Section 7 (Engine - 2.3L ECOBOOST (231KW/314PS)/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 | |
|---|---|
| 300-OTC1819E 2, 200# Floor Crane, Fold Away | |
| 303-103 (T74P-6375-A) Holding Tool, Flywheel T74P-77000-A TKIT-2009TC-F | |
| 303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 303-1565 Alignment Tool, Camshaft TKIT-2010C-FLM | |
| 303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH | |
| 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW | |
| 307-005 (T59L-100-B) Slide Hammer | |
| 310-206 Remover, Fuel Injector TKIT-2009A-FLM | |
| Mounting Stand | |
| Hose Clamp Remover/Installer |
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).
10-Speed Automatic Transmission - 10R80
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- Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
- Remove the bolts and the flexplate.
- Discard the bolts.
6-Speed Manual Transmission - MT82
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NOTE: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.
- Loosen the clutch pressure plate-to-flywheel bolts evenly, by two turns at a time.
- Remove the clutch.
- Discard the bolts.
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- Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
- Remove the bolts and the flywheel.
- Discard the bolts.
6-Speed Manual Transmission - MT82/10-Speed Automatic Transmission - 10R80
- Install engine on the mounting stand. Use the General Equipment: Mounting Stand
- Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.
- Remove the bolts and the A/C compressor mounting bracket.
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- Disconnect the CKP and vacuum valve electrical connectors.
- Detach the wiring harness retainers.
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- Detach the wiring harness retainer.
- Remove the bolt and position the ground wire harness aside.
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- Disconnect the CHT sensor electrical connector.
- Detach the wiring harness retainers.
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- Disconnect the high-pressure fuel pump, fuel supply tube pressure switch and crankcase vent tube electrical connectors.
- Detach the wiring harness retainers.
- Remove the high-pressure fuel pump cover.
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- Detach the fuel supply tube from the intake manifold retainer.
- Disconnect the fuel supply tube quick release coupling from the high-pressure fuel pump. Refer to: Quick Release Coupling .
- Detach the retainer and remove the fuel supply tube.
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- Disconnect the oil pressure switch electrical connector.
- Remove the bolts and the oil filter adapter.
10-Speed Automatic Transmission - 10R80
- Detach the wiring harness retainer.
6-Speed Manual Transmission - MT82/10-Speed Automatic Transmission - 10R80
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- Detach and disconnect the fuel injector harness electrical connector.
- Disconnect the ECT harness electrical connector.
- Detach the wiring harness retainer.
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- Disconnect the throttle body and MAPT electrical connectors.
- Detach the wiring harness retainers.
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- Disconnect the CMP sensor and EVAP canister purge valve electrical connectors.
- Disconnect the ignition coil-on-plugs and VCT oil control solenoid sensor electrical connectors.
- Detach the wiring harness retainer and remove the engine wiring harness.
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- Disconnect the EVAP canister purge valve quick release coupling.
- Remove the bolt and the EVAP canister purge valve.
- Remove the oil level indicator.
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- Disconnect the crankcase vent tube from the valve cover.
- Detach the crankcase vent tube retainer and remove.
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- Remove the coolant tube bolt.
- Remove the coolant tube.
- Remove and discard the coolant tube O-ring seal.
- Remove the bolts and the coolant tube.
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- Remove the nut for the coolant tube.
- Remove the bolts and position intake manifold back.
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- Disconnect the PCV tube quick release coupling.
- Detach the KS electrical connector retainers from the intake manifold.
- Remove the intake manifold.
- Remove the retainer and the high-pressure fuel pump drive unit cover.
- Disconnect and remove the coolant hose from thermostat housing. Use the General Equipment: Hose Clamp Remover/Installer
- Disconnect the radiator hose from the thermostat housing. Use the General Equipment: Hose Clamp Remover/Installer
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- Disconnect the turbocharger coolant hose from the coolant outlet. Use the General Equipment: Hose Clamp Remover/Installer
- Remove the bolts and the turbocharger coolant tubes.
- Remove the bolts and the turbocharger-to-cylinder block oil return tube.
- Remove and discard the O-ring seal and gasket.
- Remove the bolts and the cylinder block-to-turbocharger oil supply tube.
- 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.
- Remove the nuts, turbocharger vacuum valve and position aside.
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- Remove the nuts and the turbocharger.
- Discard the nuts.
- Remove and discard the studs and gasket.
- Loosen the coolant pump pulley bolts.
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- Install the tool and release the tension on the accessory drive belt tensioner.
- Remove the accessory drive belt.
- Release the tool and remove.
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- Remove the bolts and the accessory drive belt tensioner.
- Remove the bolts and coolant pump pulley.
- Remove the nut, bolt and the generator.
- Remove the bolts and the coolant pump.
- Remove and discard the coolant pump O-ring seal.
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- Remove the bolts and the thermostat housing.
- Remove the generator stud.
- Remove the bolt and the ground strap.
- 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 and discard the fuel tube.
- Remove the bolts and high-pressure fuel pump bracket.
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- Remove the bolts and the high-pressure fuel pump.
- Discard the bolts.
- Remove and discard the high-pressure fuel pump O-ring seal.
- Rotate the crankshaft to position the camshaft at zero lift.
- Remove the high-pressure fuel pump tappet.
- Remove the stud bolts and the high-pressure fuel pump drive unit.
- Remove and discard the CHT sensor.
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NOTE: Use compressed air to remove any foreign material from the ignition coil-on-plugs and surrounding area before removing the ignition coil-on-plugs.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.
- Remove and discard the valve cover gasket.
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NOTE: The VCT oil control solenoid seals should only be replaced if they are damaged.
Inspect the VCT oil control solenoid seals for damaged.
- If damaged, using the special tools, remove the VCT oil control solenoid seals and discard. 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: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
Make sure that the mating faces are clean and free of foreign material.
- Disconnect the coolant tube and the retainers. Use the General Equipment: Hose Clamp Remover/Installer
- Remove the bolts and the coolant outlet.
- Remove and discard the coolant outlet gasket.
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- Disconnect the KS electrical connectors.
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NOTE: Note the position of the KS for installation.
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 injectors and FRP sensor 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.
- Discard the bolts.
- Remove any of the fuel injectors that remained in the fuel rail.
- 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.
- Clean the camshaft rear bearing cap.
- Remove the camshaft drive 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).
- Remove the bolt and the crankshaft pulley.
- Discard the bolt.
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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.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
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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.
- Remove the bolts and the VCT units.
- Remove Special Service Tool: 303-1565 Alignment Tool, Camshaft.
- Remove the bolts and the VCT oil control solenoids.
- Remove 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.
- Clean the rear camshaft cap.
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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.
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- Remove the bolts and the cylinder head.
- 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.
Make sure that the mating faces are clean and free of foreign material.
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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 pump screen and pickup tube.
- Remove and discard the oil pump screen and pickup tube gasket.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
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- Remove the bolts and the crankshaft rear seal. Discard the crankshaft rear seal.
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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 of the engine block. These tools cause scratches and gouges that make leak paths. They also cause contamination that causes premature engine failure. Remove all traces of the gasket.
Make sure that the mating faces are clean and free of foreign material.
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- Release the tension on the tensioner spring.
- Remove the shoulder bolts, tensioner and timing chain.
- Remove the crankshaft sprocket.
- Remove the bolt and oil pump sprocket.
- Remove the bolts and the oil pump.
- Make sure that the mating faces are clean and free of foreign material.
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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.