Cylinder Head Cover. Removal and Installation

Special Service Tools / General Equipment

	303-1097 Locking Tool, Variable Camshaft Timing Oil Control Valve TKIT-2010B-FLM TKIT-2010B-RYAD
	303-1556 Timing Belt Locking Tool TKIT-2010B-FLM TKIT-2010B-RYAD
	303-748 Crankshaft Locking Tool TKIT-2010B-FLM TKIT-2010B-RHD
Strap wrench
Oil Drain Equipment
Heat gun
Hose Clamp Removal/Installation Tool

Materials

Removal

1. 1
   Position the vehicle in NEUTRAL on the lift.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
2. 2
   Release the fuel system pressure.
   Refer to: Fuel System Pressure Release (310-00A Fuel System — General Information — 1.5 L EcoBoost (118 kW/160 L PS) — I4, General Procedures).
3. 3
   Disconnect the battery ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
4. 4
   Remove the following components:

   1. Remove the CAC inlet tube.
      Refer to: Charge Air Cooler (CAC) Inlet Tube (303-12A Air Distribution and Filtration — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
   2. Remove the EVAP canister purge valve.
      Refer to: Evaporative Emission Canister Purge Valve (303-13A Evaporative Emissions — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
5. 5
   Drain the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Air Bleeding (303-03A Engine Cooling — 1.5 L EcoBoost (118 kW/160 L hp) — I4, General Procedures).
6. 6
   Remove and discard the axle bearing lock nuts and the drive belt.

   

7. 7
   Remove the bolts and set the axle bearing bracket aside.

   

8. 8
   Remove the engine plug bolt.

   

9. 9
   Loosen the coolant pump pulley bolts.

   

10. 10
    Disconnect the crankshaft position sensor electrical connector and the wiring harness clips.

    

11. 11
    If equipped, remove the clips and heat shield.

    

12. 12
    • Disconnect the turbocharger hose and clips.
      Use the common service equipment: hose clamp removal/installation tool.

    • Disconnect the electrical connectors from the bracket.

    

13. 13
    Disconnect the CHT sensor electrical connector.

    

14. 14
    Remove the following components:

    1. Remove the high-pressure fuel pump drive block.
       Refer to: High-Pressure Fuel Pump Drive Block (303-04A Fuel Charging and Controls – 1.5 L EcoBoost (118 kW/160 L PS) – I4, Removal and Installation).
    2. Remove the brake vacuum pump.
       Refer to: Brake Vacuum Pump — 1.5 L EcoBoost (118 kW/160 L hp) — I4 (206-07 Power Brake Actuation, Removal and Installation).
15. 15
    Disconnect the PCM electrical connector.

    

16. 16
    Disconnect the wiring harness bracket, disconnect the electrical connector, and set the wiring harness aside.

    

17. 17
    Remove the wiring harness bolt. Disconnect the wiring harness clip and set the wiring harness aside.

    

18. 18
    Disconnect the IAT sensor electrical connector and the wiring harness clip.

    

19. 19
    1. Disconnect and set aside the coolant tube.

    2. Disconnect the KS electrical connector.

    3. Disconnect the KS electrical connector.

    

20. 20
    Disconnect the TB (throttle body) electrical connector and the wiring harness clip.

    

21. 21
    Disconnect the quick-connect couplings and move the coolant hoses aside.

    

22. 22
    Disconnect the wiring harness clips.

    

23. 23
    Disconnect the clip from the coolant tube bracket.

    

24. 24
    Remove the turbocharger coolant tube clips.

    

25. 25
    Remove the bolt and set aside the turbocharger cooling tube.

    

26. 26
    Remove and discard the turbocharger coolant tube O-rings.

    

27. 27
    Remove the bolts and the turbocharger heat shield.

    

28. 28
    Remove the TC oil supply tube bolt and disconnect the tube from the engine.

    

29. 29
    Remove and discard the TC oil supply tube assembly.

    

30. 30
    Remove and discard the TC nuts.

    

31. 31
    Remove and discard the TC mounting studs and gasket.

    

32. 32
    Disconnect the coolant hose and set aside.
    Use the common service equipment: hose clamp removal/installation tool.

    

33. 33
    1. Remove the nut.

    2. Remove the stud and position the coolant outlet.

    

34. 34
    Inspect the coolant outlet O-ring and replace it if damaged.

    

35. 35
    Remove the TB (throttle body).
    Refer to: Throttle Body (303-04A Fuel Delivery and Controls — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
36. 36
    Remove the bolts and the intake manifold bracket.

    

37. 37
    Disconnect and remove the engine breather hose.
    Use the common service equipment: hose clamp removal/installation tool.

    

38. 38
    Loosen the oil separator tube attaching bolt.

