Section 2 (Engine - 2.7L ECOBOOST (238KW/324PS)): Disassembly: Engine

For information on Ford Color Coded Illustrations, refer to OEM COLOR CODING

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	303-1246 Engine Spreader Bar | TKIT-2006UF-FLM | TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1247 VCT Spark Plug Tube Seal Remover and Installer | TKIT-2006UF-FLM | TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1248 Camshaft holding tools | TKIT-2006UF-FLM | TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1634 Lift Eyes (2) | TKIT-2014D-ROW3 | TKIT-2014D-FL_ROW
Courtesy of FORD MOTOR COMPANY	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
Flat-Bladed Screwdriver

Materials 

1. Remove the bolts and the flexplate.

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2. Remove the crankshaft sensor ring and the engine-to-transmission spacer plate.

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3. Inspect the crankshaft sensor ring for damage. If the crankshaft sensor ring has been dropped or has any visual damage, it must be replaced.

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4. 1. Reposition the CKP sensor electrical connector insulator.
   2. Disconnect the CKP sensor electrical connector.
   3. Remove the bolt and the CKP sensor.

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5. Remove the bolts and the crankshaft rear seal and retainer plate.
   • Discard the crankshaft rear seal and retainer plate.

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6. Using a floor crane, install the engine on a mounting stand. Use the General Equipment: Floor Crane. Use the General Equipment: Mounting Stand

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7. Remove Special Service Tool: 303-1634 Lift Eyes (2), 303-1246 Engine Spreader Bar.

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8. • Remove the bolts and the RH engine mount bracket.
   • Discard the bolts.

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9. Follow directions to release the quick release coupling type 3. Remove the crankcase vent tube. Refer to: Quick Release Coupling .

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10. 1. Disconnect the throttle body electrical connector.
    2. Disconnect the differential pressure feedback EGR sensor electrical connector.
    3. Disconnect the MAP sensor electrical connector.
    4. Disconnect the cabin heater coolant pump electrical connector.
    5. Detach the wiring harness retainers.

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11. Detach the wiring harness connector retainers.

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12. 1. Remove the nut.

       Torque: 53 lb.in (6 Nm)

    2. Release the clamps and remove the differential pressure feedback EGR sensor.

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13. 1. Disconnect the ignition coil-on-plug electrical connector.
    2. Detach the wiring harness retainer.
    3. Remove the stud bolt and the ignition coil-on-plug.

       Torque: 53 lb.in (6 Nm)

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14. Remove the EGR tube bolts.

    Torque: 89 lb.in (10 Nm)

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15. 1. Remove the EGR tube nuts.
    2. Disconnect the engine wiring harness electrical connectors.
    3. Detach the engine wiring harness retainer.

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16. Remove the bolts and the EGR valve assembly.

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17. • Remove and discard the gasket.
    • Clean and inspect all sealing surfaces.

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18. Remove and discard the EGR tube gasket.

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19. 1. Disconnect the EVAP canister purge valve electrical connector.
    2. Follow directions to release the quick release coupling type 19. Disconnect the EVAP canister purge valve vapor tube. Refer to: Quick Release Coupling .
    3. Remove the EVAP canister purge valve.

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20. 1. Detach the wiring harness retainers from the rear of the intake manifold.
    2. Loosen the bolts and remove the intake manifold.

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21. • Remove and inspect the gaskets, replace as necessary.
    • Clean and inspect all sealing surfaces.

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22. Disconnect and remove the EGR coolant hose.

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23. 1. Release the clamp and disconnect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
    2. Remove the bolts and the coolant pump.

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24. 1. Remove the bolts and the coolant pump pulley.
    2. Remove the bolt and the idler pulley.
    3. Remove the bolt and the idler pulley.
    4. Remove the bolts and the idler pulley and bracket assembly.
    5. Remove the bolts, and the accessory drive belt tensioner.

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25. Remove the fasteners and the oil cooler.

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26. Inspect the oil cooler. If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may cause engine failure. Refer to: Engine .

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27. Remove and discard the oil cooler gasket.

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28. Remove the oil level indicator.

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29. 1. Disconnect the KS wiring harness connector.
    2. Detach the wiring harness retainers.
    3. Remove the bolt and the ground wire.
    4. Remove the stud bolt and the position wiring harness ground terminal aside.

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30. 1. Disconnect the ignition coil-on-plugs electrical connectors.
    2. Detach the engine wiring harness retainers.
    3. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

       Remove the stud bolts and the ignition coils.

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31. 1. Slide the insulator up.
    2. Disconnect the CHT sensor electrical connector.
    3. Disconnect the wastegate control actuator electrical connector.
    4. Detach the engine wiring harness retainer.

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32. 1. Disconnect the engine wiring harness electrical connectors.
    2. Detach the engine wiring harness retainers and position the harness aside.

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33. Disconnect the oil control solenoid electrical connector and detach the wiring harness retainers.

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34. 1. Disconnect the wastegate control actuator and oil pressure sensor electrical connectors.
    2. Detach the retainers and position the engine wiring harness aside.

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35. 1. Disconnect the fuel pump electrical connector.
    2. Detach the wiring harness retainers.
    3. Remove the stud bolt and the wiring harness ground terminal.

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36. 1. Disconnect the ignition coil-on-plugs electrical connectors.
    2. Detach the engine wiring harness retainers.
    3. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

       Remove the stud bolts and the ignition coils.

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37. 1. Disconnect the engine wiring harness electrical connectors.
    2. Detach the retainers and position the engine wiring harness aside.

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38. Disconnect the engine wiring harness electrical connectors and remove the engine wiring harness from the engine.

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39. Remove the retainers, then remove the high-pressure fuel pump shield.

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40. Disconnect the quick release couplings. Refer to: Quick Release Coupling .

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41. 1. Detach the wiring harness retainers.
    2. Disconnect the fuel supply quick connect coupling. Refer to: Quick Release Coupling .

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42. Remove the stud bolts and the fuel supply manifold.

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43. 1. NOTE: To release the fuel pressure in the high-pressure fuel tube, wrap the high-pressure fuel tube flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of high-pressure fuel tube flare nuts.
    2. Disconnect the fuel tube flare nuts, then remove and discard the fuel tube.

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44. Alternately loosen the high-pressure fuel pump nuts one complete revolution at a time. Remove the high-pressure fuel pump nuts, then remove the high-pressure fuel pump.

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45. Remove and discard the high-pressure fuel pump O-ring seal.

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46. Remove the high-pressure fuel pump tappet.

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

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48. Remove the stud bolts and the high-pressure fuel pump drive unit.

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49. Remove the nuts, the bolts and the EGR tube.

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50. Remove and discard the EGR tube gasket.

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51. Remove and discard the EGR tube gasket.

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52. Remove the bolts and the EGR cooler.

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53. Remove and discard the EGR cooler O-ring seals.

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54. Remove the bolts and the coolant pump.

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55. NOTE: The grommet may remain in the coolant pump housing. If this occurs, remove the grommet from the coolant pump housing.

    Remove and discard the coolant pump gasket and seal.

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56. Remove bolts and the LH turbocharger heat shield.

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57. Remove the turbocharger coolant return tube bolt, loosen the spring clamp, then disconnect and remove the turbocharger coolant return tube. Use the General Equipment: Hose Clamp Remover/Installer

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58. 1. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

       Inspect the turbocharger tube and the sealing surfaces. Ensure that the retaining bracket is not bent, check for square-ness of the retaining bracket to the O-ring area. Use brake cleaner and a nylon brush to clean. Install new components as needed.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    2. Remove and discard the O-ring seal.

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59. Remove the bolts and the turbocharger oil supply tube.

