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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L

EcoBoost (103kW/140PS) (YY) - Specifications
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ENGINE DATA

DESCRIPTION

Engine code Q0JA Q0JC SFJE SFJF SFJH SFJJ SFJK SFJN SFJP

Emission Stage Stage Stage Stage Stage Stage Stage Stage Stage
level 6 6.2 6 5 6 6 6 6.2 6.2

Firing order 1-2-3

Bore 71.9 mm

Stroke 81.9 mm

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Engine 998 cm³
capacity

Compression 10.5:1 10.0:1 10.5:1

ratio

Power output 63 kW (85 PS) / 74 kW (100 PS) / 4500 - 6500 rpm

4500 - 6500 rpm

Torque 170 Nm / 170 Nm / 1400 - 4000 rpm

1500 - 3500 rpm

Maximum 6450 rpm

permissible
engine speed
(continuous)

Maximum 6675 rpm

permissible
engine speed
(intermittent)

Idle speed 860 ± 100 rpm

Maximum oil 0.5 l / 1000 km

consumption

ENGINE DATA

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DESCRIPTION

Engine code M1JL M1JM M1JP YYJE YYJG

Emission level Stage 5 Stage 6 Stage 6.2 Stage 6 Stage 6.2

Firing order 1-2-3

Bore 71.9 mm

Stroke 81.9 mm

Engine capacity 998 cm³

Compression 10:1
ratio

Power output 92 kW (125 PS) / 6000 rpm 103 kW (140 PS) /

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6000 rpm

Torque 170 Nm / 1400 - 4500 rpm 180 Nm /

1500 - 5000 rpm

Maximum 6450 rpm

permissible
engine speed
(continuous)

Maximum 6675 rpm

permissible
engine speed
(intermittent)

Idle speed 860 ± 100 rpm

Maximum oil 0.5 l / 1000 km

consumption

ENGINE OIL

VISCOSITY SPECIFICATION

SAE 5W-20 Material: WSS-M2C948-B

(Engine Oil - SAE 5W-20)

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ENGINE OIL CAPACITY

DESCRIPTION UNIT

Initial fill including oil filter 5.05 L

Service fill including oil filter 4.6 L

Service fill without oil filter 4.4 L

VALVE CLEARANCES

DESCRIPTION UNIT

Valve clearance (engine cold), intake 0.21–0.3 mm

Valve clearance (engine cold), exhaust (CM5G FA, FB and FC 0.31–0.37 mm

camshaft)

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Valve clearance (engine cold), exhaust 0.38–0.47 mm

CYLINDER HEAD

DESCRIPTION UNIT

Maximum distortion (mating face) 0.05 mm

CRANKSHAFT DIMENSIONS

DESCRIPTION UNIT

Crankshaft end play 0.13–0.38 mm

LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES

ITEM SPECIFICATION

Primer front cover, oil pan Material: - (Primer)

Sealant, oil pan to cylinder block (front cover) Material: WSE-

M4G323-A6 (RTV
Sealant, oil pan to front cover Silicone Sealant)

Sealant, front cover to cylinder block

Sealant, valve cover to front cover

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ITEM SPECIFICATION

Sealant, valve cover to cylinder head Material: WSK-

M2G348-A5
(Sealant)

Silicone grease Material: ESE-

M1C171-A (Grease
- Silicone)

Torque Specifications

Description Nm lb.ft lb.in

Oil filter 15 11 133

Spark plug 13 10 115

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Engine oil pressure switch 20 15 177

Oil pressure control solenoid 10 7 89

Dipstick tube 7 5 62

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine -
Component Location
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Description and Operation

Front view

Item Description
1 Electric throttle plate
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2 Oil dipstick
3 Ignition coil-on-plugs
4 TC (turbocharger) Turbocharger
5 Coolant pump
6 VCT (variable camshaft timing) - Solenoid, exhaust camshaft
7 VCT - Solenoid, intake camshaft
Rear view

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Item Description
1 Vacuum pump
2 High-Pressure Fuel Rail
3 CMP (camshaft position) Sensor - exhaust camshaft
4 Fuel Pressure Sensor
5 CMP Sensor - intake camshaft
6 The MAP (manifold absolute pressure) sensor
7 EOP (engine oil pressure) switch
8 Recirculated air valve solenoid
9 Oil pressure control solenoid valve
10 High-pressure pump
11 Small/large coolant circuit thermostat
12 The ECT (engine coolant temperature) sensor
13 Boost pressure control solenoid valve
Engine serial number

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Item Description
1 Engine serial number

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Engine - 1.0L EcoBoost

(74kW/100PS)/1.0L EcoBoost
(90kW/120PS)/1.0L EcoBoost
(103kW/140PS) (YY) - Engine - Overview
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Description and Operation

General information

The following aims were at the forefront during development of the engine:
• Reduction of weight compared to 4-cylinder engines with comparable or even lower
power output
• Reduction of inner friction compared to the engines currently used through use of a
variable oil pump
• Optimization of energy efficiency through direct petrol injection and exhaust gas
turbocharging compared to the currently used 4-cylinder engines with intake manifold
injection

Following the introduction of the EcoBoost engines, the downsizing concept (reduction
in cubic capacity, number of cylinders, and size) has also been rigorously further
implemented with this engine.

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Main features:
• 3-cylinder double overhead camshaft engine with 12 valves
• Cast iron cylinder block, aluminum alloy cylinder head
• Variable camshaft timing on the intake and exhaust camshafts
• Engine oil lubricated timing belt for driving the camshafts
• Variable oil pump for delivery rate matched to meet demand
• Engine oil lubricated timing belt for driving the oil pump
• Turbocharger for increased power and reduced fuel consumption
• Additional thermostat on the short block for rapid warming up of the engine after a cold
start

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine - System
Operation and Component Description
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Description and Operation

System Operation
Variable Camshaft Timing
Electro-hydraulically controlled double variable camshaft timing is used on the intake and
exhaust camshafts in this engine.

Continuous adjustment of the valve timings allows the following to be achieved:

• Smoother idling
• Increase in power and torque
• Sufficient internal exhaust gas recirculation
• Performance optimization at wide open throttle

There is a VCT (variable camshaft timing) unit on each camshaft for making the
adjustment. The valve timings can thus be controlled by making engine speed and load
dependent adjustments of the intake and exhaust camshafts.

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Component Description
Cylinder Head

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Item Description
1 Camshaft bearing cap - intake camshaft with jacking point - high-pressure pump
2 Cover – vacuum pump
3 Drive – vacuum pump
4 Camshaft bearing cap - exhaust camshaft
Comments:
The camshaft bearing caps are identified by the numbers 1 - 4
5 Exhaust camshaft
6 VCT unit – exhaust camshaft
7 Exhaust camshaft VCT control valve
8 Intake camshaft VCT control valve
9 VCT unit – intake camshaft
10 Intake camshaft
11 Camshaft bearing cap – intake camshaft
Comments:
The camshaft bearing caps are identified by the letters A - D
12 Triple cam

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NOTICE: Make a note of the installed orientations and positions of the camshaft
bearing caps when removing them. When installing the camshafts, care must be taken
that the bearing caps are installed in the correct orientation and position and also that
they are tightened in a certain order and tightened to the specified torque. The
instructions in the current workshop literature must be observed for this.
The cylinder head is made of a light metal alloy.
The exhaust manifold is part of the cylinder head and therefore cannot be replaced
separately in service.
The intake camshaft is made longer by the additional triple cam for driving the high-
pressure pump. It is therefore impossible to confuse it with the exhaust camshaft. It is
mounted on five bearings. In addition, the intake camshaft bearing cap nearest the
transaxle forms the jacking point for the high-pressure pump used to create fuel at high
pressure. The seal to the cylinder head is achieved using sealing compound.
The exhaust camshaft is mounted on four bearings and has an additional groove by which
the vacuum pump is driven. The vacuum pump cover carries the seal for the valve cover
and the vacuum pump.
The VCT units are bolted on the corresponding camshaft with the respective VCT control
valve. The control valves are operated by a solenoid valve (see section 'Engine
management system').

NOTICE: The crankshaft and the camshafts must be brought to a defined position
before the cylinder head or the camshafts are installed. The instructions in the current
workshop literature must be observed for this.
Valves

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Item Description
1 Valve collets
2 Valve spring retainer
3 Valve springs
4 Oil shield ring

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5 Inlet valve
6 Outlet valve
7 Bucket tappet – exhaust valve
8 Bucket tappet – intake valve
There are four valves per cylinder in the cylinder head. Two intake and two exhaust valves,
where the intake valves have a larger diameter at the valve spring retainer.
The intake valves are made of one material and are solid.
The exhaust valves are designed as hollow valves. The cavity is filled with sodium.
The sodium melts at about 97°C and has good thermal conductivity. The temperature at
the valve spring retainer can thus be reduced by about 100°C.
The valves are operated by mechanical bucket tappets.
NOTE: It is not necessary to check or set the valve clearances during the service life of
the engine (240,000 km). This is only necessary if the camshafts have been removed
during repair work. The instructions in the current workshop literature must be followed
for the exact adjustment.
Cylinder head gasket

NOTE: When the cylinder head gasket is replaced, the new gasket must have the same
identification marking as the gasket which was previously installed. In addition, the
instructions in the current workshop literature must be followed for installation.
A multi-layer steel laminate cylinder head gasket is used.
Two guide sleeves are pressed into the cylinder block to locate the cylinder head and its
gasket.

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Timing gear

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Item Description
1 Intake camshaft pulley with integrated VCT
2 Exhaust camshaft pulley with integrated VCT
3 Crankshaft timing pulley
4 Automatic timing belt tensioner
5 Timing Belt
A newly developed oil bath timing belt drive is used to drive the camshafts.

Advantages of oil bath timing belt drive over an oil lubricated chain drive:
• Reduced frictional losses (about 20 per cent), thereby lower fuel consumption and thus
reduced CO2 (carbon dioxide) emission
• Reduction in noise
• The guide rails usual with chain drive are eliminated

Advantages of oil bath timing belt drive over a comparable dry timing belt drive:
• The timing belt is maintenance-free (change 240,000 km or at the latest after 10 years)

The timing belt is tensioned using an automatic timing belt tensioner.

NOTE: The instructions in the current workshop literature must be followed for removal
and installation of the timing belt.
Engine front cover

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Item Description
1 Jacking point – coolant pump
2 Guide – oil dipstick
3 Gasket – coolant inlet
4 Crankshaft front oil seal

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The aluminum timing cover seals the camshaft drive to the outside. The lower area accepts
the crankshaft oil seal which is installed from the outside. The special tools intended for the
purpose must be used to remove and install the O-ring seal (see current workshop
literature).
The seal to the engine is made using a sealing compound (arrows).
The oil dipstick guide is secured to the inside of the timing cover with three bolts.
In addition, the timing cover contains the jacking point for the coolant pump. To be able to
remove it, the coolant pump must first be detached.
NOTE: The securing bolts of the timing cover must be tightened in a certain sequence and
to a certain torque. Please refer to the instructions in the current workshop literature for
exact details of installation.
Variable Camshaft Timing

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Item Description
1 Variable camshaft timing solenoid, intake camshaft
2 Intake camshaft VCT solenoid seal
3 Intake camshaft VCT control valve
4 VCT unit – intake camshaft
5 CMP (camshaft position) Sensor - intake camshaft
6 CMP Sensor - exhaust camshaft
7 VCT unit – exhaust camshaft
8 Exhaust camshaft VCT control valve
9 Exhaust camshaft VCT solenoid seal
10 Variable camshaft timing solenoid, exhaust camshaft
This is an electro-hydraulically controlled camshaft adjustment system that allows variable
timing for the intake and exhaust camshafts independently of each other.
To do this, each camshaft is equipped with a VCT unit. The front closing plates of the units
are marked with I (intake) and e (exhaust).

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Item Description
1 VCT unit (intake camshaft)
2 Front closing plate
3 Rotor
4 Return spring

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The units have the same basic design. They are equipped with three oil brackets. A return
spring is used to reach the closing position.
The difference between the VCT unit intake and exhaust camshafts is in the closing
position. The unit of the intake camshaft closes in "retarded" position and the unit of the
exhaust camshaft closes in the "advanced" position.

The VCT units are bolted with the associated VCT control valve on the respective
camshaft. This means that:
• Securing bolt and control valve form one component.

Both VCT units have a maximum mechanical adjustment angle of 49 degrees crank angle.
The maximum programmed adjustment angle is 45 degrees crank angle.
The particular control valve is operated by a VCT solenoid. Both solenoids are secured to
the front of the timing case with three securing bolts each.

Item Description
1 Magnetic alignment of the magnetic disk
2 Signal from CMP sensor
3 Setting of the camshaft
Comments:
Figures given in degrees camshaft

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The exact angular position of the intake and exhaust camshaft is each detected by a CMP
sensor. The sensor scans a magnetic disk which is shrunk onto the particular camshaft. This
signal is changed into a square-wave signal by the built-in converter electronics and sent to
the PCM (powertrain control module).
Both sensors are mounted from above on the valve cover with one securing bolt.
NOTE: The installation position must be noted when removing the individual components.
The instructions in the current workshop literature must be followed.
Cylinder block and crank assembly

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Item Description
1 Crankshaft upper bearing shell
Comments:
Bearing shell with collar (bearing no. 2)
2 Crankshaft upper bearing shell (quantity: 3)

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3 Crankshaft bearing cap (quantity: 4)

4 Crankshaft lower bearing shell (quantity: 4)
5 Crankshaft Dimensions
6 Pistons
7 Connecting Rod Dimensions
8 Connecting rod upper bearing shell
9 Connecting rod lower bearing shell
10 Connecting rod bearing cap
The cylinder block is an 'open-deck' construction made of cast iron.
The engine code is stamped on the transmission flange on the exhaust side (arrow).
The side walls which are drawn down contribute to the rigidity of the cylinder block. These
measures achieve a low weight as well as high rigidity.

The pistons are made of an aluminum-silicon alloy and are equipped with:
• an upper compression ring,
• a lower compression ring and
• a 3-part oil scraper ring (oil scraper ring as well as upper and lower tensioning spring
elements).

