LEMON Manuals: Even more car manuals for everyone
Home >> Audi >> 2016 >> S5 Prestige, 2D Convertible >> Repair and Diagnosis >> External Pages >> Different car >> Section 1072 (Engine - 3.5L ECOBOOST (272KW/370PS)) >> Disassembly >> Engine

Section 1072 (Engine - 3.5L ECOBOOST (272KW/370PS)): Disassembly: Engine

WARNING: This page is about a different car, the 2018 Lincoln Navigator. However, it is still accessible from the selected car via links, so may be relevant.

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING .

GFD271652Courtesy of FORD MOTOR COMPANY

Special Tool(s) / General Equipment 

GFD271281Courtesy of FORD MOTOR COMPANY
 205-142 (T80T-4000-J)Installer, Differential Bearing Cone
GFD271282Courtesy of FORD MOTOR COMPANY
 205-150 (T80T-4000-S)Installer, Spindle Bearing
GFD272652Courtesy of FORD MOTOR COMPANY
 205-153 (T80T-4000-W)Handle
GFD271283Courtesy of FORD MOTOR COMPANY
 303-1246Engine Spreader Bar, TKIT-2006UF-FLM, TKIT-2006UF-ROW
GFD271284Courtesy of FORD MOTOR COMPANY
 303-1247VCT Spark Plug Tube Seal Remover and Installer, TKIT-2006UF-FLM, TKIT-2006UF-ROW
GFD271285Courtesy of FORD MOTOR COMPANY
 303-1654Lift Eyes
GFD271286Courtesy of FORD MOTOR COMPANY
 303-1655Tool, Camshaft Holding
GFD271287Courtesy of FORD MOTOR COMPANY
 303-409 (T92C-6700-CH)Remover, Crankshaft Seal, TKIT-1992-FH/FMH/FLMH, TKIT-1993-LMH/MH
Floor Crane
Three Leg Puller
Mounting Stand
Plastic Scraper
Hose Clamp Remover/Installer

Materials 

Name Specification
Motorcraft® Silicone Gasket RemoverZC-30-A -
Motorcraft® Metal Surface Prep WipesZC-31-B -
Motorcraft® Metal Brake Parts CleanerPM-4-A, PM-4-B -
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.
NOTE: The turbocharger compressor vanes can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, ensure that no debris enters the system. Failure to do so may result in damage to the turbocharger.
NOTE: Special attention needs to be given to the sealing ports for the oil feed, the oil drain, and the coolant tubes, on turbocharged engines. The sealing ports must be totally clean and free from O-ring residue, have no damage to the sealing surface and the tubes to ensure that there are no leaks or repeat repairs.
NOTE: Refer to Engine Component View .
  1. Remove the bolts and the flexplate.
    GFD271288Courtesy of FORD MOTOR COMPANY
  2. Remove the crankshaft sensor ring and the engine-to-transmission spacer plate.
    GFD271289Courtesy of FORD MOTOR COMPANY
  3. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the engine block skirt stiffener.

    Mount the engine to the mounting stand.Use Special Service Tool: 303-1246 Engine Spreader Bar., 303-1654 Lift Eyes. Use the General Equipment: Floor CraneUse the General Equipment: Mounting Stand.

    GFD272653Courtesy of FORD MOTOR COMPANY
  4. Remove the floor crane.Remove Special Service Tool: 303-1246 Engine Spreader Bar., 303-1654 Lift Eyes. Use the General Equipment: Floor Crane.
    GFD271290Courtesy of FORD MOTOR COMPANY
  5. Remove the bolts and the A/C compressor.
    GFD271291Courtesy of FORD MOTOR COMPANY
    • Remove the bolt and the RH engine mount.

    • Discard the bolt.

    GFD271292Courtesy of FORD MOTOR COMPANY
    • Remove the bolts and the RH engine mount bracket.

    • Discard the bolts.

    GFD271293Courtesy of FORD MOTOR COMPANY
    • Remove the bolts and the LH engine mount bracket.