    

39. 39
    • Loosen the intake manifold attaching bolt.

    • Using a cable tie or rubber strap, secure the intake manifold bolt in the removed position.

    

40. 40
    Remove the following components:

    1. Remove the engine mount.
       Refer to: Engine Mount (303-01A — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
    2. Remove the auxiliary drive belt.
       Refer to: Auxiliary Drive Belt (303-05A Auxiliary Drive — 1.5 L EcoBoost (118 kW/160 L PS) — I4, Removal and Installation).
41. 41
    Remove the coolant pump bolts and pulley.

    

42. 42
    1. Remove the upper generator mounting stud and, if equipped, the bracket.

    2. Remove the alternator nut.

    

43. 43
    Remove the alternator stud.

    

44. 44
    Loosen the bolt and remove the generator.

    

45. 45
    Remove the engine mount stud.

    

46. 46
    Remove the nut, bolt and bracket.

    

47. 47
    1. Remove the timing belt cover stud.

    2. Disengage the cover from the retainer and open it.

    

48. 48
    Remove the engine front cover bolts.

    

49. 49
    Remove the engine front cover.

    

50. 50
    Install a new timing belt if the old belt is contaminated with coolant or oil. Refer to Timing Belt (303-01A Engine — 1.5 L EcoBoost (118 kW/160 L PS) — I4, Removal and Installation).

    

51. 51
    Remove the bolts and the engine mount bracket.

    

52. 52
    Slowly rotate the crankshaft to the 11 o'clock position.

    

53. 53
    
    Install the special service tool: 303-748 Crankshaft Locking Tool.

    

54. 54
    Slowly rotate the crankshaft clockwise until the crankshaft counterweight aligns with the crankshaft TDC timing pin. The engine is now at TDC.

    

55. 55
    • Install the special service tool: 303-1556 Locking Tool, Timing Belt.

    • Mark the component positions before removal.

    

56. 56

    NOTICE: Do not rotate the crankshaft or camshafts with the timing belt removed.

    1. Rotate the timing belt tensioner.

    2. Common equipment: locking pin
       Install the locking pin.

    3. Carefully remove the timing belt from the VCT units.

    

57. 57
    Remove the camshaft seals.
    Refer to: Camshaft Seal (303-01A Engine — 1.5 L EcoBoost (118 kW/160 L PS) — I4, Removal and Installation).
58. 58

    NOTICE: Use a heat gun to soften the flange sealant; this will assist in removing the camshaft cap. Failure to follow these instructions may damage the camshaft cap.

    NOTICE: Do not pry on the camshafts during removal as this may damage the camshafts.

    • Remove the 20 bolts.

    • Remove the camshaft covers.

    • Heat and remove the camshaft cap.
      Use common service equipment: heat gun.

    • Remove the camshafts.

    

59. 59
    Remove the crankcase ventilation drain tube.

    

60. 60
    Inspect the crankcase ventilation drain tube and replace it if damaged.

    

61. 61
    Remove and discard the O-ring.

    

62. 62
    Make sure the mating surfaces are clean and free of foreign material.

    

63. 63
    Make sure the mating surfaces are clean and free of foreign material.

    

64. 64
    Remove and discard the cylinder head bolts.

    

65. 65
    Position the camshafts in the neutral position in the cylinder head. Install the 4 camshaft caps and 8 original bolts. Tighten the camshaft bearing cap bolts one turn at a time until they seat against the cylinder head.

    

66. 66
    Remove the cylinder head.

    

67. 67
    Remove and discard the cylinder head gasket.

    

68. 68
    Inspect the cylinder head and cylinder block for 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).

Installation

1. 1
   Refer to the cylinder head.
   Refer to: Cylinder Head (303-01A Engine — 1.5 L EcoBoost (118 kW/160 L PS) — I4, Disassembly and Assembly of Components).
2. 2
   Clean and inspect the turbocharger mounting flange.

   

3. 3

   NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools leave scratches and gouges that create leak paths. Use a plastic scraper to remove all traces of the cylinder head gasket.

   Make sure the mating surfaces are clean and free of foreign material.
   Material: Motorcraft® Metal Surface Preparation Wipes / ZC-31-B

   

4. 4
   Install the cylinder head gasket.

   

5. 5
   Install the cylinder head.

   

6. 6

   NOTICE: Failure to follow the camshaft loosening procedure may damage the camshafts. Discard the camshaft bearing cap bolts.

   If necessary, loosen the camshaft bearing cap bolts 1 turn at a time until all tension is released from the camshaft bearing caps. Remove the bolts, camshaft caps and camshafts. Discard the camshaft bearing cap bolts.