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The crankshaft runs in four bearings. The three crankshaft journals are at 120 degrees to
one another.
NOTE: Due to very fine tolerances in the areas of the bearing clearances and the bearing
shells, no repairs whatsoever are permitted on the crankshaft drive.
Crankshaft rear seal

Item Description
1 Rear seal with steel carrier
2 Crankshaft Dimensions
The crankshaft rear seal is vulcanized into a pressed steel carrier. The complete carrier
must be replaced in the event of service work.
Oil Spray Nozzles

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There are three oil spray nozzles for piston cooling, located at the bearing positions for the
crankshaft in the cylinder block.
They are aligned so that engine oil is sprayed onto the underside of the piston.
The oil spray nozzles are equipped with a ball valve. The valve opens from an engine oil
pressure of about 1.2 bar.

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Oil pan baffle/oil pan

Item Description
1 Oil baffle plate
2 Oil sump
The oil pan baffle is bolted to the cylinder block from underneath with three securing
bolts.
The oil pan is made of an aluminum alloy. It is equipped with a solid rib and at the same
time forms the lower transmission flange. This achieves a rigid engine/transaxle
combination.
There are two guide pins (arrows) on the sealing surface of the cylinder block for exact
alignment of the oil pan.
The seal of the oil pan to the cylinder block is made using sealing compound.
For installation and removal of the oil pan or the oil pan baffle, the detailed instructions in
the current workshop literature must be followed.
Crankshaft mass damper

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Item Description
1 Mass damper
2 The CKP (crankshaft position) sensor
3 Crankshaft position magnetic disk
4 Balance weight

For service only, a new friction washer needs to be installed.

Item Description
1 Friction washer (service only)
2 Crankshaft pulley
3 Crankshaft pulley bolt

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The crankshaft mass damper forms a single unit together with the magnetic disk for the
crankshaft position.
There is an exactly positioned balance weight built into the mass damper and this reduces
the vibrations of the crankshaft.
The mass damper is secured on the crankshaft only by the contact force of the securing
bolt, which must be changed for a new one after removal.
NOTE: When the mass damper is installed, it must be aligned in a defined position
(arrow). For this purpose, the crankshaft must be in the TDC (top dead center) position.
The instructions in the current workshop literature must be observed for this.
NOTE: The friction washer is for service only and is NOT fitted to factory built engines.
The friction washer prevents the pulley from rotating whilst the damper bolt is being
tightened.
It is possible that an engine may have had the damper pulley previously removed in
service. Make sure that only one friction washer is fitted to the crankshaft. If a friction
washer is already fitted, replace it.
The exact position of the crankshaft is detected by the CKP sensor. The sensor scans the
crankshaft position magnetic disk. This signal is changed into a square-wave signal by the
built-in converter electronics and sent to the PCM. When the sensor is renewed, no
adjustment is necessary because this is predetermined by the way in which the sensor is
secured.

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Item Description
1 Magnetic alignment of the magnetic disk
2 Signal from CKP sensor
3 Reference mark 90° before TDC
Comments:
Figures given in degrees crankshaft

Engine Lubrication
Oil pump

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Item Description
1 Crankshaft pulley
2 Oil pump drive timing belt
3 Oil pump pulley
4 Oil pump

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The oil pump is mounted on the cylinder block from below with three securing bolts.
Conventional oil pumps account for up to 10% of the mechanical power losses at the
nominal speed of an engine, leading to increased fuel consumption. This is caused by the
high output of the oil pump, especially at high engine speeds.
When a variable oil pump is used, the output can be matched to the required oil flow in a
flexible manner, depending on the temperature and the engine speed.
Balance Shaft Assembly (6-Speed Automatic Transmission - 6F15 only)

Item Description
1 Crankshaft pulley
2 Balance shaft assembly
3 Gear - oil pump drive

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4 Oil pump
5 Oil pump drive timing belt
Layout

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Item Description
1 vane-type pump
2 Adjusting ring, vane pump
3 Pressure spring
4 Control pressure space
The principle component of the variable oil pump is formed by a vane-cell pump with an
adjusting ring.
The illustration shows the adjusting ring in the starting position. The pressure spring
pushes the adjusting ring to the left against the stop. In this position the vane-cell pump
creates the maximum possible oil pressure.
The oil pressure in the control pressure space can be changed depending on the oil
pressure demand. If the oil pressure in the control chamber exceeds the force of the
pressure spring, then the vane-cell pump adjusting ring is moved to the right. This
reduces the supply capacity of the pump.
Operation

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Item Description
1 Oil pressure from the main channel
2 Oil pressure control solenoid valve
3 Leakage line
4 Oil sump
5 Pressure relief valve
6 Spring
7 Oil pressure to oil filter
8 Pressure channel of the transfer pump
9 Hydraulic control piston
10 Control chamber
11 Adjusting ring, vane pump
The oil pressure is controlled via a hydraulically operated control piston integrated into the
oil pump. The pressure on the control piston is determined by a solenoid valve which is
activated by the PCM according to the requirements.
In the rest position, the solenoid valve is closed (see previous illustration). The engine oil
supplied by the oil pump flows to the control chamber. Because the solenoid valve is closed,
the oil flows through the control chamber and drains to the oil pan via a bypass in the
solenoid valve. No pressure can therefore be built up in the control chamber.
The control piston is pushed to the left by the spring force. Because of this, the control
piston closes the oil channel to the vane-cell pump adjusting ring.
In this position, the pressure channel of the transfer pump has the largest aperture
cross-section. The maximum possible oil pressure is thus available for engine
lubrication.

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Item Description
1 Oil pressure from the main channel
2 Oil pressure control solenoid valve
3 Leakage line
4 Oil sump
5 Pressure relief valve
6 Spring
7 Oil pressure to oil filter
8 Pressure channel of the transfer pump
9 Hydraulic control piston
10 Control chamber
11 Adjusting ring, vane pump
When operating conditions permit the vehicle to be driven with a lower oil pressure, the
PCM opens the solenoid valve.
The oil pressure supplied by the oil pump now acts directly and via the solenoid valve
on the control chamber and with it pushes the control piston to the right against the spring
force.
Because of this, the control piston opens the oil channel to the vane-cell pump adjusting
ring. The pump pressure now acts on the adjusting ring and presses it towards the center
of the pump.
In this position, the pressure channel of the transfer pump has only a small aperture
cross-section. A lower oil pressure is thus available for engine lubrication.

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Valve Clearance
Adjustment
Print

General Procedures
Special Tool(s) / General Equipment
303-1604
Timing Peg, Crankshaft TDC

303-1605
Alignment Tool, Camshaft

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Feeler Gauge

Materials
Name Specification
Sealant WSK-M2G348-A5
Engine Oil - SAE 5W-20 WSS-M2C948-B

Check
1. Refer to: Valve Cover (303-01A Engine, Removal and Installation).

2. NOTICE: Only rotate the crankshaft clockwise.

Rotate the crankshaft until the corresponding piston is at TDC and then measure the
valve clearance(s).

Use the General Equipment: Feeler Gauge

3. Note down each cylinder number and the valve clearances measured.

4. Compare the measured valve clearance(s) with the specifications.

Refer to: Specifications (303-01A Engine, Specifications).

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Adjustment
1. NOTE: The following steps are only necessary if adjustment is required.

2. Refer to: Variable Valve Timing (VVT) Unit (303-01A Engine, Removal and Installation).

3. Remove Special Service Tool: 303-1605.

4.

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5. NOTE: Note the position of the components before removal.

6. • Remove the valve tappet and read the thickness from the underside.
• The number on the valve tappet indicates the thickness of the bottom of the
tappet. However, the number only indicates the digits after the decimal point
(example: 725 = 2.725).

7. • Calculate the required thickness of the valve tappet with the following formula: X
=S+M-V
• Required thickness of tappet = X
• Thickness of currently fitted tappet = S
• Measurement of existing valve clearance (actual value) = M
• Desired valve clearance = V

8. Install the correct valve tappet.

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9. NOTE: Make sure that the components are installed to the position noted before
removal.

10. Install the camshafts approximately at valve overlap position cylinder No. 1.

Material: WSS-M2C948-B (Engine Oil - SAE 5W-20)

11. NOTE: Install all the bolts finger tight before final tightening.
Tighten each bolt 2 turns at a time.

12. Torque: 10 Nm

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13. 1. Turn the camshafts to measure the valve clearance.
2. Measure the valve clearances and repeat this procedure as necessary until all
valve clearances are within the specified tolerance.
14. NOTE: Note the position of the components before removal.

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15. NOTICE: Make sure that the mating faces are clean and free of foreign
material.
NOTE: The component must be installed within 5 minutes of applying the sealant.
Material: WSK-M2G348-A5 (Sealant)

16. NOTICE: Make sure that the mating faces are clean and free of foreign
material.
NOTE: The component must be installed within 5 minutes of applying the sealant.
Material: WSK-M2G348-A5 (Sealant)

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17. NOTICE: Make sure that the components are installed to the position noted
before removal.

18. Install the camshafts approximately at valve overlap position cylinder No. 1.

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Material: WSS-M2C948-B (Engine Oil - SAE 5W-20)

19. NOTE: Install all the bolts finger tight before final tightening.
Tighten each bolt 2 turns at a time.

20. Torque: 10 Nm

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21.
1. Install Special Service Tool: 303-1605.

2. NOTE: Only tighten the bolts finger tight at this stage.

3. Torque: 10 Nm

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22. Install Special Service Tool: 303-1604.

23. NOTICE: Only rotate the crankshaft clockwise.

Rotate the crankshaft slowly until the crankshaft stops.

24. Remove Special Service Tool: 303-1604.

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25. Refer to: Variable Valve Timing (VVT) Unit (303-01A Engine, Removal and Installation).

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Camshafts
Print

Removal and Installation

Special Tool(s)
303-1605
Alignment Tool, Camshaft

Materials
Name Specification
Sealant WSK-M2G348-A5
Engine Oil - SAE 5W-20 WSS-M2C948-B

Removal

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1. Refer to: Variable Valve Timing (VVT) Unit (303-01A Engine, Removal and Installation).

2. Remove Special Service Tool: 303-1605.

3. NOTE: Note the position of the components before removal.

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Installation

1. NOTICE: Make sure that the mating faces are clean and free of corrosion and
foreign material.
NOTE: The component must be installed within 5 minutes of applying the sealant.
Material: WSK-M2G348-A5 (Sealant)

2. NOTICE: Make sure that the mating faces are clean and free of foreign
material.
NOTE: The component must be installed within 5 minutes of applying the sealant.
Material: WSK-M2G348-A5 (Sealant)

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3. NOTICE: Make sure that the components are installed to the position noted
before removal.

4. Install the camshafts approximately at valve overlap position cylinder No. 1.

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Material: WSS-M2C948-B (Engine Oil - SAE 5W-20)

5. NOTE: Install all the bolts finger tight before final tightening.
Tighten each bolt 2 turns at a time.

6. Torque: 10 Nm

7. Refer to: Valve Clearance Adjustment (303-01A Engine, General Procedures).

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8. Refer to: Variable Valve Timing (VVT) Unit (303-01A Engine, Removal and Installation).

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Engine - 1.0L EcoBoost

(74kW/100PS)/1.0L EcoBoost
(90kW/120PS)/1.0L EcoBoost
(103kW/140PS) (YY) - Crankshaft Front
Seal
Print

Removal and Installation

Removal and Installation

1. Refer to: Crankshaft Pulley - 6-Speed Manual Transmission – 6MX65 (303-01A Engine,
Removal and Installation).

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Crankshaft
Pulley—6-Speed Manual Transmission – 6MX65
Print

Removal and Installation

Special Tool(s) / General Equipment
303-1602
Locking Tool, Crankshaft

303-1603
Installer, Front Cover Seal

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303-1604
Timing Peg, Crankshaft TDC

303-1606
Locking Tool, Variable Camshaft Timing

303-1611
Torque Multiplier

303-1611-01
Adapter for 303-1611

303-1611-02
Adapter for 303-1611, Torque Multiplier

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303-1636
Installer, Front Cover Seal

303-293
Remover, Crankshaft Seal

303-732

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Alignment Peg, Crankshaft

Hose Clamp Remover/Installer

Removal

1. Refer to: Starter Motor - 6-Speed Manual Transmission – 6MX65 (303-06A Starting
System, Removal and Installation).

2. Refer to: Accessory Drive Belt (303-05A Accessory Drive, Removal and Installation).

3. NOTICE: Only rotate the crankshaft clockwise.

NOTE: Rotate the crankshaft until piston No. 1 is approximately 35° before top
dead center (BTDC).

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4.

5. Install Special Service Tool: 303-1604.

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6. NOTICE: Only rotate the crankshaft clockwise.
Rotate the crankshaft slowly until the crankshaft stops.

7.
• Use the General Equipment: Hose Clamp Remover/Installer

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8.

9. 1.

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10. NOTE: The O-ring seals are to be reused unless damaged.

11. Install Special Service Tool: 303-1606.

Torque: 10 Nm

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12. 1. Turn until resistance is felt.
2. Torque: 15 Nm

13. Install Special Service Tool: 303-1602.

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14.

15. 1. M8x30
2. M8x25

Install Special Service Tool: 303-1611-02.

Torque: 24 Nm

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16. Install Special Service Tool: 303-1611-01.
Torque: 24 Nm

17. NOTE: Only tighten the nut finger tight at this stage.
Install Special Service Tool: 303-1611.

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18. Loosen: 5 turn(s)

19. Remove Special Service Tool: 303-1611.

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20. 1. NOTE: Discard the friction washer.
The friction washer is for service only and is NOT fitted to factory built engines.

Refer to: Engine (303-01A Engine, Description and Operation).

21. Use Special Service Tool: 303-293.

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Installation

1.
1. 1. NOTICE: Take extra care not to damage the seal.
NOTE: Use a new seal.
NOTE: Only tighten the bolt finger tight at this stage.
NOTE: Make sure that the seal is correctly located.
Use Special Service Tools: 303-1603, 303-1636.

2. Remove Special Service Tools: 303-1603, 303-1636.

2. Remove Special Service Tool: 303-1602.

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3. NOTICE: Only rotate the crankshaft clockwise.
Rotate the crankshaft slowly until the crankshaft stops.

