). 13. x2 E134162 14.On both sides. E128788 15.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-63 303-01A-63 REMOVAL x7 E133552 16. E131901 17. E131902 x2 x6 18. E131932 19.

303-01A-64 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-64 REMOVAL E127554 20. E129713 21. E131858 x3 22. 2 x2 1 3 3 E131856 23. WARNING: Be prepared to collect escaping fluids. CAUTION: Make sure that all openings are sealed. 1 2 x2 E131936

303-01A-65 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-65 REMOVAL 24. E131905 25. E131906 26. E131820 27. x4 E131821 28.CAUTIONS: Over bending the exhaust flexible pipe may cause damage resulting in failure. Make sure that the catalytic converter is supported with suitable retaining straps. 1 x2 x2 2 E131818

303-01A-66 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-66 REMOVAL 29. 3 1 2 E131792 30. E131969 31. WARNING: Make sure that transmission assembly is on wooden blocks and secured with suitable retaining straps. CAUTION: Do not tilt the transmission. This may cause damage to the pilot bearing. Tie and support the transmission to the chassie with a suitable strap. General Equipment: Transmission Jack E128845 32. x3 E131612 33. x2 E131611

303-01A-67 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-67 REMOVAL 34. x5 E131610 35. E131935 36. E131934 37. E131937 38.Special Tool(s): 303-122 General Equipment: Hydraulic Jib Crane 303-122 E131938 39. x2 E131939

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-68 303-01A-68 REMOVAL Engine Accessories(21 139 4) Removal Special Tool(s) / General Equipment 303-122 Lifting Bracket, Engine 21068A 303-254 Locking Tool, Flywheel 21135 303-435 Mounting Stand 21187 303-435-06 Mounting Bracket for 303-435 21031B 303-435-14B Mounting Plate for 303-435-06 E62805 303-676 Release Tool, Belt Tensioner 303676 Hydraulic Jib Crane All vehicles 1. Special Tool(s): 303-122 General Equipment: Hydraulic Jib Crane 303-122 E139003 2. Special Tool(s): 303-435, 303-435-06, 303-435-14B 303-435-14B 303-435-14B x3 x3 303-435-06 303-435-06 303-435 E67897

303-01A-69 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-69 REMOVAL 3. Special Tool(s): 303-254 303-254 E133584 4. CAUTION: Loosen the clutch pressure plate retaining bolts by two turns at a time in the sequence shown. 6 1 4 X2 3 2 5 E129960 5. Discard the flywheel bolts. Special Tool(s): 303-254 1 3 303-254 6 5 4 2 E131789 6. Loosen: 3 turn(s) x3 E129498 7. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt. Special Tool(s): 303-676 303-676 E131246

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-70 303-01A-70 REMOVAL 8. CAUTION: Take extra care not to damage the wiring harnesses. x3 3 1 2 E131274 9. E138979 10.NOTE: Make sure that the hoses are installed to the noted removal position. E138981 11. NOTE: Make sure that the hoses are installed to the noted removal position. x2 1 3 x2 2 x4 E138980 12. x2 E138988 13. E138982

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-71 303-01A-71 REMOVAL 14. E138983 15. E138984 16. x5 E138985 17.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-72 303-01A-72 REMOVAL x4 x4 x2 E138986 18. E138987 x3 x4 19. E130209 20. x4 E138989

303-01A-73 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-73 REMOVAL 21. x2 E131257 22. x7 E133758 23. 2 x7 1 E133759 24. 2 1 x3 E131782 25. x3 E129578 26. E138990

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-74 303-01A-74 REMOVAL 27. x8 x3 E131992 28. x3 E138991 4x2 29. x4 E139965 4x4 30. x4 E138992 All vehicles 31. x3 E138994

