Attachment III - Technical Information
OVERVIEWOn some of the affected vehicles, it is possible that an engine cylinder head cup plug was not properly seated and may dislodge, resulting in a rapid loss of the engine coolant. Unique to this engine configuration, it is possible that a rapid loss of coolant in this area could result in a combustible glycol concentration near hot engine components and create a risk of fire. Dealers are to install a secondary cylinder head plug over the original cup plug located between the cylinder # 2 spark plug and cylinder # 3 fuel injector.
PARTS & MATERIALS
^ BM5Z-00933-A Secondary Cylinder Head Plug.
^ Motorcraft PM-4-A Metal Brake Parts Cleaner or Isopropyl Alcohol (60% minimum concentration).
^ Loctite 290 (wicking sealant).
^ Loctite 638 (retaining compound).
^ 3 ea. Cotton Swabs.
^ Oil Free Cleaning Cloths.
SERVICE PROCEDURE
WARNING:
Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury.
1. Remove the coolant degas bottle cap.
2. Remove the engine cover.
3. Disconnect the battery ground cable. For additional information, refer to Workshop Manual (WSM), Section 414-01.
4. Remove the cowl panel. For additional information, refer to WSM, Section 501-02.
5. Disconnect the EVAP line quick connect coupling from the air intake tube center section. See Figure 1.
^ Set the clip aside for reinstallation to prevent it from falling into the engine compartment.
NOTICE:
Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.
6. Loosen the 2 clamps and remove the air intake tube center section. See Figure 1.
7. Disconnect the PCV tube from the turbocharger inlet pipe. Remove the fasteners and loosen the clamp at the turbocharger. Remove the turbocharger inlet pipe. See Figure 2.
8. Remove the four ignition coil-on-plugs. For additional information, refer to WSM, Section 303-07A.
NOTICE:
Use care when removing or installing the fuel injection pump noise insulator to reduce the risk of damage to the insulator.
9. Remove the fuel injection pump noise insulator. See Figure 3.
10. Disconnect the electrical connectors, wiring harness push-pins, and the PCV hose pin-type retainer as shown below to allow for removal of the coil mounting bracket. Remove the eight fasteners and the coil mounting bracket. See Figure 4.
11. Remove the fuel injector insulator. See Figure 5.
12. Locate the cylinder head cup plug in between the cylinder # 2 spark plug and cylinder # 3 fuel injector. Inspect for any evidence of coolant leakage. See Figure 6.
^ If signs of coolant leakage ARE found, call the Special Service Support Center (SSSC).
^ If signs of coolant leakage ARE NOT found, proceed to step 13.
NOTICE:
Do not spray cleaner directly onto the engine.
13. Spray or soak the tip of a cotton swab using either Motorcraft PM-4-A Metal Brake Parts Cleaner, or Isopropyl Alcohol (60% minimum concentration). Use the cotton swab to degrease the surface on and around the cylinder head cup plug. Discard the swab. Wait 10 minutes (minimum) for all cleaner to evaporate. The cup plug must be dry before proceeding.
NOTICE:
Do not get any Loctite on the spark plug or fuel injector as this will make them difficult or impossible to remove.
14. Squeeze Loctite 290 onto the tip of a new cotton swab. Loctite 290 is a wicking compound that will weep down and fill any voids between the cylinder head cup plug and its bore. Apply the Loctite 290 at the outer edge of the existing cylinder head cup plug, and the machined bore above it. Discard the swab. Wait 10 minutes (minimum) for Loctite to weep down the cup plug bore and dry. See Figure 7.
15. Using an oil free cloth, degrease / clean the new secondary cylinder head plug using either Motorcraft PM-4-A Metal Brake Parts Cleaner or Isopropyl Alcohol (60% minimum concentration). Set the secondary cylinder head plug aside until installation. See Figure 8.
16. Squeeze Loctite 638 onto the tip of a new cotton swab. Loctite 638 is a retaining compound that will be used to affix the secondary cylinder head plug over the existing cylinder head cup plug and its bore. Apply the Loctite 638 at the outer edge of the existing cylinder head cup plug, and the machined bore above it including the chamfer. See Figure 9.
17. Using suitable long-nosed pliers, grab the secondary cylinder head plug by the protrusion and add Loctite 638 to the perimeter of the new plug. See Figure 10.
18. Install the new secondary cylinder head plug on top of the cylinder head cup plug and push down for a minimum of five seconds, with approximately one pound of force. It is normal for the secondary cylinder head plug to sit slightly above the cup plug bore. See Figure 11.
19. Verify visually that the new secondary cylinder head plug is centered over the original cup plug and seated into the bore. Check for evidence of Loctite around the secondary cylinder head plug. If Loctite is not visible around the perimeter of the plug, apply additional Loctite 638 around the perimeter using a cotton swab. See Figure 12.
20. Install the fuel injector insulator. See Figure 5.
21. Install the coil mounting bracket. Connect the wiring harness push-pins, PCV hose pin-type retainer, and electrical connectors. See Figure 4.
^ Tighten coil mounting bracket fasteners to 10 Nm (89 lb-in).
NOTICE:
Use care when removing or installing the fuel injection pump noise insulator to reduce the risk of damage to the insulator.
22. Install the fuel injection pump noise insulator. See Figure 3.
23. Install the four ignition coil-on-plugs. For additional information, refer to WSM, Section 303-07A.
NOTE:
Remove protective covers that were placed over the turbocharger air intake system before re-installing components.
24. Install the turbocharger inlet pipe and connect the PCV hose to the turbocharger inlet pipe. See Figure 2.
^ Tighten the turbocharger inlet pipe fasteners to 5 Nm (44 lb-in).
^ Tighten the turbocharger inlet pipe-to-turbocharger clamp to 5 Nm (44 lb-in).
25. Install the air intake tube center section. See Figure 1.
Tighten clamps to 5 Nm (44 lb-in).
26. Connect the EVAP line quick connect coupling to the air intake tube center section and install the retention clip. See Figure 1.
27. Install the cowl panel. For additional information, refer to WSM, Section 501-02.
28. Connect the battery ground cable. For additional information, refer to WSM, Section 414-01.
29. Install the windshield wiper pivot arms. For alignment and additional installation information, refer to WSM, Section 501-16.
30. Install the engine cover.
31. Install the cooling system degas bottle cap.
NOTE:
Allow the Loctite to cure for two hours before starting and running the vehicle.
32. Return the vehicle to the customer.