4.
1. 1. NOTICE: Make sure that a new friction washer is installed.
2.

3. 3. NOTICE: Make sure a new bolt is installed.

NOTE: Only tighten the bolt finger tight at this stage.

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5.
1. Install Special Service Tool: 303-732.

2. Torque:
Stage 1:25 Nm
Stage 2:70 Nm

6. Remove Special Service Tool: 303-732.

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7. NOTE: Only tighten the nut finger tight at this stage.
Install Special Service Tool: 303-1611.

8.
1. Torque: 60 Nm

2. Torque:
Stage 1:90°
Stage 2:90°
Stage 3:90°
Stage 4:90°
Stage 5:90°

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9. Remove Special Service Tool: 303-1611.

10.
1. Install Special Service Tool: 303-732.

2. Remove Special Service Tool: 303-732.

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11. Remove Special Service Tool: 303-1604.

12. Remove Special Service Tool: 303-1606.

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13. NOTICE: Only rotate the crankshaft clockwise.
Rotate the crankshaft 1 and 3/4 revolutions and continue until piston No. 1 is
approximately 45° before top dead center (BTDC).

14. Install Special Service Tool: 303-1604.

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15. NOTICE: Only rotate the crankshaft clockwise.
Rotate the crankshaft slowly until the crankshaft stops.

16. 1. NOTE: The special tool can only be installed if the valve timing is correct.
Install Special Service Tool: 303-732.

2. Remove Special Service Tool: 303-732.

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17. Remove Special Service Tool: 303-1604.

18. Torque: 20 Nm

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19. Remove Special Service Tool: 303-1611-01.

20. Remove Special Service Tool: 303-1611-02.

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21. Torque: 10 Nm

22. NOTE: Make sure that new bolts are installed.

NOTE: Component(s) must be lubricated with clean engine oil.
Torque: 7 Nm

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23.

24.
1. Torque: 15 Nm

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25.
1. Use the General Equipment: Hose Clamp Remover/Installer
Torque: 11 Nm

26. Refer to: Accessory Drive Belt (303-05A Accessory Drive, Removal and Installation).

27. Refer to: Starter Motor - 6-Speed Manual Transmission – 6MX65 (303-06A Starting
System, Removal and Installation).

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Crankshaft Rear
Seal
Print

Removal and Installation

Removal
6-Speed Automatic Transmission - 6F15/6-Speed
Manual Transmission 6MX65

1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2.

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6-Speed Manual Transmission 6MX65
3. Remove the following items:
• Refer to: Flywheel (303-01A Engine, Removal and Installation).

6-Speed Automatic Transmission - 6F15/6-Speed

Manual Transmission 6MX65
4.

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Installation
6-Speed Automatic Transmission - 6F15/6-Speed
Manual Transmission 6MX65
1. NOTE: Make sure that the mating faces are clean and free of foreign material.
NOTE: New crankshaft rear seal carriers are supplied with an alignment sleeve
which must be removed after installation.
NOTE: Install all the bolts finger tight before final tightening.
Torque: 10 Nm

6-Speed Manual Transmission 6MX65

2. Refer to: Flywheel (303-01A Engine, Removal and Installation).

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6-Speed Manual Transmission 6MX65

3. Remove the following items:
• Refer to: Oil Pan - 6-Speed Manual Transmission – 6MX65 (303-01A Engine,
Removal and Installation).
4. Install the following items:
• Refer to: Oil Pan - 6-Speed Manual Transmission – 6MX65 (303-01A Engine,
Removal and Installation).

6-Speed Automatic Transmission - 6F15/6-Speed

Manual Transmission 6MX65
5. NOTE: Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction
routine in the diagnostic scan tool.

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Cylinder Head
Print

Removal and Installation

General Equipment
Polydrive Bit Socket
Torx Bit Socket

Removal

1. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).
2. NOTE: Be prepared to collect escaping fluids.

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3. Remove the following items:
1. Refer to: Turbocharger (303-04F Fuel Charging and Controls - Turbocharger,
Removal and Installation).

2. Refer to: Camshafts (303-01A Engine, Removal and Installation).

4.

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5.

6. NOTE: The screw head can either be a Polydrive or Torx Bit type.
Use the General Equipments: Polydrive Bit Socket, Torx Bit Socket

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Installation

1. NOTICE: Make sure that new bolts are installed.

NOTE: Only tighten the bolts finger tight at this stage.
Use the General Equipment: Polydrive Bit Socket
Torque:
Stage 1:10 Nm
Stage 2:40 Nm
Stage 3:Loosen: 45°
Stage 4:30 Nm
Stage 5:90°
Stage 6:90°

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2. Torque: 10 Nm

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3. Torque: 10 Nm

4. NOTE: Be prepared to collect escaping fluids.

Torque: 25 Nm

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5. Install the following items:

1. Refer to: Camshafts (303-01A Engine, Removal and Installation).

2. Refer to: Turbocharger (303-04F Fuel Charging and Controls - Turbocharger,

Removal and Installation).

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6. Refer to: Specifications (303-01A Engine, Specifications).

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine Front
Cover
Print

Removal and Installation

Special Tool(s) / General Equipment
303-1668
Sealer Gun, Front Cover

303-699
Wrench, Oil Filter

Plastic Scraper

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Trolley Jack
Wooden Block

Materials
Name Specification
Primer -
RTV Silicone Sealant WSE-M4G323-A6

Removal

1. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

6-Speed Manual Transmission – 6MX65

2. Remove the following items:
1. Refer to: Crankshaft Pulley - 6-Speed Manual Transmission – 6MX65 (303-01A
Engine, Removal and Installation).

All vehicles
3. Remove the following items:
1. Refer to: Valve Cover (303-01A Engine, Removal and Installation).

2. Refer to: Generator - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) (414-02 Generator and
Regulator, Removal and Installation).
4.

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5.

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6. NOTE: Be prepared to collect escaping fluid.
NOTE: The oil drain plug with O-ring seal is to be reused unless damaged.

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7. NOTE: Be prepared to collect escaping fluid.
Use Suggested Tool: 303-699. Tool shown or a commercially available equivalent can be
used.

8.

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9.

10. NOTICE: Use a wooden block to protect the oil pan when supporting the
engine.
Use the General Equipments: Trolley Jack, Wooden Block

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11.

12. NOTE: Note the position of the component before removal.

NOTE: Discard the nuts.

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13. NOTE: Discard the bolts.

14.

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15. NOTE: This step is only necessary when installing a new component.

16. NOTE: This step is only necessary when installing a new component.

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17. NOTE: This step is only necessary when installing a new component.

18. NOTE: This step is only necessary when installing a new component.

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19.

Installation

1. NOTE: This step is only necessary when installing a new component.

Torque: 7 Nm

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2. NOTE: This step is only necessary when installing a new component.
Torque: 10 Nm

3. NOTE: This step is only necessary when installing a new component.

Torque: 25 Nm

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4. NOTE: This step is only necessary when installing a new component.
NOTE: Use a new seal.

5. NOTE: This step is only necessary when installing a new component.

NOTE: Install all the bolts finger tight before final tightening.
Torque: 10 Nm

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6. NOTE: Use a new seal.

7. NOTE: Make sure that the mating faces are clean and free of foreign material.
1. Use the General Equipment: Plastic Scraper

2. Material: - (Primer)

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8. NOTE: Make sure that the mating faces are clean and free of foreign material.
1. Use the General Equipment: Plastic Scraper

2. Material: - (Primer)

9. NOTE: The component must be installed within 10 minutes of applying the sealant.

Complete this step within: 10min

Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)

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10. NOTE: The component must be installed within 10 minutes of applying the sealant.

Complete this step within: 10min

Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)

11. NOTE: Make sure that new bolts are installed.

NOTE: Note the different lengths of the bolts.
1. Torque:
1-2, M6x60 5 Nm
3-6, M10x95 10 Nm
7-16, M6x60 5 Nm

2. Torque:

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3-6 40 Nm
3-4 70 Nm
5-6 70 Nm
1-2 9 Nm
7-16 15 Nm

3. Torque:
3-4 90°
5-6 90°
1-2 90°
7-16 90°
17-19, M6x20 10 Nm
20, M6x75 10 Nm

4. Torque:
17-19 10 Nm
20 10 Nm

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12. Torque: 18 Nm

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13. NOTE: Make sure that the component is installed to the position noted before
removal.
1. NOTE: Only tighten the bolts finger tight at this stage.
2. NOTE: Make sure that new nuts are installed.
Torque: 115 Nm

14. Remove the General Equipments: Trolley Jack, Wooden Block

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15. Torque: 48 Nm

16.

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17. NOTE: Make sure that the mating faces are clean and free of foreign material.

18. 1. NOTE: Make sure that the component is correctly installed.

2. NOTE: Only tighten the bolts finger tight at this stage.

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19. Torque:
1-3 10 Nm
4 3 Nm

20. Torque: 23 Nm

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21. NOTE: Make sure that a new O-ring seal is installed.
Torque: 10 Nm

22.

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23. Install the following items:

1. Refer to: Generator - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost
(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) (414-02 Generator and
Regulator, Removal and Installation).

2. Refer to: Valve Cover (303-01A Engine, Removal and Installation).

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6-Speed Manual Transmission – 6MX65
24. Install the following items:
• Refer to: Crankshaft Pulley - 6-Speed Manual Transmission – 6MX65 (303-01A
Engine, Removal and Installation).

All vehicles
25. NOTE: The oil drain plug with O-ring seal is to be reused unless damaged.
Torque: 25 Nm

26. NOTE: Make sure a new component is installed.

NOTE: Component(s) must be lubricated with clean engine oil.

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Use Suggested Tool: 303-699. Tool shown or a commercially available equivalent can be
used.
Torque: 15 Nm

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27. NOTICE: Make sure that the engine oil is to specification.
Refer to: Specifications (303-01A Engine, Specifications).

28. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Flexplate
Print

Removal and Installation

Special Tool(s)
303-1602
Locking Tool, Crankshaft

Removal

1. Remove the following items:

• Refer to: Transmission (307-01 Automatic Transmission, Transfer Case and Power
Transfer Unit, Removal).
2.

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1. Install Special Service Tool: 303-1602.

2. NOTE: Discard the bolts.

Installation

1. 1. NOTE: Make sure that new bolts are installed.

Torque:
1-6
Stage 1:10 Nm
Stage 2:25 Nm
Stage 3:30 Nm
Stage 4:90°

2. Remove Special Service Tool: 303-1602.

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2. Refer to: Transmission (307-01 Automatic Transmission, Transfer Case and Power
Transfer Unit, Installation).
3. NOTE: Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction
routine in the diagnostic scan tool.

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Flywheel
Print

Removal and Installation

Special Tool(s)
303-1602
Locking Tool, Crankshaft

Removal

1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Refer to: Clutch Disc and Pressure Plate (308-01B, Removal and Installation).
3.

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1. Install Special Service Tool: 303-1602.

2. NOTE: Discard the bolts.

Installation

1. 1. NOTE: Make sure that new bolts are installed.

Torque:
1-6
Stage 1:10 Nm
Stage 2:25 Nm
Stage 3:50 Nm
Stage 4:90°

2. Remove Special Service Tool: 303-1602.

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2. Refer to: Clutch Disc and Pressure Plate (308-01B, Removal and Installation).
3. NOTE: Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction
routine in the diagnostic scan tool.

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Intake Manifold
Print

Removal and Installation

General Equipment
Hose Clamp Remover/Installer

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

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2.

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3. Use the General Equipment: Hose Clamp Remover/Installer

Torque:
1 11 Nm

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4.
1. Torque: 15 Nm

5.

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6.

7.

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8.

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9.

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10.

11. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
12.

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13.

14.

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Installation

1. To install, reverse the removal procedure.

2. NOTE: Only tighten the bolts finger tight at this stage.

3. Torque:
1-10 10 Nm

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Oil Pan—6-Speed
Manual Transmission – 6MX65
Print

Removal and Installation

Special Tool(s) / General Equipment
303-1668
Sealer Gun, Front Cover

Cable Ties
Plastic Scraper

Materials
Name Specification
Primer -

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RTV Silicone Sealant WSE-M4G323-A6

Removal

1. Remove the following items:

1. Refer to: Catalytic Converter (309-00A Exhaust System, Removal and
Installation).

2. Refer to: Accessory Drive Belt (303-05A Accessory Drive, Removal and
Installation).

2. NOTICE: Make sure that no strain is placed on the refrigerant lines.

Use the General Equipment: Cable Ties

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4. NOTE: The oil drain plug with O-ring seal is to be reused unless damaged.
NOTE: Be prepared to collect escaping fluid.

5.

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6. NOTE: This step is only necessary when installing a new component.
NOTE: Note the different lengths of the bolts.

7. NOTE: This step is only necessary when installing a new component.

If equipped.

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Installation

1. NOTE: This step is only necessary when installing a new component.

NOTE: Note the different lengths of the bolts.
Torque: 10 Nm

2. NOTE: This step is only necessary when installing a new component.

If equipped.

Torque: 11 Nm

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3. NOTE: Make sure that the mating faces are clean and free of foreign material.
1. Use the General Equipment: Plastic Scraper

2. Material: - (Primer)

4. NOTE: The component must be installed within 10 minutes of applying the sealant.

Complete this step within: 10min

Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)

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5. 1. NOTE: Make sure that new bolts are installed.
NOTE: Note the different lengths of the bolts.
Torque:
1-2, M6x20 10 Nm
3, M6x75 10 Nm
4-6, M6x20 10 Nm
7, M6x75 10 Nm
8-11, M6x20 10 Nm
12-13, M6x100 10 Nm
14, M6x75 10 Nm
15, M6x20 10 Nm

2. Torque:
1-2 10 Nm
3 10 Nm
4-6 10 Nm
7 10 Nm
8-11 10 Nm
12-13 10 Nm
14 10 Nm
15 10 Nm
16-17, M10x45 48 Nm

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6. NOTICE: Make sure that no strain is placed on the refrigerant lines.
Torque: 25 Nm

7. Install the following items:

1. Refer to: Catalytic Converter (309-00A Exhaust System, Removal and
Installation).

2. Refer to: Accessory Drive Belt (303-05A Accessory Drive, Removal and
Installation).
8. NOTE: The oil drain plug with O-ring seal is to be reused unless damaged.
Torque: 25 Nm

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9.