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-75 303-01A-75 DISASSEMBLY Engine(21 134 8) Disassembly Special Tool(s) / General Equipment 100-010 Remover, O-Ring Seal 17063 303-1416 Tool, Crank Damper Holding E134674 303-409 Remover Crankshaft Seal E134603 303-428 Separator, Oil Pan 21179 303-462 Installer, Connecting Rod E139375 303-465 Tool, Camshaft Align Timing E134673 Special Tool(s) / General Equipment 303-507 Timing Peg, Crankshaft TDC PZ21210 2 mm Punch 1. x11 x3 E131737 2. CAUTION: Only rotate the crankshaft clockwise. Rotate the crankshaft until piston No. 1 is approximately 45 degrees before top dead center (TDC). 45° E131991

303-01A-76 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-76 DISASSEMBLY 3. Special Tool(s): 303-465 303-465 E134694 4. E131754 5. Special Tool(s): 303-507 303-507 E131755 6. Special Tool(s): 303-1416 303-1416 E131740 7. Special Tool(s): 303-409 303-409 E131775 8. Discard the friction washer. E68086

303-01A-77 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-77 DISASSEMBLY 9. E66316 10.Special Tool(s): 100-010 General Equipment: 2 mm Punch 2 100-010 1 3 E66041 11. x2 E134744 12.Remove the RH timing chain guide. A0032596 13.Remove the timing chain. x2 1 2 E134745 14. CAUTION: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

303-01A-78 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-78 DISASSEMBLY Remove the bolt and the exhaust camshaft sprocket. E139152 15. CAUTION: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning. Remove the bolt and the camshaft phaser and sprocket. E139153 16. CAUTION: Make sure that a new friction washer is installed. 1 2 E134760 17.Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference. A0044352 18.Remove the bolt and the VCT solenoid. E139154 19.Remove the plug and the VCT system oil filter from the intake camshaft thrust cap. E139155 20. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-79 303-01A-79 DISASSEMBLY NOTE: Mark the location and orientation of each camshaft bearing cap. 5 3 1 2 4 10 8 6 7 9 E67279 21.NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. Remove and inspect the valve tappets. 22.Discard the cylinder head bolts. 3 7 10 6 2 4 8 9 5 1 E68059 23.Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. Refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures). Refer to: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures). 24.Remove the cylinder head alignment dowels. A0032441 25.Special Tool(s): 303-428 1 303-428 x11 2 E131998 26. 2 4 5 6 3 1 E65890

303-01A-80 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-80 DISASSEMBLY 27.Remove the bolts, oil pump pickup tube and discard the gasket. A0068893 28. 2 4 3 1 E134761 29.Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the crankshaft TDC timing peg. Special Tool(s): 303-507 303-507 E131755 30.Mark the balancer unit front shafts on the top for reference that the balancer unit is at TDC. E134651 31.NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled. Remove the 4 bolts and the balancer unit. x4 E134652 32.Remove the Special Tool(s): 303-507 303-507 E131755 33.Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions. 34.NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod

303-01A-81 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-81 DISASSEMBLY bearings in numerical order for correct orientation for reassembly. Remove the connecting rod cap bolts and cap. 1 2 3 4 E97422 35. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Using the connecting rod installer, remove the piston or rod assembly from the engine block. Special Tool(s): 303-462 303-462 E139158 36.NOTE: Note the position of each component before removal. E97390 37.Repeat the previous 2 steps until all the piston or rod assemblies are removed from the engine block. 38. ‡ Remove the main bearing beam. ‡ Discard the bolts. 8 4 2 6 10 7 3 1 5 E97420 39.Remove the crankshaft from the engine block. E97394 40.NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. Remove the main bearings from the main bearing beam. x5 E97393 41.NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-82 303-01A-82 DISASSEMBLY NOTE: The center bulkhead has the thrust bearing. Remove the main bearings from the cylinder block. x5 x5 E97395 42.NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly. NOTE: The front bulkhead does not have an oil squirter. Remove the 4 oil squirters. E139161 43.Inspect the cylinder block, main bearing beam, pistons and connecting rods. Refer to: Piston Inspection (303-00 Engine System - General Information, General Procedures). Refer to: Bearing Inspection (303-00 Engine System - General Information, General Procedures). Refer to: Connecting Rod Large End Bore (303-00 Engine System - General Information, General Procedures). Refer to: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures).