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60. 1. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

       Inspect the turbocharger tube and the sealing surfaces. Ensure that the retaining bracket is not bent, check for square-ness of the retaining bracket to the O-ring area. Use brake cleaner and a nylon brush to clean. Install new components as needed.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    2. Remove and discard the O-ring seals and the turbocharger oil supply tube oil filter.

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61. Remove the bolts and the turbocharger oil return tube.

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62. 1. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

       Inspect for blockage in the turbocharger tube. Check the tube, the sealing surfaces and the flange for flatness and damage. Use brake cleaner and a nylon brush to clean. Install new components as needed.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    2. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

       Ensure that the retaining bracket is not bent, check for square-ness of the retaining bracket to the O-ring area. Use brake cleaner and a nylon brush to clean. Install new components as needed.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    3. Remove and discard the O-ring seal.

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63. Remove and discard the oil return tube tube-to-engine block gasket.

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64. Remove the TC coolant supply tube bolt.

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65. NOTE: Remove the TC coolant supply tube from the engine block while removing the TC.

    Remove the retainers and the TC.

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66. 1. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

       Inspect the turbocharger tube and the sealing surfaces. Ensure that the retaining bracket is not bent, check for square-ness of the retaining bracket to the O-ring area. Use brake cleaner and a nylon brush to clean. Install new components as needed.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    2. Remove and discard the O-ring seal.

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67. Remove and discard the turbocharger gasket.

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68. Remove the turbocharger mounting studs if needed.

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69. If needed remove the bolt, then remove the turbocharger coolant supply tube.

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70. 1. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

       Inspect the turbocharger tube and the sealing surfaces. Ensure that the retaining bracket is not bent, check for square-ness of the retaining bracket to the O-ring area. Use brake cleaner and a nylon brush to clean. Install new components as needed.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    2. If the turbocharger coolant supply tube was removed from the turbocharger, then remove and discard the O-ring seal.

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71. Remove the turbocharger coolant return tube bolt, loosen the spring clamp, then disconnect and remove the turbocharger coolant return tube. Use the General Equipment: Hose Clamp Remover/Installer

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72. NOTE: Inspect the turbocharger tube and the sealing surfaces. Ensure that the retaining bracket is not bent, check for square-ness of the retaining bracket to the O-ring area. Use brake cleaner and a NYLON brush to clean. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.

    Remove and discard the turbocharger coolant return tube O-ring seal.

    Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

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73. Remove the bolts and the TC oil supply tube.

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74. NOTE: Inspect the turbocharger tube and the sealing surfaces. Ensure that the retaining bracket is not bent, check for square-ness of the retaining bracket to the O-ring area. Use brake cleaner and a NYLON brush to clean. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.

    Remove and discard the turbocharger oil supply tube O-ring seals and the turbocharger oil supply tube oil filter.

    Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

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75. Remove the bolts and the TC oil return tube.

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76. NOTE: Inspect for blockage in the turbocharger tube. Check the tube, the sealing surfaces and the flange for flatness and damage. Use brake cleaner and a NYLON brush to clean. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.
    NOTE: Ensure that the retaining bracket is not bent, check for square-ness of the retaining bracket to the O-ring area. Use brake cleaner and a NYLON brush to clean. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.

    Remove and discard the turbocharger oil return tube O-ring seal.

    Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

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77. Remove and discard the TC oil return tube tube-to-engine block gasket.

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78. Remove the TC coolant supply tube bolt.

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79. NOTE: Remove the TC coolant supply tube from the engine block while removing the TC.

    Remove the retainers and the TC.

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80. Remove and discard the turbocharger gasket.

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81. Remove the turbocharger mounting studs if needed.

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82. If needed remove the bolt, then remove the turbocharger coolant supply tube.

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83. 1. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

       Inspect the turbocharger tube and the sealing surfaces. Ensure that the retaining bracket is not bent, check for square-ness of the retaining bracket to the O-ring area. Use brake cleaner and a nylon brush to clean. Install new components as needed.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    2. If the turbocharger coolant supply tube was removed from the turbocharger, then remove and discard the O-ring seal.

