Engine - Raptor

For information on Ford Color Coded Illustrations refer to OEM Color Coding .

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-142 (T80T-4000-J)Installer, Differential Bearing Cone
Courtesy of FORD MOTOR COMPANY	205-150 (T80T-4000-S)Installer, Spindle Bearing
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W)Handle
Courtesy of FORD MOTOR COMPANY	303-1246Engine Spreader BarTKIT-2006UF-FLMTKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1247VCT Spark Plug Tube Seal Remover and InstallerTKIT-2006UF-FLMTKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1654Lift Eyes
Courtesy of FORD MOTOR COMPANY	303-1655Tool, Camshaft Holding
Courtesy of FORD MOTOR COMPANY	303-409 (T92C-6700-CH)Remover, Crankshaft SealTKIT-1992-FH/FMH/FLMHTKIT-1993-LMH/MH
Floor Crane
Three Leg Puller
Mounting Stand
Hose Clamp Remover/Installer

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. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the engine block skirt stiffener.

   Mount the engine to the mounting stand. Use Special Service Tool: 303-1246 Engine Spreader Bar., 303-1654 Lift Eyes. Use the General Equipment: Floor Crane. Use the General Equipment: Mounting Stand

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4. Remove the floor crane. Remove Special Service Tool: 303-1246 Engine Spreader Bar., 303-1654 Lift Eyes. Use the General Equipment: Floor Crane

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5. Rotate the accessory drive belt tensioner counter clockwise and remove the accessory drive belt.

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6. Remove the A/C compressor belt.
   1. Turn the crankshaft pulley bolt clockwise and feed the stretchy belt tool on to the A/C compressor pulley approximately 180 deg..
   2. Fold the stretchy belt tool under the inside of the A/C compressor belt as shown below.
   3. NOTE: After using the stretchy belt removal tool, it may be necessary to rotate the crankshaft pulley clockwise to remove the A/C compressor belt from the A/C compressor pulley.

      In one quick motion, firmly pull the stretchy belt tool and remove the A/C compressor belt.

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7. Remove the bolts and the A/C compressor.

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8. • Remove the bolt and the RH engine mount.
   • Discard the bolt.

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

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10. • Remove the bolts and the LH engine mount bracket.
    • Discard the bolts.

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11. • Remove the crankshaft pulley bolt and washer.
    • Discard the bolt.

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12. Using a three leg puller, remove the crankshaft pulley. Use the General Equipment: Three Leg Puller

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13. Using the special tool, remove and discard the crankshaft front seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.

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14. • Remove the bolts and the coolant pump pulley.
    • Remove the bolts and the accessory drive belt tensioner
    • Remove the bolt and the idler pulley.

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15. • Release the clamp and disconnect the hose. Use the General Equipment: Hose Clamp Remover/Installer
    • Remove the bolts and the thermostat housing.

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16. Inspect the O-ring seals and replace if necessary.

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17. Remove the bolts and the water pump outlet connector.

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18. Inspect the O-ring seal and replace if necessary.

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19. Disconnect the high-pressure fuel pump electrical connector.

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20. 1. Remove and discard the high-pressure fuel tube mounting bolts.
    2. Remove and discard the high-pressure fuel tube.

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21. Remove the fuel supply tube spring lock coupling retainer from the high pressure fuel pump.

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22. Remove the fuel supply tube spring lock coupling retainer from the rear fuel line.

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23. Disconnect the retainers, fuel supply tube and remove. Refer to: Spring Lock Couplings .

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24. • Remove and discard the high-pressure fuel pump bolts.
    • Remove the high-pressure fuel pump.

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

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26. Remove the high-pressure fuel pump roller tappet.

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27. 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 necessary.

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28. Remove the bolt and the high-pressure fuel pump mounting plate.

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29. Remove any dirt or foreign material from the high-pressure fuel pump bolt holes.

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30. Disconnect the throttle body electrical connector and wiring harness retainer.

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31. Disconnect the wire harness retainers from the intake manifold.

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32. Remove the PCV tube. Refer to: Spring Lock Couplings .

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33. • Disconnect the fuel vapor tube to the intake manifold. Refer to: QUICK RELEASE COUPLING . .
    • Disconnect the vacuum hose.

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34. • Disconnect the MAPT electrical connector.
    • Disconnect the EVAP purge solenoid electrical connector and quick connect coupling. Refer to: QUICK RELEASE COUPLING . .
    • Lift the EVAP purge valve off of the intake manifold mounting tab.

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35. Remove the bolts and the intake manifold.

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36. • Remove and discard the intake manifold gaskets.
    • Clean and inspect all of the sealing surfaces of the cylinder heads and the intake manifold.

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37. Remove the fuel rail insulator.

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38. Remove the fuel supply tube spring lock coupling retainers.

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39. Disconnect and remove the fuel supply tube. Refer to: Spring Lock Couplings .

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40. Remove and discard the fuel rail-to-fuel rail high-pressure fuel tube.

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41. Disconnect the LH fuel rail harness main electrical connector.

