Section 13 (Engine - 3.5L ECOBOOST (235KW/320PS)): 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
| 205-142 (T80T-4000-J) Installer, Differential Bearing Cone |
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|---|---|
| 205-150 (T80T-4000-S) Installer, Spindle Bearing |
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| 205-153 (T80T-4000-W) Handle |
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| 303-050 (T70P-6000) Lifting Bracket, Engine |
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| 303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW |
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| 303-1248 Camshaft holding tools TKIT-2006UF-FLM TKIT-2006UF-ROW |
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| 303-1529 Lift Eye, Engine TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW |
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| 303-1530 Tool, Chain Tensioner Hold Down TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW |
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| 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH |
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| Floor Crane | |
| Three Leg Puller | |
| Mounting Stand | |
| Hose Clamp Remover/Installer |
Materials
| Name | Specification |
|---|---|
| Motorcraft® Silicone Gasket Remover ZC-30-A |
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| Motorcraft® Metal Surface Prep Wipes ZC-31-B |
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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 .
- Remove the bolts and the flexplate.
- Remove the crankshaft sensor ring and the engine-to-transmission spacer plate.
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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 Special Service Tool: 303-1529 Lift Eye, Engine, 303-050 (T70P-6000) Lifting Bracket, Engine. Use the General Equipment: Floor Crane
- Remove the bolts and the LH engine mount bracket.
- Remove the bolts and the RH engine mount bracket.
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- Loosen the clamp and disconnect the vacuum hose from the intake manifold. Use the General Equipment: Hose Clamp Remover/Installer
- Disconnect the vacuum tube coupling from the vacuum pump. Refer to: Quick Release Coupling .
- Detach the retainers and remove the vacuum tube assembly.
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- Disconnect the EVAP purge valve electrical connector.
- Disconnect the vapor tube coupling from the intake manifold. Refer to: Quick Release Coupling .
- Remove the stud bolt and the vapor tube assembly.
- Remove the PCV tube.
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- Disconnect the vacuum hoses from the turbochargers.
- Disconnect the electrical connector from the vacuum solenoid.
- Detach the vacuum hose retainers from the valve covers.
- Remove the pin-type retainer, the retaining plate and the vacuum solenoid assembly.
- Disconnect the throttle body electrical connector and wiring harness retainer.
- Disconnect the MAPT sensor electrical connector and wiring harness retainer.
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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.
Loosen the bolts and remove the intake manifold.
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- Discard the gaskets.
- Clean and inspect all of the sealing surfaces of the cylinder heads and the intake manifold.
- Remove the bolts and the A/C compressor.
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- Remove the crankshaft pulley bolt and washer.
- Discard the bolt.
- Using a three leg puller, remove the crankshaft pulley. Use the General Equipment: Three Leg 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, coolant pump pulley and the accessory drive belt tensioner.
- Remove the bolts and the thermostat housing.
- Inspect the O-ring seal and replace if necessary.
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- Remove the coolant pipe.
- Discard the O-ring seals.
- Remove the bolts and the coolant outlet.
- Remove and discard the gaskets.
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- Remove the high pressure fuel tube bracket nut, the high pressure fuel tube bracket bolt and discard.
- Disconnect the high pressure fuel tube flare nuts, remove the high pressure fuel tube and discard.
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- Disconnect the high-pressure fuel pump electrical connector.
- Alternately loosen the high-pressure fuel pump bolts one complete revolution at a time and remove the pump.
- Discard the bolts.
- Remove and discard the O-ring seal.
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- Remove the high-pressure fuel pump tappet.
- Inspect the high-pressure fuel pump tappet for flat spots or scoring. If any damage is found, inspect the fuel injection pump and the fuel injection pump tappet drive lobe. Install new components as necessary.
- Loosen the fitting and separate the RH turbocharger coolant supply tube and fitting from the cylinder head.
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- Remove the oil return tube bolt.
- Remove the coolant/oil tube assembly bolt.
- Release the coolant tube from the fitting.
- Remove the bolts and the RH turbocharger.
- Remove the coolant tube fitting.
- Inspect the coolant tube fitting and replace as needed.
- Discard the gasket and O-ring seal.
- Remove and discard the turbocharger fitting and oil filter assembly.
- Loosen the fitting and separate the LH turbocharger coolant supply tube and fitting from the cylinder head.
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- Remove the oil return tube bolt.
- Remove the coolant/oil tube assembly bolt.
- Release the coolant tube from the fitting.
- Remove the bolts and the LH turbocharger.
- Remove the coolant tube fitting.
- Inspect the coolant tube fitting and replace as needed.
- Discard the gasket and O-ring seal.
- Remove and discard the turbocharger fitting and oil filter assembly.
- Remove the bolts and the generator.
- Remove the generator stud bolt.
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- Slide the insulator off of the CHT sensor electrical connector.
- Disconnect the CHT sensor electrical connector.
- Detach the wiring harness retainer and position the harness aside.
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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 bolt and the oil cooler.
- Discard the oil cooler.
- Remove the bolts and the oil filter adapter.
- Inspect the gasket and replace if necessary.
- Remove the LH block coolant drain plug and allow coolant to drain from the cylinder block.
- Remove the RH block coolant drain plug and allow coolant to drain from the cylinder block.
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- Remove the bolts and the brake vacuum pump.
- Remove the nut, bolt and the heat shield.
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NOTE: Make sure the oil tube filter screen is free of contaminants prior to installation.
Inspect the gasket and the oil tube filter screen. Replace the gasket if necessary.
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- Disconnect the CHT sensor electrical connector and wiring harness retainer.
- Remove the stud bolt and the ground wire.
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- Disconnect the KS electrical connector.
- Disconnect the fuel pressure sensor electrical connector.
- Disconnect the RH and LH fuel charge harness electrical connectors.
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- Disconnect the CMP sensor electrical connectors.
- Detach the wiring harness retainer.
- Remove the stud bolt and the ground wire.
- Remove the nut, bolt and the heat shield.
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- Remove the stud bolt.
- Detach the wiring harness grommet from the cylinder block.
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- Disconnect the CKP sensor electrical connector.
- Remove the bolt, the CKP sensor electrical connector and position the wiring harness aside.
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- Remove the oil level indicator.
- Disconnect the VCT sensor electrical connectors.
- Disconnect the coil-on-plug electrical connectors.
- Detach the wiring harness retainers.
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- Disconnect the VCT sensor electrical connectors.
- Disconnect the CMP sensor electrical connectors.
- Disconnect the coil-on-plug electrical connectors.
- Detach the wiring harness retainers and remove the engine wiring harness.
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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 bolts and the CMP sensors.
- Inspect the coil seals for rips, nicks or tears.
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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 valve cover.
- Discard the gasket.
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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 valve cover.
- Discard the gasket.
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NOTE: RH shown, LH similar.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: RH shown, LH similar.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.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
- Remove the bolts and the CMP sensors.
- Remove the bolts and the coolant pump.
- Remove and discard the coolant pump gasket and O-ring seal.
- Remove the bolts.
- Using a pry tool, locate the 5 pry pads shown and pry the engine front cover loose and remove.
- Using the special tools, remove the engine front cover to coolant pipe seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 205-150 (T80T-4000-S) Installer, Spindle Bearing.
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- Clean and prepare the RTV sealing surface. 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.
- 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 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 solenoid will aid in the removal of the timing chain.NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoids.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 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 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 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 secondary timing chain.
- Remove Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.
- Remove Special Service Tool: 303-1248 Camshaft holding tools.
- Remove the bolts and the camshaft bearing cap.
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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: 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: 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.
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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.
Make sure that the mating faces of the cylinder head are clean and free of foreign material.
- Remove and discard the cylinder head gasket.
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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 or the oil pan, may cause engine failure.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.
Make sure that the mating faces of the engine block are clean and free of foreign material.
- 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.
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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.
Make sure that the mating faces of the cylinder head are clean and free of foreign material.
- Remove and discard the cylinder head gasket.
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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 or the oil pan, may cause engine failure.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.
Make sure that the mating faces of the engine block are clean and free of foreign material.
- 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 channel cover plate.
- 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.
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- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .
- Thoroughly wash the oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
- Remove the bolts and the oil pump screen and the pickup tube.
- Remove and discard the oil pump screen and the 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.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
- 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 while removing the pistons.
Remove the piston/rod assembly from the engine block.
- Inspect the pistons. Refer to: Piston Inspection .
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NOTE: Early build engines have a 13 mm bolt head with coarse threads for the main bearing caps. Late build engines have a 15 mm bolt head with fine threads for the main bearing caps. The main bearing cap side bolts remain the same.NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.
Remove and discard the 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 bearings 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 hexagonal screwdriver, remove the piston oil cool valves.
- Inspect the cylinder block distortion. Refer to: Cylinder Block Distortion .
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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 or the oil pan, 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 cylinder block are clean and free of foreign material.
Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B