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-83 303-01A-83 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Cylinder Head(21 165 6) Special Tool(s) 303-361B Compressor, Valve Spring E62757 303-361B-06 Adapter for 303-361B E62041 303-362 Installer, Valve Stem Collets 21156 303-508 Pliers, Valve Stem Seal 21211 Disassembly NOTE: Disassembly steps in this procedure may contain assembly details. 1. Refer to: Cylinder Head (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 2. 1. Torque: 10 Nm 2. Torque: 48 Nm 1 x2 x4 2 E134785 3. 1. Torque: 25 Nm 2. Torque: 17 Nm 3. Torque: 45 Nm 3 3 1 x7 x2 2 E134789 4. E66111

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-84 303-01A-84 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES 5. Special Tool(s): 303-361B, 303-361B-06, 303-362 303-361B-06 303-362 303-361B E134799 6. Special Tool(s): 303-508 303-508 E134800 Assembly 7. To assemble, reverse the disassembly procedure.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-85 303-01A-85 ASSEMBLY Engine(21 134 8) Assembly Special Tool(s) 100-002 Holding Fixture with Dial Indicator Gauge E139373 303-1416 Tool, Crank Damper Holding E134674 303-318 Aligner/Installer, Crankshaft Front Seal 21148 303-328 Replacer, Rear Oil Seal E134675 303-462 Installer, Connecting Rod E139375 303-465 Tool, Camshaft Align Timing E134673 Special Tool(s) 303-507 Timing Peg, Crankshaft TDC PZ21210 303-D032 Compressor, Piston Ring E139376 Materials Name Specification Hypoid Oil 85W-90 SQ-M2C9002-AA / A72SX-19K261-CA Silicone Sealant LB WSE-M4G323-A4 / 2U7J-M4G323-AA 1. CAUTIONS: 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, using diamond washers between the flange faces on each part. 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 may occur. 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,

303-01A-86 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-86 ASSEMBLY coolant passages or the oil pan, can cause engine failure. NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. 2. 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. Install the 4 oil squirters. Torque: 4 Nm E139161 3. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal. 2 1 E139173 4. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block. E139174 5. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts. Torque: ‡ Stage 1: 5 Nm ‡ Stage 2: 25 Nm ‡ Stage 3: 90 ° 8 4 2 6 10 7 3 1 5 E97420 6. ‡ Measure each crankshaft block main bearing bore diameter. ‡ Remove the bolts and the main bearing beam. ‡ Discard the main bearing beam bolts. E139176

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-87 303-01A-87 ASSEMBLY 7. Using the chart, select the crankshaft main E139177 8. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur. Using the original connecting rod cap bolts, install the connecting caps and bolts. Torque: ‡ Stage 1: 29 Nm ‡ Stage 2: 90 ƒ 1 2 3 4 E97422 bearings. 9. ‡ Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod. ‡ Remove the bolts and the connecting rod cap. ‡ Discard the connecting rod cap bolts. 1 2 2 A0026938 10.Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.

303-01A-88 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-88 ASSEMBLY Record the smallest measurement for each connecting rod journal. 2 1 E139178 E139179 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. NOTE: Make sure that these components are installed to the noted removal position. 11. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-89 303-01A-89 ASSEMBLY Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block. x5 E97400 13.NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly. Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam. x5 E97402 14.Lubricate journals on the crankshaft with clean engine oil. 15.Position the crankshaft in the cylinder block. E97394 16.Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil. E139181 17.Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block. E139182 18. CAUTION: Make sure that new bolts are installed. 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