    • Discard the bolts.

    GFD271294Courtesy of FORD MOTOR COMPANY
    • Disconnect the auxiliary coolant pump electrical connector.

    • Release the clamp and disconnect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer.

    • Remove the bolts and the auxiliary coolant pump.

    GFD271295Courtesy of FORD MOTOR COMPANY
    • Remove the crankshaft pulley bolt and washer.

    • Discard the bolt.

    GFD271296Courtesy of FORD MOTOR COMPANY
  11. Using a three leg puller, remove the crankshaft pulley. Use the General Equipment: Three Leg Puller.
    GFD271297Courtesy of FORD MOTOR COMPANY
  12. Using the special tool, remove and discard the crankshaft front seal.Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.
    GFD271298Courtesy of FORD MOTOR COMPANY
    • Remove the bolts and the coolant pump pulley.

    • Remove the bolts and the accessory drive belt tensioner

    • Remove the bolt and the idler pulley.

    GFD271299Courtesy of FORD MOTOR COMPANY
    • Release the clamp and disconnect the hose. Use the General Equipment: Hose Clamp Remover/Installer.

    • Remove the bolts and the thermostat housing.

    GFD271300Courtesy of FORD MOTOR COMPANY
  15. Inspect the O-ring seals and replace if necessary.
    GFD271301Courtesy of FORD MOTOR COMPANY
  16. Remove the bolts and the water pump outlet connector.
    GFD271302Courtesy of FORD MOTOR COMPANY
  17. Inspect the O-ring seal and replace if necessary.
    GFD271303Courtesy of FORD MOTOR COMPANY
  18. Disconnect the high-pressure fuel pump electrical connector.
    GFD271304Courtesy of FORD MOTOR COMPANY
    1. Remove and discard the high-pressure fuel tube mounting bolts.
    2. Remove and discard the high-pressure fuel tube.
    GFD272654Courtesy of FORD MOTOR COMPANY
  20. Remove the fuel supply tube spring lock coupling retainers.
    GFD272655Courtesy of FORD MOTOR COMPANY
  21. Disconnect the retainers, fuel supply tube and remove. Refer to: Spring Lock Couplings .
    GFD271305Courtesy of FORD MOTOR COMPANY
    • Remove and discard the high-pressure fuel pump bolts.

    • Remove the high-pressure fuel pump.

    GFD271306Courtesy of FORD MOTOR COMPANY
  23. Remove and discard the high-pressure fuel pump O-ring seal.
    GFD271307Courtesy of FORD MOTOR COMPANY
  24. Remove the high-pressure fuel pump roller tappet.
    GFD271308Courtesy of FORD MOTOR COMPANY
  25. Inspect the high-pressure fuel pump roller tappet. If any flat spots or scoring are found, especially in the indicated areas, then inspect the high-pressure fuel pump and the high-pressure fuel pump roller tappet drive lobe. Install new components as necessary.
    GFD271309Courtesy of FORD MOTOR COMPANY
  26. Remove the bolt and the high-pressure fuel pump mounting plate.
    GFD271310Courtesy of FORD MOTOR COMPANY
  27. Remove any dirt or foreign material from the high-pressure fuel pump bolt holes.
    GFD271311Courtesy of FORD MOTOR COMPANY
  28. Remove the fuel supply tube spring lock coupling retainers.
    GFD271312Courtesy of FORD MOTOR COMPANY
  29. Disconnect and remove the fuel supply tube. Refer to: Spring Lock Couplings .
    GFD271313Courtesy of FORD MOTOR COMPANY
  30. Remove and discard the fuel rail-to-fuel rail high-pressure fuel tube.
    GFD271314Courtesy of FORD MOTOR COMPANY
  31. Disconnect the RH TC electrical connector.
    GFD271315Courtesy of FORD MOTOR COMPANY
  32. Remove the bolt and separate the RH TC coolant return tube from the cylinder head.
    GFD271316Courtesy of FORD MOTOR COMPANY
  33. Remove the bolts and theRHTC oil supply tube then discard the TC oil supply tube.
    GFD271317Courtesy of FORD MOTOR COMPANY
  34. Remove the RHTC oil return tube bolts, then remove and discard the TC oil return tube.
    GFD271318Courtesy of FORD MOTOR COMPANY
  35. Remove the bolt and separate the RHTC coolant supply tube the engine block.
    GFD271319Courtesy of FORD MOTOR COMPANY
  36. NOTE: Remove the coolant tubes with the turbocharger. If the 2 piece turbocharger cooling tubes are separated, then the rubber gasket must be replaced.

