Section 1 (Engine - 1.0L ECOBOOST (92KW/125PS)): Disassembly: Engine

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Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	300-OTC1819E2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	303-1602 Locking Tool, Crankshaft
Courtesy of FORD MOTOR COMPANY	303-1611 Torque Multiplier
Courtesy of FORD MOTOR COMPANY	303-1611-01 Adapter for 303-1611
Courtesy of FORD MOTOR COMPANY	303-1611-02 Adapter for 303-1611, Torque Multiplier TKIT-2014A-FL TKIT-2014A-ROW
Courtesy of FORD MOTOR COMPANY	303-293 Remover, Crankshaft Seal
Courtesy of FORD MOTOR COMPANY	307-005 (T59L-100-B) Slide Hammer
Courtesy of FORD MOTOR COMPANY	310-206 Remover, Fuel Injector TKIT-2009A-FLM
Mounting Stand
Polydrive Bit Socket
Hot Air Gun
Hose Clamp Remover/Installer
4 mm Drill Bit

6-Speed Manual Transmission - B6 

1. Loosen each bolt 2 turns at a time until all bolts are removed.
   • Remove the pressure plate and the clutch disc.

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   6-Speed Automatic Transmission - 6F15/6-Speed Manual Transmission - B6 

2. Install engine on the mounting stand. Use the General Equipment: Mounting Stand

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3. Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.

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4. WARNING: Take extra care when handling the compressed spring.

   Remove the bolts and the accessory drive belt tensioner. Use the General Equipment: 4 mm Drill Bit

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5. Remove the bolts and the generator.

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6. Remove the bolt and the accessory drive belt idler pulley.

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7. Release the clamp, remove the bolts and the coolant hose assembly. Use the General Equipment: Hose Clamp Remover/Installer

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8. NOTE: Inspect the O-ring seal on the turbocharger drain tube. Replace the turbocharger drain tube, if necessary.
   • Remove the retainers and the turbocharger oil drain tube.
   • Remove and discard the gasket.

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9. • Remove the retainers, banjo bolt and the turbocharger oil supply tube.
   • Discard the turbocharger oil supply tube.
   • Release the vacuum hose clamps. Use the General Equipment: Hose Clamp Remover/Installer
   • Remove the nuts and the turbocharger assembly.

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10. Remove and discard the turbocharger gasket.

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11. • Remove the bolt and the heat shield.
    • Discard the heat shield.

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12. Remove and discard the studs.

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13. • Disconnect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
    • Detach the coolant hose from the retainers.
    • Remove the bolts and the coolant hose assembly.

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14. Disconnect the PCV tube coupling.

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15. • Release the clamp and disconnect the vacuum hose.
    • Disconnect the vacuum harness quick connector.
    • Remove the vacuum solenoid nuts.
    • Detach the retainers and remove the vacuum harness.

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16. Remove the stud bolts and the vacuum pump.

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17. Remove the bolts and the ignition coil-on-plugs.

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18. Remove and discard the high pressure fuel tube.

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19. • Loosen each bolt 1 turn at a time until all bolts are removed.
    • Discard the bolts.

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20. Remove the high-pressure fuel pump tappet.

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21. Inspect the high-pressure fuel pump tappet. If any flat spots or scoring are found, especially in the indicated areas, then inspect the high-pressure fuel pump and the fuel pump tappet drive lobe. Install new components as needed.

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22. • Remove the retainers and the CMP sensors.
    • Detach the retainers, disconnect the fuel injector electrical connectors and remove the wire harness.

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23. NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
    NOTE: Use regulated low pressure compressed air to remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and the fuel injectors.
    NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder head and require the use of a Fuel Injector Remover tool to extract.

    Remove the bolts and the fuel rail.

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24. NOTE: Take extra care when handling the components.
    NOTE: Make sure that the component is clean, free of foreign material and lubricant.
    NOTE: Only use moderate force.

    Remove any of the fuel injectors that remained in the fuel rail.

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25. NOTE: Take extra care when handling the components

    Remove and discard the fuel injector clip.

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26. NOTE: This step is only necessary if the component remains in the cylinder head.

    Remove and discard the fuel injector clip.

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27. NOTE: This step is only necessary if the component remains in the cylinder head.

    Remove the fuel injectors. Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer., 310-206 Remover, Fuel Injector.

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28. NOTE: Take extra care when handling the components
    NOTE: Make sure that the component is clean, free of foreign material and lubricant.

    Remove and discard the fuel injector seal, washer and O-ring seal.

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29. 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.

    Remove the bolts, studs and the intake manifold.

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30. NOTE: A new oil cooler must be installed or severe damage to the engine occur.
    • Remove the bolt and the oil cooler.
    • Discard the oil cooler.

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31. 1. Remove the retainer and the oil pump control solenoid.
    2. NOTE: Note the position of the components before removal.

       Remove the bolts and the KS.

    3. Remove and discard the oil pressure switch.

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32. Remove the bolts and the VCT solenoids.

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33. • Remove the oil level indicator.
    • Remove the studs, bolts and the valve cover.

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34. Inspect the valve cover gasket, replace if necessary.

