Section 677 (ENGINE - 3.5L ECOBOOST (272kW/370PS)): 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
| 205-142 (T80T-4000-J) Installer, Differential Bearing Cone | |
|---|---|
| 205-150 (T80T-4000-S) Installer, Spindle Bearing | |
| 205-153 (T80T-4000-W) Handle | |
| 303-1246 Engine Spreader Bar TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 303-1248 Camshaft holding tools TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 303-1530 Tool, Chain Tensioner Hold Down TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW | |
| 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 | |
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:
If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.
NOTE:
Refer to the exploded view under the Engine Component View .
- 3.NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.
Mount the engine to the mounting stand. Use the General Equipment: Mounting Stand
- 10.
- Disconnect the vacuum hoses from the turbochargers.
- Disconnect the electrical connector from the vacuum solenoid.
- Detach the vacuum hose retainers from the valve covers.
- 12.
Using a three leg puller, remove the crankshaft pulley. Use the General Equipment: Three Leg Puller
- 13.
Using the special tool, remove and discard the crankshaft front seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.
- 21.
Loosen the fitting and separate the RH turbocharger coolant return tube and fitting from the cylinder head.
- 22.
- Remove the oil return tube bolt.
- Remove the coolant/oil tube assembly bolt.
- Remove the bolts and the RH turbocharger.
- 24.
Loosen the fitting and separate the LH turbocharger coolant return tube and fitting from the cylinder head.
- 25.
- Remove the oil return tube bolt.
- Remove the coolant/oil tube assembly bolt.
- Remove the bolts and the LH turbocharger.
- 31.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.
- 37.NOTE: Make sure the oil tube filter screen is free of contaminants prior to installation.
Inspect the gasket and the oil tube filter screen. Replace the gasket if necessary.
- 38.
- Disconnect the CHT sensor electrical connector and wiring harness retainer.
- Remove the stud bolt and the ground wire.
- 39.
- Disconnect the KS electrical connector.
- Disconnect the fuel pressure sensor electrical connector.
- Disconnect the RH and LH fuel charge harness electrical connectors.
- 40.
- Remove the bolt and the ground strap.
- Disconnect the CMP sensor electrical connectors.
- Remove the nut and detach the wiring harness retainer.
- Remove the stud bolt and the ground wire.
- 43.
- Disconnect the CKP sensor electrical connector.
- Remove the bolt, the CKP sensor electrical connector and position the wiring harness aside.
- 44.
- Remove the oil level indicator.
- Disconnect the VCT sensor electrical connectors.
- Disconnect the coil-on-plug electrical connectors.
- Detach the wiring harness retainers.
- 45.
- Disconnect the VCT sensor electrical connectors.
- Disconnect the CMP sensor electrical connectors.
- Disconnect the coil-on-plug electrical connectors.
- Detach the wiring harness retainers and remove the engine wiring harness.
- 46.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.
- 48.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 bolts and remove the LH valve cover.
- 50.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 bolts and remove the RH valve cover.
- 52.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.
- 53.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.
- 58.
Using a pry tool, locate the 5 pry pads shown below and pry the engine front cover loose and remove.
- 59.
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.
- 60.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 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.
Material
: Motorcraft ® Silicone Gasket Remover / ZC-30-A
Material
: Motorcraft ® Metal Surface Prep / ZC-31-B
- Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
- 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.
- 61.NOTE: Rotate the crankshaft in a clockwise direction only.
Rotate the crankshaft clockwise and align the timing marks on the intake VCT units as shown below.
- 63.NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install Special Service Tool: 303-1248 Camshaft holding tools.
- 65.NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install Special Service Tool: 303-1248 Camshaft holding tools.
NOTE:
The following 3 steps are for primary timing chains that the colored links are not visible.
- 66.
Mark the timing chain link that aligns with the timing mark on the LH intake VCT unit as shown below.
- 67.
Mark the timing chain link that aligns with the timing mark on the RH intake VCT unit as shown below.
- 68.NOTE: The crankshaft sprocket timing mark should be between the colored links.
Mark the timing chain links that aligns with the timing mark on the crankshaft sprocket as shown below.
- 72.NOTE: Removal of the VCT oil control solenoid will aid in the removal of the timing chain.NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoids.NOTE: Keep the VCT oil control solenoid clean of dirt and debris.
Remove the bolts and the VCT oil control solenoids.
- 75.NOTE: Do not use power tools to remove the bolt or damage to the LH primary timing chain guide may occur.
Remove the bolt and the upper LH timing chain guide.
- 76.NOTE: The VCT oil control solenoids are removed for clarity.
Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.
- 81.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, camshaft caps and the camshafts.
- 82.NOTE: The VCT oil control solenoids are removed for clarity.
Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.
- 88.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, camshaft caps and the camshafts.
- 89.NOTE: Do not use power tools to remove the bolt or damage to the RH primary timing chain guide may occur.
Remove the bolts and the RH timing chain guide.
- 90.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.
Remove the valve tappets from the cylinder heads.
- 93.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 surfaceNOTE: 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.
- 96.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 surfaceNOTE: 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.
- 98.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 ® Silicone Gasket Remover / ZC-30-A
Material
: Motorcraft ® Metal Surface Prep / ZC-31-B
- 99.
Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
- 104.
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.
- 105.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 / ZC-31-B
- Thoroughly wash the oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.
- 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.
- 109.
- Remove the bolts and the crankshaft rear seal retainer.
- Discard the crankshaft rear seal retainer.
- 111.
- Remove and discard the bolts in the sequence shown below.
- Remove the main bearing cap support brace.
- 112.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.
- 113.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.
- 114.
Inspect the pistons. Refer to: Piston Inspection .
- 115.NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.
Remove and discard the bolts in the sequence shown below.
- 116.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.
- 117.
Remove the lower crankshaft thrust washer from the back side of the No. 4 rear main bearing cap.
- 118.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.
- 119.NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
Remove the crankshaft.
- 121.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.
- 123.
Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
- 124.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 / ZC-31-B
Material
: Metal Brake Parts Cleaner / PM-4-A, PM-4-B