    Remove the bolts and RHTC.

    GFD271320Courtesy of FORD MOTOR COMPANY
  37. NOTE: Use brake cleaner and a nylon brush to clean. Do not use a metal brush, damage to sealing area will result in leaks.

    Remove and discard the TC coolant supply and the TC coolant return tube O-ring seals. Clean the TC coolant tubes sealing surfaces. Inspect the sealing surfaces for debris or damage and make sure the retaining bracket is not bent, check for squareness of the O-ring area. Install new components if necessary.

    Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    GFD271321Courtesy of FORD MOTOR COMPANY
  38. Remove and discard the TC gasket
    GFD271322Courtesy of FORD MOTOR COMPANY
  39. If needed remove the TC exhaust flange stud bolts and the TC exhaust flange.
    GFD272656Courtesy of FORD MOTOR COMPANY
  40. If the flange was removed, remove and discard the turbocharger exhaust flange gasket.
    GFD271323Courtesy of FORD MOTOR COMPANY
  41. Remove and discard the RHTC fitting and oil filter assembly from the engine block.
    GFD271324Courtesy of FORD MOTOR COMPANY
  42. Disconnect the LHTC electrical connector.
    GFD271325Courtesy of FORD MOTOR COMPANY
  43. Remove the bolt and separate the LHTC coolant return tube from the cylinder head.
    GFD271326Courtesy of FORD MOTOR COMPANY
  44. Remove the bolts and the LH oil supply tube then discard the TC oil supply tube.
    GFD271327Courtesy of FORD MOTOR COMPANY
  45. Remove the LHTC oil return tube bolts, then remove and discard the TC oil return tube.
    GFD272657Courtesy of FORD MOTOR COMPANY
  46. Remove the bolt and separate the LHTC coolant supply tube the engine block.
    GFD272658Courtesy of FORD MOTOR COMPANY
  47. NOTE: Remove the coolant tubes with the turbocharger. If the 2 piece turbocharger cooling tubes are separated, then the rubber gasket must be replaced.

    Remove the bolts and LHTC.

    GFD272659Courtesy of FORD MOTOR COMPANY
  48. NOTE: Use brake cleaner and a nylon brush to clean. Do not use a metal brush, damage to sealing area will result in leaks.

    Remove and discard the TC coolant supply and the TC coolant return tube O-ring seals. Clean the TC coolant tubes sealing surfaces. Inspect the sealing surfaces for debris or damage and make sure the retaining bracket is not bent, check for squareness of the O-ring area. Install new components if necessary.

    Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    GFD272660Courtesy of FORD MOTOR COMPANY
  49. Remove and discard the TC gasket
    GFD271328Courtesy of FORD MOTOR COMPANY
  50. If needed remove the TC exhaust flange stud bolts and the TC exhaust flange.
    GFD272656Courtesy of FORD MOTOR COMPANY
  51. If the flange was removed, remove and discard the turbocharger exhaust flange gasket.
    GFD271323Courtesy of FORD MOTOR COMPANY
  52. Remove and discard the LHTC fitting and oil filter assembly from the engine block.
    GFD271329Courtesy of FORD MOTOR COMPANY
  53. Remove the nuts and the CAC tube bracket.
    GFD271330Courtesy of FORD MOTOR COMPANY
  54. Remove the nut, bolt and the generator.
    GFD271331Courtesy of FORD MOTOR COMPANY
  55. Remove the generator stud bolt.
    GFD271332Courtesy of FORD MOTOR COMPANY
  56. Disconnect the EOP sensor electrical connector and the wire harness retainer.
    GFD272661Courtesy of FORD MOTOR COMPANY
  57. NOTE: If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may cause engine failure.