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35. NOTE: Flywheel shown, flexplate similar

    Install Special Service Tool: 303-1602 Locking Tool, Crankshaft.

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36. 1. M8x30
    2. M8x25Install Special Service Tool: 303-1611-02 Adapter for 303-1611, Torque Multiplier.

       Torque

       : 18 lb.ft (24 Nm)

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37. Install Special Service Tool: 303-1611-01 Adapter for 303-1611.

    Torque

    : 18 lb.ft (24 Nm)

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38. Only tighten the nut finger tight at this stage. Install Special Service Tool: 303-1611 Torque Multiplier.

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39. Loosen:: 5 turn(s)

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40. Remove Special Service Tool: 303-1611 Torque Multiplier.

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41. • Remove and discard the crankshaft bolt.
    • Remove the crankshaft pulley.
    • NOTE: The production engine is not equipped with a friction washer. Whenever the crankshaft pulley is removed, a friction washer (base part number 6378) must be installed.

      If equipped, remove and discard the friction washer.

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42. Remove Special Service Tool: 303-1611-01 Adapter for 303-1611.

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43. Remove Special Service Tool: 303-1611-02 Adapter for 303-1611, Torque Multiplier.

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44. NOTE: Flywheel shown, flexplate similar

    Remove the bolts and the flywheel or flexplate.

    • Discard the bolts.

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45. Remove and discard the crankshaft front seal. Use Special Service Tool: 303-293 Remover, Crankshaft Seal.

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46. Remove the bolt and the CKP sensor.

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47. Remove the bolts and the engine lifting bracket.

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48. NOTE: Note the different lengths of the bolts.
    • Remove and discard the bolts (1 to 16).
    • Remove the oil pan to engine front cover bolts and the engine front cover.

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49. Remove and discard the gasket.

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50. 1. Rotate the timing belt tensioner clockwise.
    2. Install a suitable locking pin.
    3. Remove the timing belt.

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51. WARNING: The tensioner is under spring tension. Be careful when handling the tensioner. Failure to follow this instruction may result in personal injury.

    Remove the bolt and the tensioner.

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52. • NOTE: Note the position of the component before removal.

      Remove the bolt, remove and discard the oil supply filter.

    • Remove the timing drive pulley.

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53. NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

    Remove the bolts and the VCT units.

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54. NOTE: Note the position of the components before removal.
    NOTE: Use a heat gun to soften the flange sealant, this will aid in the removal of the rear camshaft caps. Failure to follow these directions may result in damage to the camshaft caps.
    NOTE: Inspect the camshaft bores for any scratches that can be felt by hand.

    Loosen the camshaft bearing caps bolts in sequence, 2 turns at a time until all tension is released from the camshaft bearing caps and remove the bolts, caps and the camshafts. Use the General Equipment: Hot Air Gun

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55. NOTE: Note the position of the components before removal.

    Remove the valve tappets.

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56. 1. Using a Polydrive #10 bit, remove and discard the cylinder head bolts. Use the General Equipment: Polydrive Bit Socket
    2. Remove the cylinder head.

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57. Remove and discard the cylinder head gasket.

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58. Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
59. Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
60. 1. Before removing the pistons, inspect the top of the cylinder bores.
    2. NOTE: Do not scratch the cylinder wall, remove all debris from the cylinder.

       If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad.

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61. Remove the bolts and the thermostat.

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62. Remove the bolts and the oil pan.

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    6-Speed Manual Transmission - B6 

63. Remove the oil pump cover.

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64. NOTE: Note the position of the component before removal.

    Remove the oil pump drive belt and the oil pump drive pulley.

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65. Remove the bolts and the oil pump.

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66. Remove the bolts and the oil pan baffle.

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    6-Speed Automatic Transmission - 6F15 

67. NOTE: Take extra care when handling the component.

    Remove the oil pump cover.

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68. Install a 4 mm drill bit into the balance shaft gear. Use the General Equipment: 4 mm Drill Bit

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69. Remove and discard the bolts.
    • Remove the oil pump and balance shaft gears.

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70. Remove the balance shaft weight.

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71. 1. Using a suitable tool, rotate the oil pump belt tensioner.
    2. Remove the oil pump belt.
    3. NOTE: Note the position of the component before removal.

       Remove the oil pump drive pulley.

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72. Remove the bolts and the oil pump belt tensioner.

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73. NOTE: Discard the bolts.

    Remove the bolts and the oil pump.

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    6-Speed Automatic Transmission - 6F15/6-Speed Manual Transmission - B6 

74. • Remove the bolts and the crankshaft rear seal.
    • Discard the crankshaft rear seal.

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75. NOTE: Mark the position of the parts, so they can be installed in their original positions.

    Remove the bolts and the connecting rod caps.

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76. NOTE: Mark the position of the parts, so they can be installed in their original positions.
    NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

    Remove the pistons.

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77. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
    • Remove the bolts and the main bearing caps.
    • Remove the crankshaft.

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78. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
    • Remove the crankshaft main bearings.
    • Remove the bolts and the engine piston oil cooler valves.

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