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Section 217 (Engine Mechanical - 2.0L GTDI): Disassembly: Engine

WARNING: This page is about a different car, the 2014 Ford Edge. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL DESCRIPTION

G08028546
 Camshaft Alignment Tool
303-1565 
G07958493
 Handle
205-153  (T80T-4000-W)
G06181654
 Holding Tool, Flywheel
303-103  (T74P-8375-A)
G07959023
 Remover, Fuel Injector
310-206 
G06061943
 Remover, Oil Seal
303-409  (T92C-6700-CH)
G06061916
 Remover, VCT Spark Plug Tube Seal
303-1247  /1
G07962084
 Slide Hammer
307-005  (T59L-100-B) or equivalent
G07958537
 Strap Wrench
303-D055  or equivalent
G06096788
 Timing Peg, Crankshaft TDC
303-507 
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® Metal Surface Prep
ZC-31-A		 -
Motorcraft® Silicone Gasket Remover
ZC-30		 -
NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
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  .
  1. NOTE: Do not reuse the flexplate bolts.

    Install the Flywheel Holding Tool and remove the 6 bolts and the flexplate.

    • Discard the bolts.
    • Mount the engine on a suitable Engine Stand.
      G08028726
  2. Loosen the turbocharger outlet tube clamp.
    G08653647
  3. Remove the 2 bolts and the turbocharger outlet tube.
    G08653648
  4. Loosen the turbocharger inlet tube clamp.
    G08612479
  5. Remove the engine appearance cover mounting stud and position the EVAP  canister purge valve aside.
    G09085403
  6. Remove the bolt, stud bolt and the turbocharger inlet tube.
    G08653653
  7. Remove the 2 turbocharger coolant tube banjo bolts and discard the gaskets.
    • Loosen the 2 clamps and remove the turbocharger coolant tube.
      G09294678
  8. Disconnect the 2 turbocharger control vacuum hoses and 2 electrical connectors.
    G09085406
  9. Loosen the clamps and disconnect the 2 turbocharger control vacuum hoses.
    G09085407
  10. NOTE: Do not reuse the turbocharger oil supply tube/gaskets, new parts must be installed.

    Remove the 2 banjo bolts and the turbocharger oil supply tube.

    • Discard the turbocharger oil supply tube and gaskets.
      G09294681
  11. Remove and discard the turbocharger oil filter.
    G08617223
  12. NOTE: Do not reuse the turbocharger oil return tube/gaskets, new parts must be installed.

    Remove the 4 bolts and the turbocharger oil return tube.

    • Discard the turbocharger oil return tube and gaskets.
      G08612487
  13. Remove the 2 bolts and the turbocharger heat shield.
    G08612488
  14. Remove the 4 nuts and the turbocharger.
    • Discard the nuts.
      G09085412
  15. Remove and discard the turbocharger gasket and the 4 turbocharger-to-cylinder head studs.
    G08612490
  16. Slide the insulator up and disconnect the CHT  sensor electrical connector.
    • Detach the wiring harness retainer.
    • Disconnect the ECT  sensor electrical connector.
    • Remove the bolt and the ground wire.
      G08653662
  17. Disconnect the CKP  sensor electrical connector.
    • Detach the 2 wiring harness retainers.
    • Remove the nut and the ground strap.
      G09085415
  18. Remove the 2 bolts and the RH halfshaft bracket.
    G08653663
  19. Remove the 2 bolts and the accessory drive belt tensioner.
    • Remove the accessory drive belt.
      G09085417
  20. Remove the 3 bolts and the power steering pump.
    G09294691
  21. Remove the 3 bolts and the coolant pump pulley.
    • Remove the 4 bolts and the power steering pump bracket.
    • Remove the 3 bolts and the generator.
      G09294692
  22. Remove the 3 bolts and the coolant pump.
    • Remove the bolt, the nut and the idler pulley and bracket assembly.
      G09085419
  23. Disconnect the EVAP  tube quick connect coupling. For additional information, refer to the QUICK CONNECT COUPLING .
    • Detach the heater hose retainer from the intake manifold.
    • Loosen the clamp and remove the heater hose.
    • Loosen the clamp and remove the CAC  outlet tube.
      G09085420
  24. Disconnect the EOP  switch electrical connector.
    • Remove the 4 bolts and the oil filter adapter.
      • Discard the gasket.
        G09294695
  25. Disconnect the EVAP  tube quick connect coupling. For additional information, refer to the QUICK CONNECT COUPLING .
    • Detach the 2 EVAP  tube retainers.
      G09294696
  26. Disconnect the EVAP  canister purge valve electrical connector.
    • Remove the EVAP  canister purge valve and tube assembly.
      G09085619
  27. Disconnect the 2 brake vacuum tube quick connect couplings. For additional information, refer to the QUICK CONNECT COUPLING .
    • Depress the quick release locking ring and pull the brake vacuum tube out of the intake manifold quick connect fitting.
      G09294698
  28. Disconnect the MAP  sensor, the FRP  sensor and fuel charge harness electrical connectors.
    G09085616
  29. Disconnect the 2 vacuum hoses from the intake manifold.
    • Detach the vacuum tube retainer from the intake manifold.
      G09085615
  30. Remove the 5 intake manifold bolts and position the intake manifold toward the cooling fan.
    G09085429
  31. Disconnect the TB  electrical connector and detach the wiring harness retainer from the TB  .
    • Detach the 2 KS  wiring harness retainers from the intake manifold.
    • Disconnect the PCV hose and remove the intake manifold.
      G08028514
  32. Disconnect the 2 KS  electrical connectors.
    • Remove the 2 bolts and the 2 KS  .
    • Detach the 2 wiring harness retainers.
      G08612511
  33. Remove the 8 bolts and the crankcase vent oil separator.
    • Loosen the 2 clamps and remove the coolant bypass hose.
      G08612512
  34. Disconnect the 4 fuel injector electrical connectors and remove the fuel charge wiring harness.
    G08612513
  35. Remove the 2 pin-type retainers and the fuel rail insulator.
    G08612514
  36. Disconnect the fuel injection pump electrical connector.
    • Remove the fuel injection pump insulator.
      G08653681
  37. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of the fuel injection pump flare nut.

