Section 12 (Engine - 2.7L ECOBOOST (238KW/324PS)): Disassembly: Engine
WARNING: This page is about a different variant/trim than selected.
Special Tool(s) / General Equipment
| 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 | |
| 303-1634 Lift Eyes (2) TKIT-2014D-FL_ROW TKIT-2014D-ROW3 | |
| 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.
- 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.
- 4.
- 1.
Reposition the CKP sensor electrical connector insulator.
- 2.
Disconnect the CKP sensor electrical connector.
- 3.
Remove the bolt and the CKP sensor.
- 1.
- 5.
Remove the bolts and the crankshaft rear seal and retainer plate.- Discard the crankshaft rear seal and retainer plate.
- 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
- 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
- 9.
Remove and discard the engine mount bracket-to-engine bolts.- 1.
Remove the engine mount and bracket as an assembly.
- 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.
- 1.
- 10.
- Disconnect the auxiliary coolant pump electrical connector.
- Release the clamps and disconnect the coolant hoses.
- 14.
- Remove the bolts and the coolant pump pulley.
- Remove the bolt and the idler pulley.
- Remove the bolt, the nut and the generator.
- 18.
- 1.
Release the clamp and disconnect the heater hose.
- 2.
Remove the nuts and the bracket and heater hose.
- 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 .
- 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.
- 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.
- 26.
Disconnect the oil control solenoid electrical connector and detach the wiring harness retainers.
- 30.
Disconnect the engine wiring harness electrical connectors and detach the retainers.- Remove the engine wiring harness from the engine.
- 32.
- 1.
Release the clamp and disconnect the vacuum hose from the TC.
- 2.
Remove the vacuum control solenoid bolts.
- 3.
Disconnect the vacuum tube quick release coupling. Refer to: Quick Release Coupling .
- 4.
Detach the retainers and remove the vacuum tube assembly from the engine.
- 1.
- 33.
Disconnect the quick release coupling and remove the EVAP purge valve. Refer to: Quick Release Coupling .
- 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.
- 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.
- 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.
- 39.NOTE: Alternately loosen the high-pressure fuel pump nuts one revolution at a time.
Remove the nuts and the high-pressure fuel pump.
- 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.
- 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
- 45.
- Loosen the fuel rail-to-fuel rail high-pressure fuel tube flare nuts.
- Remove and discard the high-pressure fuel tube.
- 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
- 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.
- 67.
Remove the TC coolant return tube bolt, then disconnect the TC coolant return tube and position out of the way.
- 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.
- 79.
- 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.
- 2.NOTE: Do not reuse the oil pan.
Remove and discard the oil pan.
- 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
- 83.
Remove and discard the gasket.- Clean the valve cover gasket groove with soap and water or a suitable solvent.
- 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.
- 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
- 88.
Remove and discard the gasket.- Clean the valve cover gasket groove with soap and water or a suitable solvent.
- 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.
- 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
- 92.
Using the 3 Leg Puller and a step plate, remove the crankshaft pulley. Use the General Equipment: Three Leg Puller
- 93.NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
- 1.
Install the crankshaft pulley bolt.
- 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.
- 3.NOTE: Retain the original crankshaft pulley bolt for turning the crankshaft while the pulley is removed.
Remove the crankshaft pulley bolt.
- 1.
- 94.NOTE: There are 4 different types of fasteners, note location of each fastener for assembly.
Remove the engine front cover fasteners.
- 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
- 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
- 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
- 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.
- 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.
Rotate the crankshaft clockwise.
- 2.
Position the crankshaft sprocket keyway at the 11 o'clock position.
- 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).
- 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.
Rotate the crankshaft clockwise one revolution (360 degrees).
- 2.
Position the crankshaft sprocket keyway at the 11 o'clock position.
- 3.
The circle timing marks on the VCT units will be at the 10 o'clock (intake) and 12:30 (exhaust) positions.
- 1.
- 109.
- 1.
Rotate the oil pump drive chain tensioner counterclockwise.
- 2.
Insert a small hex wrench or pin into the holes of the tensioner to secure the end of the spring.
- 1.
- 119.
- 1.
Install Special Service Tool: 303-1248 Camshaft holding tools.
- 2.
Remove and discard the VCT unit bolts.
- 3.
Remove the VCT units.
- 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.
- 123.
- 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.
- 1.
- 124.
- 1.
Release the clamp and disconnect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
- 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.
- 1.
- 127.
- Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
- Refer to: Cylinder Head Distortion .
- Refer to: Cylinder Block Distortion .
- 128.
- 1.
Install Special Service Tool: 303-1248 Camshaft holding tools.
- 2.
Remove and discard the VCT unit bolts.
- 3.
Remove the VCT units.
- 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.
- 132.
- 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.
- 1.
- 133.
- 1.
Release the clamp and disconnect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
- 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.
- 1.
- 136.
- Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
- Refer to: Cylinder Head Distortion .
- Refer to: Cylinder Block Distortion .
- 137.
- 1.
Detach the wiring harness retainer from the stud bolt
- 2.
Remove the stud bolt, the nuts and the coolant outlet connector pipe.
- 1.
- 141.
Using a suitable pry bar at the 4 pry pad locations, release the engine block skirt stiffener-to-engine block seal.
- 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
- 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.
- 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.
- 147.
- Remove the connecting rod bearings.
- Disassemble and inspect the pistons. Refer to: Piston . Refer to: Piston Inspection .
- 149.
- 1.
Remove the main bearing caps.
- 2.
Remove the lower thrust washer.
- 3.
Remove the lower main bearings.
- 1.