10. NOTE: Change engine oil and oil filter.

Refer to: Specifications (303-01A Engine, Specifications).

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Oil Pump—6-Speed
Manual Transmission – 6MX65
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Oil Pan - 6-Speed Manual Transmission – 6MX65 (303-01A Engine, Removal
and Installation).
2.

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3. Torque: 25 Nm

4.

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Installation

1. To install, reverse the removal procedure.

2.

3.

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Timing Belt
Print

Removal and Installation

Special Tool(s)
303-1054
Locking Tool, Timing Belt Tensioner

303-1605
Alignment Tool, Camshaft

Removal

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1. Refer to: Engine Front Cover (303-01A Engine, Removal and Installation).
2.

3.
1. Install Special Service Tool: 303-1605.

2. NOTE: Only tighten the bolts finger tight at this stage.

3. Torque: 10 Nm

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4. WARNING: The tensioner is under spring tension. Be careful when handling
the tensioner. Failure to follow this instruction may result in personal injury.
Install Special Service Tool: 303-1054.

Installation

1. NOTE: If installing a new component, determine the part number.

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2. WARNING: The tensioner is under spring tension. Be careful when handling
the tensioner. Failure to follow this instruction may result in personal injury.
Remove Special Service Tool: 303-1054.

3. Remove Special Service Tool: 303-1605.

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4. NOTE: Make sure that a new component is installed.
NOTE: Only tighten the bolt finger tight at this stage.

5. NOTE: Only tighten the bolt finger tight at this stage.

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6. NOTE: Only tighten the bolt finger tight at this stage.

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7. Torque: 10 Nm

8. Torque: 10 Nm

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9. Torque: 30 Nm

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10. Refer to: Engine Front Cover (303-01A Engine, Removal and Installation).

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Valve Cover
Print

Removal and Installation

Special Tool(s) / General Equipment
303-1668
Sealer Gun, Front Cover

310-137
Disconnect Tool, Fuel Line

Hose Clamp Remover/Installer

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Materials
Name Specification
RTV Silicone Sealant WSE-M4G323-A6
Sealant WSK-M2G348-A5

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Fuel Rail (303-04A Fuel Charging and Controls, Removal and Installation).
2.

3.
1. Use the General Equipment: Hose Clamp Remover/Installer
Torque: 11 Nm

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4. NOTE: The O-ring seal is to be reused unless damaged.

5.

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6.

WARNING: Fuel may remain pressurized in some fuel lines after the Fuel
System Pressure Release procedure. Wear safety gloves and a face shield when
disconnecting pressure lines to avoid skin and eye contact. Failure to follow this
instruction may result in serious personal injury.
NOTE: Make sure that the quick release couplings are correctly engaged.
NOTE: Be prepared to collect escaping fluid.
Always wrap the fuel line connection with a towel before disconnecting it.

Use Special Service Tool: 310-137.

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7. Loosen each bolt 1 turn at a time until all bolts are removed.

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8.

9.

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10. Use the General Equipment: Hose Clamp Remover/Installer

11. Torque:
1 11 Nm
2 6 Nm

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12.

13.

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Installation

1. To install, reverse the removal procedure.

2. NOTE: Make sure that the component is clean, free of foreign material and
lubricant.
1. Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)

2. Material: WSK-M2G348-A5 (Sealant)

3. NOTE: Only tighten the bolts finger tight at this stage.

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4. Torque: 10 Nm

5. 1. NOTE: Use a new seal.

NOTE: Component(s) must be lubricated with clean engine oil.
2. NOTE: Only use moderate force.

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6. 1. NOTE: Make sure that new bolts are installed.
NOTE: Only tighten the bolts finger tight at this stage.
Tighten each bolt 0.5 turn at a time.
2. Torque:
Stage 1:5 Nm
Stage 2:13 Nm

7. 1. NOTE: The O-ring seal is to be reused unless damaged.

NOTE: Component(s) must be lubricated with clean engine oil.
2. Torque: 10 Nm

3.

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Valve Stem Seals
Print

Removal and Installation

Special Tool(s)
303-060-11
Adapter for 303-060

303-361B
Compressor, Valve Spring

303-508

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Pliers, Valve Stem Seal

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Camshafts (303-01A Engine, Removal and Installation).
2. NOTE: Note the position of the components before removal.

3. NOTE: Rotate the crankshaft until the relevant piston is at top dead center (TDC).

4. Install Special Service Tools: 303-361B, 303-060-11.

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5. Use Special Service Tool: 303-508.

Installation

1. To install, reverse the removal procedure.

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Variable Valve
Timing (VVT) Unit
Print

Removal and Installation

Special Tool(s) / General Equipment
303-1054
Locking Tool, Timing Belt Tensioner

303-1605
Alignment Tool, Camshaft

303-1606

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Locking Tool, Variable Camshaft Timing

303-1668
Sealer Gun, Front Cover

Cable Ties
Hose Clamp Remover/Installer
Plastic Scraper
Trolley Jack
Wooden Block

Materials
Name Specification
Primer -
RTV Silicone Sealant WSE-M4G323-A6
Sealant WSK-M2G348-A5

Removal

1. Refer to: Timing Belt (303-01A Engine, Removal and Installation).

2. NOTICE: Use an open-ended wrench to hold the camshafts by the hexagon to

prevent the camshafts from turning.

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Installation

1. NOTE: If installing a new component, determine the part number.

2.
1. Install Special Service Tool: 303-1606.

2.
3. NOTE: Ensure that the installation marks are aligned and orientated to a 12
o’clock position.

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3. NOTE: Only tighten the bolts finger tight at this stage.

4. Remove Special Service Tool: 303-1606.

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5. NOTE: If installing a new component, determine the part number.

6. WARNING: The tensioner is under spring tension. Be careful when handling

the tensioner. Failure to follow this instruction may result in personal injury.
Remove Special Service Tool: 303-1054.

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7. NOTE: Make sure that the mating faces are clean and free of foreign material.
1. Use the General Equipment: Plastic Scraper

2. Material: - (Primer)

8. NOTE: Make sure that the mating faces are clean and free of foreign material.
1. Use the General Equipment: Plastic Scraper

2. Material: - (Primer)

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9. NOTE: The component must be installed within 10 minutes of applying the sealant.

Complete this step within: 10min

Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)

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10. NOTE: The component must be installed within 10 minutes of applying the sealant.

Complete this step within: 10min

Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)

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11. NOTE: Make sure that new bolts are installed.
NOTE: Note the different lengths of the bolts.
1. Torque:
1-2, M6x60 5 Nm
3-6, M10x95 10 Nm
7-16, M6x60 5 Nm

2. Torque:
3-6 40 Nm
3-4 70 Nm
5-6 70 Nm
1-2 9 Nm
7-16 15 Nm

3. Torque:
3-4 90°
5-6 90°
1-2 90°
7-16 90°
17-19, M6x20 10 Nm
20, M6x75 10 Nm

4. Torque:
17-19 10 Nm
20 10 Nm

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12. Torque: 10 Nm

13. NOTE: Make sure that the component is installed to the position noted before
removal.
1. Torque: 80 Nm

2. NOTE: Only tighten the bolts finger tight at this stage.

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14. Remove the General Equipments: Trolley Jack, Wooden Block

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15. Torque: 90 Nm

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16. Install Special Service Tool: 303-1606.

Torque: 10 Nm

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17. 1. Turn until resistance is felt.
2. Torque: 15 Nm

18. NOTICE: Use an open-ended wrench to hold the camshafts by the hexagon to
prevent the camshafts from turning.
Torque: 30 Nm

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19. Remove Special Service Tool: 303-1605.

20. NOTE: Make sure that a new component is installed.

NOTE: Only tighten the bolt finger tight at this stage.

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21. NOTE: Only tighten the bolt finger tight at this stage.

22. NOTE: Only tighten the bolt finger tight at this stage.

23. Torque: 10 Nm

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24. Torque: 10 Nm

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25. Torque: 30 Nm

26. NOTICE: Use an open-ended wrench to hold the camshafts by the hexagon to
prevent the camshafts from turning.
Torque:
Stage 1:50 Nm
Stage 2:95 Nm
Stage 3:45°

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27. Refer to: Crankshaft Pulley - 6-Speed Manual Transmission – 6MX65 (303-01A Engine,
Removal and Installation).
28. NOTE: Make sure that the mating faces are clean and free of foreign material.

29. 1. NOTE: Make sure that the component is correctly installed.

2. NOTE: Only tighten the bolts finger tight at this stage.

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30. Torque:
1-3 10 Nm
4 3 Nm

31. NOTE: Make sure that the component is clean, free of foreign material and
lubricant.
1. Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)

2. Material: WSK-M2G348-A5 (Sealant)

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32. NOTE: Only tighten the bolts finger tight at this stage.

33. Torque: 10 Nm

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34.

35. Torque:
1 10 Nm
2 10 Nm

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36. Refer to: Catalytic Converter (309-00A Exhaust System, Removal and Installation).

37. Torque:
1 11 Nm
2 6 Nm

38. Use the General Equipment: Hose Clamp Remover/Installer

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39.

40.

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41. Refer to: High-Pressure Fuel Pump (303-04A Fuel Charging and Controls, Removal and
Installation).

42. Refer to: Fuel Rail (303-04A Fuel Charging and Controls, Removal and Installation).
43.

44.
1. Torque: 15 Nm

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45. Torque: 25 Nm

46. Torque: 48 Nm

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47. WARNING: The tensioner is under spring tension. Be careful when handling
the tensioner. Failure to follow this instruction may result in personal injury.
Torque: 25 Nm

48.

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49.

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50. Torque: 15 Nm

51. Torque: 10 Nm

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Vehicles with air conditioning

52. Use the General Equipment: Cable Ties

Torque: 25 Nm

Vehicles without air conditioning

53. Torque: 25 Nm

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All vehicles

54. Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine—6-Speed
Manual Transmission – 6MX65
Print

Removal
Special Tool(s) / General Equipment
310-137
Disconnect Tool, Fuel Line

Cable Ties
Floor Crane
Hose Clamp Remover/Installer
Lifting Bracket
Trolley Jack
Wooden Block

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1. Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information,
General Procedures).

2. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).
3. Remove the following items:
1. Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).

2. Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).

3. Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and
Installation).

4. Refer to: Evaporative Emission Canister Purge Valve (303-13A Evaporative

Emissions, Removal and Installation).

5. Refer to: Starter Motor - 6-Speed Manual Transmission – 6MX65 (303-06A

Starting System, Removal and Installation).

6. Refer to: Catalytic Converter (309-00A Exhaust System, Removal and

Installation).

7. Refer to: Accessory Drive Belt (303-05A Accessory Drive, Removal and
Installation).

4. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).

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5.

6. Use the General Equipment: Hose Clamp Remover/Installer

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7. Use the General Equipment: Hose Clamp Remover/Installer

8. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).

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9. Use the General Equipment: Hose Clamp Remover/Installer

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10.

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11.

12.

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13.

14.

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15.

16. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
17.

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18. NOTICE: Make sure that no strain is placed on the refrigerant lines.
NOTE: Make sure that the component is secured with suitable cable ties.
Use the General Equipment: Cable Ties

19.

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20.

21.

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22.
• Install the General Equipment: Wooden Block

• Install the General Equipment: Trolley Jack

23.

WARNING: Fuel may remain pressurized in some fuel lines after the Fuel
System Pressure Release procedure. Wear safety gloves and a face shield when
disconnecting pressure lines to avoid skin and eye contact. Failure to follow this
instruction may result in serious personal injury.
NOTE: Be prepared to collect escaping fluid.

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Always wrap the fuel line connection with a towel before disconnecting it.

Install Special Service Tool: 310-137.

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24.
• Install the General Equipment: Lifting Bracket

• Install the General Equipment: Floor Crane

25. NOTE: Discard the nuts.

NOTE: Note the position of the component before removal.

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26.

27.

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28. NOTE: Make sure that no components catch.
Use the General Equipments: Floor Crane, Lifting Bracket

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine
Accessories—6-Speed Manual Transmission – 6MX65
Print

Removal
Special Tool(s) / General Equipment
205-047
Slide Hammer

205-047-08
Adapter for 205-047

303-1473

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Mounting Plate, Engine

303-1602
Locking Tool, Crankshaft

303-699
Wrench, Oil Filter

310-206
Remover, Fuel Injector

Floor Crane
Hose Clamp Remover/Installer
Lifting Bracket

1. Refer to: Clutch Disc and Pressure Plate (308-01B Clutch, Removal and Installation).

2. Use Special Service Tool: 303-1602.

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3. Install Special Service Tool: 303-1473.

4.
• Remove the General Equipment: Floor Crane

• Remove the General Equipment: Lifting Bracket

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5.

6.

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7. 1.
2. Use the General Equipment: Hose Clamp Remover/Installer

8. cardiagn.com

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9. Use the General Equipment: Hose Clamp Remover/Installer

10.

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11.

Vehicles without Auto-Start-Stop

12.

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Vehicles with Auto-Start-Stop
13.

All vehicles
14.

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15. Use the General Equipment: Hose Clamp Remover/Installer

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16.

17.

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18.

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19.

20. Loosen each bolt 1 turn at a time until all bolts are removed.

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21.

22. NOTICE: Take extra care when handling the components.

NOTE: Only use moderate force. cardiagn.com

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23. NOTICE:

Take extra care when handling the components.

Make sure that the component is clean, free of foreign material and lubricant.
NOTE: Only use moderate force.

24. NOTICE: Take extra care when handling the components

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25. NOTE: This step is only necessary if the component remains in the cylinder head.

26. NOTE: This step is only necessary if the component remains in the cylinder head.
Use Special Service Tools: 205-047, 310-206, 205-047-08.

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27. NOTICE:

Take extra care when handling the components

Make sure that the component is clean, free of foreign material and lubricant.

28.

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29. Use Special Service Tool: 303-699.

30.

31.

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32. NOTE: Note the position of the components before removal.

