Engine Block Skirt Stiffener
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 | |
| 303-1634 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 | |
| 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 | - |
- 1.
Remove the engine from the vehicle. Refer to: Engine .
- 4.
Inspect the crankshaft sensor ring for damage. If the crankshaft sensor ring has been dropped or has any visual damage, it must be replaced.
- 5.
- 1.
Reposition the CKP sensor electrical connector insulator.
- 2.
Disconnect the CKP sensor electrical connector.
- 3.
Remove the bolt and the CKP sensor.
- 1.
- 6.
Remove the bolts and the crankshaft rear seal and retainer plate.- Discard the crankshaft rear seal and retainer plate.
- 7.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
- 8.
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
- 10.
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.
- 11.
- Disconnect the auxiliary coolant pump electrical connector.
- Release the clamps and disconnect the coolant hoses.
- 15.
- Remove the bolts and the coolant pump pulley.
- Remove the bolt and the idler pulley.
- Remove the bolt, the nut and the generator.
- 19.
- 1.
Release the clamp and disconnect the heater hose.
- 2.
Remove the nuts and the bracket and heater hose.
- 1.
- 21.
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 .
- 24.
- 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.
- 26.
- 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.
- 27.
Disconnect the oil control solenoid electrical connector and detach the wiring harness retainers.
- 31.
Disconnect the engine wiring harness electrical connectors and detach the retainers.- Remove the engine wiring harness from the engine.
- 33.
- 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.
- 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: The grommet may remain in the coolant pump housing. If this occurs, remove the grommet from the coolant pump housing.
Remove and discard the coolant pump gasket and seal.
- 44.
- 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.
- 46.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
- 48.
Remove and discard the gasket.- Clean the valve cover gasket groove with soap and water or a suitable solvent.
- 49.
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.
- 50.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
- 53.
Remove and discard the gasket.- Clean the valve cover gasket groove with soap and water or a suitable solvent.
- 54.
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.
- 55.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
- 57.
Using the 3 Leg Puller and a step plate, remove the crankshaft pulley. Use the General Equipment: Three Leg Puller
- 58.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.
- 59.NOTE: There are 4 different types of fasteners, note location of each fastener for assembly.
Remove the engine front cover fasteners.
- 60.
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
- 63.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
- 64.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
- 65.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.
- 66.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.
- 72.
- 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.
- 78.
Using a suitable pry bar at the 4 pry pad locations, release the engine block skirt stiffener-to-engine block seal.
- 80.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