    • Remove the bolt and the oil cooler.

    • Discard the oil cooler.

    GFD271333Courtesy of FORD MOTOR COMPANY
  58. Remove the bolts and the oil filter adapter.
    GFD272662Courtesy of FORD MOTOR COMPANY
  59. Inspect the gasket and replace if necessary.
    GFD271334Courtesy of FORD MOTOR COMPANY
  60. Remove the LH block coolant drain or block heater and allow coolant to drain from the cylinder block.
    GFD271335Courtesy of FORD MOTOR COMPANY
  61. Remove the RH block coolant drain plug and allow coolant to drain from the cylinder block.
    GFD271336Courtesy of FORD MOTOR COMPANY
  62. Remove the studbolt, bolt and the heat shield.
    GFD271337Courtesy of FORD MOTOR COMPANY
    • Disconnect the CHT sensor electrical connector.

    • Disconnect the CMP sensor electrical connectors.

    • Detach the wire harness retainer, remove the studbolt and the ground wire.

    GFD271338Courtesy of FORD MOTOR COMPANY
    • Disconnect the KS electrical connector.

    • Disconnect the RH and LH port injection fuel rail electrical connectors.

    • Disconnect the RH and LH direct injection fuel rail electrical connectors

    GFD272663Courtesy of FORD MOTOR COMPANY
    • Position aside the wire harness retainer. Remove the stud bolt and the ground wire.

    • Remove the bolt and position aside the body ground strap.

    GFD272664Courtesy of FORD MOTOR COMPANY
  66. Remove the nut, bolt and the heat shield.
    GFD272665Courtesy of FORD MOTOR COMPANY
    • Remove the studbolt.

    • Detach the wiring harness grommet from the cylinder block.

    GFD272666Courtesy of FORD MOTOR COMPANY
    • Disconnect the CKP sensor electrical connector.

    • Remove the bolt, the CKP sensor electrical connector and position the wiring harness aside.

    GFD271339Courtesy of FORD MOTOR COMPANY
  69. Disconnect the oil control solenoid electrical connector and detach the wire harness retainers.
    GFD272667Courtesy of FORD MOTOR COMPANY
    • Remove the oil level indicator.

    • Disconnect the VCT oil control solenoid electrical connectors.

    • Disconnect the CMP sensor electrical connectors.

    • Disconnect the ignition coil-on-plug electrical connectors.

    • Detach the wire harness retainers.

    GFD271340Courtesy of FORD MOTOR COMPANY
    • Disconnect the VCT oil control solenoid electrical connectors.

    • Disconnect the ignition coil-on-plug electrical connectors.

    • Detach the wire harness retainers and remove the engine wiring harness.

    GFD272668Courtesy of FORD MOTOR COMPANY
  72. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

    • Remove the bolts and the ignition coil-on-plugs.

    • Remove the bolts and the CMP sensors.

    GFD272669Courtesy of FORD MOTOR COMPANY
  73. Inspect the coil seals for rips, nicks or tears.
    GFD272670Courtesy of FORD MOTOR COMPANY
  74. NOTE: While removing the valve cover do not apply excessive force to the VCT oil control solenoid or damage may occur.
    NOTE: If the VCT oil control solenoid sticks to the VCT seal, carefully wiggle the valve cover until the bond breaks free or damage to the VCT seal and VCT oil control solenoid may occur.

    Loosen the fasteners and remove the LH valve cover.

    GFD272671Courtesy of FORD MOTOR COMPANY
  75. Remove and discard the valve cover and intake port gaskets.
    GFD271341Courtesy of FORD MOTOR COMPANY
  76. NOTE: While removing the valve cover do not apply excessive force to the VCT oil control solenoid or damage may occur.
    NOTE: If the VCT oil control solenoid sticks to the VCT seal, carefully wiggle the valve cover until the bond breaks free or damage to the VCT seal and VCT oil control solenoid may occur.