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine—6-Speed
Manual Transmission – 6MX65
Print

Disassembly
Special Tool(s) / General Equipment
303-1054
Locking Tool, Timing Belt Tensioner

303-1602
Locking Tool, Crankshaft

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303-1611
Torque Multiplier

303-1611-01
Adapter for 303-1611

303-1611-02
Adapter for 303-1611, Torque Multiplier

303-293
Remover, Crankshaft Seal

Polydrive Bit Socket

Torx Bit Socket

1. Use Special Service Tool: 303-1602.

Torque:

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2-7
Stage 1:25 Nm
Stage 2:100 Nm
Stage 3:15°

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2.

3. 1. M8x30
2. M8x25

Install Special Service Tool: 303-1611-02.

Torque: 24 Nm

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4. Install Special Service Tool: 303-1611-01.
Torque: 24 Nm

5. NOTE: Only tighten the nut finger tight at this stage.

Install Special Service Tool: 303-1611.

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6. Loosen: 5 turn(s)

7. Remove Special Service Tool: 303-1611.

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8. 1. NOTE: Discard the friction washer.
If equipped.

9. Use Special Service Tool: 303-293.

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10. Remove Special Service Tool: 303-1611-01.

11. Remove Special Service Tool: 303-1611-02.

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12. Use Special Service Tool: 303-1602.

13.

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14.

15.

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16.

17. If equipped.

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18. NOTE: The oil drain plug with O-ring seal is to be reused unless damaged.
NOTE: Be prepared to collect escaping fluid.

19.

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20. NOTE: Discard the bolts.

21. Install Special Service Tool: 303-1054.

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22. WARNING: The tensioner is under spring tension. Be careful when handling
the tensioner. Failure to follow this instruction may result in personal injury.

23. NOTE: Note the position of the component before removal.

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24.

25. NOTE: Note the position of the component before removal.

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26.

27. NOTICE: Use an open-ended wrench to prevent the component from turning.

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28. NOTICE: Note the position of the components before removal.

29. NOTE: The screw head can either be a Polydrive or Torx Bit type.
Use the General Equipments: Torx Bit Socket, Polydrive Bit Socket

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30.

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Cylinder Head
Print

Disassembly and Assembly of Subassemblies

Special Tool(s)
303-060
Compressor, Valve Spring

303-060-11
Adapter for 303-060

303-508
Pliers, Valve Stem Seal

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Disassembly

1. Torque: 10 Nm

2. Torque: 23 Nm

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3. NOTE: Note the position of the components before removal.

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4. Install Special Service Tools: 303-060, 303-060-11.

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5. Use Special Service Tool: 303-508.

Assembly

6. To install, reverse the removal procedure.

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine—6-Speed
Manual Transmission – 6MX65
Print

Assembly
Special Tool(s) / General Equipment
205-072
Universal Flange Holding Wrench

303-1054
Locking Tool, Timing Belt Tensioner

303-1603
Installer, Front Cover Seal

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303-1604
Timing Peg, Crankshaft TDC

303-1605
Alignment Tool, Camshaft

303-1606
Locking Tool, Variable Camshaft Timing

303-1611
Torque Multiplier

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303-1611-01
Adapter for 303-1611

303-1611-02
Adapter for 303-1611, Torque Multiplier

303-1636
Installer, Front Cover Seal

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303-1668
Sealer Gun, Front Cover

303-732
Alignment Peg, Crankshaft

Plastic Scraper
Polydrive Bit Socket

Materials
Name Specification
Primer -
RTV Silicone Sealant WSE-M4G323-A6
Sealant WSK-M2G348-A5
1. NOTE: Make sure that the mating faces are clean and free of foreign material.
NOTE: New crankshaft rear seal carriers are supplied with an alignment sleeve
which must be removed after installation.
NOTE: Install all the bolts finger tight before final tightening.
Torque: 10 Nm

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2. Torque: 23 Nm

3. NOTE: Make sure that the component is installed to the position noted before
removal.
NOTE: If installing a new component, determine the part number.
NOTE: Make sure that the component is correctly installed.
NOTE: Component must be lubricated with clean engine oil.

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4.

5. NOTICE: Make sure that no fluids are present in the cylinder head bolt
threaded bores.
NOTE: Make sure that new bolts are installed.
NOTE: Install all the bolts finger tight before final tightening.
Use the General Equipment: Polydrive Bit Socket
Torque:
Stage 1:10 Nm
Stage 2:40 Nm
Stage 3:Loosen: 45°
Stage 4:30 Nm

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Stage 5:90°
Stage 6:90°

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6. NOTE: Make sure that the mating faces are clean and free of foreign material.
NOTE: The component must be installed within 5 minutes of applying the sealant.

Complete this step within: 5min

Material: WSK-M2G348-A5 (Sealant)

7. NOTE: Make sure that the mating faces are clean and free of foreign material.
NOTE: The component must be installed within 5 minutes of applying the sealant.

Complete this step within: 5min

Material: WSK-M2G348-A5 (Sealant)

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8. 1. NOTE: Make sure that the components are installed to the position noted
before removal.
NOTE: Make sure that new bolts are installed.
Bearing must be lubricated with clean engine oil.
2. Install the camshafts approximately at valve overlap position cylinder No. 1.
3. NOTE: Install all the bolts finger tight before final tightening.

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Tighten each bolt 2 turns at a time.
4. Torque: 10 Nm

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9. Measure the valve clearance and if necessary, adjust by installing new valve tappets.

Refer to: Valve Clearance Adjustment (303-01A Engine, General Procedures).

10. NOTICE:

Take extra care not to damage the mating faces.

Only rotate the crankshaft clockwise.

Rotate the crankshaft until piston No. 1 is approximately 35° before top dead center
(BTDC).

Use Suggested Tool: 205-072. Tool shown or a commercially available equivalent can be
used.

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11.

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12. Install Special Service Tool: 303-1604.

13. NOTICE:

Take extra care not to damage the mating faces.

Only rotate the crankshaft clockwise.

Rotate the crankshaft slowly until the crankshaft stops.

Use Suggested Tool: 205-072. Tool shown or a commercially available equivalent can be
used.

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14.
1. Install Special Service Tool: 303-1605.

2. NOTE: Only tighten the bolts finger tight at this stage.

3. Torque: 10 Nm

15. NOTE: If installing a new component, determine the part number.

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16.
1. Install Special Service Tool: 303-1606.

2.
3. NOTE: Ensure that the installation marks are aligned and orientated to a 12
o’clock position.

17. NOTE: Make sure that new bolts are installed.

NOTE: Only tighten the bolts finger tight at this stage.

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18. Remove Special Service Tool: 303-1606.

19. NOTE: Make sure that the component is installed to the position noted before
removal.
NOTE: If installing a new component, determine the part number.
NOTE: Make sure that the component is correctly installed.
NOTE: Component must be lubricated with clean engine oil.

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20. WARNING: The tensioner is under spring tension. Be careful when handling
the tensioner. Failure to follow this instruction may result in personal injury.
Torque: 26 Nm

21. NOTE: If installing a new component, determine the part number.

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22. WARNING: The tensioner is under spring tension. Be careful when handling
the tensioner. Failure to follow this instruction may result in personal injury.
Remove Special Service Tool: 303-1054.

23. NOTE: Use a new seal.

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24. NOTE: Make sure that the mating faces are clean and free of foreign material.
1. Use the General Equipment: Plastic Scraper

2. Material: - (Primer)

25. NOTE: The component must be installed within 10 minutes of applying the sealant.

Complete this step within: 10min

Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)

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26. NOTE: The component must be installed within 10 minutes of applying the sealant.

Complete this step within: 10min

Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)

27. NOTE: Make sure that new bolts are installed.

NOTE: Note the different lengths of the bolts.
1. Torque:
1-2, M6x60 5 Nm
3-6, M10x95 10 Nm
7-16, M6x60 5 Nm

2. Torque:

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3-6 40 Nm
3-4 70 Nm
5-6 70 Nm
1-2 9 Nm
7-16 15 Nm

3. Torque:
3-4 90°
5-6 90°
1-2 90°
7-16 90°

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28.

29. NOTE: Make sure that the mating faces are clean and free of foreign material.

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1. Use the General Equipment: Plastic Scraper

2. Material: - (Primer)

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30. NOTE: The component must be installed within 10 minutes of applying the sealant.

Complete this step within: 10min

Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)

31. 1. NOTE: Make sure that new bolts are installed.

NOTE: Note the different lengths of the bolts.
Torque:

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1-2, M6x20 10 Nm
3, M6x75 10 Nm
4-6, M6x20 10 Nm
7, M6x75 10 Nm
8-11, M6x20 10 Nm
12-13, M6x100 10 Nm
14, M6x75 10 Nm
15, M6x20 10 Nm

2. Torque:
1-2 10 Nm
3 10 Nm
4-6 10 Nm
7 10 Nm
8-11 10 Nm
12-13 10 Nm
14 10 Nm
15 10 Nm

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32. NOTE: The oil drain plug with O-ring seal is to be reused unless damaged.
Torque: 25 Nm

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33. NOTICE: Take extra care not to damage the seal.
NOTE: Use a new seal.
1. NOTE: Only tighten the bolt finger tight at this stage.
Use Special Service Tools: 303-1603, 303-1636.

2. NOTE: Make sure that the seal is correctly located.

3.
4.
5. Remove Special Service Tools: 303-1603, 303-1636.

34. Torque: 10 Nm

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35. Install Special Service Tool: 303-1606.
Torque: 10 Nm

36. 1. Turn until resistance is felt.

2. Torque: 15 Nm

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37. NOTICE: Use an open-ended wrench to prevent the component from turning.
Torque: 30 Nm

38. Remove Special Service Tool: 303-1605.

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39. NOTICE: Use an open-ended wrench to prevent the component from turning.
Torque:
Stage 1:50 Nm
Stage 2:95 Nm
Stage 3:45°

40.
1. 1. NOTICE: Make sure that a new friction washer is installed.
2.

3. 3. NOTICE: Make sure that a new bolt is installed.

NOTE: Only tighten the bolt finger tight at this stage.

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41.
1. Install Special Service Tool: 303-732.

2. Torque:
Stage 1:25 Nm
Stage 2:70 Nm

42. Remove Special Service Tool: 303-732.

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43. 1. M8x30
2. M8x25

Install Special Service Tool: 303-1611-02.

Torque: 24 Nm

44. Install Special Service Tool: 303-1611-01.

Torque: 24 Nm

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45. NOTE: Only tighten the nut finger tight at this stage.
Install Special Service Tool: 303-1611.

46.
1. Torque: 60 Nm

2. Torque:
Stage 1:90°
Stage 2:90°
Stage 3:90°
Stage 4:90°
Stage 5:90°

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47. Remove Special Service Tool: 303-1611.

48.
1. Install Special Service Tool: 303-732.

2. Remove Special Service Tool: 303-732.

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49. Remove Special Service Tool: 303-1604.

50. Remove Special Service Tool: 303-1606.

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51. NOTICE: Only rotate the crankshaft clockwise.
Rotate the crankshaft 1 and 3/4 revolutions and continue until piston No. 1 is
approximately 45° before top dead center (BTDC).

52. Install Special Service Tool: 303-1604.

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53. NOTICE: Only rotate the crankshaft clockwise.
Rotate the crankshaft slowly until the crankshaft stops.

54. 1. NOTE: The special tool can only be installed if the valve timing is correct.
Install Special Service Tool: 303-732.

2. Remove Special Service Tool: 303-732.

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55. Remove Special Service Tool: 303-1604.

56. Torque: 20 Nm

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57. Remove Special Service Tool: 303-1611-01.

58. Remove Special Service Tool: 303-1611-02.

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59. Torque: 10 Nm

60. NOTE: Make sure that the component is clean, free of foreign material and
lubricant.
1. Use Special Service Tool: 303-1668.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)

2. Material: WSK-M2G348-A5 (Sealant)

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61. NOTE: Only tighten the bolts finger tight at this stage.

62. Torque: 10 Nm

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63. 1. NOTE: Component must be lubricated with clean engine oil.
NOTE: The O-ring seal is to be reused unless damaged.
2. NOTE: Make sure that new bolts are installed.
Torque: 7 Nm

64. Torque: 23 Nm

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65. If equipped.

Torque: 11 Nm

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine—6-Speed
Manual Transmission – 6MX65
Print

Installation
General Equipment
Floor Crane
Hose Clamp Remover/Installer
Lifting Bracket
Trolley Jack
Wooden Block

Materials
Name Specification

1. Apply a thin coating.

Material: ESD-M1C220-A (Grease - High Temperature)

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2. NOTE: Make sure that no components catch.
Use the General Equipments: Floor Crane, Lifting Bracket

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3. Torque: 48 Nm

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4. Torque: 48 Nm

5. Torque: 18 Nm

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6. NOTE: Make sure that the component is installed to the position noted before
removal.
1. NOTE: Only tighten the bolts finger tight at this stage.
2. NOTE: Make sure that new nuts are installed.
Torque: 115 Nm

7. Torque: 48 Nm

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8.
• Remove the General Equipment: Floor Crane

• Remove the General Equipment: Lifting Bracket

9.
• Remove the General Equipment: Trolley Jack

• Remove the General Equipment: Wooden Block

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10. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

11. Torque: 48 Nm

12. Torque: 48 Nm

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13.

14. NOTICE: Make sure that no strain is placed on the refrigerant lines.
NOTE: Make sure that the component is secured with suitable cable ties.
Torque: 25 Nm

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15.

16. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

17. NOTICE: Take extra care not to damage the wiring harnesses.
Torque: 18 Nm

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18.

19.

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20.

21.

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22.

23. Torque:
1 10 Nm
2 12 Nm

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24. Use the General Equipment: Hose Clamp Remover/Installer

25.

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26. Use the General Equipment: Hose Clamp Remover/Installer

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27. Use the General Equipment: Hose Clamp Remover/Installer

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28.

29.

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30. Install the following items:
1. Refer to: Starter Motor - 6-Speed Manual Transmission – 6MX65 (303-06A
Starting System, Removal and Installation).

2. Refer to: Catalytic Converter (309-00A Exhaust System, Removal and

Installation).

3. Refer to: Accessory Drive Belt (303-05A Accessory Drive, Removal and
Installation).

4. Refer to: Evaporative Emission Canister Purge Valve (303-13A Evaporative

Emissions, Removal and Installation).

5. Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and
Installation).

6. Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).