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-90 303-01A-90 ASSEMBLY the front of the cylinder block before tightening the main bearing beam bolts. Torque: ‡ Stage 1: 5 Nm ‡ Stage 2: 25 Nm ‡ Stage 3: Loosen: 90° 8 4 2 6 10 7 3 1 5 E97420 19. ‡ Using the dial indicator gauge with holding fixture, measure crankshaft end play. Special Tool(s): 100-002 ‡ Position the crankshaft to the rear of the cylinder block. ‡ Zero the dial indicator gauge with holding fixture. ‡ Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. ‡ Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary. 100-002 E139183 20. CAUTION: 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: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil. NOTE: Make sure the piston arrow on top is facing toward the front of the engine. ‡ Using the piston ring compressor and the connecting rod installer, install the piston and connecting rod assemblies. Special Tool(s): 303-D032, 303-462 ‡ When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap. ‡ The position of the upper and lower compression ring gaps are not controlled for installation. 303-462 303-D032 E139184 21. CAUTION: 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

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-91 303-01A-91 ASSEMBLY connecting rods for cylinders 2 and 3 and tighten. NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation. Install the connecting rod caps and the new bolts. Torque: ‡ Stage 1: 29 Nm ‡ Stage 2: 90 ° 1 2 3 4 E97422 22.Install the crankshaft TDC timing peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the crankshaft TDC timing peg. The engine is now at TDC. Special Tool(s): 303-507 303-507 E131755 23.NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled. NOTE: The original adjustment shims must be installed in their original positions. NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit. Install the adjustment shims in their original positions on the seat faces of the balancer unit. 24.With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear. E134651 25.Install the balancer unit bolts. Torque: ‡ Stage 1: 25 Nm ‡ Stage 2: 50 Nm 1 3 4 2 E134653 26.Remove the Special Tool(s): 303-507 303-507 E131755

303-01A-92 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-92 ASSEMBLY 27.Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear. 28. ‡ Install the crankshaft TDC timing peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the crankshaft TDC timing peg. Special Tool(s): 303-507 303-507 E131755 29.Remove the Special Tool(s): 303-507 303-507 E131755 30.NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements. NOTE: The measurement must be taken with the dial indicator gauge with holding fixture, a 5 mm allen wrench and worm clamp set up as shown. Mark the allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and allen wrench are not touching the balance shaft housing. NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown. ‡ Position the dial indicator gauge with holding fixture as shown. Measure the gear backlash. Special Tool(s): 100-002 ‡ Position the dial indicator gauge with holding fixture (1) on the allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit. ‡ Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. ‡ Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in). ‡ If the backlash exceeds the specified range, carry out the balance shaft backlash procedure. Refer to: Balance Shaft Backlash (303-01 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures). 1 E134654 31. CAUTION: Failure to position the No. 1 piston at TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-93 303-01A-93 ASSEMBLY Turn the crankshaft clockwise to position the No. 1 piston at TDC. 32.NOTE: The crankshaft TDC timing peg 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. Install the crankshaft TDC timing peg. Install the crankshaft TDC timing peg. Special Tool(s): 303-507 303-507 E131755 33.NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface prep. Torque: ‡ Stage 1: 10 Nm ‡ Stage 2: 20 Nm 2 4 3 1 E134761 34.Install a new oil pump pickup tube gasket and the pickup tube. Torque: 10 Nm A0068893 35. CAUTION: Install the crankshaft rear seal carriers within five minutes of applying the sealer. NOTE: Do not damage the mating faces. NOTE: Mating surface should not have traces of oil to improve the adhesion. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant 3mm E131791

303-01A-94 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-94 ASSEMBLY 36.NOTE: New crankshaft rear seal carriers are supplied with an alignment sleeve which must be removed after installation. Special Tool(s): 303-328 Torque: 10 Nm 2 4 303-328 5 6 1 3 E134698 37.Remove the Special Tool(s): 303-328 303-328 E131790 38. 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 to remove traces of sealant. Clean and inspect all mating surfaces. 39.Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block. N0039349 40. CAUTION: Install the oil pan within five minutes of applying the sealer. NOTE: Do not damage the mating faces. NOTE: Mating surface should not have traces of oil to improve the adhesion. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant 3mm E131617 41. CAUTION: Install the oil pan within five minutes of applying the sealer. NOTE: Do not damage the mating faces.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-95 303-01A-95 ASSEMBLY NOTE: Mating surface should not have traces of oil to improve the adhesion. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant 3mm E131616 42.Install the oil pan. Torque: 25 Nm 7 12 3 2 6 11 13 4 8 10 1 5 E131625 43. ‡ Install the cylinder head alignment dowels. ‡ Dowels must be fully seated in the cylinder block. A0032441 44. 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. NOTE: 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. ‡ Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence. 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. 45.Apply silicone gasket and sealant to the locations shown. A0032324

