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Section 675 (Engine - 2.7L ECOBOOST (238KW/324PS)): Disassembly: Engine

WARNING: This page is about a different car, the 2015 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

Special Tool(s) / General Equipment 

GFD38522Courtesy of FORD MOTOR COMPANY
 205-153 (T80T-4000-W) Handle
GFD39292Courtesy of FORD MOTOR COMPANY
 303-1246 Engine Spreader Bar TKIT-2006UF-FLM TKIT-2006UF-ROW
GFD39257Courtesy of FORD MOTOR COMPANY
 303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
GFD39287Courtesy of FORD MOTOR COMPANY
 303-1248 Camshaft holding tools TKIT-2006UF-FLM TKIT-2006UF-ROW
GFD39293Courtesy of FORD MOTOR COMPANY
 303-1634 Lift Eyes (2) TKIT-2014D-FL_ROW TKIT-2014D-ROW3
GFD39089Courtesy 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
Flat-Bladed Screwdriver

Materials 

Name Specification
Motorcraft ® Silicone Gasket Remover ZC-30-A -
Motorcraft ® Metal Surface Prep ZC-31-B -
Metal Brake Parts Cleaner PM-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: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
NOTE: If the components are to be reinstalled, they must be installed in their original location. Mark the components for installation into their original location.
NOTE: Refer to the exploded view under the Engine Component View  in the Description and Operation.

  1. 1.

    Remove the bolts and the flexplate.
GFD39336Courtesy of FORD MOTOR COMPANY

  1. 2.

    Remove the crankshaft sensor ring and the engine-to-transmission spacer plate.
GFD39337Courtesy of FORD MOTOR COMPANY

  1. 3.

    Inspect the crankshaft sensor ring for damage. If the crankshaft sensor ring has been dropped or has any visual damage, it must be replaced.
GFD39101Courtesy of FORD MOTOR COMPANY

  1. 4.

    1. 1.

      Reposition the CKP sensor electrical connector insulator.

    1. 2.

      Disconnect the CKP sensor electrical connector.

    1. 3.

      Remove the bolt and the CKP sensor.
GFD39102Courtesy of FORD MOTOR COMPANY

  1. 5.

    Remove the bolts and the crankshaft rear seal and retainer plate.
    • Discard the crankshaft rear seal and retainer plate.
GFD39103Courtesy of FORD MOTOR COMPANY

  1. 6.

    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 all traces of old sealant.

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

    Material

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

    Material

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

    Material

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

GFD39104Courtesy of FORD MOTOR COMPANY

  1. 7.

    Using a floor crane, install the engine on a mounting stand. Remove Special Service Tool: 303-1246 Engine Spreader Bar., 303-1634 Lift Eyes (2). Use the General Equipment: Floor Crane Use the General Equipment: Mounting Stand
GFD39338Courtesy of FORD MOTOR COMPANY

  1. 8.

    Remove the bolts and the engine mount-to-cylinder block bracket.
    • Discard the bolts.
GFD39165Courtesy of FORD MOTOR COMPANY

  1. 9.

    Remove and discard the engine mount bracket-to-engine bolts.

    1. 1.

      Remove the engine mount and bracket as an assembly.

    1. 2.

      Clean the engine mount bracket-to-cylinder block and engine mount-to-frame mating surfaces of any dirt or foreign material prior to installation.
GFD39339Courtesy of FORD MOTOR COMPANY

  1. 10.

    • Disconnect the auxiliary coolant pump electrical connector.
    • Release the clamps and disconnect the coolant hoses.
GFD39340Courtesy of FORD MOTOR COMPANY

  1. 11.

    Remove the bolts and the auxiliary coolant pump.
GFD39341Courtesy of FORD MOTOR COMPANY

  1. 12.

    Loosen the coolant pump pulley bolts.
GFD39342Courtesy of FORD MOTOR COMPANY

  1. 13.

    Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.
GFD39343Courtesy of FORD MOTOR COMPANY

  1. 14.