   

7. 7
   Install the new cylinder head bolts and tighten them in the sequence shown.
   Torque:
   Stage 1: 44 lb-in (5 N·m)
   Stage 2: 133 lb-in (15 N·m)
   Stage 3: 26 lb-ft (35 N·m)
   Stage 4: 90°
   Stage 5: 90°

   

8. 8
   Install the new mega cover O-ring seal.

   

9. 9
   Install the crankcase ventilation drain tube.

   

10. 10
    Apply a 2 mm diameter bead of flange sealant.
    Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

    

11. 11

    NOTICE: Failure to follow the camshaft tightening procedure may damage the camshafts.

    NOTICE: Make sure the camshafts and camshaft bearing caps are installed in their original positions or engine damage may occur.

    • Evenly tighten the bolts, one-half turn at a time, until the camshaft bearing caps and VCT bridge seat against the cylinder head.
      Material: Engine Oil — SAE 5W-20 — Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)
      Torque:
      Stage 1: Tighten bolts 1 through 16 to: 62 lb-in (7 N·m)
      Stage 2: Tighten bolts 17 through 20 to: 89 lb-in (10 N·m)
      Stage 3: Tighten bolts 1 through 16 an additional: 45°
      Stage 4: Tighten bolts 17 and 18 an additional: 70°
      Stage 5: Tighten bolts 19 and 20 an additional: 53°

    

12. 12
    Install the camshaft seals.
    Refer to: Camshaft Seal (303-01A Engine – 1.5 L EcoBoost (118 kW/160 L PS) – I4, Removal and Installation).
13. 13
    Install the timing belt on the VCT units.

    

14. 14
    1. Make sure the timing belt is correctly aligned.

    2. Remove the retaining pin.

    

15. 15
    1. Before removal, make sure that the components are installed in the specified position.

    2. Remove the special service tool: 303-1556 Timing Belt Locking Tool.

    

16. 16
    
    Remove the special service tool: 303-748 Locking Tool, Crankshaft.

    

17. 17
    
    Remove the special service tool: 303-1097 Locking Tool, Variable Cam Timing Oil Control Valve.

    

18. 18
    Install the engine mount bracket and bolts.
    Torque: 41 lb-ft (55 N·m)

    

19. 19
    Install the engine front cover.

    

20. 20
    Install the front engine cover bolts.
    Torque: 89 lb-in (10 N·m)

    

21. 21
    Install the front engine cover side panel and stud.
    Torque: 89 lb-in (10 N·m)

    

22. 22
    Install the bracket, nut and bolt.
    Torque:
    Bolt: 17 lb-ft (23 N·m)
    Nut: 62 lb-in (7 N·m)

    

23. 23
    Install the engine mount stud, hand-tightening it.

    

24. 24
    Install the generator in position and install the stud.
    Torque: 89 lb-in (10 N·m)

    

25. 25
    1. Install the bracket, if equipped, and the generator upper stud.
       Torque: 35 lb-ft (47 N·m)

    2. Install the generator nut.
       Torque: 35 lb-ft (47 N·m)

    

26. 26
    Tighten the generator lower bolt.
    Torque: 35 lb-ft (47 N·m)

    

27. 27
    Install the coolant pump pulley and bolts.

    

28. 28
    Install the following components:

    1. Install the accessory drive belt.
       Refer to: Accessory Drive Belt (303-05A Accessory Drive — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
    2. Install the engine mount.
       Refer to: Engine Mount (303-01A Engine — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
29. 29
    Install the intake manifold bolt.
    Torque: 159 lb-in (18 N·m)

    

30. 30
    Install the crankcase ventilation oil separator inlet pipe and bolt.
    Torque: 35 lb-in (4 N·m)

    

31. 31
    Install and connect the engine breather hose.
    Use common equipment: hose clamp removal and installation tool.

    

32. 32
    Install the intake manifold bracket and bolts.
    Torque:
    Cylinder head bolt: 159 lb-in (18 N·m)
    Intake manifold bolt: 89 lb-in (10 N·m)

    

33. 33
    Install the TB (throttle body).
    Refer to: Throttle Body (303-04A Fuel Charging and Controls — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
34. 34
    Lubricate the coolant outlet port O-ring with clean coolant.
    Material: Motorcraft® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

    

35. 35
    • Reinstall the coolant outlet port and install the stud.
      Torque: 44 lb-in (5 N·m)

    • Install the nut.
      Torque: 159 lb-in (18 N·m)

    

36. 36
    Install and connect the coolant hose.
    Use common equipment: hose clamp removal and installation tool.