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42. 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 to remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and the fuel injectors.
    NOTE: Should any of the fuel injectors remain in the cylinder head, then the injector electrical connectors will need to be disconnected as the fuel rail is being removed.

    Remove the LH fuel rail retaining bolts and then remove the fuel rail.

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43. 1. Disconnect the fuel injector electrical connectors.
    2. Remove the fuel injector retaining clips.
    3. Remove the fuel injectors from the fuel rail.

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44. Remove and discard all of the fuel injector O-ring seals.

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45. Disconnect the RH fuel rail harness main electrical connector.

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46. Disconnect the fuel rail fuel feed tube quick release coupling. Refer to: QUICK RELEASE COUPLING . .

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47. 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 to remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and the fuel injectors.
    NOTE: Should any of the fuel injectors remain in the cylinder head, then the injector electrical connectors will need to be disconnected as the fuel rail is being removed.

    Remove the RH fuel rail retaining bolts and then remove the fuel rail.

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48. 1. Disconnect the fuel injector electrical connectors.
    2. Remove the fuel injector retaining clips.
    3. Remove the fuel injectors from the fuel rail.

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49. Remove and discard all of the fuel injector O-ring seals.

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50. Disconnect the RH TC electrical connector.

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51. Remove the bolt and separate the RH TC coolant return tube from the cylinder head.

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52. Remove the bolts and the RH TC oil supply tube then discard the TC oil supply tube.

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53. Remove the RH TC oil return tube bolts, then remove and discard the TC oil return tube.

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54. Remove the bolt and separate the RH TC coolant supply tube the engine block.

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55. NOTE: Remove the coolant tubes with the turbocharger. If the 2 piece turbocharger cooling tubes are separated, then the rubber gasket must be replaced.

    Remove the bolts and RH TC.

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56. NOTE: 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 TC coolant supply and the TC coolant return tube O-ring seals. Clean the TC coolant tubes sealing surfaces. Inspect the sealing surfaces for debris or damage and make sure the retaining bracket is not bent, check for squareness of the O-ring area. Install new components if necessary.

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

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57. Remove and discard the TC gasket

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58. If needed remove the TC exhaust flange stud bolts and the TC exhaust flange.

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59. If the flange was removed, remove and discard the turbocharger exhaust flange gasket.

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60. Remove and discard the RH TC fitting and oil filter assembly from the engine block.

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61. Disconnect the LH TC electrical connector.

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62. Remove the bolt and separate the LH TC coolant return tube from the cylinder head.

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63. Remove the bolts and the LH oil supply tube then discard the TC oil supply tube.

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64. Remove the LH TC oil return tube bolts, then remove and discard the TC oil return tube.

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65. Remove the bolt and separate the LH TC coolant supply tube the engine block.

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66. NOTE: Remove the coolant tubes with the turbocharger. If the 2 piece turbocharger cooling tubes are separated, then the rubber gasket must be replaced.

    Remove the bolts and LH TC.

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67. NOTE: 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 TC coolant supply and the TC coolant return tube O-ring seals. Clean the TC coolant tubes sealing surfaces. Inspect the sealing surfaces for debris or damage and make sure the retaining bracket is not bent, check for squareness of the O-ring area. Install new components if necessary.

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

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68. Remove and discard the TC gasket

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69. If needed remove the TC exhaust flange stud bolts and the TC exhaust flange.

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70. If the flange was removed, remove and discard the turbocharger exhaust flange gasket.

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71. Remove and discard the LH TC fitting and oil filter assembly from the engine block.

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72. Remove the nuts and the CAC tube bracket.

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73. Remove the nut, bolt and the generator.

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74. Remove the generator stud bolt.

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75. Disconnect the EOP sensor electrical connector and the wire harness retainer.

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76. 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.

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77. Remove the bolts and the oil filter adapter.

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78. Inspect the gasket and replace if necessary.

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79. Remove the LH block coolant drain or block heater and allow coolant to drain from the cylinder block.

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80. Remove the RH block coolant drain plug and allow coolant to drain from the cylinder block.

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81. Remove the studbolt, bolt and the heat shield.

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82. • Disconnect the CHT sensor electrical connector.
    • Disconnect the CMP sensor electrical connectors.
    • Detach the wire harness retainer, remove the studbolt and the ground wire.

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83. • Disconnect the KS electrical connector.
    • Disconnect the RH and LH port injection fuel rail electrical connectors.
    • Disconnect the RH and LH direct injection fuel rail electrical connectors

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84. • Position aside the wire harness retainer. Remove the stud bolt and the ground wire.
    • Remove the bolt and position aside the body ground strap.

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85. Remove the nut, bolt and the heat shield.

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86. • Remove the studbolt.
    • Detach the wiring harness grommet from the cylinder block.

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87. • Disconnect the CKP sensor electrical connector.
    • Remove the bolt, the CKP sensor electrical connector and position the wiring harness aside.

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88. Disconnect the oil control solenoid electrical connector and detach the wire harness retainers.

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89. • Remove the oil level indicator.
    • Disconnect the VCT oil control solenoid electrical connectors.
    • Disconnect the CMP sensor electrical connectors.
    • Disconnect the ignition coil-on-plug electrical connectors.
    • Detach the wire harness retainers.