    Loosen the fasteners and remove the RH valve cover.

    GFD271342Courtesy of FORD MOTOR COMPANY
  77. Remove and discard the valve cover and intake port gaskets.
    GFD272672Courtesy of FORD MOTOR COMPANY
  78. NOTE: RH shown, LH similar.
    NOTE: Inspect the VCT solenoid seals. Remove any damaged seals.

    Using the special tools, remove and discard the seal(s).Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone., 205-153 (T80T-4000-W) Handle.

    GFD272673Courtesy of FORD MOTOR COMPANY
  79. NOTE: RH shown, LH similar.
    NOTE: Inspect the spark plug tube seals. Remove any damaged seals.

    Using the special tools, remove and discard the seal(s).Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

    GFD271343Courtesy of FORD MOTOR COMPANY
  80. Remove the bolts and the CMP sensors.
    GFD272674Courtesy of FORD MOTOR COMPANY
  81. Remove the bolts and the coolant pump.
    GFD271344Courtesy of FORD MOTOR COMPANY
  82. Remove and discard the coolant pump gasket and O-ring seal.
    GFD272675Courtesy of FORD MOTOR COMPANY
  83. Remove the bolts.
    GFD271345Courtesy of FORD MOTOR COMPANY
  84. Using a pry tool, locate the 5 pry pads shown and pry the engine front cover loose and remove.
    GFD271346Courtesy of FORD MOTOR COMPANY
  85. Using the special tools, remove the engine front cover to coolant pipe seal.Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-150 (T80T-4000-S) Installer, Spindle Bearing.
    GFD272676Courtesy of FORD MOTOR COMPANY
  86. Using the special tools, remove and discard the oil pump electrical connector seal.Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-142 (T80T-4000-J) Installer, Differential Bearing Cone.
    GFD272677Courtesy of FORD MOTOR COMPANY
  87. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean. These tools cause scratches and gouges that make leak paths.

    • Clean the engine front cover using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 rpm. Refer to: RTV Sealing Surface Cleaning and Preparation .

      Material: Motorcraft® Silicone Gasket Remover / ZC-30-A

      Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    • Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.

  88. Install the crankshaft pulley bolt.
    GFD272678Courtesy of FORD MOTOR COMPANY
    1. Rotate the crankshaft clockwise.
    2. Position the crankshaft sprocket keyway at the 11 o'clock position.
    3. Verify the timing marks on the VCT units are at the 12:30 (intake) and 11 o'clock (exhaust) positions.
    GFD272679Courtesy of FORD MOTOR COMPANY
  90. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install Special Service Tool: 303-1655 Tool, Camshaft Holding.

    GFD271347Courtesy of FORD MOTOR COMPANY
  91. Remove the bolts and the RH timing chain guide.
    GFD271348Courtesy of FORD MOTOR COMPANY
  92. Remove the bolts and the RH timing chain tensioner.
    GFD271349Courtesy of FORD MOTOR COMPANY
  93. Remove the RH timing chain tensioner arm.
    GFD271350Courtesy of FORD MOTOR COMPANY
  94. Remove the RH timing chain.
    GFD272680Courtesy of FORD MOTOR COMPANY
  95. Verify the timing marks on the VCT units are at the 11:30 (intake) and 1:00 o'clock (exhaust) positions.
    GFD272681Courtesy of FORD MOTOR COMPANY
  96. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install Special Service Tool: 303-1655 Tool, Camshaft Holding.

