Section 37 (ENGINE - 3.5L DURATEC (212kW/278PS)): Disassembly: Engine
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Special Tool(s) / General Equipment
| 205-142 (T80T-4000-J) Installer, Differential Bearing Cone | |
|---|---|
| 205-153 (T80T-4000-W) Handle | |
| 303-103 (T74P-6375-A) Holding Tool, Flywheel T74P-77000-A TKIT-2009TC-F | |
| 303-1245 Engine Lift Eye 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 | |
| 303-1529 Lift Eye, Engine TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW | |
| 303-1530 Tool, Chain Tensioner Hold Down TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW | |
| 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH | |
| Floor Crane | |
| Mounting Stand | |
| Hose Clamp Remover/Installer | |
| Puller |
Materials
| Name | Specification |
|---|---|
| Motorcraft® Silicone Gasket Remover ZC-30-A | - |
| Motorcraft® Metal Surface Prep Wipes ZC-31-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:
If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.
NOTE:
Refer to Engine Component View .
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- Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
- Remove the bolts and the flexplate.
- Remove Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
- Remove the crankshaft sensor ring.
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NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.
Mount the engine to the mounting stand. Use the General Equipment: Mounting Stand
- Remove the floor crane. Use the General Equipment: Floor Crane
- Remove Special Service Tool: 303-1529 Lift Eye, Engine.
- Remove Special Service Tool: 303-1245 Engine Lift Eye.
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- Remove the crankshaft pulley bolt and washer.
- Discard the bolt.
- Using a 3 Jaw Puller, remove the crankshaft pulley. Use the General Equipment: Puller
- 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 accessory drive belt tensioner.
- Remove the crankcase vent tube.
- Disconnect the LH electrical connectors and wire harness retainers.
- Disconnect the electrical connector and the wire retainer.
- Disconnect the LH CMP and CMS (catalyst monitor sensor) electrical connectors. Disconnect the wire harness retainers.
- Remove the nut, bolt and the heat shield.
- Remove the wiring harness retainer stud bolt.
- Remove the wiring harness grommet.
- Disconnect the CKP electrical connector.
- Disconnect the electrical connectors and wire retainer.
- Disconnect the electrical connector and wire retainer.
- Disconnect the retainers for the coolant hose.
- Disconnect the engine vent hose. Use the General Equipment: Hose Clamp Remover/Installer
- Remove the upper intake manifold bracket bolt.
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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.
Remove the bolts and the upper intake manifold.
- Remove and discard the upper intake manifold gaskets.
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NOTE: Index-mark the location of the bracket on the cylinder head for installation.
Remove the bolt and the upper intake manifold bracket.
- Remove the engine vent hose. Use the General Equipment: Hose Clamp Remover/Installer
- Disconnect the RH CMP and KS sensor electrical connectors. Disconnect the wire harness retainer.
- Disconnect the CHT electrical connector.
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- Disconnect the RH electrical connectors and the wire harness retainers.
- Remove the engine wire harness.
- Remove the bolts and the A/C compressor.
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- Remove the nut and the bolt.
- Remove the stud and the generator.
- Remove the bolts and the heat shield.
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- Remove the nuts and the LH catalytic converter.
- Discard the nuts.
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- Remove and discard the exhaust manifold gasket.
- Remove and discard the studs.
- Clean and inspect the catalytic converter flange. Refer to: Exhaust Manifold Cleaning and Inspection .
- Remove the RH block coolant drain plug or block heater and allow coolant to drain from the cylinder block.
- Remove the LH block coolant drain plug and allow coolant to drain from the cylinder block.
- Remove the pin-type retainer and the cover.
- Remove the bolts and the LH CMP sensors.
- Remove the bolts and the RH CMP sensors.
- Remove the thermostat housing bolts.
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NOTE: Make sure that the fuel rail and the fuel injectors do not come out of the lower intake manifold.
Remove the bolts and the lower intake manifold.
- Remove and discard the lower intake manifold gaskets.
- Remove the coolant tube assembly.
- Remove and discard the O-ring seals.
- Remove the bolt and the CKP sensor.
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NOTE: If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may cause engine failure.
- Remove the bolts and the oil cooler.
- Discard the oil cooler.
- Remove and discard the oil cooler O-ring gaskets.
- Remove the bolts and the oil filter adapter.
- Remove and discard the oil filter adapter gasket.
- Remove the oil pressure switch.
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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 and the ignition coil-on-plugs.
- Remove the oil level indicator.
- Inspect the coil seals for rips, nicks or tears and replace if necessary.
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NOTE: While removing the valve cover do not apply excessive force to the VCT oil control solenoid or damage may occur.NOTE: If the VCT oil control solenoid sticks to the VCT seal, carefully wiggle the valve cover until the bond breaks free or damage to the VCT seal and VCT oil control solenoid may occur.
Loosen the bolts and remove the LH valve cover.
- Remove and discard the gasket.
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NOTE: Inspect the VCT solenoid seals. Remove any damaged seals.
Using the special tools, remove and discard the seal(s). Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone, 205-153 (T80T-4000-W) Handle.
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NOTE: Inspect the spark plug tube seals. Remove any damaged seals.
Using the special tools, remove and discard the seal(s). Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.
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NOTE: While removing the valve cover do not apply excessive force to the VCT oil control solenoid or damage may occur.NOTE: If the VCT oil control solenoid sticks to the VCT seal, carefully wiggle the valve cover until the bond breaks free or damage to the VCT seal and VCT oil control solenoid may occur.