    • Remove the bolts and the coolant pump pulley.
    • Remove the bolt and the idler pulley.
    • Remove the bolt, the nut and the generator.
GFD39344Courtesy of FORD MOTOR COMPANY

  1. 15.

    Remove the bolts, the accessory drive belt tensioner and the idler pulley.
GFD39345Courtesy of FORD MOTOR COMPANY

  1. 16.

    Remove the bolts and the A/C compressor.
GFD39346Courtesy of FORD MOTOR COMPANY

  1. 17.

    Remove the nuts and the bracket.
GFD39262Courtesy of FORD MOTOR COMPANY

  1. 18.

    1. 1.

      Release the clamp and disconnect the heater hose.

    1. 2.

      Remove the nuts and the bracket and heater hose.
GFD39347Courtesy of FORD MOTOR COMPANY

  1. 19.

    Remove the bolts and the oil cooler.
GFD39348Courtesy of FORD MOTOR COMPANY

  1. 20.

    Inspect the oil cooler. If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may cause engine failure. Refer to: Engine .
GFD39202Courtesy of FORD MOTOR COMPANY

  1. 21.

    Remove and discard the oil cooler gasket.
GFD39349Courtesy of FORD MOTOR COMPANY

  1. 22.

    Remove the bolts and the engine appearance cover bracket.
GFD39184Courtesy of FORD MOTOR COMPANY

  1. 23.

    • Remove the stud bolt and the wiring harness ground terminal from the rear of the LH cylinder head.
    • Disconnect the KS wiring harness connector and detach the retainer.
GFD39350Courtesy of FORD MOTOR COMPANY

  1. 24.

    Remove the nut and the ground terminal from the rear of the RH cylinder head.
GFD39351Courtesy of FORD MOTOR COMPANY

  1. 25.

    • Remove the stud bolt and the wiring harness ground terminal from the rear of the RH cylinder head.
    • Disconnect the fuel pump electrical connector.
    • Detach the wiring harness retainers.
GFD39352Courtesy of FORD MOTOR COMPANY

  1. 26.

    Disconnect the oil control solenoid electrical connector and detach the wiring harness retainers.
GFD39353Courtesy of FORD MOTOR COMPANY

  1. 27.

    Disconnect the engine wiring harness electrical connectors and detach the retainers.
GFD39354Courtesy of FORD MOTOR COMPANY

  1. 28.

    Disconnect the engine wiring harness electrical connectors and detach the retainers.
GFD39186Courtesy of FORD MOTOR COMPANY

  1. 29.

    Disconnect the engine wiring harness electrical connectors and detach the retainers.
GFD39355Courtesy of FORD MOTOR COMPANY

  1. 30.

    Disconnect the engine wiring harness electrical connectors and detach the retainers.
    • Remove the engine wiring harness from the engine.
GFD39356Courtesy of FORD MOTOR COMPANY

  1. 31.

    Detach the vacuum hose retainers.
    • Release the clamp and disconnect the vacuum hose from the TC.
GFD39357Courtesy of FORD MOTOR COMPANY

  1. 32.

    1. 1.

      Release the clamp and disconnect the vacuum hose from the TC.

    1. 2.

      Remove the vacuum control solenoid bolts.

    1. 3.

      Disconnect the vacuum tube quick release coupling. Refer to: QUICK RELEASE COUPLING

    1. 4.

      Detach the retainers and remove the vacuum tube assembly from the engine.
GFD39358Courtesy of FORD MOTOR COMPANY

  1. 33.

    Disconnect the quick release coupling and remove the EVAP purge valve. Refer to: QUICK RELEASE COUPLING .
GFD39372Courtesy of FORD MOTOR COMPANY

  1. 34.

    NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

    Remove the stud bolts and the ignition-on-coils.

GFD39359Courtesy of FORD MOTOR COMPANY

  1. 35.

    Remove the bolts and position the coolant pipe aside.
GFD39191Courtesy of FORD MOTOR COMPANY

  1. 36.

    NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

    Loosen the bolts and remove the intake manifold.

GFD39373Courtesy of FORD MOTOR COMPANY

  1. 37.