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90. • Disconnect the VCT oil control solenoid electrical connectors.
    • Disconnect the ignition coil-on-plug electrical connectors.
    • Detach the wire harness retainers and remove the engine wiring harness.

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91. 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.

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92. Inspect the coil seals for rips, nicks or tears.

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93. 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 fasteners and remove the LH valve cover.

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94. Remove and discard the valve cover and intake port gaskets.

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95. 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 fasteners and remove the RH valve cover.

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96. Remove and discard the valve cover and intake port gaskets.

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97. 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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98. 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.

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99. Remove the bolts and the CMP sensors.

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100. Remove the bolts and the coolant pump.

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101. Remove and discard the coolant pump gasket and O-ring seal.

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102. Remove the bolts.

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103. Using a pry tool, locate the 5 pry pads shown below and pry the engine front cover loose and remove.

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104. 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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105. Using the special tools, remove and discard the oil pump electrical connector seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-142 (T80T-4000-J) Installer, Differential Bearing Cone.

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106. • Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .
107. Install the crankshaft pulley bolt.

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108. 1. Rotate the crankshaft clockwise.
     2. Position the crankshaft sprocket keyway at the 11 o'clock position.
     3. Verify the timing marks on the VCT units are at the positions shown below.

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109. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

     Install Special Service Tool: 303-1655 Tool, Camshaft Holding.

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

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

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112. Remove the RH timing chain tensioner arm.

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113. Remove the RH timing chain.

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114. Remove Special Service Tool: 303-1655 Tool, Camshaft Holding.

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115. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

     Install Special Service Tool: 303-1655 Tool, Camshaft Holding.

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116. Verify the timing marks on the VCT units are at the (exhaust) positions shown below.

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117. Remove the crankshaft pulley bolt.

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

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119. Remove the retainers and the LH timing chain tensioner.

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120. Remove the LH timing chain tensioner arm.

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121. Remove the LH timing chain.

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122. Remove the crankshaft sprocket.

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123. Remove and discard the LH VCT unit bolts.

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124. Remove the LH VCT units.

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125. Remove Special Service Tool: 303-1655 Tool, Camshaft Holding.

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126. 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 and the front camshaft bearing mega cap.
     • Remove the bolts and the camshaft bearing caps.
     • Remove the intake and exhaust camshafts.

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127. Remove and discard the RH VCT unit bolts.

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128. Remove the RH VCT units.

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129. 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 and the front camshaft bearing mega cap.
     • Remove the bolts and the camshaft bearing caps.
     • Remove the intake and exhaust camshafts.

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130. 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.
     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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131. Remove the nuts and the RH exhaust manifold. Discard the nuts.

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132. Remove the nuts, the RH exhaust manifold gasket and discard.

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133. Remove and discard the RH M6 bolt.

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134. 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 surface
     NOTE: 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 RH cylinder head.
     • Remove the cylinder head.

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135. Remove and discard the LH cylinder head gasket.

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136. Remove the nuts and the LH exhaust manifold. Discard the nuts.

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137. Remove the nuts, the LH exhaust manifold gasket and discard.

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138. Remove and discard the LH M6 bolt.

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139. 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 surface
     NOTE: 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 LH cylinder head.
     • Remove the cylinder head.

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140. Remove and discard the LH cylinder head gasket.

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141. 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® Metal Surface Prep Wipes / ZC-31-B

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

142. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
143. Remove the bolts and the KS.

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144. Remove the bolts and the channel cover plate.

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145. Inspect and replace if necessary.

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146. Remove the oil pan bolts.

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147. 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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148. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the oil pan and engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean. These tools cause scratches and gouges that make leak paths.
     • Clean the oil pan using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 RPM.

       Material: Motorcraft® Silicone Gasket Remover / ZC-30-A

       Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

     • Thoroughly wash the oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.

149. Remove the bolts and the oil pump screen and pickup tube.

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150. Remove and discard the oil pump screen and pickup tube O-ring seal.

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151. Remove the bolts and the oil pump.

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152. • Remove the bolts and the crankshaft rear seal retainer.
     • Discard the crankshaft rear seal retainer.

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153. Inspect and clean the specified component with a abrasive pad.

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154. • Remove and discard the bolts in sequence shown below.
     • Remove the main bearing cap support brace.
     Fig 1: Main Bearing Cap Support Brace Bolts Removal Sequence (Raptor)

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155. 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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156. 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.

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157. Inspect the pistons. Refer to: Piston Inspection .
158. NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.

     Remove and discard the bolts in sequence shown below.

     Fig 2: Main Bearing Caps Bolts Removal Sequence (Raptor)

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159. 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.

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160. Remove the lower crankshaft thrust washer from the back side of the No. 4 rear main bearing cap.

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161. 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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162. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.

     Remove the crankshaft.

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163. Remove the crankshaft thrust bearings from the rear main bearing bulkhead.

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164. 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.

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

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166. Check the cylinder block distortion. Refer to: Cylinder Head Distortion .
167. Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .