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Section 631 (Engine - 2.7L ECOBOOST (238KW/324PS)): Disassembly: Engine

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Special Tool(s) / General Equipment 

GFD552651Courtesy of FORD MOTOR COMPANY
 205-153 (T80T-4000-W)Handle
GFD552680Courtesy of FORD MOTOR COMPANY
 303-1246Engine Spreader Bar, TKIT-2006UF-FLM, TKIT-2006UF-ROW
GFD552652Courtesy of FORD MOTOR COMPANY
 303-1247VCT Spark Plug Tube Seal Remover and Installer, TKIT-2006UF-FLM, TKIT-2006UF-ROW
GFD552675Courtesy of FORD MOTOR COMPANY
 303-1248Camshaft holding tools, TKIT-2006UF-FLM, TKIT-2006UF-ROW
GFD552681Courtesy of FORD MOTOR COMPANY
 303-1634Lift Eyes (2), TKIT-2014D-ROW3, TKIT-2014D-FL_ROW
GFD552459Courtesy 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 

Name Specification
Motorcraft® Metal Brake Parts CleanerPM-4-A, PM-4-B -
NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
NOTE: The turbocharger compressor vanes can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, ensure that no debris enters the system. Failure to do so may result in damage to the turbocharger.
NOTE: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
NOTE: If the components are to be reinstalled, they must be installed in their original location. Mark the components for installation into their original location.
NOTE: Refer to the exploded view under the Engine Component View in the Description and Operation.
  1. Remove the bolts and the flexplate.
    GFD552574Courtesy of FORD MOTOR COMPANY
  2. Remove the crankshaft sensor ring and the engine-to-transmission spacer plate.
    GFD552682Courtesy of FORD MOTOR COMPANY
  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.
    GFD552472Courtesy of FORD MOTOR COMPANY
    1. Reposition the CKP sensor electrical connector insulator.
    2. Disconnect the CKP sensor electrical connector.
    3. Remove the bolt and the CKP sensor.
    GFD552473Courtesy of FORD MOTOR COMPANY
  5. Remove the bolts and the crankshaft rear seal and retainer plate.

    • Discard the crankshaft rear seal and retainer plate.

    GFD552474Courtesy of FORD MOTOR COMPANY
  6. Using a floor crane, install the engine on a mounting stand. Remove Special Service Tool: 303-1246 Engine Spreader Bar., 303-1634 Lift Eyes (2).Use the General Equipment: Floor CraneUse the General Equipment: Mounting Stand
    GFD552683Courtesy of FORD MOTOR COMPANY
  7. Remove the bolts and the engine mount-to-cylinder block bracket.

    • Discard the bolts.

    • Clean the engine mount bracket-to-cylinder block and engine mount-to-frame mating surfaces of any dirt or foreign material prior to installation.

    GFD552552Courtesy of FORD MOTOR COMPANY
  8. Remove and discard the engine mount bracket-to-engine bolts.

    1. Remove the engine mount and bracket as an assembly.
    2. Clean the engine mount bracket-to-cylinder block and engine mount-to-frame mating surfaces of any dirt or foreign material prior to installation.

    GFD552684Courtesy of FORD MOTOR COMPANY
    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.
    GFD552685Courtesy of FORD MOTOR COMPANY
    1. Loosen the coolant pump pulley bolts.
    2. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.
    GFD552686Courtesy of FORD MOTOR COMPANY
    1. Remove the bolts and the coolant pump pulley.
    2. Remove the bolt and the idler pulley.
    3. Remove the bolts, and the accessory drive belt tensioner.
    4. Remove the bolt and the idler pulley.
    5. Remove the bolt, the nut and the generator.
    GFD552687Courtesy of FORD MOTOR COMPANY
  12. Remove the bolts and the A/C compressor.
    GFD552688Courtesy of FORD MOTOR COMPANY
    1. Release the clamp and disconnect the heater hose.
    2. Remove the nuts and the bracket and heater hose.
    GFD552689Courtesy of FORD MOTOR COMPANY
  14. Remove the bolts and the oil cooler.
    GFD552690Courtesy of FORD MOTOR COMPANY
  15. 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 - Gasoline .
    GFD552595Courtesy of FORD MOTOR COMPANY
  16. Remove and discard the oil cooler gasket.
    GFD552691Courtesy of FORD MOTOR COMPANY
  17. Remove the oil level indicator.
    GFD552692Courtesy of FORD MOTOR COMPANY
    1. Disconnect the KS wiring harness connector.
    2. Detach the wiring harness retainer.
    3. Remove the bolt and the ground wire.
    4. Remove the stud bolt and the position wiring harness ground terminal aside.
    GFD552772Courtesy of FORD MOTOR COMPANY
    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.

    GFD552694Courtesy of FORD MOTOR COMPANY
    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 retainers.
    GFD552656Courtesy of FORD MOTOR COMPANY
    1. Disconnect the engine wiring harness electrical connectors.
    2. Detach the engine wiring harness retainers and position the harness aside.
    GFD552657Courtesy of FORD MOTOR COMPANY
  22. Disconnect the oil control solenoid electrical connector and detach the wiring harness retainers.
    GFD552517Courtesy of FORD MOTOR COMPANY
    1. Disconnect the wastegate control actuator and oil pressure sensor electrical connectors.
    2. Detach the retainers and position the engine wiring harness aside.
    GFD552695Courtesy of FORD MOTOR COMPANY
    1. Disconnect the fuel pump electrical connector.
    2. Detach the wiring harness retainers.
    3. Remove the stud bolt and the wiring harness ground terminal.
    GFD552696Courtesy of FORD MOTOR COMPANY
    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.

    GFD552697Courtesy of FORD MOTOR COMPANY
    1. Disconnect the engine wiring harness electrical connectors.
    2. Detach the retainers and position the engine wiring harness aside.
    GFD552698Courtesy of FORD MOTOR COMPANY
  27. Disconnect the engine wiring harness electrical connectors and remove the engine wiring harness from the engine.
    GFD552699Courtesy of FORD MOTOR COMPANY
  28. Remove the retainers, then remove the high-pressure fuel pump shield.
    GFD552773Courtesy of FORD MOTOR COMPANY
  29. NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

    Remove the fuel injection pump noise insulator.

    GFD552774Courtesy of FORD MOTOR COMPANY
  30. Disconnect the quick release couplings. Refer to: Quick Release Coupling .
    GFD552485Courtesy of FORD MOTOR COMPANY
    1. Detach the wiring harness retainers.
    2. Disconnect the fuel supply quick connect coupling. Refer to: Quick Release Coupling .
    GFD552775Courtesy of FORD MOTOR COMPANY
  32. Remove the stud bolts and the fuel supply manifold.
    GFD552776Courtesy of FORD MOTOR COMPANY
    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.
    GFD552777Courtesy of FORD MOTOR COMPANY
  34. 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.
    GFD552778Courtesy of FORD MOTOR COMPANY
  35. Remove and discard the high-pressure fuel pump O-ring seal.
    GFD552779Courtesy of FORD MOTOR COMPANY
  36. Remove the high-pressure fuel pump tappet.
    GFD552780Courtesy of FORD MOTOR COMPANY
  37. 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.
    GFD552781Courtesy of FORD MOTOR COMPANY
  38. Remove the stud bolts and the high-pressure fuel pump drive unit.
    GFD552782Courtesy of FORD MOTOR COMPANY
  39. Remove the nuts, the bolts and the EGR tube.
    GFD552700Courtesy of FORD MOTOR COMPANY
  40. Remove and discard the EGR tube gasket.
    GFD552701Courtesy of FORD MOTOR COMPANY
  41. Remove and discard the EGR tube gasket.
    GFD552702Courtesy of FORD MOTOR COMPANY
  42. Remove the bolts and the EGR cooler.
    GFD552703Courtesy of FORD MOTOR COMPANY
  43. Remove and discard the EGR cooler O-ring seals.
    GFD552704Courtesy of FORD MOTOR COMPANY
  44. Remove the bolts and the coolant pump.
    GFD552705Courtesy of FORD MOTOR COMPANY
  45. 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.

    GFD552706Courtesy of FORD MOTOR COMPANY
  46. 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
    GFD552783Courtesy of FORD MOTOR COMPANY
    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.
    GFD552784Courtesy of FORD MOTOR COMPANY
  48. Remove the bolts and the turbocharger oil supply tube.
    GFD552785Courtesy of FORD MOTOR COMPANY
    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.
    GFD552786Courtesy of FORD MOTOR COMPANY
  50. Remove the bolts and the turbocharger oil return tube.
    GFD552707Courtesy of FORD MOTOR COMPANY
    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.
    GFD552708Courtesy of FORD MOTOR COMPANY
  52. Remove and discard the oil return tube tube-to-engine block gasket.
    GFD552709Courtesy of FORD MOTOR COMPANY
  53. Remove the TC coolant supply tube bolt.
    GFD552787Courtesy of FORD MOTOR COMPANY
  54. NOTE: Remove the TC coolant supply tube from the engine block while removing the TC.

    Remove the retainers and the TC.

    GFD552788Courtesy of FORD MOTOR COMPANY
    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.
    GFD552789Courtesy of FORD MOTOR COMPANY
  56. Remove and discard the turbocharger gasket.
    GFD552790Courtesy of FORD MOTOR COMPANY
  57. Remove the turbocharger mounting studs if needed.
    GFD552791Courtesy of FORD MOTOR COMPANY
  58. If needed remove the bolt, then remove the turbocharger coolant supply tube.
    GFD552792Courtesy of FORD MOTOR COMPANY
    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.
    GFD552793Courtesy of FORD MOTOR COMPANY
  60. 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
    GFD552794Courtesy of FORD MOTOR COMPANY
  61. 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

    GFD552784Courtesy of FORD MOTOR COMPANY
  62. Remove the bolts and the TC oil supply tube.
    GFD552795Courtesy of FORD MOTOR COMPANY
  63. 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

    GFD552786Courtesy of FORD MOTOR COMPANY
  64. Remove the bolts and the TC oil return tube.
    GFD552710Courtesy of FORD MOTOR COMPANY
  65. 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

    GFD552711Courtesy of FORD MOTOR COMPANY
  66. Remove and discard the TC oil return tube tube-to-engine block gasket.
    GFD552709Courtesy of FORD MOTOR COMPANY
  67. Remove the TC coolant supply tube bolt.
    GFD552796Courtesy of FORD MOTOR COMPANY
  68. NOTE: Remove the TC coolant supply tube from the engine block while removing the TC.

    Remove the retainers and the TC.

    GFD552797Courtesy of FORD MOTOR COMPANY
  69. Remove and discard the turbocharger gasket.
    GFD552798Courtesy of FORD MOTOR COMPANY
  70. Remove the turbocharger mounting studs if needed.
    GFD552799Courtesy of FORD MOTOR COMPANY
  71. If needed remove the bolt, then remove the turbocharger coolant supply tube.
    GFD552800Courtesy of FORD MOTOR COMPANY
    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.
    GFD552801Courtesy of FORD MOTOR COMPANY
  73. Remove the bolts and the oil pan.
    GFD552608Courtesy of FORD MOTOR COMPANY
  74. Remove and discard the oil pan press-in-place gasket.
    GFD552609Courtesy of FORD MOTOR COMPANY
  75. Remove and discard the oil pump seal.
    GFD552610Courtesy of FORD MOTOR COMPANY
  76. Loosen the fasteners and remove the valve cover.
    GFD552668Courtesy of FORD MOTOR COMPANY
    1. Remove and discard the gasket.
    2. Clean the valve cover gasket groove with soap and water or a suitable solvent.
    GFD552669Courtesy of FORD MOTOR COMPANY
  78. 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.
    GFD552670Courtesy of FORD MOTOR COMPANY
  79. Loosen the fasteners and remove the valve cover.
    GFD552658Courtesy of FORD MOTOR COMPANY
    1. Remove and discard the gasket.
    2. Clean the valve cover gasket groove with soap and water or a suitable solvent.
    GFD552659Courtesy of FORD MOTOR COMPANY
  81. 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.
    GFD552660Courtesy of FORD MOTOR COMPANY
  82. Remove the bolts and the cover.
    GFD552426Courtesy of FORD MOTOR COMPANY
  83. Remove and discard the gaskets.
    GFD552427Courtesy of FORD MOTOR COMPANY
  84. Remove the crankshaft pulley bolt.
    GFD552712Courtesy of FORD MOTOR COMPANY
  85. 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.

    GFD552464Courtesy of FORD MOTOR COMPANY
  86. 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.

    GFD552713Courtesy of FORD MOTOR COMPANY
  87. NOTE: There are 5 different types of fasteners, note location of each fastener for assembly.

    Remove the engine front cover fasteners.

    GFD552518Courtesy of FORD MOTOR COMPANY
  88. 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
    GFD552519Courtesy of FORD MOTOR COMPANY
  89. Remove and discard the engine front cover gaskets.
    GFD552520Courtesy of FORD MOTOR COMPANY
  90. Remove and discard the oil gallery seal (6G068).
    GFD552521Courtesy of FORD MOTOR COMPANY
  91. 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.

    GFD552623Courtesy of FORD MOTOR COMPANY
  92. 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).

    GFD552624Courtesy of FORD MOTOR COMPANY
  93. Remove the bolts and the RH timing chain tensioner.
    GFD552625Courtesy of FORD MOTOR COMPANY
  94. Remove the RH timing chain tensioner arm.
    GFD552626Courtesy of FORD MOTOR COMPANY
  95. Remove the bolts and the RH timing chain guide.
    GFD552627Courtesy of FORD MOTOR COMPANY
  96. Remove the RH timing chain.
    GFD552628Courtesy of FORD MOTOR COMPANY
  97. 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.

    GFD552631Courtesy of FORD MOTOR COMPANY
  98. Remove the original crankshaft pulley bolt.
    GFD552629Courtesy of FORD MOTOR COMPANY
  99. Remove the timing chain sprocket.
    GFD552630Courtesy of FORD MOTOR COMPANY
  100. Slide the oil pump drive belt off of the crankshaft sprocket and remove the belt.
    GFD552619Courtesy of FORD MOTOR COMPANY
  101. Remove the crankshaft sprocket.
    GFD552632Courtesy of FORD MOTOR COMPANY
  102. Remove the bolts and the LH timing chain tensioner.
    GFD552633Courtesy of FORD MOTOR COMPANY
  103. Remove the LH timing chain tensioner arm.
    GFD552634Courtesy of FORD MOTOR COMPANY
  104. Remove the bolts and the LH timing chain guide.
    GFD552635Courtesy of FORD MOTOR COMPANY
  105. Remove the LH timing chain.
    GFD552636Courtesy of FORD MOTOR COMPANY
  106. Remove the timing chain sprocket.
    GFD552637Courtesy of FORD MOTOR COMPANY
  107. Remove the bolts and the oil pump.
    GFD552714Courtesy of FORD MOTOR COMPANY
    1. Install Special Service Tool: 303-1248 Camshaft holding tools.
    2. Remove and discard the VCT unit bolts.
    3. Remove the VCT units.
    GFD552802Courtesy of FORD MOTOR COMPANY
  109. 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.

    GFD552803Courtesy of FORD MOTOR COMPANY
  110. Remove the bolts and the camshaft bearing caps.
    GFD552804Courtesy of FORD MOTOR COMPANY
  111. Remove the intake and exhaust camshafts.
    GFD552805Courtesy of FORD MOTOR COMPANY
    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.
    GFD552806Courtesy of FORD MOTOR COMPANY
    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.

    GFD552807Courtesy of FORD MOTOR COMPANY
    • 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.

    GFD552501Courtesy of FORD MOTOR COMPANY
    • Remove and discard the cylinder head bolts.

    • Remove the cylinder head.

    GFD552502Courtesy of FORD MOTOR COMPANY
  116. Remove and discard the cylinder head gasket.
    GFD552503Courtesy of FORD MOTOR COMPANY
    • Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.

    GFD552504Courtesy of FORD MOTOR COMPANY
    1. Install Special Service Tool: 303-1248 Camshaft holding tools.
    2. Remove and discard the VCT unit bolts.
    3. Remove the VCT units.
    GFD552808Courtesy of FORD MOTOR COMPANY
  119. 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.

    GFD552809Courtesy of FORD MOTOR COMPANY
  120. Remove the bolts and the camshaft bearing caps.
    GFD552810Courtesy of FORD MOTOR COMPANY
  121. Remove the intake and exhaust camshafts.
    GFD552811Courtesy of FORD MOTOR COMPANY
    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.
    GFD552812Courtesy of FORD MOTOR COMPANY
    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.

    GFD552813Courtesy of FORD MOTOR COMPANY
    • Remove and discard the cylinder head bolts.

    • Remove the cylinder head.

    GFD552492Courtesy of FORD MOTOR COMPANY
  125. Remove and discard the cylinder head gasket.
    GFD552493Courtesy of FORD MOTOR COMPANY
    • Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.

    GFD552494Courtesy of FORD MOTOR COMPANY
    1. Detach the wiring harness retainer from the stud bolt.
    2. Remove the stud bolt, the bolts and the coolant outlet connector pipe.
    GFD552814Courtesy of FORD MOTOR COMPANY
    1. Disconnect the ECT sensor electrical connector.
    2. Remove the bolts and the KS assembly.
    GFD552815Courtesy of FORD MOTOR COMPANY
  129. NOTE: Do not reuse the ECT sensor, install a new sensor.

    Remove and discard the ECT sensor.

    GFD552816Courtesy of FORD MOTOR COMPANY
  130. Remove the engine block skirt stiffener bolts.
    GFD552715Courtesy of FORD MOTOR COMPANY
  131. Using a suitable pry bar at the 4 pry pad locations, release the engine block skirt stiffener-to-engine block seal.
    GFD552716Courtesy of FORD MOTOR COMPANY
    • Remove the engine block skirt stiffener.

    • Remove and discard the oil seal.

    GFD552717Courtesy of FORD MOTOR COMPANY
    • 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.

    GFD552817Courtesy of FORD MOTOR COMPANY
  134. Remove the bolts and the connecting rod cap.
    GFD552818Courtesy of FORD MOTOR COMPANY
  135. 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.

    GFD552819Courtesy of FORD MOTOR COMPANY
    • Remove the connecting rod bearings.

    GFD552820Courtesy of FORD MOTOR COMPANY
  137. Remove and discard the main bearing cap bolts.
    GFD552821Courtesy of FORD MOTOR COMPANY
    1. Remove the main bearing caps.
    2. Remove the lower thrust washer.
    3. Remove the lower main bearings.
    GFD552822Courtesy of FORD MOTOR COMPANY
    1. Remove the crankshaft.
    2. Remove the lower main bearings.
    3. Remove the lower thrust bearing.
    GFD552823Courtesy of FORD MOTOR COMPANY
  140. Remove the bolts and the piston cooling jets from the cylinder block.
GFD552824Courtesy of FORD MOTOR COMPANY
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