    

37. 37
    Install a new TC mounting gasket and studs.
    Torque: 89 lb-in (10 N·m)

    

38. 38
    Install the TC nuts.
    Torque:
    Step 1: 62 lb-in (7 N·m)
    Step 2: 124 lb-in (14 N·m)
    Step 3: 17 lb-ft (23 N·m)

    

39. 39
    Lubricate the new O-rings with clean engine oil.
    Material: Engine Oil — SAE 5W-20 — Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    

40. 40
    Install the new TC oil feed pipe assembly.
    Torque: 19 lb-ft (26 N·m)

    

41. 41

    NOTICE: When installing the oil feed pipe, the sleeve on the oil feed pipe must be fully seated into the cylinder head with both O-rings inserted before the fasteners are tightened.

    Position the oil feed pipe and install the bolt.
    Torque: 89 lb-in (10 N·m)

    

42. 42
    Install the turbocharger heat shield and bolts.
    Torque: 89 lb-in (10 N·m)

    

43. 43
    Install the new turbocharger coolant tube O-rings and lubricate them with clean engine coolant.
    Material: Motorcraft® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

    

44. 44
    Reinstall the TC coolant tubes and install the bolt.
    Torque: 89 lb-in (10 N·m)

    

45. 45
    1. Install the turbocharger coolant tube bolt.
       Torque: 17 lb-ft (23 N·m)

    2. Install the turbocharger coolant tube bolt.
       Torque: 97 lb-in (11 N·m)

    

46. 46
    Connect the clip to the coolant tube bracket.

    

47. 47
    Attach the wiring harness retainers.

    

48. 48
    Reinstall the coolant hoses and connect the quick-connect couplings.

    

49. 49
    Connect the TB (throttle body) electrical connector and the wiring harness clip.

    

50. 50
    1. Connect the KS electrical connector.

    2. Connect the KS electrical connector.

    3. Reinstall and connect the coolant hose.

    

51. 51
    Connect the IAT sensor electrical connector and the wiring harness clip.

    

52. 52
    Reinstall the wiring harness and attach the wiring harness clip. Install the wiring harness bolt.
    Torque: 89 lb-in (10 N·m)

    

53. 53
    Connect the electrical connector and attach the wiring harness clip.

    

54. 54
    Connect the PCM electrical connector.

    

55. 55
    Install the following components:

    1. Install the brake vacuum pump.
       Refer to: Brake Vacuum Pump — 1.5 L EcoBoost (118 kW/160 L hp) — I4 (206-07 Power-Assisted Brake Actuation, Removal and Installation).
    2. Install the high-pressure fuel pump drive block.
       Refer to: High-Pressure Fuel Pump Drive Block (303-04A Fuel Charging and Controls — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
56. 56
    Connect the CHT sensor electrical connector and install the cover.

    

57. 57
    • Connect the electrical connectors to the bracket.

    • Connect the turbocharger vacuum hose and clamps.
      Use common equipment: hose clamp removal and installation tool.

    

58. 58
    If equipped, install the heat shield and retainers.

    

59. 59
    Connect the crankshaft position sensor electrical connector and the wiring harness clips.

    

60. 60
    Tighten the coolant pump pulley bolts.
    Torque: 18 lb-ft (24 N·m)

    

61. 61
    Install the engine plug bolt.
    Torque: 177 lb-in (20 N·m)

    

62. 62
    Position the half shaft bearing bracket and install the bolts.
    Torque: 35 lb-ft (48 N·m)

    

63. 63
    1. Install the half shaft bearing bracket clamp and lock nuts.
       Torque: 44 lb-in (5 N·m)

    2. Tighten the nut.
       Torque: 18 lb-ft (25 N·m)

    3. Tighten the nut.
       Torque: 18 lb-ft (25 N·m)

    

64. 64
    Remove and discard the engine oil filter.
    Use common equipment: oil drain equipment.
    Use general equipment: strap wrench.

    

65. 65
    Remove the drain plug, drain the engine oil, and install the drain plug.
    Use common shop equipment: oil drain equipment
    Torque: 21 lb-ft (28 N·m)

    

66. 66
    Lubricate the O-ring seal and install a new engine oil filter.
    Material: Engine oil — SAE 5W-20 — synthetic engine oil / XO-5W20-Q1SP (WSS-M2C945-B1)
    Torque: 133 lb-in (15 N·m)

    

67. 67
    Install the underbody shield and clips.

    

68. 68
    1. Install the EVAP canister purge valve.
       Refer to: Fuel Vapor Management Valve (303-13A Evaporative Emission Control — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).

    2. Install the CAC inlet tube.
       Refer to: Charge Air Cooler (CAC) Inlet Tube (303-12A Intake Air Distribution and Filtering — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
69. 69
    Fill the engine with clean engine oil.
    Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    

70. 70
    Connect the battery ground cable.
    Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
71. 71
    Fill and bleed the cooling system.
    Refer to: Engine Cooling System Draining, Vacuum Filling and Air Bleeding (303-03A Engine Cooling — 1.5 L EcoBoost (118 kW/160 L hp) — I4, General Procedures).