Special Tools
WARNING: This page is about a different car, the 2011 Mercury Milan and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)
| 3 Jaw Puller 303-D121 |
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| Installer, Connecting Rod 303-462 (T94P-6136-AH) |
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| Plate, Water Pump Pulley 303-456 (T94P-6312-AH1), part of 303-S455 |
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| Protector, Water Pump Shaft 303-457 (T94P-6312-AH2), part of 303-S455 |
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| Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) |
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| Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) |
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| Remover, Oil Seal 303-409 (T92C-6700CH) |
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| Remover, Stretchy Belt 303-1419 |
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| Slide Hammer 307-005 (T59L-100-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:
For additional information, refer to the exploded view under the Assembly procedure in this service information.
All engines
- Remove the 8 bolts and the flexplate.
- Remove the engine-to-transaxle separator plate.
- Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear oil seal.
- Mount the engine on a suitable stand.
- Detach the 2 B+ wiring harness retainers from the valve cover stud bolts.
- Disconnect the A/C compressor clutch electrical connector.
- Disconnect the generator electrical connector.
- Remove the nut and the B+ wire from the generator.
- Remove the B+ harness from the engine.
- Disconnect the 3 engine wiring connectors.
- Disconnect the engine block Knock Sensor (KS) electrical connector.
- Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
- Disconnect the cylinder head KS electrical connector.
- Disconnect the electronic throttle control electrical connector.
- Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
- Disconnect the EGR regulator electrical connector and detach the wiring retainer.
- Disconnect the PCV valve electrical connector.
- Detach the wiring harness retainer from the upper intake manifold.
- Disconnect the Manifold Absolute Pressure (MAP) electrical connector and detach the wiring retainer.
- Disconnect the RH coil-on-plug electrical connectors.
- Detach the 2 wiring harness retainers.
- Disconnect the RH Variable Camshaft Timing (VCT) electrical connector and detach the wiring harness retainer from the valve cover stud bolt.
- Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the 2 wiring harness retainers.
- Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors and detach the wiring harness retainer from the engine front cover stud bolt.
- Disconnect the fuel injector wiring harness electrical connector and detach the wiring harness retainer.
- Disconnect the LH VCT electrical connector.
- Remove the nut and the radio frequency interference capacitor.
- Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wiring retainer from the oil indicator tube.
- Disconnect the 3 LH coil-on-plug electrical connectors.
- Detach the 2 wiring harness retainers.
- Remove the 2 upper intake manifold bracket bolts (1 shown in the illustration).
- Remove the 7 bolts and the upper intake manifold.
- Remove and discard the gaskets.
- Remove the 4 bolts and the fuel rail and injectors as an assembly.
- Remove the 8 lower intake manifold bolts and the lower intake manifold.
- Remove and discard the gaskets.
FWD vehicles
- Remove the 3 bolts and the RH heat shield.
- Remove the 3 nuts and the RH catalytic converter.
- Discard the nuts and gasket.
All engines
- Remove the 6 RH exhaust manifold nuts and the manifold.
- Discard the nuts and gasket.
- Clean and inspect the RH catalytic converter manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
- Remove and discard the 6 RH catalytic converter manifold studs.
- Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
- Remove the 3 bolts and the A/C compressor.
- Remove the bolt, 2 nuts and the generator.
- Remove the 3 bolts and the A/C compressor bracket.
- Position the Stretchy Belt Remover under the coolant pump belt as shown in the illustration.
- Turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant pump pulley as shown in the illustration.
- Remove the coolant pump belt.
- Fold the Stretchy Belt Remover over the top of the coolant pump belt.
- In one quick motion, pull the Stretchy Belt Remover up and toward the front of the engine removing the coolant pump belt.
- Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.
- Remove the 5 coolant pump housing bolts.
- Loosen the clamp and detach the coolant hose.
- Remove the coolant pump housing.
- Remove the stud bolt and the oil level indicator and tube.
- Remove and discard the O-ring seal.
- Remove the EOP switch and, if equipped, the block heater.
- Remove the bolts and the 6 coil-on-plugs.
- Remove the bolts and the RH valve cover.
- Discard the gasket.
- Remove the bolts and the LH valve cover.
- Discard the gasket.
- Remove the 15 bolts and the oil pan.
- Discard the gasket.
- Remove the 2 bolts and the oil pump screen and pickup tube.
- Remove and discard the O-ring seal.
- Remove the oil pan baffle.
- Remove the 4 M6 oil pan baffle nuts.
- Remove the 4 M8 oil pan baffle nuts.
- Remove the 3 bolts and the accessory drive belt tensioner.
- Remove the crankshaft pulley bolt and washer.
- Discard the crankshaft pulley bolt.
- Using the 3 Jaw Puller, remove the crankshaft pulley.
- Using the Oil Seal Remover, remove and discard the crankshaft front seal.
- Remove the 2 bolts and the LH VCT.
- Remove the 2 bolts and the RH VCT.
- Remove the 14 bolts, 2 stud bolts and the engine front cover.
- Discard the gaskets.
- Remove the LH and RH spark plugs.