303-01A-96 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-96 ASSEMBLY 46.Install a new head gasket. A0087577 47. CAUTION: Make sure that new bolts are installed. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. NOTE: Lubricate the bolts with clean engine oil prior to installation. Torque: ‡ Stage 1: 5 Nm ‡ Stage 2: 15 Nm ‡ Stage 3: 45 Nm ‡ Stage 4: Loosen: 90° ‡ Stage 5: Loosen: 90° 8 4 1 5 9 7 3 2 6 10 E68060 48.NOTE: Coat the valve tappets with clean engine oil prior to installation. Install the valve tappets. 49. CAUTION: Make sure that the camshafts and camshaft bearing caps are installed in their original locations. NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil. Install the camshafts approximately at valve overlap position cylinder No. 4 and tighten the camshaft bearing cap bolts one at a time until finger-tight. Material: Hypoid Oil 85W-90 (SQ-M2C9002-AA / A72SX-19K261-CA) transmission fluid Torque: ‡ Stage 1: 7 Nm ‡ Stage 2: 16 Nm 5 3 1 2 4 10 8 6 7 9 E67279 50.Install the variable camshaft timing (VCT) system oil filter and the plug in the intake camshaft thrust cap. Torque: 17 Nm E139155 51.Install the VCT solenoid and the bolt. Torque: 10 Nm E139154

303-01A-97 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-97 ASSEMBLY 52.NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket. ‡ Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket. ‡ The crankshaft sprocket flange must be facing away from the engine block. A0083166 53. CAUTION: Make sure that a new friction washer is installed. 1. Torque: 10 Nm 2. Torque: 25 Nm 1 2 E134760 54.Special Tool(s): 303-465 303-465 E134694 55.NOTE: Hand tighten the bolts at this stage. Install the camshaft sprockets and the bolts. E139186 56.Install the timing chain guide and the bolts. Torque: 10 Nm A0032598 57.Install the timing chain. E139187 58.NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-98 303-01A-98 ASSEMBLY Install the timing chain guide. A0032596 59. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly. Using the edge of a vise, compress the timing chain tensioner plunger. A0032539 60.Using a small pick, push back and hold the ratchet mechanism. A0032540 61.While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. A0032541 62.Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation. A0032542 63.Install the timing chain tensioner and the bolts. Torque: 10 Nm 1 x2 2 E134747

303-01A- Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A- ASSEMBLY 64. CAUTION: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning. Torque: 72 Nm E139188 65. CAUTION: Install the engine front cover within five minutes of applying the sealer. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant 3mm 3mm E131784 66.Torque: ‡ 1 - 8 10 Nm ‡ 9 48 Nm ‡ 10 - 19 10 Nm ‡ 20 - 22 48 Nm 19 18 12 20 22 8 11 21 4 7 1 5 3 2 6 13 10 14 17 16 15 E131787 67. CAUTION: Make sure that a new friction washer is installed. E68086

303-01A-100 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-100 ASSEMBLY 68.Special Tool(s): 303-318 Torque: 50 Nm 303-318 E131777 69.Remove the Special Tool(s): 303-318 303-318 E131776 70.NOTE: Hand tighten the bolt at this stage. ‡ Bolt M6 x 18 mm E131756 71. CAUTION: Make sure that a new bolt is installed. Special Tool(s): 303-1416 Torque: ‡ Stage 1: 100 Nm ‡ Stage 2: 90° 303-1416 E131740 72.Remove the 6 mm x 18 mm bolt. E131758 73.Remove the Special Tool(s): 303-507 303-507 E131755