    • Remove and inspect the gaskets, replace as necessary.
    • Clean and inspect all sealing surfaces.
GFD39193Courtesy of FORD MOTOR COMPANY

  1. 38.

    NOTE: To release the fuel pressure in the high-pressure fuel tube, wrap the high-pressure fuel tube flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of high-pressure fuel tube flare nuts.
    • Loosen the high-pressure fuel pump-to-fuel rail high-pressure fuel tube flare nuts.
    • Remove and discard the high-pressure fuel tube.
GFD39374Courtesy of FORD MOTOR COMPANY

  1. 39.

    NOTE: Alternately loosen the high-pressure fuel pump nuts one revolution at a time.

    Remove the nuts and the high-pressure fuel pump.

GFD39375Courtesy of FORD MOTOR COMPANY

  1. 40.

    Remove and discard the high-pressure fuel pump O-ring seal.
GFD39376Courtesy of FORD MOTOR COMPANY

  1. 41.

    Remove the high-pressure fuel pump tappet.
GFD39377Courtesy of FORD MOTOR COMPANY

  1. 42.

    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.
GFD39378Courtesy of FORD MOTOR COMPANY

  1. 43.

    Remove the stud bolts and the high-pressure fuel pump drive unit.
GFD39379Courtesy of FORD MOTOR COMPANY

  1. 44.

    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 all traces of old sealant.

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

    Material

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

    Material

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

    Material

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

GFD39380Courtesy of FORD MOTOR COMPANY

  1. 45.

    • Loosen the fuel rail-to-fuel rail high-pressure fuel tube flare nuts.
    • Remove and discard the high-pressure fuel tube.
GFD39113Courtesy of FORD MOTOR COMPANY

  1. 46.

    Remove the bolts and the brake vacuum pump.
GFD39381Courtesy of FORD MOTOR COMPANY

  1. 47.

    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 all traces of old sealant.

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

    Material

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

    Material

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

    Material

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

GFD39382Courtesy of FORD MOTOR COMPANY

  1. 48.

    Remove the bolts and the coolant pump.
GFD39360Courtesy of FORD MOTOR COMPANY

  1. 49.

    Remove and discard the coolant pump gasket and seal.
GFD39361Courtesy of FORD MOTOR COMPANY

  1. 50.

    Remove the TC coolant return tube bolt, then disconnect and remove the TC coolant return tube.
GFD39383Courtesy of FORD MOTOR COMPANY

  1. 51.

    Remove and discard the TC coolant return tube O-ring seal.
GFD39384Courtesy of FORD MOTOR COMPANY

  1. 52.

    Remove the and discard the upper left TC nut.
GFD39385Courtesy of FORD MOTOR COMPANY

  1. 53.

    Remove the and discard the upper left TC mounting stud.
GFD39386Courtesy of FORD MOTOR COMPANY

  1. 54.

    Remove the TC oil supply tube bolt and then disconnect the TC oil supply tube from the TC.
GFD39387Courtesy of FORD MOTOR COMPANY

  1. 55.

    Remove the TC oil supply tube bolt and then remove the TC oil supply tube.
GFD39388Courtesy of FORD MOTOR COMPANY

  1. 56.

    Remove and discard the TC oil supply tube O-ring seals and the TC oil supply tube oil filter.
GFD39389Courtesy of FORD MOTOR COMPANY

  1. 57.

    Remove the TC oil return tube bolts and then remove the TC oil return tube.
GFD39362Courtesy of FORD MOTOR COMPANY

  1. 58.

    Remove and discard the TC oil return tube O-ring seal.
GFD39363Courtesy of FORD MOTOR COMPANY

  1. 59.

    Remove and discard the TC oil return tube tube-to-engine block gasket.
GFD39364Courtesy of FORD MOTOR COMPANY

  1. 60.

    Remove the TC coolant supply tube bolt.
GFD39390Courtesy of FORD MOTOR COMPANY

  1. 61.

    NOTE: Remove the TC coolant supply tube from the engine block while removing the TC.