    Loosen the 2 high pressure fuel tube flare nuts.

    • Remove the 2 bolts and the high pressure fuel tube.
    • Discard the high pressure fuel tube.
      G08612515
  38. NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors.
    NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain in the cylinder head and require the use of a Fuel Injector Remover tool to extract.

    Remove the 5 bolts and the fuel rail.

    • Discard the bolts.
      G08612516
  39. Remove any of the fuel injectors that remained in the fuel rail.
    G08653684
  40. Using the Slide Hammer and the Fuel Injector Remover, remove the fuel injectors that remained in the cylinder head.
    G08612518
  41. Remove and discard the fuel injector clips.
    G08030331
  42. Discard the upper fuel injector O-ring seals and the upper fuel injector O-ring seal support rings.
    G08653687
  43. NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.
    NOTE: Be very careful when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.

    Pull the lower Teflon® seal away from the injector with narrow tip pliers.

    G08030335
  44. Carefully cut and discard the lower fuel injector Teflon® seals.
    G08030336
  45. Remove the 3 bolts and the thermostat housing.
    G08612522
  46. Remove the 3 bolts and the brake vacuum pump.
    G08617173
  47. Remove the 2 bolts and the fuel injection pump bracket.
    G08030302
  48. Alternately loosen the 2 fuel injection pump bolts one complete revolution at a time.
    • Remove the fuel injection pump.
      G08030303
  49. Remove and discard the fuel injection pump O-ring seal.
    G08030304
  50. Slide the fuel injection pump tappet out of the fuel injection pump housing.
    G08612527
  51. Using the crankshaft pulley bolt, rotate the engine clockwise until the fuel injection cam lobe is at zero lift.
    G08030308
  52. Remove the 4 stud bolts and the fuel injection pump housing.
    G08653697
  53. Disconnect the 9 wiring harness electrical connectors.
    • Detach the 7 retainers and remove the wiring harness from the engine.
      G09085584
  54. Detach the 2 retainers and slide the vacuum hose assembly off of the valve cover tab.
    G09085452
  55. Remove the oil level indicator.
    • Remove the 4 bolts and the 4 coil-on-plugs.
    • Remove the nut, bolt and CAC  intermediate tube mounting bracket.
      G08653700
  56. Loosen the 14 valve cover retainers and remove the valve cover.
    • Discard the valve cover gasket.
      G09085454
  57. NOTE: The VCT  solenoid seals should only be replaced if they are damaged.

    Remove any damaged VCT  solenoid seals using the VCT  Spark Plug Tube Seal Remover and Handle.

    G08028535
  58. Remove the 2 bolts and the rear intake camshaft cap.
    G08028552
  59. Using a wrench on the flats of the intake camshaft to prevent cam rotation, remove the brake vacuum pump adapter.
    G08028553
  60. NOTE: Turn the engine in the normal direction of rotation only.

    Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the TDC  marked tooth on the crankshaft pulley (located on the 20th tooth counterclockwise from the missing tooth) at the 6 o'clock position.

    G08030561
  61. Remove the engine plug bolt.
    G08613976
  62. Install the Crankshaft TDC  Timing Peg.
    G08613977
  63. NOTE: The Crankshaft TDC  Timing Peg will contact the crankshaft and prevent it from turning past TDC  . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC  position during the crankshaft pulley removal and installation.
    NOTE: The engine front cover is shown in illustration removed in graphic for clarity.

    Rotate the crankshaft slowly clockwise until the crankshaft contacts the Crankshaft TDC  Timing Peg.

    • The TDC  marked tooth on the crankshaft pulley will align with the center line of the CKP  sensor.
      G08030565
  64. NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Tool cannot be installed, remove the TDC  Timing Peg and rotate the crankshaft three-fourths of a revolution clockwise and repeat the previous 2 steps of this procedure.