    GFD272682Courtesy of FORD MOTOR COMPANY
  97. Remove the crankshaft pulley bolt.
    GFD272683Courtesy of FORD MOTOR COMPANY
  98. Remove the bolts and the LH timing chain guide.
    GFD272684Courtesy of FORD MOTOR COMPANY
  99. Remove the retainers and the LH timing chain tensioner.
    GFD272685Courtesy of FORD MOTOR COMPANY
  100. Remove the LH timing chain tensioner arm.
    GFD272686Courtesy of FORD MOTOR COMPANY
  101. Remove the LH timing chain.
    GFD272687Courtesy of FORD MOTOR COMPANY
  102. Remove the crankshaft sprocket.
    GFD272688Courtesy of FORD MOTOR COMPANY
  103. Remove and discard the LH VCT unit bolts.
    GFD272689Courtesy of FORD MOTOR COMPANY
  104. Remove the LH VCT units.
    GFD272690Courtesy of FORD MOTOR COMPANY
  105. Remove Special Service Tool: 303-1655 Tool, Camshaft Holding.
    GFD272682Courtesy of FORD MOTOR COMPANY
  106. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
    NOTE: Mark the exhaust and intake camshafts for installation into their original locations.

    • Remove the bolts and the front camshaft bearing mega cap.

    • Remove the bolts and the camshaft bearing caps.

    • Remove the intake and exhaust camshafts.

    GFD272691Courtesy of FORD MOTOR COMPANY
  107. Remove and discard the RH VCT unit bolts.
    GFD272692Courtesy of FORD MOTOR COMPANY
  108. Remove the RH VCT units.
    GFD272693Courtesy of FORD MOTOR COMPANY
  109. Remove Special Service Tool: 303-1655 Tool, Camshaft Holding.
    GFD271347Courtesy of FORD MOTOR COMPANY
  110. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
    NOTE: Mark the exhaust and intake camshafts for installation into their original locations.

    • Remove the bolts and the front camshaft bearing mega cap.

    • Remove the bolts and the camshaft bearing caps.

    • Remove the intake and exhaust camshafts.

    GFD272694Courtesy of FORD MOTOR COMPANY
  111. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
    NOTE: RH shown, LH similar.

    1. Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
    2. Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
    3. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Replace damaged components as necessary.

    GFD272695Courtesy of FORD MOTOR COMPANY
  112. Remove and discard the RH M6 bolt.
    GFD272696Courtesy of FORD MOTOR COMPANY
  113. NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
    NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.

    • Remove and discard the bolts from the RH cylinder head.

    • Remove the cylinder head.

    GFD272697Courtesy of FORD MOTOR COMPANY
  114. Remove and discard the RH cylinder head gasket.
    GFD272698Courtesy of FORD MOTOR COMPANY
  115. Remove and discard the LH M6 bolt.
    GFD272699Courtesy of FORD MOTOR COMPANY
  116. NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
    NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.

    • Remove and discard the bolts from the LH cylinder head.

    • Remove the cylinder head.

    GFD272700Courtesy of FORD MOTOR COMPANY
  117. Remove and discard the LH cylinder head gasket.
    GFD272701Courtesy of FORD MOTOR COMPANY
  118. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging.

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

    Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

    Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

  119. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
  120. Remove the bolts and the KS.
    GFD272702Courtesy of FORD MOTOR COMPANY
  121. Remove the bolts and the channel cover plate.
    GFD272703Courtesy of FORD MOTOR COMPANY
  122. Inspect and replace if necessary.
    GFD272704Courtesy of FORD MOTOR COMPANY

    Vehicles with late build oil pan 

  123. Remove the oil pan bolts.
    GFD272705Courtesy of FORD MOTOR COMPANY
  124. Using a pry tool, locate the pry pads at the LH and RH side of the oil pan and pry the oil pan loose and remove.
    GFD272706Courtesy of FORD MOTOR COMPANY
  125. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the oil pan and engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean. These tools cause scratches and gouges that make leak paths.

    • Clean the oil pan using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 rpm.

      Material: Motorcraft® Silicone Gasket Remover / ZC-30-A

      Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

    • Thoroughly wash the oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.

    Vehicles with early build oil pan 

  126. Remove the oil pan bolts.
    GFD272707Courtesy of FORD MOTOR COMPANY
  127. Using a pry tool on the pry pads, remove and discard the oil pan.
    GFD272708Courtesy of FORD MOTOR COMPANY
  128. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant.