    Remove and discard the TC retainers and then remove the TC.

GFD39391Courtesy of FORD MOTOR COMPANY

  1. 62.

    Remove and discard the TC coolant supply tube O-ring seal.
GFD39392Courtesy of FORD MOTOR COMPANY

  1. 63.

    Remove and discard the TC gasket.
GFD39393Courtesy of FORD MOTOR COMPANY

  1. 64.

    Remove and discard the TC mounting stud.
GFD39394Courtesy of FORD MOTOR COMPANY

  1. 65.

    Remove the TC oil supply tube bolts and then remove the TC oil supply tube.
GFD39395Courtesy of FORD MOTOR COMPANY

  1. 66.

    Remove and discard the TC oil supply tube O-ring seals and the TC oil supply tube oil filter.
GFD39389Courtesy of FORD MOTOR COMPANY

  1. 67.

    Remove the TC coolant return tube bolt, then disconnect the TC coolant return tube and position out of the way.
GFD39396Courtesy of FORD MOTOR COMPANY

  1. 68.

    Remove and discard the TC coolant return tube O-ring seal.
GFD39384Courtesy of FORD MOTOR COMPANY

  1. 69.

    Remove the TC oil return tube bolts and then remove the TC oil return tube.
GFD39365Courtesy of FORD MOTOR COMPANY

  1. 70.

    Remove and discard the TC oil return tube O-ring seal.
GFD39363Courtesy of FORD MOTOR COMPANY

  1. 71.

    Remove and discard the TC oil return tube tube-to-engine block gasket.
GFD39364Courtesy of FORD MOTOR COMPANY

  1. 72.

    Remove the TC coolant supply tube bolt.
GFD39397Courtesy of FORD MOTOR COMPANY

  1. 73.

    Remove and discard the TC bolt.
GFD39398Courtesy of FORD MOTOR COMPANY

  1. 74.

    NOTE: Remove the TC coolant supply tube from the engine block while removing the TC.

    Remove and discard the TC nuts and then remove the TC.

GFD39399Courtesy of FORD MOTOR COMPANY

  1. 75.

    Remove and discard the TC coolant supply tube O-ring seal.
GFD39384Courtesy of FORD MOTOR COMPANY

  1. 76.

    Remove and discard the TC gasket.
GFD39400Courtesy of FORD MOTOR COMPANY

  1. 77.

    Remove and discard the TC mounting studs.
GFD39401Courtesy of FORD MOTOR COMPANY

  1. 78.

    Remove the oil pan bolts.
GFD39213Courtesy of FORD MOTOR COMPANY

  1. 79.

    1. 1.

      Using a large flat-bladed screwdriver and the indicated pry pads, release the sealer and separate the oil pan from the bottom of the engine.

    1. 2.

      NOTE: Do not reuse the oil pan.

    Remove and discard the oil pan.

GFD39214Courtesy of FORD MOTOR COMPANY

  1. 80.

    Remove and discard the oil pump seal.
GFD39215Courtesy of FORD MOTOR COMPANY

  1. 81.

    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 oil pan sealing surfaces of the cylinder block and engine front cover 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

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

    Material

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

GFD39216Courtesy of FORD MOTOR COMPANY

  1. 82.

    Loosen the fasteners and remove the valve cover.
GFD39279Courtesy of FORD MOTOR COMPANY

  1. 83.

    Remove and discard the gasket.
    • Clean the valve cover gasket groove with soap and water or a suitable solvent.
GFD39280Courtesy of FORD MOTOR COMPANY

  1. 84.

    Inspect the spark plug seals. Remove any damaged seals using the special tools. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.
GFD39281Courtesy of FORD MOTOR COMPANY

  1. 85.

    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 all traces of old sealant.

    Clean the valve cover mating surface of the cylinder head and engine front cover. 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 / ZC-31-B

    Material

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

GFD39282Courtesy of FORD MOTOR COMPANY

  1. 86.

    Remove the oil level indicator.
GFD39261Courtesy of FORD MOTOR COMPANY

  1. 87.

