Section 2 (Engine - 2.0L ECOBOOST (184KW/250PS) - Mi4): Disassembly: Engine
WARNING: This page is about a different variant/trim than selected.
For information on Ford Color Coded Illustrations refer to OEM COLOR CODING
Special Tool(s) / General Equipment
| 205-153 (T80T-4000-W) Handle | |
|---|---|
| 300-OTC1819E2, 200# Floor Crane, Fold Away | |
| 303-103 (T74P-6375-A) Holding Tool, Flywheel T74P-77000-A TKIT-2009TC-F | |
| 303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 303-1565 Alignment Tool, Camshaft TKIT-2010C-FLM | |
| 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH | |
| 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW | |
| 307-005 (T59L-100-B) Slide Hammer | |
| 310-206 Remover, Fuel Injector TKIT-2009A-FLM | |
| Strap Wrench | |
| Plastic Scraper |
Materials
| Name | Specification |
|---|---|
| Motorcraft® Metal Surface Prep Wipes ZC-31-B | - |
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. 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. All parts must be thoroughly cleaned and 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 it is necessary to install a new timing chain tensioner, a cast iron tensioner is to be replaced with an aluminum tensioner (6K254). The existing bolts must be discarded and replaced with new bolts (6K282).
- Loosen each bolt 2 turns at a time until all bolts are removed in sequence shown and remove the clutch disc.
- Using the special tool, remove the bolts and the flywheel. Discard the bolts. Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
- Install the engine assembly onto a suitable engine stand.
- Remove the Floor Crane and the special tool. Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.
- Loosen the TC inlet pipe clamp.
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- Remove the bolt, stud and the TC inlet pipe.
- Remove the oil level indicator.
- Disconnect the CKP sensor electrical connector.
- Detach the wiring harness retainers.
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- Remove the clamps, bolts and the TC cooling tube assembly.
- Remove and discard the TC coolant tube sealing washers.
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- Disconnect the TC waste gate regulating valve solenoid electrical connector.
- Disconnect and position aside the TC control actuator hose.
- Remove the bolts and the TC oil feed tube. Discard the sealing washers.
- Remove and discard the TC oil supply filter.
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- Remove the bolts and the TC oil drain tube.
- Discard the TC oil drain tube and gaskets.
- Remove the bolts and the TC heat shield.
- Remove the nuts and the TC. Discard the bolts.
- Remove and discard the TC mounting studs and the gasket.
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- Slide the insulator up and disconnect the CHT sensor electrical connector.
- Remove the bolts, detach the wiring harness retainers and disconnect the electrical connector.
- Remove the fuel injection pump cover.
- Remove the bolts and the RH halfshaft support bracket.
- Loosen the coolant pump pulley bolts.
- Remove the A/C compressor belt. Refer to: Air Conditioning (A/C) Compressor Belt .
- Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
- Loosen the clamp and remove the TC inlet pipe.
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- Detach the wiring harness retainer and disconnect the A/C compressor electrical connector.
- Remove the nut, stud, bolts and remove the A/C compressor.
- Slide the generator insulator up.
- Remove the nut, disconnect the generator electrical connector and position the wiring harness aside.
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- Remove the bolts and the coolant pump pulley.
- Remove the bolts and the generator.
- Remove the bolts and the accessory drive belt tensioner.
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- Remove the bolts and the coolant pump.
- Remove the bolts and the A/C compressor mounting bracket.
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- Disconnect the coolant hose.
- Disconnect and remove the coolant hose.
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NOTE: A new oil cooler must be installed or severe damage to the engine can occur.
Remove the bolt and the oil cooler. Discard the oil cooler.
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- Disconnect the oil filter adaptor electrical connector.
- Remove the bolts and the oil filter adaptor. Discard the gasket.
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- Disconnect the fuel evaporative tube quick release coupling. Refer to: Quick Release Coupling .
- Detach the fuel evaporative tube retainer.
- Detach the fuel evaporative tube retainer.
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- Disconnect the EVAP canister purge valve electrical connector.
- Disconnect the fuel tube coupling, remove the bolts and the fuel evaporative tube assembly.
- Disconnect the electrical connectors.
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- Detach the wiring harness retainers.
- Disconnect the PCV coupling.
- Remove the bolts and the intake manifold.
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- Detach the retainer and remove the wiring harness.
- Detach the retainer and position wiring harness aside.
- Disconnect the electrical connector, remove the bolts and the KS.
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- Remove the bolts and the crankcase vent oil separator.
- Remove the coolant bypass hose.
- Disconnect the fuel injector electrical connectors.
- Release the tabs and remove the fuel rail cover.
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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 during the loosening of the fuel injection pump flare nut.
Loosen the flare nuts and remove the bolts and the high pressure fuel tube. Discard the high pressure fuel tube.
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NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.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 bolts and the fuel rail assembly.
- Remove any of the fuel injectors that remained in the fuel rail.
- Remove any of the fuel injectors that remained in the fuel rail. Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer., 310-206 Remover, Fuel Injector.
- Remove and discard the fuel injector clip.
- Remove and discard the fuel injector seal and washer.
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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. Long-nosed pliers.
- Carefully cut and discard the lower fuel injector Teflon® seals. Cutting knife.
- Discard the specified component. Follow local disposal regulations.
- Remove the bolts and the thermostat assembly.
- Disconnect the vacuum tube coupling.
- Remove the bolts and the vacuum pump.
- Remove the bolts and the high-pressure fuel pump cover.
- Remove the bolts and the high-pressure fuel pump.