    • Make sure that the engine block skirt stiffner sealing surfaces are free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation . Use the General Equipment: Plastic Scraper.

      Material: Motorcraft® Silicone Gasket Remover / ZC-30-A

      Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    GFD272709Courtesy of FORD MOTOR COMPANY
  129. Remove the engine block skirt stiffener bolts.
    GFD272710Courtesy of FORD MOTOR COMPANY
  130. Using a pry tool on the pry pads, remove the engine block skirt stiffener.
    GFD272711Courtesy of FORD MOTOR COMPANY
  131. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant.

    Clean and inspect the mating surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation . Use the General Equipment: Plastic Scraper.

    Material: Motorcraft® Silicone Gasket Remover / ZC-30-A

    Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

    Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    GFD271351Courtesy of FORD MOTOR COMPANY

    All vehicles 

  132. Remove the bolts and the oil pump screen and pickup tube.
    GFD271352Courtesy of FORD MOTOR COMPANY
  133. Remove and discard the oil pump screen and pickup tube O-ring seal.
    GFD271353Courtesy of FORD MOTOR COMPANY
  134. Remove the bolts and the oil pump.
    GFD272712Courtesy of FORD MOTOR COMPANY
    • Remove the bolts and the crankshaft rear seal retainer.

    • Discard the crankshaft rear seal retainer.

    GFD272713Courtesy of FORD MOTOR COMPANY
  136. Inspect and clean the specified component with a abrasive pad.
    GFD272714Courtesy of FORD MOTOR COMPANY
    • Remove and discard the bolts in sequence shown.

    • Remove the main bearing cap support brace.

    Fig 1: Main Bearing Cap Support Brace Loosening Sequence
    GFD272715Courtesy of FORD MOTOR COMPANY
  138. NOTE: The connecting rod cap bolts are a torque-to-yield design. The original connecting rod cap bolts will be used when measuring the connecting rod large end bore during assembly. The connecting rod cap bolts will be discarded after measurement.
    NOTE: Clearly mark the position and orientation of the connecting rods, connecting rod caps and connecting rod bearings for reassembly.

    Remove the connecting rod cap bolts and caps.

    GFD272716Courtesy of FORD MOTOR COMPANY
  139. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod while removing the pistons.

    Remove the piston/rod assembly from the engine block.

    GFD272717Courtesy of FORD MOTOR COMPANY
  140. Inspect the pistons. Refer to: Piston Inspection .
  141. NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.

    Remove and discard the bolts in sequence shown.

    Fig 2: Main Bearing Loosening Sequence
    GFD272718Courtesy of FORD MOTOR COMPANY
  142. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
    NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.

    Remove the main bearing caps.

    GFD272719Courtesy of FORD MOTOR COMPANY
  143. Remove the lower crankshaft thrust washer from the back side of the No. 4 rear main bearing cap.
    GFD272720Courtesy of FORD MOTOR COMPANY
  144. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

    Remove the crankshaft main bearings from the main bearing caps.

    GFD272721Courtesy of FORD MOTOR COMPANY
  145. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.

    Remove the crankshaft.

    GFD272722Courtesy of FORD MOTOR COMPANY
  146. Remove the crankshaft thrust bearings from the rear main bearing bulkhead.
    GFD272723Courtesy of FORD MOTOR COMPANY
  147. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

    Remove the crankshaft main bearings from the cylinder block.

    GFD272724Courtesy of FORD MOTOR COMPANY
  148. Remove the bolts and the piston cooling jets from the cylinder block.
    GFD272725Courtesy of FORD MOTOR COMPANY
  149. Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
  150. NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
    NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.

    Make sure that the mating faces of the cylinder block are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation . Use the General Equipment: Plastic Scraper.

    Material: Motorcraft® Silicone Gasket Remover / ZC-30-A

    Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

    Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

scientia non olet · About LEMON Manuals