Section 3 (Engine - 2.3L ECOBOOST (257KW/350PS) - 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 | |
|---|---|
| 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 | |
| Floor Crane | |
| Mounting Stand | |
| Plastic Scraper | |
| Hose Clamp Remover/Installer |
Materials
| Name | Specification |
|---|---|
| Motorcraft® Silicone Gasket Remover ZC-30-A | - |
| Motorcraft® Metal Surface Prep Wipes ZC-31-B | - |
| Motorcraft® Metal Brake Parts Cleaner PM-4-A, PM-4-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.
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- Remove and discard the bolts in sequence shown.
- Remove the flywheel.
- Install engine on the mounting stand. Use the General Equipment: Mounting Stand
- Remove the engine lifting equipment. Use the General Equipment: Floor Crane
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- Disconnect the crankcase pressure sensor electrical connector.
- Disconnect the crankcase vent tube from valve cover.
- Remove the engine cover mounting stud.
- Remove the turbocharger inlet pipe nut.
- Loosen the clamp and remove the turbocharger inlet pipe.
- Disconnect the electrical connectors and the wiring harness retainers.
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- Disconnect the CHT sensor electrical connector.
- Detach the wiring harness retainers.
- Remove the ground wire bolt and position wiring harness aside.
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- Disconnect the electrical connectors.
- Detach the wiring harness retainer.
- Detach the HO2S and catalyst monitor sensor electrical connectors from the bracket.
- If equipped, remove the fuel pump insulator.
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- Disconnect the MAP sensor electrical connector.
- Disconnect the throttle body electrical connector and wiring harness retainer.
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- Disconnect the electrical connectors.
- Detach the wiring harness retainers and position aside.
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- Disconnect the electrical connectors.
- Detach the wiring harness retainers and position aside.
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- Disconnect the electrical connectors.
- Detach the wiring harness retainers and remove the engine wiring harness.
- Position the generator B+ protective cover aside and remove the generator B+ terminal nut and wiring.
- Detach the generator B+ wiring harness retainer and remove the battery feed wiring harness.
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- Disconnect the EVAP canister purge valve quick release coupling. Refer to: Quick Release Coupling .
- Detach the EVAP canister purge valve tube retainers.
- Remove the nuts and the EVAP canister purge valve.
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- Disconnect the vacuum tube at the brake vacuum pump.
- Detach the turbocharger control valve from the valve cover and position aside.
- Remove the oil level indicator.
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- Detach the vacuum tube retainers.
- Disconnect the vacuum tubes from the turbocharger. Use the General Equipment: Hose Clamp Remover/Installer
- Remove the nuts and remove the turbocharger vacuum control valve and vacuum tube assembly.
- Remove the bolts and position the intake manifold aside.
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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.
- Disconnect the KS sensors wiring harness electrical connectors retainers.
- Disconnect the crankcase vent oil separator tube and remove the intake manifold.
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- Disconnect the coolant hoses and the coolant hose retainers. Use the General Equipment: Hose Clamp Remover/Installer
- Remove the bolts and the thermostat housing and hoses.
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- Disconnect the turbocharger coolant outlet tube. Use the General Equipment: Hose Clamp Remover/Installer
- Remove the bolt for the turbocharger coolant inlet tube.
- Remove the bolt and the turbocharger coolant outlet and inlet tubes.
- Remove the bolts and the turbocharger-to-cylinder block oil return pipe.
- Discard the O-ring seal and gasket.
- Remove the bolts and the cylinder block-to-turbocharger oil supply pipe.
- Remove and discard the washers and O-ring seal.
- Remove and discard the oil supply filter.
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- Remove the nuts, bolt and the heat shield.
- Discard the nuts.
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- Remove the nuts and turbocharger.
- Discard the nuts.
- Remove the bolt captured by the turbocharger from the block.
- Remove and discard the studs and gasket.
- Loosen the coolant pump pulley bolts.
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- Install tool and release the tension on the accessory drive belt tensioner.
- Remove the accessory drive belt.
- Release the tool and remove.
- Remove the bolts and the accessory belt tensioner.
- Remove the bolts and coolant pump pulley.
- Remove the bolts and the generator.
- Remove the bolts and the coolant pump.
- Remove and discard the coolant pump O-ring seal.
- Remove the bolts and the halfshaft bracket.
- If equipped, remove the block heater.
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- Remove the A/C compressor bracket nut.
- Remove the bolt and the A/C compressor bracket.
- Remove the stud.
- Remove the bolts and the brake vacuum pump.
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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 pressure during the loosening of the fuel injection pump flare nut.
- Remove the high pressure fuel tube nut and bolt.