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84. Remove the bolts and the oil pan.

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85. Remove and discard the oil pan press-in-place gasket.

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86. Remove the nut and the bracket.

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87. Loosen the fasteners and remove the valve cover.

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88. 1. Remove and discard the gasket.
    2. Clean the valve cover gasket groove with soap and water or a suitable solvent.

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89. Inspect the spark plug seals. Remove any damaged seals using the special tools. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

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90. Loosen the fasteners and remove the valve cover.

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91. 1. Remove and discard the gasket.
    2. Clean the valve cover gasket groove with soap and water or a suitable solvent.

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92. Inspect the spark plug seals. Remove any damaged seals using the special tools. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

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93. Remove the bolts and the cover.

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94. Remove and discard the gaskets.

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95. Remove the crankshaft pulley bolt.

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96. NOTE: Use a universal puller (such as an OTC 6667, or equivalent).
    NOTE: Dual generator engine shown, single generator similar.

    Using a universal puller, remove the crankshaft pulley.

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97. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
    1. Install the original crankshaft pulley bolt.
    2. Using the special tool, remove and discard the crankshaft front oil seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.
    3. NOTE: Retain the original crankshaft pulley bolt for turning the crankshaft while the pulley is removed.

       Remove the crankshaft pulley bolt.

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98. NOTE: There are 5 different types of fasteners, note location of each fastener for assembly.

    Remove the engine front cover fasteners.

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99. Using a large flat-bladed screwdriver and the indicated pry pads, release the sealer and remove the engine front cover. Use the General Equipment: Flat-Bladed Screwdriver

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100. Remove and discard the engine front cover gaskets.

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101. Remove and discard the oil gallery seal (6G068).

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102. NOTE: Rotate the crankshaft utilizing only the original crankshaft pulley bolt. Failure to follow this direction may cause damage to the crankshaft and result in engine failure.

     Install the original crankshaft pulley bolt.

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103. NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For removal and installation of the RH side the triangle marks are used.
     1. Rotate the crankshaft clockwise.
     2. Position the crankshaft sprocket keyway at the 11 o'clock position.
     3. Verify the triangle  timing marks on the VCT units are at the 2 o'clock (intake) and 11 o'clock (exhaust) positions. If the circle  timing marks are at these positions the crankshaft must be turned clockwise one revolution (360 degrees).

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104. Remove the bolts and the RH timing chain tensioner.

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105. Remove the RH timing chain tensioner arm.

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106. Remove the bolts and the RH timing chain guide.

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107. Remove the RH timing chain.

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108. NOTE: The VCT units have 2 timing marks on them, a triangle and a circle. For removal and installation of the LH side the circle marks are used.
     1. Rotate the crankshaft clockwise one revolution (360 degrees).
     2. Position the crankshaft sprocket keyway at the 11 o'clock position.
     3. The circle  timing marks on the VCT units will be at the 10 o'clock (intake) and 12:30 (exhaust) positions.

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109. Remove the original crankshaft pulley bolt.

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110. Remove the timing chain sprocket.

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111. Slide the oil pump drive belt off of the crankshaft sprocket and remove the belt.

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112. Remove the crankshaft sprocket.

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113. Remove the bolts and the LH timing chain tensioner.

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114. Remove the LH timing chain tensioner arm.

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115. Remove the bolts and the LH timing chain guide.

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116. Remove the LH timing chain.

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117. Remove the timing chain sprocket.

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118. Remove the bolts and the oil pump pickup.

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119. Remove and discard the oil pump pickup O-ring seal.

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120. Remove the bolts and the oil pump.

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121. 1. Install Special Service Tool: 303-1248 Camshaft holding tools.
     2. Remove and discard the VCT unit bolts.
     3. Remove the VCT units.

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122. NOTE: The front camshaft bearing mega cap must be removed first and then the remaining camshaft bearing caps. Failure to follow this direction may result in damage to the engine.