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-101 303-01A-101 ASSEMBLY 74.Install the engine plug bolt. Torque: 20 Nm E131754 75.Remove the Special Tool(s): 303-465 303-465 E134694 76.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 prep. Material: Silicone Sealant LB (WSE-M4G323-A4 / 2U7J-M4G323-AA) sealant E80569 77.NOTE: The gasket is to be reused unless damaged. Torque: 10 Nm 11 6 3 7 12 10 2 13 1 14 5 4 8 E131760

303-01A-102 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-102 INSTALLATION Engine – Vehicles With: 5-Speed Manual Transmission - MT75(21 132 0; 21 132 6; 21 132 7) Installation Special Tool(s) / General Equipment 303-122 Lifting Bracket, Engine 21068A Hydraulic Jib Crane 1. Special Tool(s): 303-122 General Equipment: Hydraulic Jib Crane 303-122 E131938 2. NOTE: Hand tighten the nut at this stage. E131937 3. NOTE: Hand tighten the bolts at this stage. x2 E134106 4. NOTE: Hand tighten the nut at this stage. E131934 5. Initially hand tighten the bolts. Torque: 48 Nm x5 E131610

303-01A-103 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-103 INSTALLATION 6. Initially hand tighten the bolts. Torque: 48 Nm x2 E131611 7. Initially hand tighten the bolts. Torque: 48 Nm x3 E131612 8. Torque: 80 Nm E131937 9. Torque: 48 Nm x2 E134106 10.Torque: 80 Nm E131934 11. Remove the Special Tool(s): 303-122 General Equipment: Hydraulic Jib Crane 303-122 E131938

303-01A-104 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-104 INSTALLATION 12.Torque: 30 Nm E131935 13. E131969 14. 1. Torque: 10 Nm 3. Torque: 10 Nm 3 1 2 E131792 15. CAUTION: Over bending the exhaust flexible pipe may cause damage resulting in failure. 1. Install the exhaust flexible pipe flange nuts. Torque: 48 Nm 2. Install the exhaust flexible pipe flange studs. Torque: 25 Nm 1 x2 x2 2 E131818 16.Torque: 10 Nm x4 E131821 17. E131820

303-01A-105 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-105 INSTALLATION 18.Torque: 11 Nm E131906 19. E131905 20.Torque: 35 Nm 1 2 x2 E131936 21.Torque: 20 Nm 2 x2 1 3 3 E131856 22.Torque: 23 Nm E131858 23. E129713 24.

303-01A-106 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-106 INSTALLATION E127554 25.Torque: 11 Nm E131932 26. E131902 x3 27.Torque: 10 Nm E131901 28.Torque: 14 Nm

303-01A-107 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-107 INSTALLATION x7 E133552 29.On both sides. E128788 30.Torque: 1 Nm 1 x2 E134162 x2 x6 31.Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation). 32.Torque: 30 Nm x4 E131940 33. x7 E131904

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-108 303-01A-108 INSTALLATION 34. x9 E131903 35.Torque: 30 Nm 1 x4 2 E128859 36.Refer to: Fuel System Pressure Release (310-00 Fuel System - General Information - 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures). 37.Refer to: Brake System Health and Safety Precautions (100-00 General Information, Description and Operation). 38.Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures). 39.Refer to: Starter Motor (303-06 Starting System - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation). 40.Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 41.Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 42.Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures).

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-109 303-01A-109 INSTALLATION Engine Accessories(21 139 4) Installation Special Tool(s) / General Equipment 303-122 Lifting Bracket, Engine 21068A 303-1417 Tool, Crank Sensor Alignment E134676 303-254 Locking Tool, Flywheel 21135 303-435 Mounting Stand 21187 303-435-06 Mounting Bracket for 303-435 21031B 303-435-14B Mounting Plate for 303-435-06 E62805 Special Tool(s) / General Equipment 303-676 Release Tool, Belt Tensioner 303676 308-204 Aligner, Clutch Disc 16067 Hydraulic Jib Crane All vehicles 1. Torque: 48 Nm x3 E138994 4x4 2. Torque: 25 Nm x4 E138992

303-01A-110 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-110 INSTALLATION 4x2 3. Torque: 25 Nm x4 E139965 All vehicles 4. Torque: 25 Nm x3 E138991 5. NOTE: The gasket is to be reused unless damaged. Torque: 10 Nm x8 x3 E131992 6. Torque: 23 Nm x3 E138990 7. NOTE: Make sure that the mating faces are clean and free of foreign material. Torque: 10 Nm x3 E129578 8. 1. Torque: 25 Nm 2. NOTE: Install all the bolts finger tight before final tightening. 2 1 x3 E131782

303-01A-111 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-111 INSTALLATION 9. Torque: 17 Nm 1 x7 2 E139024 10.NOTE: Make sure that a new exhaust manifold gasket is installed. Torque: 55 Nm 4 1 6 3 7 5 2 E139020 11. NOTE: The accessory drive belt tensioner must be replaced as a complete unit. Torque: 25 Nm x2 E131257 12.Torque: 8 Nm x4 E138989 13.Torque: 23 Nm E130209 14.Torque: 10 Nm E138987 15.

303-01A-112 Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-112 INSTALLATION x4 x4 x2 E138986 16.NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools can cause scratches and gouges which can make leak paths. Use a plastic scraping tool to remove all traces of the old intake manifold gaskets. 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: The gasket is to be reused unless damage. x3 x4 Clean the sealing surfaces and inspect the gaskets. Install new gaskets if necessary. Torque: 19 Nm x5 E138985

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-113 303-01A-113 INSTALLATION 17.Torque: 20 Nm E138984 18. E138983 19. E138982 20.Special Tool(s): 303-1417 303-1417 E135214 21.Torque: 7 Nm x2 E138988 22.NOTE: The gasket is to be reused unless damaged. 1. Torque: 25 Nm 2. Torque: 10 Nm 3. Torque: 48 Nm x2 1 3 x2 2 x4 E138980

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-114 303-01A-114 INSTALLATION 23. E138981 24. E138979 25. CAUTION: Take extra care not to damage the wiring harnesses. 1. Torque: 48 Nm 2. Torque: 48 Nm 3. Torque: 48 Nm 4. Torque: 15 Nm 2 3 1 4 E139966 26.Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt. Special Tool(s): 303-676 303-676 E131246 27.Torque: 20 Nm x3 E129498 28.Special Tool(s): 303-254 Torque: ‡ Stage 1: 50 Nm ‡ Stage 2: 80 Nm ‡ Stage 3: 1 12 Nm 1 3 303-254 6 5 4 2 E139023

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-115 303-01A-115 INSTALLATION 29.NOTE: The cone on the special tool must only be tightened finger tight to prevent damage to the clutch disc. Special Tool(s): 308-204 308-204 E129961 30.NOTE: Check the pilot bearing for damage. Replace it, if necessary. Refer to: Pilot Bearing - 2.5L Duratec-HE (122kW/165PS) - MI4 (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission - MT75, Removal and Installation). 31.NOTE: Only tighten the bolt finger tight at this stage. Special Tool(s): 308-204 308-204 E129962 32.Special Tool(s): 308-204 Torque: 30 Nm 6 1 4 308-204 3 2 5 E129963 33.Remove the Special Tool(s): 308-204 2 1 308-204 E129984

Engine – 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A-116 303-01A-116 INSTALLATION 34.Remove the Special Tool(s): 303-254 303-254 E133584 35.Special Tool(s): 303-122 General Equipment: Hydraulic Jib Crane 303-122 E139003 36.Remove the Special Tool(s): 303-435, 303-435-06, 303-435-14B 303-435-14B 303-435-14B x3 x3 303-435-06 303-435-06 303-435 E67897