    Install the Camshaft Alignment Tool into the rear of both of the camshaft slots as shown in illustration.

    • Tighten the retainer.
      G09294735
  65. NOTE: The crankshaft must remain in the TDC  position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Strap Wrench and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
    NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley.

    Use the Strap Wrench to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt.

    • Remove and discard the crankshaft pulley bolt and washer.
    • Remove the crankshaft pulley.
      G08028560
  66. NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur.

    If the diamond washer did not come off with the crankshaft pulley, remove the diamond washer.

    G08028562
  67. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

    Using the Oil Seal Remover, remove the crankshaft front oil seal.

    G08028583
  68. Remove the 2 bolts and the CKP  sensor.
    G08028587
  69. NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

    Remove the 20 bolts, 2 stud bolts and the engine front cover.

    • Clean and inspect the mounting surfaces of the engine and the front cover.
      G09294465
  70. NOTE: Do not rely on the Camshaft Alignment Tool to prevent camshaft rotation. Damage to the tool or the camshaft can occur.

    Using a wrench on the flats of the exhaust camshaft to prevent camshaft rotation, loosen the exhaust camshaft phaser and sprocket bolt.

    G08028607
  71. NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

    Using a wrench on the flats of the intake camshaft to prevent camshaft rotation, loosen the intake camshaft phaser and sprocket bolt.

    G09294742
  72. Compress the timing chain tensioner in the following sequence.
    1. Using a small pick, release and hold the ratchet mechanism.
    2. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.
    3. Insert a paper clip into the hole to retain the tensioner.
      G08028609
  73. Remove the 2 bolts and the timing chain tensioner.
    G08028610
  74. Remove the timing chain tensioner arm.
    • Remove the 2 bolts and the timing chain guide.
    • Remove the timing chain.
      G08028611
  75. Remove the 2 bolts and the intake and exhaust camshaft phaser and sprockets.
    G08028633
  76. NOTE: Washers are not required for installation of the VCT  units.

    If equipped, discard the washers.

    G08028634
  77. Remove the 2 bolts and the 2 VCT  solenoids.
    G08030599
  78. Remove the 3 bolts and the front camshaft bearing cap.
    G08028626
  79. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
    NOTE: Note the position of the camshaft lobes on the No. 1 cylinder for installation reference.
    NOTE: Mark the location and orientation of each camshaft bearing cap.

    Remove the camshafts from the engine.

    • Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.
    • Remove the camshaft bearing caps.
    • Remove the camshafts.
      G08028627
  80. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.

    Remove the 16 valve tappets.

    G08028653
  81. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.

    Inspect the valve tappets. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

  82. Remove the 10 bolts and the cylinder head.
    • Discard the bolts.
      G08028654
  83. 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 of the silicone gasket remover and the metal surface prep.
    NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

    Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.

    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
  84. NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

    Support the cylinder head 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 .

  85. Remove and discard the head gasket.
    G08028655
  86. Remove the 2 cylinder head alignment dowels.
    G08612565
  87. Remove the 13 bolts and the oil pan.
    G09294429
  88. Remove the 6 bolts and the crankshaft rear seal with retainer plate.
    G08028736
  89. Remove the 2 bolts and the oil pump screen and pickup tube.
    • Discard the gasket.
      G08612672
  90. Remove the oil pump drive chain tensioner.
    1. Push the tensioner spring down and release the spring from under the shoulder bolt.
    2. Remove the 2 shoulder bolts and the tensioner.
      • Remove the oil pump chain.
        G08612570
  91. Remove the crankshaft sprocket.
    G08612571
  92. NOTE: The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur.

    Remove the diamond washer.

    G08612572
  93. Remove the bolt and oil pump sprocket.
    G08028700
  94. Remove the 4 bolts and the oil pump.
    G08028701
  95. Make sure the Crankshaft TDC  Timing Peg is still installed and the engine is still at TDC  .
    • If necessary, rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC  Timing Peg.
      G08612153
  96. Mark the balance shaft assembly front shafts on the top for reference that the balance shaft assembly is at TDC  .
    G08612849
  97. NOTE: Due to the precision interior construction of the balance shaft assembly, it should not be disassembled.

    Remove the 4 bolts and the balance shaft assembly.

    G08612155
  98. Remove the Crankshaft TDC  Timing Peg.
    G08613977
  99. 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.
  100. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.

    Remove the 8 bolts and the 4 connecting rod caps.

    G08612581
  101. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

    Remove the 4 piston and rod assemblies from the engine block.

    G08611836
  102. Remove the 10 bolts in the sequence shown in illustration.
    • Remove the main bearing beam.
      G09294769
  103. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.

    Remove the main bearings from the main bearing beam.

    G08612585
  104. Remove the crankshaft from the engine block.
    G08612586
  105. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly. The center bulkhead has the thrust bearing.

    Remove the main bearings from the cylinder block.

    G08612587
  106. Remove the 4 bolts and the 4 engine piston oil coolers.
    G08611842
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