7. Refer to: Hood (501-02 Front End Body Panels, Removal and Installation).

31. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

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Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine
Accessories—6-Speed Manual Transmission – 6MX65
Print

Installation
Special Tool(s) / General Equipment
303-1473
Mounting Plate, Engine

303-1602
Locking Tool, Crankshaft

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303-699
Wrench, Oil Filter

310-128
Installer Set, Teflon Seal

Floor Crane
Hose Clamp Remover/Installer
Lifting Bracket
Mounting Stand
1. NOTE: Make sure that the component is correctly installed.
Torque: 20 Nm

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2. Torque: 20 Nm

3. NOTE: Make sure that a new component is installed.

If equipped.

Torque: 11 Nm

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4. Torque: 55 Nm

5. NOTE: Make sure that a new component is installed.

1. NOTE: Component(s) must be lubricated with clean engine oil.
2. Use Suggested Tool: 303-699. Tool shown or a commercially available equivalent
can be used.
Torque: 15 Nm

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6. NOTE: Only tighten the bolts finger tight at this stage.

7. Torque:
1-10 10 Nm

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8.

9. NOTICE: Make sure that the component is clean, free of foreign material and
lubricant.
NOTE: Make sure that new components are installed.

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10. NOTICE: Make sure that the area around the component is clean and free of
foreign material.
1. Use Special Service Tool: 310-128.

2. NOTE: Use a new seal.

3. 3. NOTICE: Take extra care not to damage the seal.

To install the seal, position the tool with the smaller opening towards the seal.
4. Remove Special Service Tool: 310-128.

11.
1. Use Special Service Tool: 310-128.

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2. Position the tool with the larger opening towards the seal. Push while turning the
tool 180 degrees.
3. Once the tool is installed, check and make sure the seal is in the sizing portion of
the tool.
4. After one minute, turn the tool back 180 degrees and remove the tool.

Remove Special Service Tool: 310-128.

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

13. NOTICE:

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Take extra care when handling the components.

Make sure that the component is clean, free of foreign material and lubricant.

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14.

15. 1. NOTE: Only use moderate force.

2. NOTE: Only tighten the bolts finger tight at this stage.
Tighten each bolt 1 turn at a time.
3.

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16. Torque: 23 Nm

17. 1. NOTE: The O-ring seal is to be reused unless damaged.

2. Torque: 10 Nm

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18. NOTE: Install all the bolts finger tight before final tightening.
Torque: 10 Nm

19.

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20. NOTE: Component(s) must be lubricated with clean engine oil.

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21. 1. NOTE: Use a new seal.
NOTE: Component(s) must be lubricated with clean engine oil.
2. NOTE: Only use moderate force.

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22. 1. NOTE: Make sure that new bolts are installed.
NOTE: Only tighten the bolts finger tight at this stage.
Tighten each bolt 0.5 turn at a time.
2. Torque:
Stage 1:5 Nm
Stage 2:13 Nm

23. 1. NOTE: Make sure that a new component is installed.

NOTE: Only tighten the nuts finger tight at this stage.
2. Torque:
Stage 1:14 Nm
Stage 2:20 Nm
Stage 3:20°

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24. Torque: 10 Nm

25. Use the General Equipment: Hose Clamp Remover/Installer

Torque:
1 10 Nm
2 10 Nm
3 10 Nm

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Vehicles with Auto-Start-Stop

26. NOTE: Only tighten the bolts finger tight at this stage.
1. NOTE: Make sure that new bolts are installed.

Vehicles without Auto-Start-Stop

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27. NOTE: Only tighten the bolts finger tight at this stage.
1. NOTE: Make sure that new bolts are installed.

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All vehicles

28. Torque:
1-5 10 Nm
6-7
Stage 1:15 Nm
Stage 2:90°

29. Torque: 25 Nm

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30. Torque: 6 Nm

31. NOTE: Make sure that new components are installed.

Torque: 10 Nm

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32. NOTE: Make sure that a new component is installed.
Torque: 10 Nm

33. 1. NOTE: Make sure that a new component is installed.

2. NOTE: Install all the bolts finger tight before final tightening.
Torque:
2 10 Nm
3 10 Nm

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34. 1.
2. NOTE: Install all the bolts finger tight before final tightening.
Torque: 10 Nm

35. NOTE: Only tighten the nuts and bolts finger tight at this stage.

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36. Torque:
1-4 19 Nm
1-4 24 Nm
1-4 24 Nm
5 10 Nm
6 25 Nm

37. Torque: 6 Nm

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38. 1. NOTE: Install all the bolts finger tight before final tightening.
Torque:
1 10 Nm
2 10 Nm

2. Use the General Equipment: Hose Clamp Remover/Installer

39. Torque: 25 Nm

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40. Torque: 25 Nm

41. Torque: 25 Nm

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42.

43. Install the General Equipments: Lifting Bracket, Floor Crane

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44. Remove Special Service Tool: 303-1473.
Remove the General Equipment: Mounting Stand

45.
1. Install Special Service Tool: 303-1602.

2. NOTE: Make sure that new bolts are installed.

Torque:
1-6
Stage 1:10 Nm
Stage 2:25 Nm
Stage 3:50 Nm
Stage 4:90°

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3. Remove Special Service Tool: 303-1602.

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46. Refer to: Clutch Disc and Pressure Plate (308-01B Clutch, Removal and Installation).

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Engine Cooling - 1.0L EcoBoost

(74kW/100PS)/1.0L EcoBoost
(90kW/120PS)/1.0L EcoBoost
(103kW/140PS) (YY) - Specifications
Print

LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES

SPECIFICATIONS

Material: WSS-M97B44-D (Antifreeze)

CAPACITIES

INITIAL FILL VOLUME

1.1L Duratec 5.1 L

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1.0L EcoBoost (Manual Transmission) 5.6 L

1.0L EcoBoost (Automatic Transmission) 7.2 L

ANTIFREEZE

PERCENT ANTIFREEZE/COOLANT TO DISTILLED WATER FREEZE PROTECTION

42/58 -26°C

58/42 (Extreme Cold Climates) -50°C

THERMOSTAT

Thermostat (starts to open) 92 ± 2°C

Thermostat (fully open) 106°C

Cylinder Block Thermostat (starts to open) 50 ± 2°C

Cylinder Block Thermostat (fully open) 65°C

COOLING SYSTEM PRESSURE

DESCRIPTION PRESSURE

Coolant expansion tank cap release pressure 1.4 bar

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Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine Cooling -
Component Location
Print

Description and Operation

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Item Description
1 Coolant expansion tank
2 Coolant pump
3 Electric coolant pump
4 Radiator
5 Thermostat

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Item Description
1 Cooling fan
2 Oil Cooler
3 Thermostat housing with thermostat

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Engine Cooling - 1.0L EcoBoost

(74kW/100PS)/1.0L EcoBoost
(90kW/120PS)/1.0L EcoBoost
(103kW/140PS) (YY) - Engine Cooling -
Overview
Print

Description and Operation

Special features
A three circuit cooling system is used on this engine. In addition to the conventional
thermostat for the small and large coolant circuit, a further thermostat for controlling a
mini coolant circuit is used.
The mini coolant circuit means that the coolant only flows through the exhaust side of the
cylinder head during the first stage of the warm-up phase. From here the coolant
arrives at the oil cooler via the heat exchanger and from there it is passed to the coolant
pump. In this phase there is no coolant flow in the cylinder block nor on the intake side of
the cylinder head.
This leads to rapid warm-up of the engine and the engine oil, through which the friction at
the lubrication points is reduced at an early stage.

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Furthermore, in addition to the usual mechanical coolant pump, an electric coolant pump
is installed in the coolant circuit.

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Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L

EcoBoost (103kW/140PS) (YY) - Engine Cooling - System Operation and Component
Description
Print

Description and Operation

System Diagram

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Item Description
1 Reservoir
2 Heat exchanger
3 Oil cooler
4 Thermostat housing – small/large coolant circuit and bypass valve
5 Cylinder head – exhaust side
6 Short block thermostat
7 Cylinder block and cylinder head – intake side
8 Mechanical coolant pump
9 Electric coolant pump
10 Turbocharger
11 Radiator

System Operation
Cooling system function
The cooling system is controlled in 3 phases.
Phase 1

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When the engine is cold, the small/large coolant circuit thermostat and the short block
thermostat are closed.
The mechanical coolant pump delivers the coolant only to the exhaust-side part of the
cylinder head. In this phase, the coolant in the coolant jacket around the cylinder and in the
intake-side part of the cylinder head remains motionless.
Below a coolant temperature of approximately 50°C and below an engine speed of
approximately 3000 rpm, only the exhaust-side part of the cylinder head is cooled.

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Item Description
1 Reservoir
2 Heat exchanger
3 Oil cooler
4 Casing – Thermostat – Small/large coolant circuit and bypass valve
5 Cylinder head – exhaust side
6 Short block thermostat
7 Cylinder block and cylinder head – intake side
8 Mechanical coolant pump
9 Electric coolant pump
10 Turbocharger
11 Radiator
The coolant flows from the part of the cylinder head on the exhaust side into the thermostat
housing in the small/large coolant circuit and bypass valve and, from there, via the heater
core to the oil cooler and then back to the coolant pump.
In addition, part of the coolant flows from the short block through the electrical coolant
pump and, from there, on past the exhaust gas turbocharger to the coolant expansion tank
and then back to the coolant pump.

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Item Description
1 Coolant flow from oil cooler
2 Coolant flow to heat exchanger
3 Small/large coolant circuit thermostat
4 Bypass valve
5 Coolant flow to mechanical coolant pump
6 Coolant flow from exhaust-side part of the cylinder head
Below a coolant temperature of approximately 50°C and below an engine speed of
approximately 3000 rpm, the small/large coolant circuit thermostat and the bypass valve are
closed.

Item Description
1 Coolant flow from oil cooler

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2 Coolant flow to heat exchanger

3 Small/large coolant circuit thermostat
4 Bypass valve
5 Coolant flow to mechanical coolant pump
6 Excessive coolant flow from exhaust-side part of the cylinder head
If the engine speed exceeds approximately 3000 rpm, the bypass valve opens. The now
increased coolant pressure from the engine opens the bypass valve so that the increase
pressure can escape directly to the intake side of the coolant pump.
Phase 2

The short block thermostat opens at a coolant temperature of 50 °C and is completely open
at 85 °C.
As with a conventional system, this opens the small coolant circuit.
The coolant pump now also delivers the coolant to the cooling jacket around the cylinder,
washes around it and enters the entire cylinder head via the bore holes.

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Item Description
1 Reservoir
2 Heat exchanger
3 Oil cooler
4 Thermostat housing – small/large coolant circuit and bypass valve
5 Cylinder head – exhaust side
6 Short block thermostat
7 Cylinder block and cylinder head – intake side
8 Mechanical coolant pump
9 Electric coolant pump

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10 Turbocharger
11 Radiator
Phase 3

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Item Description
3 Small/large coolant circuit thermostat
4 Bypass valve
7 Coolant flow to the radiator
The small/large coolant circuit thermostat opens at a coolant temperature of 92 °C and is
completely open at 106 °C. At the same time, the bypass valve thermostat closes. This
ensures that the entire coolant flow, regardless of the coolant pressure, is always routed via
the radiator.

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Item Description
1 Reservoir
2 Heat exchanger
3 Oil cooler
4 Casing – Thermostat – Small/large coolant circuit and bypass valve
5 Cylinder head – exhaust side
6 Short block thermostat
7 Cylinder block and cylinder head – intake side
8 Mechanical coolant pump
9 Electric coolant pump
10 Turbocharger
11 Radiator

Component Description
Electric coolant pump

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With this engine, in addition to the usual mechanical coolant pump, an electric coolant pump
is installed in the coolant circuit.
The pump is secured onto the cooling fan housing via a retaining device.
The coolant pump is only activated whenever the coolant temperatures exceeds a
critical value. This can occur in particular if the engine has been operated at a high load for
a long time and is then parked immediately afterwards. For example, after a long motorway
journey at high speed, with subsequent parking at a service station. This can lead to an
excessive build-up of heat around the engine after the engine has been switched off.
The PCM (powertrain control module) activates the electric coolant pump to prevent any
damage due to this build-up of heat.
It can therefore be the case that the electrical coolant pump continues to run for a certain
period of time.

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Item Description
1 Reservoir
2 Heat exchanger
3 Oil cooler
4 Thermostat housing – small/large coolant circuit and bypass valve
5 Cylinder head – exhaust side
6 Short block thermostat
7 Cylinder block and cylinder head – intake side
8 Mechanical coolant pump
9 Electric coolant pump
10 Turbocharger
11 Radiator
With the electrical coolant pump activated, the coolant flows through the exhaust gas
turbocharger to the coolant expansion tank and from there through the mechanical coolant
pump in the short block to the electrical coolant pump.

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Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine Cooling
System Draining, Vacuum Filling and Bleeding
Print

General Procedures
General Equipment
Cooling System Vacuum Tester and Refiller
Fluid Container

Draining
1. Refer to: Engine Cooling System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2.

WARNING: When releasing the cooling system pressure, cover the coolant
expansion tank cap with a thick cloth to prevent the possibility of scalding. Failure
to follow this instruction may result in personal injury.

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3. Remove the following items:
• Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
4.

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5.

6.

7. NOTE: Be prepared to collect escaping fluid.

Use the General Equipment: Fluid Container

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Loosen: 2 turn(s)

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8. Torque: 2 turn(s)

9. Torque: 10 Nm

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10. Torque: 10 Nm

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11.

12. Install the following items:

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• Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).

Filling
NOTE: Always follow the manufacturer's instructions when handling the equipment.
1. Refer to: Specifications (303-03A Engine Cooling, Specifications).

2. Install the vacuum cooling system filler and follow the manufacturer's instructions to fill
and bleed the system.

Use the General Equipment: Cooling System Vacuum Tester and Refiller
3. Fill the coolant expansion tank to the top of the MAX FILL line.
4. Install the degas bottle coolant expansion tank cap until it contacts the hard stop.