- Loosen the flare nuts, remove and discard the fuel tube.
- Remove the bolts and fuel injection pump bracket.
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- Remove the bolts and the fuel injection pump.
- Discard the bolts.
- Remove and discard the fuel injection pump O-ring seal.
- Rotate the crankshaft to position the camshaft at zero lift.
- Remove the fuel injection pump tappet.
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- Remove the nut, bolt and the coolant tube.
- Remove and discard the CHT sensor.
- Remove the stud bolts and the fuel injection pump housing.
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NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
Remove the bolts, stud bolts and the ignition coil-on-plugs.
- Loosen the fasteners and remove the valve cover.
- Discard the valve cover gasket.
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NOTE: The VCT solenoid seals should only be replaced if they are damaged upon inspection.
Inspect and if necessary, using the special tool, remove the VCT seals.
- Discard the seals if damaged. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer., 205-153 (T80T-4000-W) Handle.
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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.
Clean the valve cover.
- Remove the bolts and the coolant outlet.
- Remove the bolts and the oil filter adapter.
- Remove and discard the oil filter adapter gasket.
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- Disconnect the KS electrical connectors.
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NOTE: Note the position of the KS.
Remove the bolts and the KS.
- Remove the bolts and the crankcase vent separator.
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- Remove the fuel rail shield.
- Disconnect the fuel rail electrical connectors.
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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.
- Remove any of the fuel injectors that remained in the fuel rail.
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NOTE: Use minimal force to remove the fuel injectors that remained in the cylinder head with the Fuel Injector Remover tool or damage to the fuel injector assembly may occur. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.
Remove any of the fuel injectors that remained in the cylinder head. Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer., 310-206 Remover, Fuel Injector.
- Remove the fuel injector clip.
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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.
- Carefully cut and discard the lower fuel injector Teflon® seals.
- Remove and discard the fuel injector seal and O-ring seal.
- Remove the bolts and camshaft rear bearing cap.
- Using a wrench on the flats of the intake camshaft to prevent cam rotation, 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 bolts and the CKP sensor.
- Remove the engine plug bolt.
- Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
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NOTE: The special tool 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 clockwise until it contacts the special tool. 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.
- Using a strap wrench, remove and discard the crankshaft pulley bolt and washer. Use the General Equipment: Strap Wrench
- Remove the crankshaft pulley.
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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 crankshaft seal remover, remove the crankshaft front seal and discard. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.
- Remove the bolts and the engine front cover.
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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 engine front cover sealing surfaces. 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 Brake Parts Cleaner / PM-4-A, PM-4-B
Material
: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
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NOTE: Use an open-ended wrench to prevent the component from turning.
Loosen the bolt for the exhaust VCT unit.
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NOTE: Use an open-ended wrench to prevent the component from turning.
Loosen the bolt for the intake VCT unit.
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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.
- Remove the bolts and the timing chain guide, timing chain and tensioner arm.
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- Remove the bolts and the VCT units.
- Discard the VCT units bolts.
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NOTE: Washers are not required for installation of the VCT units.
If equipped, discard the washers.
- Remove Special Service Tool: 303-1565 Alignment Tool, Camshaft.
- Remove the bolts and the VCT oil control solenoids.
- Remove the bolts and front camshaft bearing 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.NOTE: Inspect the camshaft bores for any scratches that can be felt by hand.
Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps and remove the camshaft bearing caps and camshafts.
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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 valve tappets.
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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.
Inspect the valve tappets.
- Remove the bolts and the cylinder head and discard the bolts.
- Remove and discard the cylinder head gasket.
- Remove the cylinder block bushings.
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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: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
Clean the cylinder head sealing surfaces.
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- Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
- Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
- Remove the bolts and the oil pan.
- Remove the bolts and the oil pickup and screen.
- Discard the oil pickup and screen O-ring seal.
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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 oil pan sealing surfaces. 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 Brake Parts Cleaner / PM-4-A, PM-4-B
Material
: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- Remove the bolts and the crankshaft rear seal. Discard the crankshaft rear seal.
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- Release the tension on the tensioner spring.
- Remove the shoulder bolts, tensioner and timing 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 oil pump sprocket.
- Remove the bolts and the oil pump.
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NOTE: Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at TDC.
Rotate the crankshaft until it contacts the special tool.
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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.
Index-mark the balance shaft assembly.
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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 balance shaft assembly.
- Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
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- Inspect ridge.
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NOTE: Remove the carbon buildup, do not scratch the cylinder wall. Remove all debris from the cylinder.
Clean with 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 bearings. Refer to: Piston Inspection .
- Remove the bolts 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 main bearing 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.