    Loosen the fasteners and remove the valve cover.
GFD39263Courtesy of FORD MOTOR COMPANY

  1. 88.

    Remove and discard the gasket.
    • Clean the valve cover gasket groove with soap and water or a suitable solvent.
GFD39264Courtesy of FORD MOTOR COMPANY

  1. 89.

    Inspect the spark plug seals. Remove any damaged seals using the special tools. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.
GFD39265Courtesy of FORD MOTOR COMPANY

  1. 90.

    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 all traces of old sealant.

    Clean the valve cover mating surface of the cylinder head and engine front cover. 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 / ZC-31-B

    Material

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

GFD39266Courtesy of FORD MOTOR COMPANY

  1. 91.

    Remove the crankshaft pulley bolt.
GFD39090Courtesy of FORD MOTOR COMPANY

  1. 92.

    Using the 3 Leg Puller and a step plate, remove the crankshaft pulley. Use the General Equipment: Three Leg Puller
GFD39091Courtesy of FORD MOTOR COMPANY

  1. 93.

    NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

    1. 1.

      Install the crankshaft pulley bolt.

    1. 2.

      Using the special tool, remove and discard the crankshaft front oil seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.

    1. 3.

      NOTE: Retain the original crankshaft pulley bolt for turning the crankshaft while the pulley is removed.

      Remove the crankshaft pulley bolt.

GFD39366Courtesy of FORD MOTOR COMPANY

  1. 94.

    NOTE: There are 4 different types of fasteners, note location of each fastener for assembly.

    Remove the engine front cover fasteners.

GFD39136Courtesy of FORD MOTOR COMPANY

  1. 95.

    Using a large flat-bladed screwdriver and the indicated pry pads, release the sealer and remove the engine front cover. Use the General Equipment: Flat-Bladed Screwdriver
GFD39137Courtesy of FORD MOTOR COMPANY

  1. 96.

    Remove and discard the engine front cover gaskets.
GFD39138Courtesy of FORD MOTOR COMPANY

  1. 97.

    Remove and discard the oil gallery seal (6G068).
GFD39139Courtesy of FORD MOTOR COMPANY

  1. 98.

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

      Material

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

      Material

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

      Material

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

GFD39140Courtesy of FORD MOTOR COMPANY

  1. 99.

    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 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 engine 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

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

    Material

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

GFD39141Courtesy of FORD MOTOR COMPANY

  1. 100.

    NOTE: Rotate the crankshaft utilizing only the original crankshaft pulley bolt. Failure to follow this direction may cause damage to the crankshaft and result in engine failure.

    Install the original crankshaft pulley bolt.

GFD39226Courtesy of FORD MOTOR COMPANY

  1. 101.

    NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For removal and installation of the RH side the triangle marks are used.

    1. 1.

      Rotate the crankshaft clockwise.

    1. 2.

      Position the crankshaft sprocket keyway at the 11 o'clock position.

    1. 3.

      Verify the triangle  timing marks on the VCT units are at the 2 o'clock (intake) and 11 o'clock (exhaust) positions. If the circle  timing marks are at these positions the crankshaft must be turned clockwise one revolution (360 degrees).
GFD39227Courtesy of FORD MOTOR COMPANY

  1. 102.

    Remove the bolts and the RH timing chain tensioner.
GFD39228Courtesy of FORD MOTOR COMPANY

  1. 103.

    Remove the RH timing chain tensioner arm.
GFD39229Courtesy of FORD MOTOR COMPANY

  1. 104.

    Remove the bolts and the RH timing chain guide.
GFD39230Courtesy of FORD MOTOR COMPANY

  1. 105.

    Remove the RH timing chain.
GFD39231Courtesy of FORD MOTOR COMPANY

  1. 106.

    NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For removal and installation of the LH side the circle marks are used.

    1. 1.

      Rotate the crankshaft clockwise one revolution (360 degrees).

    1. 2.

      Position the crankshaft sprocket keyway at the 11 o'clock position.

    1. 3.

