Ford Fusion Manuals

Ford Fusion: Engine - 1.5L EcoBoost (118kW/160PS) – I4 / Variable Camshaft Timing (VCT) Unit. Removal and Installation

Ford Fusion 2013–2020 Service Manual / Powertrain / Engine / Engine - 1.5L EcoBoost (118kW/160PS) – I4 / Variable Camshaft Timing (VCT) Unit. Removal and Installation

Special Tool(s) / General Equipment

Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation 303-1097
Locking Tool, Variable Camshaft Timing Oil Control Unit
TKIT-2010B-FLM
TKIT-2010B-ROW
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation 303-1552
Alignment Tool, Camshaft
TKIT-2012A-FL
TKIT-2012A-ROW
Hot Air Gun
Hose Clamp Remover/Installer

Materials

Name Specification
Flange Sealant
CU7Z-19B508-A
WSS-M2G348-A11
 
Motorcraft® Metal Surface Prep Wipes
ZC-31-B
-
 
Flange Sealant - Anaerobic
Loctite® 51031
WSK-M2G348-A7
 

Removal

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

  1. Remove the following items:
    1. Remove the high-pressure fuel pump.
      Refer to: High-Pressure Fuel Pump (303-04A Fuel Charging and Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
    2. Remove the upper air cleaner outlet pipe.
      Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
    3. Remove the air cleaner.
      Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
    • Disconnect the wiring harness electrical connector and retainer.
    • Disconnect the coupling release the clamp and remove the PCV hose.
      Use the General Equipment: Hose Clamp Remover/Installer
    • Disconnect and position the brake vacuum hose aside.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
    • Detach the retainers and disconnect the electrical connectors.
    • Disconnect the TC bypass hose.
    • Loosen the clamps, remove the bolt and the TC outlet pipe.
      Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Remove the following items:
    1. Remove the valve cover.
      Refer to: Valve Cover (303-01A Engine - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
    2. Remove the timing belt.
      Refer to: Timing Belt (303-01A Engine - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
  1. Disconnect the wiring harness electrical connectors and retainer.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Remove the nuts, bracket and position the EVAP canister purge valve aside.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
    • Detach the retainer and disconnect the vacuum hose.
    • Remove the stud bolts and the vacuum pump. Discard the stud bolts.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Remove and discard the vacuum pump gasket.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Detach the retainer, remove the bolt and the exhaust CMP sensor.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Remove the bolts and the support bracket.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
    • Remove the bolts, heat and break the adhesive bond and remove the high-pressure fuel pump drive unit.
      Use the General Equipment: Hot Air Gun
    • Remove and discard the O-ring seal.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
    • Remove the engine cover mounting stud.
    • Remove the bolts and the stud.
    • Heat and break the adhesive bond and remove the brake vacuum pump cap.
      Use the General Equipment: Hot Air Gun
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Remove the bolts and the engine lifting bracket.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Remove Special Service Tool: 303-1097  Locking Tool, Variable Camshaft Timing Oil Control Unit.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

    Remove the VCT unit caps.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

    Remove the bolts and the VCT unit. Discard the bolts.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation

Installation

  1. NOTE: It may be necessary to use an open-ended wrench to turn the camshafts by the hexagon to align the camshafts.

    Install Special Service Tool: 303-1552  Alignment Tool, Camshaft.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Install the VCT unit at the 12 o'clock position.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. NOTE: The timing mark of each VCT unit must be at the 12 o'clock position.

    NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

    Install the new VCT unit bolts.
    Install Special Service Tool: 303-1097  Locking Tool, Variable Camshaft Timing Oil Control Unit.
    Torque: 18 lb.ft (25 Nm)
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Remove Special Service Tool: 303-1097  Locking Tool, Variable Camshaft Timing Oil Control Unit.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Remove Special Service Tool: 303-1552  Alignment Tool, Camshaft.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

    Tighten the VCT units bolts.
    Torque: 75°
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. NOTE: The special tool can only be installed if the valve timing is correct.

    Install Special Service Tool: 303-1552  Alignment Tool, Camshaft.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. NOTE: The timing mark of each VCT unit must be at the 12 o'clock position.