Bleeding
1. Turn the climate control system off.
2. Start the engine and increase the engine speed to 3,500 rpm and hold for 30 seconds.
3. Turn the engine off and wait for 1 minute to purge any large air pockets from the
cooling system.
4. Check the engine coolant level in the coolant expansion tank and, if necessary, fill to the

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top of the MAX FILL line.
5. Start the engine and let it idle until the engine reaches normal operating temperature
and the thermostat is fully open.
6. Increase the engine speed to 3,500 rpm and hold for 30 seconds.
7. Allow the engine to idle for 30 seconds.
8. Turn the engine off for 1 minute.
9. Repeat steps 6 through 8 a total of 10 times to remove any remaining air trapped in the
system.
10. Check the engine coolant level in the coolant expansion tank and, if necessary, fill to the
top of the MAX FILL line.

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Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Coolant Pump
Print

Removal and Installation

Removal

1. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

2. Loosen: 2 turn(s)

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3. Refer to: Accessory Drive Belt (303-05A Accessory Drive, Removal and Installation).
4.

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Vehicles without Auto-Start-Stop

5.

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Vehicles with Auto-Start-Stop
6.

Installation
Vehicles with Auto-Start-Stop
1. NOTE: Only tighten the bolts finger tight at this stage.
1. NOTE: Make sure that new components are installed.

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Vehicles without Auto-Start-Stop
2. NOTE: Only tighten the bolts finger tight at this stage.
1. NOTE: Make sure that new components are installed.

All vehicles

3. Torque:
1-5 10 Nm
6-7
Stage 1:15 Nm
Stage 2:90°

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4. NOTE: Only tighten the bolts finger tight at this stage.

5. Refer to: Accessory Drive Belt (303-05A Accessory Drive, Removal and Installation).

6. Torque: 25 Nm

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7. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

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Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Cooling Fan Motor
and Shroud—6-Speed Manual Transmission – 6MX65
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).
2.

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3.

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4. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
5.

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6.

7.

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Installation

1. To install, reverse the removal procedure.

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Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Cylinder Block
Thermostat
Print

Removal and Installation

General Equipment
Hose Clamp Remover/Installer

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

2. Refer to: Generator - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L

EcoBoost (103kW/140PS) (YY) (414-02 Generator and Regulator, Removal and
Installation).

3. Use the General Equipment: Hose Clamp Remover/Installer

4. NOTE: Make sure that new O-ring seals are installed.

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Torque: 10 Nm

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Installation

1. To install, reverse the removal procedure.

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Engine Cooling - 1.0L EcoBoost

(74kW/100PS)/1.0L EcoBoost
(90kW/120PS)/1.0L EcoBoost
(103kW/140PS) (YY) - Electric Coolant
Pump
Print

Removal and Installation

Removal and Installation

1. Refer to: Charge Air Cooler (CAC) Coolant Pump (303-12A Intake Air Distribution and
Filtering, Removal and Installation).

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Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Radiator—6-Speed
Manual Transmission – 6MX65
Print

Removal and Installation

Removal

1. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).

2. Refer to: Cooling Fan Motor and Shroud - 6-Speed Manual Transmission – 6MX65 (303-
03A Engine Cooling, Removal and Installation).
3.

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4.

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5.

Installation

1. To install, reverse the removal procedure.

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Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Thermostat
Housing
Print

Removal and Installation

General Equipment
Hose Clamp Remover/Installer

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).
2.

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3.

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4. NOTE: Be prepared to collect escaping fluid.
Use the General Equipment: Hose Clamp Remover/Installer

5. NOTE: Be prepared to collect escaping fluid.

Use the General Equipment: Hose Clamp Remover/Installer

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6. Torque: 10 Nm

Installation

1. To install, reverse the removal procedure.

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Fuel Charging and Controls - 1.0L EcoBoost (74kW/100PS)/1.0L

EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Fuel
Charging and Controls - Component Location
Print

Description and Operation

Low-pressure System

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Item Description
1 FPDM (fuel pump driver module) – bolted to the vehicle floor from the inside
2 Fuel pump unit
3 Fuel line
4 Fuel pressure sensor – (low pressure)
High-pressure System

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Item Description
1 High-pressure fuel line
2 High-Pressure Fuel Rail
3 Fuel Pressure Sensor
4 injectors
5 Mounting, high-pressure pump
6 High-pressure pump

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Fuel Charging and Controls - 1.0L

EcoBoost (74kW/100PS)/1.0L EcoBoost
(90kW/120PS)/1.0L EcoBoost
(103kW/140PS) (YY) - Fuel Charging and
Controls - Overview
Print

Description and Operation

General information
Direct petrol injection systems feature high-pressure fuel injection directly into the
combustion chamber.
The air/fuel mixture is produced inside the combustion chamber in the same way as in a
diesel engine (internal mixture formation).

The direct petrol injection system consists basically of the following components:
• High-pressure pump
• High-Pressure Fuel Rail
• injectors

The high pressure fuel pipe connects the high pressure pump to the fuel rail.

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The fuel pressure sensor and the jacking points for the fuel injectors are on the fuel rail.
Advantage of direct fuel injection compared with intake manifold injection
With intake manifold injection, fuel is injected into the intake port. The injected fuel
comes into contact with the surfaces of the intake port and the fuel injector during this
process. Depending on the prevailing wall and mixture temperature, this causes fuel to
condense on the surfaces of the components and thus a wall film forms.
The fuel which is deposited as a wall film is called wall film loss.
Direct fuel injection offers few impediments to the fuel flow. The wall film losses are
therefore also correspondingly low. This has a positive effect on the fuel consumption and
exhaust emissions.
Cooling effect
The temperature in the combustion chamber is reduced through direct injection of the fuel.
This increases the geometric compression ratio relative to a comparable turbo engine
with intake manifold injection and thus increases the efficiency of the engine.
Demand-based fuel low pressure control
The fuel low pressure system has no fuel return. The fuel low pressure is regulated
according to demand in accordance with the engine operating conditions.
A separate FPDM (fuel pump driver module), which is accessible from the passenger
compartment, is installed to control the fuel pressure. This sets the required fuel pressure
according to information from the PCM (powertrain control module).

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Fuel Charging and Controls - 1.0L EcoBoost (74kW/100PS)/1.0L

EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Fuel
Charging and Controls - System Operation and Component Description
Print

Description and Operation

System Operation
High-pressure generation
The electric fuel pump supplies fuel to the high-pressure pump.
The high-pressure pump creates the fuel system pressure, depending on the engine
operating point.
The fuel reaches the fuel rail under high pressure and is stored there.
The fuel pressure is measured by the fuel pressure sensor. A fuel pressure of between 40
and 150 bar is set by the fuel metering valve.
The fuel injectors are located on the fuel rail. They are controlled by the PCM (powertrain
control module) and inject the fuel into the combustion chamber of the cylinder.
Combustion process

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With direct petrol injection, the term "combustion process" describes the way in which the
mixture is formed and energy is converted.
On this engine the spray-guided combustion process is used. The fuel injectors are
located centrally at the top of the combustion chamber in the relevant cylinder, centered
between the intake and exhaust valves. This enables even more uniform distribution of the
fuel - and therefore even more optimized mixture formation - in the combustion chamber.

Component Description
High-pressure pump

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Item Description
1 High-pressure pump
2 Triple cam
3 Bucket tappets
4 O-ring
5 Pump tappet
The high-pressure pump of the type HDP5 is a cam-driven single-cylinder pump that is
immersed in fluid.

The following are integrated in the pump:

• the fuel metering valve,
• a pressure relief valve on the high-pressure side and
• a pressure damper on the low-pressure side.

The pump piston plunger is driven by a triple cam. The cam is part of the intake camshaft.
A bucket tappet forms the interface between the triple cam on the intake camshaft and the
pump piston plunger.
The seal to the high pressure pump is made using an O-ring.
The quantity of fuel delivered to the fuel rail is controlled via a fuel metering valve. The
delivered fuel quantity depends on the engine speed and the actuation of the fuel metering
valve.
The high-pressure pump generates a maximum fuel pressure of 150 bar.
NOTE: The fuel metering valve cannot be replaced separately during servicing. In the
event of a fault, the complete high-pressure pump must be replaced.
High-pressure fuel line

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NOTE: Each time the high-pressure fuel line is disconnected, a new one must always be
installed. Reason: the union nuts of the old line may deform and cause leaks when they
are retightened.
injectors

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Item Description
1 Spacer ring
2 Combustion chamber seal
3 Support washer
4 O-ring
5 Holding-down device
6 High-Pressure Fuel Rail
7 Fuel Pressure Sensor

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8 Injector
The fuel injectors, together with the fuel rail, are mounted on the cylinder head from above.
As a result no additional high-pressure fuel lines are required.
NOTE: The retaining bolts of the fuel rail must be loosened and tightened in a particular
sequence. The instructions in the current workshop literature must be observed here.
At the upper end of the fuel injector there is an O-ring for creating the seal to the fuel rail.
A washer under the O-ring supports it and therefore ensures an accurate seat.
The combustion chamber sealing ring (Teflon ring) at the lower end of the injector seals the
injector towards the combustion chamber.
Note: A special tool must be used to install a new combustion chamber sealing ring. The
instructions in the current workshop literature must be observed for this.
There is a holding-down device between each fuel injector and each seat in the fuel rail.
These tappet hold down tools pretension the fuel injectors. The fuel injector is supported on
a spacer ring. This ensures that the fuel injectors are accurately seated in the combustion
chamber openings on the cylinder head.
Service instructions

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Item Description
1 Fuel injector jacking point on the fuel rail
2 Fuel injector electrical line
3 Holding-down device
4 Body guide
After removing the fuel injectors, the bodies must be replaced.
Before installing the fuel rail, the fuel injectors must be aligned in the correct position. To
do this, the body must be pushed into the guide on the fuel injector. Ensure that the
electrical line of the fuel injector does not become trapped (arrow).

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Fuel Charging and Controls - 1.0L

EcoBoost (74kW/100PS)/1.0L EcoBoost
(90kW/120PS)/1.0L EcoBoost
(103kW/140PS) (YY) - Fuel Injector
Print

Removal and Installation

Removal and Installation

1. Refer to: Fuel Rail (303-04A Fuel Charging and Controls, Removal and Installation).

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Fuel Charging and Controls - 1.0L EcoBoost (74kW/100PS)/1.0L

EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Fuel Rail
Print

Removal and Installation

Special Tool(s)
205-047
Slide Hammer

205-047-08
Adapter for 205-047

310-128
Installer Set, Teflon Seal

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310-206
Remover, Fuel Injector

Removal

1. Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information,
General Procedures).
2. Remove the following items:
• Refer to: Ignition Coil-On-Plug (303-07A Engine Ignition, Removal and
Installation).

3.

WARNING: Fuel may remain pressurized in some fuel lines after the Fuel
System Pressure Release procedure. Wear safety gloves and a face shield when
disconnecting pressure lines to avoid skin and eye contact. Failure to follow this
instruction may result in serious personal injury.
NOTE: Be prepared to collect escaping fluid.
Always wrap the fuel line connection with a towel before disconnecting it.

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4.

5. NOTICE: Take extra care when handling the components.

NOTE: Only use moderate force.

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6. NOTICE:

Take extra care when handling the components.

Make sure that the component is clean, free of foreign material and lubricant.
NOTE: Only use moderate force.

7. NOTICE: Take extra care when handling the components.

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8. NOTE: This step is only necessary if the component remains in the cylinder head.

9. NOTE: This step is only necessary if the component remains in the cylinder head.
Use Special Service Tools: 205-047, 310-206, 205-047-08.

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10. NOTICE:

Take extra care when handling the components.

Make sure that the component is clean, free of foreign material and lubricant.

Installation

1. NOTICE: Make sure that the component is clean, free of foreign material and
lubricant.
NOTE: Make sure that new components are installed.

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2. NOTICE: Make sure that the area around the component is clean and free of
foreign material.
1. Use Special Service Tool: 310-128.

2. NOTE: Use a new seal.

3. 3. NOTICE: Take extra care not to damage the seal.

To install the seal, position the tool with the smaller opening towards the seal.
4. Remove Special Service Tool: 310-128.

3.
1. Use Special Service Tool: 310-128.

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2. Position the tool with the larger opening towards the seal. Push while turning the
tool 180 degrees.
3. Once the tool is installed, check and make sure the seal is in the sizing portion of
the tool.
4. After one minute, turn the tool back 180 degrees and remove the tool.

Remove Special Service Tool: 310-128.

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

5. NOTICE:

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Take extra care when handling the components.

Make sure that the component is clean, free of foreign material and lubricant.

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6.

7. 1. NOTE: Only use moderate force.

2. NOTE: Only tighten the bolts finger tight at this stage.
Tighten each bolt 1 turn at a time.
3.

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8. Torque: 23 Nm

9. 1. NOTE: Make sure that a new component is installed.

NOTE: Only tighten the nuts finger tight at this stage.
2. Torque:
Stage 1:14 Nm
Stage 2:20 Nm
Stage 3:20°

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10.

11. Refer to: Ignition Coil-On-Plug (303-07A Engine Ignition, Removal and Installation).

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Fuel Charging and Controls - 1.0L EcoBoost (74kW/100PS)/1.0L

EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - High-
Pressure Fuel Pump
Print

Removal and Installation

Special Tool(s)
310-137
Disconnect Tool, Fuel Line

Removal

1. Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information,
General Procedures).

2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).

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3.

4.

WARNING: Fuel may remain pressurized in some fuel lines after the Fuel
System Pressure Release procedure. Wear safety gloves and a face shield when
disconnecting pressure lines to avoid skin and eye contact. Failure to follow this
instruction may result in serious personal injury.

NOTICE: Make sure that the quick release couplings are correctly engaged.
NOTE: Be prepared to collect escaping fluid.
NOTE: Always wrap the fuel line connection with a towel before disconnecting it.
Use Special Service Tool: 310-137.

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5.

WARNING: Fuel may remain pressurized in some fuel lines after the Fuel
System Pressure Release procedure. Wear safety gloves and a face shield when
disconnecting pressure lines to avoid skin and eye contact. Failure to follow this
instruction may result in serious personal injury.
NOTE: Be prepared to collect escaping fluid.
NOTE: Always wrap the fuel line connection with a towel before disconnecting it.

6. Loosen each bolt 1 turn at a time until all bolts are removed.

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7.

Installation

1.

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2. NOTE: Component(s) must be lubricated with clean engine oil.