- Remove the ignition pulse wheel.
- Install the crankshaft pulley bolt and washer.
- Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the No. 1 cylinder at Top Dead Center (TDC).
- Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
- Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
- Verify that the RH camshafts are in the neutral position.
- Remove the RH timing chain tensioner arm.
- Remove the 2 bolts.
- Remove the tensioner.
- Remove the tensioner arm.
- Remove the 2 bolts and the RH timing chain guide.
- Remove the RH timing chain from the engine.
- Rotate the crankcase clockwise 600 degrees (one and two-thirds turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
- Verify the LH camshafts are in the neutral position.
- Remove the LH timing chain and tensioner arm.
- Remove the 2 bolts.
- Remove the tensioner.
- Remove the tensioner arm.
- Remove the 2 bolts and the LH timing chain guide.
- Remove the LH timing chain from the engine.
- Remove the crankshaft pulley bolt and the crankshaft sprocket.
- Remove the 4 bolts in the sequence shown in the illustration.
- Remove the oil pump.
- Using the Oil Seal Remover, remove the camshaft oil seal and discard.
- Remove the 2 bolts and the camshaft oil seal retainer.
- Discard the press-in-place gasket.
- Verify the LH camshafts are in the neutral position.
- Remove the 3 bolts and the LH camshaft phaser and sprocket.
- Remove and discard the VCT system oil filter screen from the LH camshaft.
- If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
- Loosen the bolts evenly in the sequence shown in the illustration.
- Remove the camshaft bearing thrust caps (1L and 5L).
- Remove the remaining camshaft bearing caps.
- Remove the camshafts from the cylinder head.
- Verify the RH camshafts are in the neutral position.
- Remove the 3 bolts and the RH camshaft phaser and sprocket.
- Remove and discard the VCT system oil filter screen from the RH camshaft.
- If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
- Loosen the bolts evenly in the sequence shown in the illustration.
- Remove the camshaft bearing thrust caps (5R and 1R).
- Remove the remaining camshaft bearing caps.
- Remove the camshafts from the cylinder head.
- Remove the LH and RH camshaft roller followers.
- Mark the location of the roller followers, using a permanent-type marker.
- Remove the hydraulic lash adjusters.
- Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
- Discard the bolts and the gaskets.
- Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
- Remove the bolts and the oil separator cover.
- Discard the gasket.
- Remove the crankshaft key.
- Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
- Remove the connecting rod cap bolts and cap.
- Discard the connecting rod cap bolts.
- Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
- Repeat these 2 steps until all the piston/rod assemblies are removed from the engine block.
- Remove the engine block from the stand and place on a workbench.
- Remove the bolts and studs in the indicated sequence.
- Discard the lower cylinder block bolts.
- Remove the lower cylinder block.
- Remove the crankshaft rear main seal.
- Remove the crankshaft.
- Remove the crankshaft thrust bearing from the cylinder block.
- Remove the bearings from the lower cylinder block.
- Remove the crankshaft main bearings from the cylinder block.
- Inspect the cylinder block, lower cylinder block, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
NOTE:
Feed the Stretchy Belt Remover on to the camshaft coolant pump pulley 90 degrees.
Fig 37: Turning Crankshaft Clockwise And Feed Stretchy Belt Remover Evenly On Camshaft Coolant Pump Pulley
NOTE:
Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
NOTE:
LH shown in illustration, RH similar.
NOTE:
Note the position of the alignment dowel on the engine front cover.
NOTE:
Note the position of the alignment dowel on the engine front cover.
NOTE:
Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
NOTE:
Note the location of all bolts and stud bolts for installation.
NOTE:
Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
NOTE:
LH shown in the illustration, RH similar.
NOTE:
This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30RFF" (orange in color).
NOTE:
Do not scratch the camshaft sealing surface while removing the camshaft oil seal. If scratched, camshaft oil seal leakage may occur.
NOTE:
The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
NOTE:
Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket or damage to the engine may occur.
NOTE:
Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the camshaft phaser and sprocket bolts.
NOTE:
Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in illustration). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original positions may result in severe engine damage.
NOTE:
After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (1L and 5L) first, or damage to the thrust caps may occur.
NOTE:
Make sure the camshaft bearing caps are marked as instructed in the previous step.
NOTE:
The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
NOTE:
Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket or damage to the engine may occur.
NOTE:
Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the camshaft phaser and sprocket bolts.
NOTE:
Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in illustration). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original positions may result in severe engine damage.
NOTE:
After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (5R and 1R) first, or damage to the thrust caps may occur.
NOTE:
Make sure the camshaft bearing caps are marked as instructed in the previous step.
NOTE:
The camshaft roller followers must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
NOTE:
RH shown in the illustration, LH similar.
NOTE:
The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
NOTE:
RH shown in the illustration, LH similar.
NOTE:
Clearly mark the position and orientation of the pistons, connecting rods, connecting rod caps and connecting rod bearings for reassembly.
NOTE:
Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE:
If the main bearings are being reused, mark them for correct position and orientation for reassembly.
NOTE:
If the main bearings are being reused, mark them for correct position and orientation for reassembly.