     Remove the bolts and the front camshaft bearing mega cap.

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123. Remove the bolts and the camshaft bearing caps.

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124. Remove the intake and exhaust camshafts.

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125. 1. Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
     2. Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
     3. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Replace damaged components as necessary.

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126. 1. Release the clamp and disconnect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
     2. NOTE: Do not pry the cylinder head to coolant outlet connector behind the bracket. If necessary, use gripping pliers to pull the cylinder head to coolant outlet connector from the cylinder head.

        Remove the bolt and the cylinder head to coolant outlet connector hose assembly.

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127. • NOTE: To release the fuel pressure in the high-pressure fuel tube, wrap the high-pressure fuel tube flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of the high-pressure fuel tube flare nuts.

       Loosen the high-pressure fuel tube flare nuts.

     • Remove and discard the high-pressure fuel tube.

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128. • Remove and discard the cylinder head bolts.
     • Remove the cylinder head.

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129. Remove and discard the cylinder head gasket.

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130. • Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
     • Refer to: Cylinder Head Distortion .
     • Refer to: Cylinder Block Distortion .

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131. 1. Install Special Service Tool: 303-1248 Camshaft holding tools.
     2. Remove and discard the VCT unit bolts.
     3. Remove the VCT units.

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132. NOTE: The front camshaft bearing mega cap must be removed first and then the remaining camshaft bearing caps. Failure to follow this direction may result in damage to the engine.

     Remove the bolts and the front camshaft bearing mega cap.

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133. Remove the bolts and the camshaft bearing caps.

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134. Remove the intake and exhaust camshafts.

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135. 1. Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
     2. Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
     3. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Replace damaged components as necessary.

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136. 1. Release the clamp and disconnect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
     2. NOTE: Do not pry the cylinder head to coolant outlet connector behind the bracket. If necessary, use gripping pliers to pull the cylinder head to coolant outlet connector from the cylinder head.

        Remove the bolt and the cylinder head to coolant outlet connector hose assembly.

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137. • Remove and discard the cylinder head bolts.
     • Remove the cylinder head.

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138. Remove and discard the cylinder head gasket.

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139. • Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
     • Refer to: Cylinder Head Distortion .
     • Refer to: Cylinder Block Distortion .

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140. 1. Detach the wiring harness retainer from the stud bolt.
     2. Remove the stud bolt, the bolts and the coolant outlet connector pipe.

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141. 1. Disconnect the ECT sensor electrical connector.
     2. Remove the bolts and the KS assembly.

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142. NOTE: Do not reuse the ECT sensor, install a new sensor.

     Remove and discard the ECT sensor.

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143. If equipped, remove the block heater.

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144. Remove the engine block skirt stiffener bolts.

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145. Using a suitable pry bar at the 4 pry pad locations, release the engine block skirt stiffener-to-engine block seal.

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146. • Remove the engine block skirt stiffener.
     • Remove and discard the oil seal.

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147. • 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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148. Remove the bolts and the connecting rod cap.

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149. NOTE: Position the cylinder bank for the piston serviced in a vertical position. Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.
     NOTE: Do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.
     1. NOTE: A commercially available piston rod installer must be used to prevent damage to the crankshaft journal.

        Install a piston rod installer over the crankshaft journal and into the bolt holes of the connecting rod.

     2. Remove the piston through the top of the cylinder block.
     • Repeat the steps for each of the remaining pistons.

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150. • Remove the connecting rod bearings.
     • Disassemble and inspect the pistons. Refer to: Piston . Refer to: Piston Inspection .

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151. Remove and discard the main bearing cap bolts.

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152. 1. Remove the main bearing caps.
     2. Remove the lower thrust washer.
     3. Remove the lower main bearings.

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153. 1. Remove the crankshaft.
     2. Remove the lower main bearings.
     3. Remove the lower thrust bearing.

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154. Remove the bolts and the piston cooling jets from the cylinder block.

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