- Remove and discard the high-pressure fuel pump O-ring seal.
- Remove high-pressure fuel pump tappet.
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NOTE: The fuel injection cam lobe must be positioned at zero lift before removing the fuel injection pump housing.
Rotate the crankshaft pulley clockwise slowly until fuel injection cam lobe must be positioned at zero lift.
- Remove the studs and the high-pressure fuel pump drive unit.
- Detach the retainers, remove the electrical connectors and the wiring harness.
- Remove the bolts and the ignition coil-on-plugs.
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NOTE: Early build vehicles equipped with metal vacuum tubes.
Detach the vacuum tubes retainers.
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NOTE: Late build vehicles equipped with nylon vacuum tubes.
Detach the retainers and remove the vacuum tubes.
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- Remove the bolts and the valve cover.
- Remove and discard the valve cover gaskets.
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NOTE: The VCT solenoid seals should only be replaced if they are damaged upon inspection.
- Using the special tools, remove and inspect the VCT solenoid seals. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer., 205-153 (T80T-4000-W) Handle.
- Discard the VCT solenoid seals if they are damaged.
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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.
Make sure that the surface is clean and free of foreign material.
Material
: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- Remove the bolts and the rear intake camshaft cap.
- Remove the brake vacuum pump adapter.
- Turn the crankshaft clockwise until the No. 1 piston is 45 degrees BTDC using the guide holes on the engine front cover and the crankshaft pulley.
- Remove the engine plug bolt.
- Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
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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 removed from graphic for clarity.
Rotate the crankshaft slowly until the crankshaft stops. Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
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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.
Tighten the retainer. Install Special Service Tool: 303-1565 Alignment Tool, Camshaft.
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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: If equipped, the crankshaft sprocket diamond washer may come off with the crankshaft pulley.
- Remove and discard the crankshaft pulley bolt. Use the General Equipment: Strap Wrench
- Using the Strap Wrench, remove the crankshaft pulley. Use the General Equipment: Strap Wrench
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NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.
If equipped, remove the diamond washer.
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NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
Using the special tool, remove and discard the crankshaft front seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.
- Remove the bolts and the CKP sensor.
- Remove the bolts and the engine front cover.
- Using an open-ended wrench, loosen the exhaust VCT unit bolt.
- Using an open-ended wrench, loosen the intake VCT unit bolt.
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NOTE: If equipped with cast iron timing chain tensioner.
- Using a small pick, release and hold the ratchet mechanism.
- While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.
- Insert a holding pin into the hole to retain the tensioner.
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NOTE: If it is necessary to install a new timing chain tensioner, a cast iron tensioner is to be replaced with an aluminum tensioner (6K254). The existing bolts must be discarded and replaced with new bolts (6K282).NOTE: If equipped with cast iron timing chain tensioner.
Remove the bolts and the timing chain tensioner.
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NOTE: If equipped with aluminum timing chain tensioner.
Remove the bolts and the timing chain tensioner.
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- Remove the timing chain and tensioner arm.
- Remove the bolts and the timing chain guide.
- Remove the bolts and the VCT units.
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NOTE: Washers are not required for installation of the VCT units.
If equipped. Remove and discard the VCT units washers.
- Remove Special Service Tool: 303-1565 Alignment Tool, Camshaft.
- Remove the bolts and the VCT oil control solenoids.
- Remove the bolts and the front camshaft cap.
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NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.NOTE: Note the location and orientation of each camshaft bearing cap and the position of the camshaft lobes on the No. 1 cylinder for installation reference.
Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.
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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 tappets, replace any tappets with the correct tappets selected during the valve clearance check.
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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.
- Visual check the valve tappets.
- Install new components as necessary.
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- Remove the bolts and the cylinder head.
- Discard the bolts.
- Remove and discard the cylinder head gasket.
- Remove the dowels.
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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 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.
Make sure that the mating faces are clean and free of foreign material.
Material
: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
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- Check the cylinder block distortion.
- Check the cylinder head distortion.
- Remove the bolts and the oil pan.
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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.
Clean the mating surface for the oil pan with plastic scraper. Use the General Equipment: Plastic Scraper
- Remove the bolts and the crankshaft rear seal. Discard the crankshaft rear seal.
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- Remove the bolts, oil pump screen and pickup tube.
- Remove and discard the oil pump screen and pickup tube O-ring seal.
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- Release the tension on the tensioner spring.
- Remove the shoulder bolts, tensioner and the oil pump chain.
- Remove the crankshaft sprocket.
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NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.
If equipped, remove the diamond washer.
- Remove the bolt and the oil pump sprocket.
- Remove the bolts and the oil pump.
- Clean the mating surfaces of the oil pump.
Material
: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
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NOTE: Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at TDC.
Visual check for engine is still at TDC.
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NOTE: Mark the balance shaft assembly front shafts on the top for reference that the balance shaft assembly is at TDC.
Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC.
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NOTE: Due to the precision interior construction of the balance shaft assembly, it should not be disassembled.
Remove the bolts and the balancer unit.
- Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
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- 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.
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NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
Remove the bolts and the connecting rod caps.
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NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Remove the pistons.
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NOTE: Mark the position of the parts, so they can be installed in their original positions.
- Remove the connecting rod main bearings.
- Inspect the pistons.
- Remove the bolts in sequence shown and the main bearing beam.
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NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
Remove the crankshaft main beam bearings.
- Remove the crankshaft.
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NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.NOTE: The center bulkhead has the thrust bearing.
Remove the crankshaft main bearings.
- Remove the bolts and the engine piston oil cooler valves.