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3. 1. NOTE: Use a new seal.
NOTE: Component(s) must be lubricated with clean engine oil.
2. NOTE: Only use moderate force.

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4. 1. NOTE: Make sure that new bolts are installed.
NOTE: Only tighten the bolts finger tight at this stage.
Tighten each bolt 0.5 turn at a time.
2. Torque:
Stage 1:5 Nm
Stage 2:13 Nm

5. 1. NOTE: Make sure that a new component is installed.

NOTE: Only tighten the nuts finger tight at this stage.
2. Torque:
Stage 1:14 Nm
Stage 2:20 Nm
Stage 3:20°

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6.

7.

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8. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).

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Fuel Charging and Controls - 1.0L

EcoBoost (74kW/100PS)/1.0L EcoBoost
(90kW/120PS)/1.0L EcoBoost
(103kW/140PS) (YY) - High-Pressure
Fuel Pump Drive Unit
Print

Removal and Installation

Materials
Name Specification
Sealant WSK-M2G348-A5

Removal

1. Refer to: Valve Cover (303-01A Engine, Removal and Installation).

2.

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Installation

1. NOTICE: Make sure that the mating faces are clean and free of foreign
material.
NOTE: The component must be installed within 5 minutes of applying the sealant.
Material: WSK-M2G348-A5 (Sealant)

2. Torque: 10 Nm

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3. Refer to: Valve Cover (303-01A Engine, Removal and Installation).

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Fuel Charging and Controls - 1.0L EcoBoost (74kW/100PS)/1.0L

EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Throttle
Body
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.
1. Torque: 15 Nm

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2.

3. Torque: 8 Nm

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Installation

1. To install, reverse the removal procedure.

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Fuel Charging and Controls - Turbocharger - 1.0L EcoBoost

(74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost
(103kW/140PS) (YY) - Turbocharger
Print

Description and Operation

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Item Description
1 Recirculated air valve
2 TC (turbocharger) pressure control
3 Vacuum line
4 Ambient air line (to intake pipe)
5 Boost pressure control solenoid valve
6 Vacuum pump
7 Coolant inlet hose connection
8 Coolant outlet hose connection

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Item Description
1 Oil supply tube
2 Oil return tube

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Fuel Charging and Controls - Turbocharger - 1.0L EcoBoost

(74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost
(103kW/140PS) (YY) - Turbocharger
Print

Removal and Installation

General Equipment
Hose Clamp(s)
Hose Clamp Remover/Installer

Removal

1. Refer to: Catalytic Converter (309-00A Exhaust System, Removal and Installation).
2.
1. Use the General Equipment: Hose Clamp Remover/Installer

2. Install the General Equipment: Hose Clamp(s)

3.
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4.

5.

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6.

Installation

1. NOTE: Make sure that a new component is installed.

NOTE: Install all the bolts finger tight before final tightening.
Torque: 10 Nm

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2. NOTE: Make sure that a new component is installed.
Torque: 10 Nm

3. Torque: 10 Nm

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4. NOTE: Make sure that new nuts are installed.
NOTE: Only tighten the nuts and bolts finger tight at this stage.

5. Torque:
1-4
Stage 1:19 Nm
Stage 2:24 Nm
Stage 3:Wait 30 s
Stage 4:24 Nm
5 10 Nm
6 30 Nm

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6.

7.
1. Use the General Equipment: Hose Clamp Remover/Installer

2. Remove the General Equipment: Hose Clamp(s)

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8. Refer to: Catalytic Converter (309-00A Exhaust System, Removal and Installation).

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Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L

EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) -
Electronic Engine Controls - Component Location
Print

Description and Operation

Front of Engine

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Item Description
1 VCT (variable camshaft timing) oil control solenoid - intake camshaft
2 VCT oil control solenoid - exhaust camshaft
3 Turbocharger boost pressure sensor
4 CKP (crankshaft position) sensor
Top of Engine

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Item Description
1 Crankcase pressure sensor
2 CMP (camshaft position) sensor - exhaust camshaft
3 FRP (fuel rail pressure) sensor
4 CMP sensor - intake camshaft
5 MAPT (manifold absolute pressure and temperature) sensor
6 PCM (powertrain control module)
7 MAFT (mass air flow and temperature) sensor
8 ECT (engine coolant temperature) sensor
9 Catalyst monitor sensor
10 HO2S (heated oxygen sensor)
Right Side of Engine

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Item Description
1 KS (knock sensor)
2 EOP (engine oil pressure) sensor
3 Engine oil level and temperature sensor
4 Engine oil pressure control solenoid
CPP (clutch pedal position) Switches

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Item Description
1 CPP switch - top of travel
2 CPP switch - bottom of travel

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Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Camshaft Position
(CMP) Sensor
Print

Removal and Installation

Removal

1. NOTE: The O-ring seal is to be reused unless damaged.

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Installation

1. 1. NOTE: The O-ring seal is to be reused unless damaged.

NOTE: Component(s) must be lubricated with clean engine oil.
2. Torque: 10 Nm

3.

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Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Catalyst Monitor
Sensor
Print

Removal and Installation

Special Tool(s)
303-476
Socket, Exhaust Gas Oxygen Sensor

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

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2.
Use Suggested Tool: 303-476. Tool shown or a commercially available equivalent can be
used.
Torque: 48 Nm

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Installation

1. To install, reverse the removal procedure.

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Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Crankshaft
Position (CKP) Sensor
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

2. Torque: 10 Nm

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Installation

1. To install, reverse the removal procedure.

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Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Cylinder Head
Temperature (CHT) Sensor
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Remove the following items:
• Refer to: Turbocharger (303-04F Fuel Charging and Controls - Turbocharger,
Removal and Installation).
2. NOTE: Make sure that a new component is installed.
Torque: 11 Nm

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Installation

1. To install, reverse the removal procedure.

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Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine Coolant
Temperature (ECT) Sensor
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Engine Cooling System Health and Safety Precautions (100-00 General
Information, Description and Operation).

2.

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3.

4.
NOTE: Be prepared to collect escaping fluid.

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Installation

1. To install, reverse the removal procedure.

2. NOTICE: Make sure that fluid level is to the MAX mark.

Refer to: Specifications (303-03A Engine Cooling, Specifications).

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Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Fuel Rail Pressure
(FRP) Sensor
Print

Removal and Installation

Materials
Name Specification
Lubricant Spray -

Removal

1. Release the fuel system pressure.

Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information,
General Procedures).

2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).

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3.

WARNING: Fuel may remain pressurized in some fuel lines after the Fuel
System Pressure Release procedure. Wear safety gloves and a face shield when
disconnecting pressure lines to avoid skin and eye contact. Failure to follow this
instruction may result in serious personal injury.
NOTICE:

Make sure that the area around the component is clean and free of foreign
material.

Extreme cleanliness must be exercised when handling the component.

Make sure that all openings are sealed with clean blanking caps.
NOTE: Be prepared to collect escaping fluid.

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Installation

1. NOTE: The component must be installed by hand before final tightening.

Lubricate sealing cone and thread with silicone free oil only.

Material: - (Lubricant Spray)

Torque: 33 Nm

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2. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).

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Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Heated Oxygen
Sensor (HO2S)
Print

Removal and Installation

Special Tool(s)
303-476
Socket, Exhaust Gas Oxygen Sensor

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

2. 1. cardiagn.com
2. Use Suggested Tool: 303-476. Tool shown or a commercially available equivalent
can be used.
Torque: 48 Nm

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Installation

1. To install, reverse the removal procedure.

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Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Knock Sensor (KS)
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2.

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3. NOTE: Make sure that the component is installed to the position noted before
removal.
NOTE: Note the position of the component before removal.
Torque: 20 Nm

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Installation

1. To install, reverse the removal procedure.

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Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Manifold Absolute
Pressure (MAP) Sensor
Print

Removal and Installation

General Equipment
Hose Clamp Remover/Installer

Removal

1.
1. Use the General Equipment: Hose Clamp Remover/Installer
Torque: 11 Nm

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2. Torque: 4 Nm

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Installation

1. To install, reverse the removal procedure.

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Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Manifold Absolute
Pressure and Temperature (MAPT) Sensor
Print

Removal and Installation

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Torque: 8 Nm

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Installation

1. To install, reverse the removal procedure.

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Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Powertrain Control
Module (PCM)
Print

Removal and Installation

General Equipment
Ford approved diagnostic tool
Ford Diagnostic Equipment

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. NOTE: This step is only necessary when installing a new component.
Download the module information to the diagnostic tool using the Programmable
Modules Installation routine.

Use the General Equipment: Ford Diagnostic Equipment

2.

Vehicles without powertrain control module (PCM)

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security shield
3. Remove the following items:
• Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and
Installation).
4.

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5.

6. Torque: 5 Nm

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Vehicles with powertrain control module (PCM) security
shield
7. Remove the following items:
• Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and
Installation).

Installation

1. To install, reverse the removal procedure.

2. NOTE: This step is only necessary when installing a new component.
Upload the PCM configuration information into the PCM, using the Programmable
Modules Installation routine.

Use the General Equipment: Ford approved diagnostic tool

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Electronic Engine Controls - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Variable Camshaft
Timing (VCT) Oil Control Solenoid
Print

Removal and Installation

General Equipment
Hose Clamp Remover/Installer

Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
General Procedures).
2.

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3.
1. Use the General Equipment: Hose Clamp Remover/Installer
Torque: 11 Nm

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4.
1. Torque: 15 Nm

5.

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6. NOTE: Note the position of the components before removal.
NOTE: The O-ring seals are to be reused unless damaged.
NOTE: Discard the bolts.

Installation

1. To install, reverse the removal procedure.

2. NOTE: Make sure that the components are installed to the position noted before
removal.
1. NOTE: Component(s) must be lubricated with clean engine oil.
2. NOTE: Make sure that new bolts are installed.
Torque: 7 Nm

3.

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Fuel System - General Information - 1.0L EcoBoost (74kW/100PS)/1.0L

EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Fuel
System Pressure Check
Print

General Procedures
Special Tool(s) / General Equipment
310-025-18
Test Hose for 310-025

310-025-19A
Test Hose for 310-025

310-137
Disconnect Tool, Fuel Line

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Ford Diagnostic Equipment
GV2323 Connector
Pressure Vacuum Transducer (C219) Adapter
Pressure Vacuum Transducer (C407)

Connect
1. Refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety Precautions
(100-00 General Information, Description and Operation).

2. Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information,
General Procedures).
3.

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4.
NOTE: Use suitable paper to absorb any escaping fluid.
NOTE: Be prepared to collect escaping fluid.
Always wrap the fuel line connection with a towel before disconnecting it.

Use Special Service Tool: 310-137.

5. Install Special Service Tools: 310-025-18, 310-025-19A.

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6. Install Special Service Tools: 310-025-18, 310-025-19A.
Use the General Equipment: GV2323 Connector

7. Connect the following items:

• Use the General Equipment: GV2323 Connector

• Use the General Equipment: Pressure Vacuum Transducer (C219) Adapter

8. Connect the following items:

• Use the General Equipment: Pressure Vacuum Transducer (C407)

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• Use the General Equipment: Pressure Vacuum Transducer (C219) Adapter

Check
1. Using the digital multi-meter function, measure the fuel system pressure.

Use the General Equipment: Ford Diagnostic Equipment

2. Use the General Equipment: Ford Diagnostic Equipment

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3. Use the General Equipment: Ford Diagnostic Equipment

Disconnect
1. NOTE: Be prepared to collect escaping fluid.
Release the fuel system pressure.

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2. Disconnect the following items:

• Use the General Equipment: Pressure Vacuum Transducer (C407)

• Use the General Equipment: Pressure Vacuum Transducer (C219) Adapter

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3. Disconnect the following items:
• Use the General Equipment: GV2323 Connector

• Use the General Equipment: Pressure Vacuum Transducer (C219) Adapter

4. Remove Special Service Tools: 310-025-19A, 310-025-18.

Use the General Equipment: GV2323 Connector

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5. Remove Special Service Tools: 310-025-19A, 310-025-18.

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6.

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7.

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Fuel System - General Information - 1.0L EcoBoost (74kW/100PS)/1.0L

EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Fuel
System Pressure Release
Print

General Procedures

Pressure release
1. Refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety Precautions
(100-00 General Information, Description and Operation).
2.

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3. Start the engine and allow it to idle until the engine stalls.
4. Crank the engine for approximately five seconds to make sure that the fuel rail pressure
is released.
5.

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Fuel System - General Information - 1.0L EcoBoost (74kW/100PS)/1.0L

EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Fuel
Tank Draining
Print

General Procedures
General Equipment
Fuel Tank Draining Equipment
Hose Clamp(s)
Hose Clamp Remover/Installer

Draining

WARNING: 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 may be
present and may be ignited. Failure to follow these instructions may result in serious
personal injury.

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1. Refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety Precautions
(100-00 General Information, Description and Operation).

2. Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

3. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
4. NOTE: Use suitable paper to absorb any escaping fluid.
NOTE: Be prepared to collect escaping fluid.
• Use the General Equipment: Hose Clamp Remover/Installer

• NOTICE: Only use the specified general equipment.

Install the General Equipment: Hose Clamp(s)

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5. 1. NOTE: Use suitable paper to absorb any escaping fluid.

NOTE: Be prepared to collect escaping fluid.
Remove the General Equipment: Hose Clamp(s)

2. Drain the reservoir.

Use the General Equipment: Fuel Tank Draining Equipment

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6. NOTE: Make sure that a new clamp is installed.
NOTE: Make sure that the clamp is installed to the same orientation as when
removed.

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Fuel System - General Information - 1.0L EcoBoost (74kW/100PS)/1.0L

EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Quick
Release Coupling
Print

General Procedures

Check
1. Refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety Precautions
(100-00 General Information, Description and Operation).

Disconnect
NOTE: Type 1
1.

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2.

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Connect
1.

2.

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Disconnect
NOTE: Type 2
1.

Connect
1.

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Disconnect
NOTE: Type 3
1.

Connect
1.

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2.

Disconnect
NOTE: Type 4
1.

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Connect
1.

Disconnect
NOTE: Type 5
1.

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Connect
1.

Disconnect
NOTE: Type 6
1.

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Connect
1.

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