    If the special tools cannot be installed, repeat the adjustment according to the preceding steps.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Remove Special Service Tool: 303-1097  Locking Tool, Variable Camshaft Timing Oil Control Unit.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Remove Special Service Tool: 303-1552  Alignment Tool, Camshaft.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

    Install the VCT unit caps.
    Torque: 142 lb.in (16 Nm)
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. NOTE: The timing mark of each VCT unit must be at the 12 o'clock position.

    Install Special Service Tool: 303-1097  Locking Tool, Variable Camshaft Timing Oil Control Unit.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Install the engine lifting bracket and the bolts.
    Torque: 168 lb.in (19 Nm)
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

    Make sure that the mating faces are clean and free of foreign material.
    Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

    Make sure that the mating faces are clean and free of foreign material.
    Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

    Make sure that the mating faces are clean and free of foreign material.
    Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Apply a 1.5 mm (0.059 in) beads of gasket maker as shown.
    Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
    • Install the brake vacuum pump cap, bolts and the stud.
      Torque:
         1-3:  
        Stage 1:  35 lb.in (4 Nm)
        Stage 2:  89 lb.in (10 Nm)
    • Install the engine cover mounting stud.
      Torque: 44 lb.in (5 Nm)
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
    • Install the new O-ring seal.
    • Install the high-pressure fuel pump drive unit and the bolts, tighten in sequence shown in 3 stages.
      Torque:
        Stage 1:  1-8:   35 lb.in (4 Nm)
        Stage 2:  1-8:   124 lb.in (14 Nm)
        Stage 3:  9-10:   97 lb.in (11 Nm)
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Install the support bracket and the bolts.
    Torque:
       1:   97 lb.in (11 Nm)
       2:   71 lb.in (8 Nm)
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
    • Install the CMP sensor and the bolt.
      Torque: 80 lb.in (9 Nm)
    • Position the wiring harness and attach the retainer.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Install the new vacuum pump gasket.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Apply a 3 mm (0.118 in) beads of flange sealant as shown.
    Material: Flange Sealant - Anaerobic / Loctite® 51031 (WSK-M2G348-A7)
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. NOTE: Manually align the brake vacuum pump drive key with the camshaft slot before installation.

    NOTE: Install new bolts.

    • Install the vacuum pump and the stud bolts.
      Torque: 89 lb.in (10 Nm)
    • Connect the vacuum hose and attach the retainer.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Position the EVAP canister purge valve, install the bracket and the nuts.
    Torque: 62 lb.in (7 Nm)
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Connect the wiring harness electrical connectors and retainer.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Install the following items:
    1. Install the timing belt.
      Refer to: Timing Belt (303-01A Engine - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
    2. Install the valve cover.
      Refer to: Valve Cover (303-01A Engine - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
    1. Install the TC outlet pipe, bolt and tighten the clamps.
      Torque:
         2:   71 lb.in (8 Nm)
         3:   44 lb.in (5 Nm)
    1. Connect the TC bypass hose.
      Use the General Equipment: Hose Clamp Remover/Installer
    1. Attach the wiring harness retainers and connect the electrical connectors.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
    • Position and connect the brake vacuum hose.
    • Install the PCV hose.
      Use the General Equipment: Hose Clamp Remover/Installer
    • Connect the wiring harness electrical connector and retainer.
Ford Fusion. Variable Camshaft Timing (VCT) Unit. Removal and Installation
  1. Install the following items:
    1. Install the air cleaner.
      Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
    2. Install the upper air cleaner outlet pipe.
      Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
    3. Install the high-pressure fuel pump.
      Refer to: High-Pressure Fuel Pump (303-04A Fuel Charging and Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).

    Valve Cover. Removal and Installation

    Special Tool(s) / General Equipment Hose Clamp Remover/Installer Materials Name Specification Flange SealantCU7Z-19B508-A WSS-M2G348-A11  Motorcraft® Metal Surface Prep WipesZC-31-B -  Engine Oil - SAE 5W-20 - Synthetic Blend Motor OilXO-5W20-Q1SP WSS-M2C945-B1  Removal Release the fuel system pressure...

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