      The circle  timing marks on the VCT units will be at the 10 o'clock (intake) and 12:30 (exhaust) positions.
GFD39235Courtesy of FORD MOTOR COMPANY

  1. 107.

    Remove the original crankshaft pulley bolt.
GFD39234Courtesy of FORD MOTOR COMPANY

  1. 108.

    Remove the timing chain sprocket.
GFD39233Courtesy of FORD MOTOR COMPANY

  1. 109.

    1. 1.

      Rotate the oil pump drive chain tensioner counterclockwise.

    1. 2.

      Insert a small hex wrench or pin into the holes of the tensioner to secure the end of the spring.
GFD39236Courtesy of FORD MOTOR COMPANY

  1. 110.

    Remove the bolt and oil pump drive chain tensioner.
GFD39237Courtesy of FORD MOTOR COMPANY

  1. 111.

    Remove the bolts and oil pump drive chain guide.
GFD39238Courtesy of FORD MOTOR COMPANY

  1. 112.

    Remove the oil pump drive chain.
GFD39239Courtesy of FORD MOTOR COMPANY

  1. 113.

    Remove the bolts and the LH timing chain tensioner.
GFD39240Courtesy of FORD MOTOR COMPANY

  1. 114.

    Remove the LH timing chain tensioner arm.
GFD39241Courtesy of FORD MOTOR COMPANY

  1. 115.

    Remove the bolts and the LH timing chain guide.
GFD39242Courtesy of FORD MOTOR COMPANY

  1. 116.

    Remove the LH timing chain.
GFD39243Courtesy of FORD MOTOR COMPANY

  1. 117.

    Remove the timing chain sprocket.
GFD39244Courtesy of FORD MOTOR COMPANY

  1. 118.

    Remove the bolts and the oil pump.
GFD39367Courtesy of FORD MOTOR COMPANY

  1. 119.

    1. 1.

      Install Special Service Tool: 303-1248 Camshaft holding tools.

    1. 2.

      Remove and discard the VCT unit bolts.

    1. 3.

      Remove the VCT units.
GFD39288Courtesy of FORD MOTOR COMPANY

  1. 120.

    NOTE: The front camshaft bearing mega cap must be removed first and then the remaining camshaft bearing caps. Failure to follow this direction may result in damage to the engine.

    Remove the bolts and the front camshaft bearing mega cap.

GFD39079Courtesy of FORD MOTOR COMPANY

  1. 121.

    Remove the bolts and the camshaft bearing caps.
GFD39080Courtesy of FORD MOTOR COMPANY

  1. 122.

    Remove the intake and exhaust camshafts.
GFD39081Courtesy of FORD MOTOR COMPANY

  1. 123.

    1. 1.

      Remove the camshaft roller follower and hydraulic lash adjuster assemblies.

    1. 2.

      Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.

    1. 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.
GFD39082Courtesy of FORD MOTOR COMPANY

  1. 124.

    1. 1.

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

    1. 2.

      NOTE: Do not pry the cylinder head to coolant outlet connector behind the bracket. If necessary, use gripping pliers to pull the cylinder head to coolant outlet connector from the cylinder head.

    Remove the bolt and the cylinder head to coolant outlet connector hose assembly.

GFD39121Courtesy of FORD MOTOR COMPANY

  1. 125.

    • Remove and discard the cylinder head bolts.
    • Remove the cylinder head.
GFD39122Courtesy of FORD MOTOR COMPANY

  1. 126.

    Remove and discard the cylinder head gasket.
GFD39123Courtesy of FORD MOTOR COMPANY

  1. 127.

    • Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
GFD39124Courtesy of FORD MOTOR COMPANY

  1. 128.

    1. 1.

      Install Special Service Tool: 303-1248 Camshaft holding tools.

    1. 2.

      Remove and discard the VCT unit bolts.

    1. 3.

      Remove the VCT units.
GFD39289Courtesy of FORD MOTOR COMPANY

  1. 129.

    NOTE: The front camshaft bearing mega cap must be removed first and then the remaining camshaft bearing caps. Failure to follow this direction may result in damage to the engine.