Loosen the bolts and remove the RH valve cover.
- Remove and discard the gasket.
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NOTE: Inspect the VCT solenoid seals. Remove any damaged seals.
Using the special tools, remove and discard the seal(s). Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone, 205-153 (T80T-4000-W) Handle.
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NOTE: Inspect the spark plug tube seals. Remove any damaged seals.
Using the special tools, remove and discard the seal(s). Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.
- Remove the CHT jumper harness.
- Remove the engine front cover bolts.
- Using a pry tool, locate the pry pads shown and pry the engine front cover loose and remove.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
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NOTE: Rotate the crankshaft in a clockwise direction only.
Rotate the crankshaft clockwise and align the timing marks on the intake VCT units as shown.
- Remove the bolts and the LH oil tube.
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NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install Special Service Tool: 303-1248 Camshaft holding tools.
- Remove the bolts and the RH oil tube.
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NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install Special Service Tool: 303-1248 Camshaft holding tools.
NOTE: The following 3 steps are for primary timing chains that the colored links are not visible. - Mark the timing chain link that aligns with the timing mark on the LH intake VCT unit as shown.
- Mark the timing chain link that aligns with the timing mark on the RH intake VCT unit as shown.
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NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Mark the timing chain links that aligns with the timing mark on the crankshaft sprocket as shown.
- Remove the bolts and the timing chain tensioner.
- Remove the timing chain tensioner arm.
- Remove the bolts and the lower LH timing chain guide.
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NOTE: Removal of the VCT oil control solenoids will aid in the removal of the timing chain.NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.NOTE: Keep the VCT oil control solenoid clean of dirt and debris.
Remove the bolts and the VCT oil control solenoids.
- Remove the timing chain.
- Remove the crankshaft sprocket.
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NOTE: Do not use power tools to remove the bolt or damage to the LH primary timing chain guide may occur.
Remove the bolt and the upper LH timing chain guide.
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NOTE: The 2 VCT oil control solenoids are removed for clarity.
Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.
- Remove and discard the LH VCT unit bolts.
- Remove the LH VCT units and the secondary timing chain.
- Remove Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.
- Remove Special Service Tool: 303-1248 Camshaft holding tools.
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NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.NOTE: Mark the exhaust and intake camshafts for installation into their original locations.
Remove the bolts, camshaft caps and the camshafts.
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NOTE: The 2 VCT oil control solenoids are removed for clarity.
Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.
- Remove and discard the RH VCT unit bolts.
- Remove the RH VCT units and the secondary timing chain.
- Remove Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.
- Remove Special Service Tool: 303-1248 Camshaft holding tools.
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NOTE: Do not use power tools to remove the bolt or damage to the RH primary timing chain guide may occur.
Remove the bolt and the RH timing chain guide.
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NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.NOTE: Mark the exhaust and intake camshafts for installation into their original locations.
Remove the bolts, camshaft caps and the camshafts.
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NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.NOTE: RH shown, LH similar.
Remove the valve tappets from the cylinder heads.
- Inspect and install new components as necessary.
- Remove and discard the M6 bolt.
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NOTE: Place clean 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 or the oil pan, may cause engine failure.NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surfaceNOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
- Remove and discard the bolts from the cylinder head.
- Remove the cylinder head.
- Remove and discard the cylinder head gasket.
- Remove and discard the M6 bolt.
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NOTE: Place clean 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 or the oil pan, may cause engine failure.NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surfaceNOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
- Remove and discard the bolts from the cylinder head.
- Remove the cylinder head.
- Remove and discard the cylinder head gasket.
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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.
Make sure that the mating faces are clean and free of foreign material.
Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
- Remove the bolts and the KS.
- Remove the bolts and the coolant pump.
- Inspect and replace if necessary.
- Remove the oil pan bolts.
- Using a pry tool, locate the pry pads at the LH and RH side of the oil pan and pry the oil pan loose and remove.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
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- Remove the bolts and the oil pump screen and pickup tube.
- Remove and discard the oil pump screen and pickup tube O-ring seal.
- Remove the bolts and the oil pump.
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- Remove the bolts and the crankshaft rear seal.
- Discard the crankshaft rear seal.
- Inspect and clean the specified component with a abrasive pad.
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- Remove and discard the bolts in the sequence shown.
- Remove the main bearing cap support brace.
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NOTE: The connecting rod cap bolts are a torque-to-yield design. The original connecting rod cap bolts will be used when measuring the connecting rod large end bore during assembly. The connecting rod cap bolts will be discarded after measurement.NOTE: Clearly mark the position and orientation of the connecting rods, connecting rod caps and connecting rod bearings for reassembly.
Remove the connecting rod cap bolts and caps.
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NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Remove the piston/rod assembly from the engine block.
- Inspect the pistons. Refer to: Piston Inspection .
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NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.
Remove and discard the main bearing cap bolts in the sequence shown.
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NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.
Remove the main bearing caps.
- Remove the lower crankshaft thrust washer from the back side of the No. 4 rear main bearing cap.
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NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Remove the crankshaft main bearing from the main bearing caps.
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NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
Remove the crankshaft.
- Remove the crankshaft thrust bearings from the rear main bearing bulkhead.
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NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Remove the crankshaft main bearings from the cylinder block.
- Using a hex bit, remove the piston oil cool valves.
- Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .