Engine - Vehicles With: Dual Generators
WARNING: This page is about a different car, the 2021 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.
For information on Ford Color Coded Illustrations refer to OEM COLOR CODING INFORMATION
Special Tool(s) / General Equipment
| 100-001 (T50T-100-A)Slide Hammer | |
|---|---|
| 205-142 (T80T-4000-J)Installer, Differential Bearing Cone | |
| 205-153 (T80T-4000-W)Handle | |
| 303-1247VCT Spark Plug Tube Seal Remover and InstallerTKIT-2006UF-FLMTKIT-2006UF-ROW | |
| 303-448 (T93P-6303-A)Holding Tool, CrankshaftTKIT-1993-FLMTKIT-1993-LM | |
| 303-519 (T95P-6701-EH)Remover, Crankshaft Rear Oil SealTKIT-1995-FH/FLMHTKIT-1995-LMH/MH | |
| 303-F047Lifting Bracket, Engine | |
| Floor Crane | |
| Three Leg Puller | |
| Mounting Stand |
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:
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.
- Using the special tools, remove and discard the crankshaft rear seal. Use Special Service Tool: 303-519 (T95P-6701-EH) Remover, Crankshaft Rear Oil Seal., 100-001 (T50T-100-A) Slide Hammer.
- Using a floor crane, install the engine on a mounting stand and remove the special tool. Remove Special Service Tool: 303-F047 Lifting Bracket, Engine.Use the General Equipment: Floor CraneUse the General Equipment: Mounting Stand
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- Remove the oil level indicator.
- Remove the nuts.
- Remove the oil level indicator tube.
- Inspect the O-ring seal and replace as necessary.
- Remove the bolts and the LH engine mount-to-cylinder block bracket.
- Discard the bolts.
- Remove the bolts and theRH engine mount and bracket as an assembly.
- Discard the bolts.
- Rotate the tensioner clockwise and remove the A/C compressor drive belt.
- Remove the bolts and the A/C compressor.
- Remove the bolts and the RH exhaust manifold heat shield.
- Remove and discard the nuts.
- Remove the exhaust manifold.
- Clean and inspect the exhaust manifold. Refer to: Exhaust Manifold Cleaning and Inspection .
- Remove and discard the gaskets.
- Remove and discard the studs.
- Remove the bolts and the LH exhaust manifold heat shield.
- Remove and discard the nuts.
- Remove the exhaust manifold.
- Clean and inspect the exhaust manifold. Refer to: Exhaust Manifold Cleaning and Inspection .
- Remove and discard the gasket.
- Remove and discard the studs.
- Follow directions to release the quick release coupling type 3. Remove the crankcase vent tube. Refer to: Quick Release Coupling
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- Remove and fasteners and the LH valve cover insulator.
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- Slide the insulator to access the electrical connector.
- Disconnect the engine wiring harness electrical connectors.
- Detach the engine wiring harness retainers.
- Detach the engine wiring harness retainers.
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- Disconnect the engine wiring harness electrical connectors.
- Detach the engine wiring harness retainers.
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- Disconnect the engine wiring harness electrical connectors.
- Detach the engine wiring harness retainers.
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- Slide the insulator to access the electrical connector.
- Remove the bolt and position the RFI capacitor aside.
- Disconnect the engine wiring harness electrical connectors.
- Detach the engine wiring harness retainer.
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- Disconnect the engine wiring harness electrical connectors.
- Detach the engine wiring harness retainers.
- Remove the nut and the wiring harness.
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- Disconnect the knock sensor electrical connectors.
- Detach the retainers and remove the knock sensor harness.
- Remove the bolts and the knock sensors.
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NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
Release the retainer, then remove the fuel injection pump noise insulator.
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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 RH ignition coil-on-plug retaining bolts.
- Remove the RH ignition coil-on-plugs.
- Inspect the ignition coil-on-plug assembly for cracks, rips, or tears. Replace any damaged coil-on-plug assemblies.
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- Make note of the high-pressure fuel pump supply Oetiker® clamp end location for correct installation.
- Disconnect the high-pressure fuel pump fuel feed quick release coupling. Follow the directions for the quick release coupling type 2. Refer to: Quick Release Coupling .
- Remove the fasteners and the high-pressure fuel tube shield.
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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.
- Remove the high-pressure fuel tube fasteners.
- Loosen the high-pressure fuel tube flare nuts,
- Remove and discard the high-pressure fuel tube.
- Remove the spacer.
- Alternately loosen the high-pressure fuel pump nuts one complete revolution at a time and remove, then remove the high-pressure fuel pump.
- Remove and discard the high-pressure fuel pump O-ring seal.
- Remove the high-pressure fuel pump roller tappet.
- 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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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 LH ignition coil-on-plug retaining bolts.
- Remove the LH ignition coil-on-plugs.
- Inspect the ignition coil-on-plug assembly for cracks, rips, or tears. Replace any damaged coil-on-plug assemblies.
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- Remove the bolt and the secondary generator drive belt idler pulley.
- Remove the bolt and the A/C compressor drive belt tensioner.
- Remove the bolts and the coolant pump pulley.
- Remove the crankshaft pulley bolt and washer.
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NOTE: Use a universal puller (such as an OTC 6667, or equivalent).
Using a universal puller, remove the crankshaft pulley. Use the General Equipment: Three Leg Puller
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NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
Install the original crankshaft pulley bolt and use the special tool to remove the crankshaft front oil seal.
- Discard the seal.
- Discard the bolt.
- Remove the bolts and the coolant pump.
- Remove and discard the coolant pump O-ring seal.
- Loosen the fasteners and remove the valve cover.
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NOTE: Clean the valve cover gasket groove with soap and water or a suitable solvent.
Remove and discard the gaskets.
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- Inspect the VCT variable force solenoid seal, the VCT oil control solenoid seal and the cylinder deactivation solenoid seals.
- Remove and discard any damaged seals using the special tools. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-142 (T80T-4000-J) Installer, Differential Bearing Cone.
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- Inspect the spark plug seals.
- Remove and discard 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.
- Remove the engine front cover-to-oil filter adapter bolt.
- Using a 10 mm Hex Bit loosen the engine front cover-to-oil filter adapter jack screw.
- Remove the fasteners.
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NOTE: There are 3 different fasteners used, note the location of fasteners for assembly.
Remove the bolts and stud bolts.
- Remove the engine front cover from the front cover-to-cylinder block dowels.
- Remove and discard the gaskets.
- Loosen the fasteners and remove the valve cover.
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NOTE: Clean the valve cover gasket groove with soap and water or a suitable solvent.
Remove and discard the gasket.
- If necessary, remove the bolts and the crankcase vent oil separator.
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NOTE: This step is only necessary if the crankcase vent oil separator was removed.
- Inspect the crankcase vent oil separator seals.
- Remove and discard 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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- Inspect the spark plug seals.
- Remove and discard 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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- Inspect the VCT oil control solenoid seal and the cylinder deactivation solenoid seals.
- Remove and discard any damaged seals using the special tools. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-142 (T80T-4000-J) Installer, Differential Bearing Cone.
- Remove the 8 spark plugs.
- Using the special tool, rotate the crankshaft clockwise until the keyway is at the 9:00 position. Use Special Service Tool: 303-448 (T93P-6303-A) Holding Tool, Crankshaft.
- Verify the timing mark on the RHVCT unit is on top, if not, rotate the crankshaft clockwise one complete revolution so the keyway is at the 9:00 position.
- Remove the bolts and the RH primary timing chain tensioner.
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NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the RH timing chain tensioner arm. Return the crankshaft keyway to the 9:00 position after removing the RH timing chain tensioner arm.
Remove the RH timing chain tensioner arm.
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NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the RH timing chain guide. Return the crankshaft keyway to the 9:00 position after removing the RH timing chain guide.
Remove the bolt and the RH timing chain guide.
- Remove the RH timing chain.
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- Loosen the fasteners and remove the oil tube.
- Loosen the fasteners and remove the oil tube.
- Remove the bolts and the camshaft cap.
- Remove the bolts and the camshaft and carrier assembly.
- Remove and discard the gasket.
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- Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
- Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
- Inspect the hydraulic lash adjusters and roller followers for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Replace damaged components as necessary.
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- Remove and discard the bolts.
- Remove the cylinder head.
- Remove and discard the cylinder head gasket.
- Remove the dowels.
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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.NOTE: Clean the cylinder head bolt holes in the cylinder block using compressed air. Make sure all coolant, oil or other foreign material is removed.
- 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 .
- Using the special tool, rotate the crankshaft clockwise one complete revolution. Use Special Service Tool: 303-448 (T93P-6303-A) Holding Tool, Crankshaft.
- Using the special tool, rotate the crankshaft clockwise until the keyway is at the 4:00 position. Use Special Service Tool: 303-448 (T93P-6303-A) Holding Tool, Crankshaft.
- Remove the bolts and the LH primary timing chain tensioner.
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NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the LH timing chain tensioner arm. Return the crankshaft keyway to the 4:00 position after removing the LH timing chain tensioner arm.
Remove the LH timing chain tensioner arm.
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NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the LH timing chain guide. Return the crankshaft keyway to the 4:00 position after removing the LH timing chain guide.
Remove the bolt and the LH timing chain guide.
- Remove the LH timing chain.
- Remove the timing chain sprocket.
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- Loosen the fasteners and remove the oil tube.
- Loosen the fasteners and remove the oil tube.
- Remove the bolts and the camshaft and carrier assembly.
- Remove and discard the gasket.
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- Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
- Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
- Inspect the hydraulic lash adjusters and roller followers for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Replace damaged components as necessary.
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- Remove and discard the bolts.
- Remove the cylinder head.
- Discard the cylinder head gasket.
- Remove the dowels.
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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.NOTE: Clean the cylinder head bolt holes in the cylinder block using compressed air. Make sure all coolant, oil or other foreign material is removed.
- 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 .
- Remove the bolt and the CKP sensor.
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NOTE: A new oil cooler must be installed or severe damage to the engine can occur.
Remove the threaded fitting and the oil cooler.
- Discard the oil cooler.
- Remove the fasteners and the oil filter adapter.
- Remove and discard the oil filter adapter gasket.
- Remove the bolts, stud bolts and the oil pan.
- Remove and discard the oil pan gasket.
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- Remove the oil pump bolts.
- Lower the rear of the oil pump assembly.
- Separate the oil pump sprocket from the oil pump drive belt.
- Remove the oil pump drive belt.
- Remove the fasteners and the cam drive install aid.
- Remove the bolts and the crankshaft rear seal retainer plate.
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- 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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NOTE: Verify that the connecting rod and rod cap have orientation numbers cast into them. If not, number the connecting rod and rod cap for correct orientation. Failure to do so can result in engine damage.
Remove the bolts and the connecting rod cap.
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NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.
Remove the piston through the top of the cylinder block
- Remove the upper and lower rod bearings
- Repeat the previous 3 steps for each of the remaining pistons.
- Disassemble the 8 pistons. Refer to: Piston .
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- Remove and discard the cross-mounted main cap bolts.
- Remove and discard the main bearing cap inner bolts.
- Remove and discard the main bearing cap outer bolts.
- Remove the main bearing caps (1), the lower crankshaft main bearings (2) and the lower thrust bearing (3).
- Remove the crankshaft (1), the upper crankshaft main bearings (2) and the upper thrust washer (3) from the cylinder block.
- Remove the bolts and the piston cooling jets from the cylinder block.