    Remove the bolts and the front camshaft bearing mega cap.

GFD39071Courtesy of FORD MOTOR COMPANY

  1. 130.

    Remove the bolts and the camshaft bearing caps.
GFD39072Courtesy of FORD MOTOR COMPANY

  1. 131.

    Remove the intake and exhaust camshafts.
GFD39073Courtesy of FORD MOTOR COMPANY

  1. 132.

    1. 1.

      Remove the camshaft roller follower and hydraulic lash adjuster assemblies.

    1. 2.

      Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.

    1. 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.
GFD39074Courtesy of FORD MOTOR COMPANY

  1. 133.

    1. 1.

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

    1. 2.

      NOTE: Do not pry the cylinder head to coolant outlet connector behind the bracket. If necessary, use gripping pliers to pull the cylinder head to coolant outlet connector from the cylinder head.

    Remove the bolt and the cylinder head to coolant outlet connector hose assembly.

GFD39111Courtesy of FORD MOTOR COMPANY

  1. 134.

    • Remove and discard the cylinder head bolts.
    • Remove the cylinder head.
GFD39114Courtesy of FORD MOTOR COMPANY

  1. 135.

    Remove and discard the cylinder head gasket.
GFD39115Courtesy of FORD MOTOR COMPANY

  1. 136.

    • Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
GFD39116Courtesy of FORD MOTOR COMPANY

  1. 137.

    1. 1.

      Detach the wiring harness retainer from the stud bolt

    1. 2.

      Remove the stud bolt, the nuts and the coolant outlet connector pipe.
GFD39402Courtesy of FORD MOTOR COMPANY

  1. 138.

    1. 1.

      Disconnect the ECT sensor electrical connector.

    1. 2.

      Remove the bolts and the KS assembly.
GFD39403Courtesy of FORD MOTOR COMPANY

  1. 139.

    NOTE: Do not reuse the ECT sensor, install a new sensor.

    Remove and discard the ECT sensor.

GFD39404Courtesy of FORD MOTOR COMPANY

  1. 140.

    Remove the engine block skirt stiffener bolts.
GFD39368Courtesy of FORD MOTOR COMPANY

  1. 141.

    Using a suitable pry bar at the 4 pry pad locations, release the engine block skirt stiffener-to-engine block seal.
GFD39369Courtesy of FORD MOTOR COMPANY

  1. 142.

    • Remove the engine block skirt stiffener.
    • Remove and discard the oil seal.
GFD39370Courtesy of FORD MOTOR COMPANY

  1. 143.

    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 all traces of old 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

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

    Material

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

GFD39371Courtesy of FORD MOTOR COMPANY

  1. 144.

    • 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.
GFD39405Courtesy of FORD MOTOR COMPANY

  1. 145.

    Remove the bolts and the connecting rod cap.
GFD39406Courtesy of FORD MOTOR COMPANY

  1. 146.

    NOTE: Position the cylinder bank for the piston serviced in a vertical position. Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.
    • Remove the piston through the top of the cylinder block
    • Repeat the steps for each of the remaining pistons.
GFD39407Courtesy of FORD MOTOR COMPANY

  1. 147.

    • Remove the connecting rod bearings.
GFD39408Courtesy of FORD MOTOR COMPANY

  1. 148.

    Remove and discard the main bearing cap bolts.
GFD39409Courtesy of FORD MOTOR COMPANY

  1. 149.

    1. 1.

      Remove the main bearing caps.

    1. 2.

      Remove the lower thrust washer.

    1. 3.

      Remove the lower main bearings.
GFD39410Courtesy of FORD MOTOR COMPANY

  1. 150.

    1. 1.

      Remove the crankshaft.

    1. 2.

      Remove the lower main bearings.

    1. 3.

      Remove the lower thrust bearing.
GFD39411Courtesy of FORD MOTOR COMPANY

  1. 151.

    Remove the bolts and the piston cooling jets from the cylinder block.
GFD39412Courtesy of FORD MOTOR COMPANY
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