Section 141 (Engine - 3.5L ECOBOOST (235KW/320PS)): Disassembly: Engine

WARNING: This page is about a different car, the 2024 Ford Transit-350 HD, 2024 Ford Transit-350, 2024 Ford Transit-250, and 2024 Ford Transit-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

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	303-1247VCT Spark Plug Tube Seal Remover and Installer
Courtesy of FORD MOTOR COMPANY	303-1248Camshaft holding tools
Courtesy of FORD MOTOR COMPANY	303-1530Tool, Chain Tensioner Hold Down
Courtesy of FORD MOTOR COMPANY	303-409 (T92C-6700-CH)Remover, Crankshaft Seal
Courtesy of FORD MOTOR COMPANY	310-205Fuel Injector Brush
Floor Crane
Three Leg Puller
Mounting Stand
Plastic Scraper
Hose Clamp Remover/Installer
Long Nose Pliers

Materials

Name	Specification
Gasket Remover	-
Metal Cleaner	-
Brake Cleaner	-

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: If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.

NOTE: Refer to the exploded view under the Engine Component View in the Description and Operation.

Remove the bolts and the flexplate.

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

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NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.

Mount the engine to the mounting stand.Use the General Equipment: Mounting Stand

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Remove the commercially avaialable quick links and the floor crane.Use the General Equipment: Floor Crane

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Remove the coolant hose.

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Remove the bolts and the LH engine mount bracket.

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Remove the bolts and the RH engine mount bracket.

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- Disconnect the crankcase pressure sensor electrical connector.
- Follow the directions to release coupling type 3. Disconnect the quick release coupling and remove the PCV tube. Refer to: QUICK RELEASE COUPLING
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- Loosen the clamp and disconnect the vacuum hose from the intake manifold.Use the General Equipment: Hose Clamp Remover/Installer
- Follow the directions to release coupling type 4. Remove the vacuum tube coupling from the vacuum pump. Refer to: QUICK RELEASE COUPLING
- Detach the retainers and remove the vacuum tube assembly.
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- Disconnect the EVAP purge valve electrical connector.
- Follow the directions to release coupling type 4. Disconnect the vapor tube coupling from the intake manifold. Refer to: QUICK RELEASE COUPLING
- Remove the stud bolt and the vapor tube assembly.
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Follow the directions to release coupling type 3. Remove the PCV tube. Refer to: QUICK RELEASE COUPLING

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- Disconnect the vacuum hoses from the turbochargers.
- Disconnect the electrical connector from the vacuum solenoid.
- Detach the vacuum hose retainers from the valve covers.
- Remove the pin-type retainer, the retaining plate and the vacuum solenoid assembly.
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Disconnect the throttle body electrical connector and wiring harness retainer.

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Disconnect the MAPT sensor electrical connector and wiring harness retainer.

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NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Loosen the bolts and remove the intake manifold.

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- Discard the gaskets.
- Clean and inspect all of the sealing surfaces of the cylinder heads and the intake manifold.
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Remove the bolts and the A/C compressor.

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- Remove the crankshaft pulley bolt and washer.
- Discard the bolt.
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Using a three leg puller, remove the crankshaft pulley.Use the General Equipment: Three Leg Puller

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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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Remove the bolts, coolant pump pulley and the accessory drive belt tensioner.

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Remove the bolts and the thermostat housing.

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Inspect the O-ring seal and replace if necessary.

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- Remove the coolant pipe.
- Discard the O-ring seals.
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Remove the bolts and the coolant outlet.

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Remove and discard the gaskets.

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- Remove the high pressure fuel tube bracket nut, the high pressure fuel tube bracket bolt and discard.
- Disconnect the high pressure fuel tube flare nuts, remove the high pressure fuel tube and discard.
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- Disconnect the high-pressure fuel pump electrical connector.
- Alternately loosen the high-pressure fuel pump bolts one complete revolution at a time and remove the pump.
- Discard the bolts.
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Remove and discard the O-ring seal.

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- Remove the high-pressure fuel pump tappet.
- Inspect the high-pressure fuel pump tappet for flat spots or scoring. If any damage is found, inspect the fuel injection pump and the fuel injection pump tappet drive lobe. Install new components as necessary.
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NOTE: Use a 3/8" Jiffy-Tite® quick disconnect tool, close the tool around the tube, press the tool into the fitting and rotate until the tool is fully seated into the fitting.

Disconnect the TC coolant return tube at the TC and at the cylinder head.

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Remove the bolt for the TC coolant supply tube and the TC oil feed tube.

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Remove the upper TC oil tube manifold assembly bolts at the TC oil tube manifold assembly.

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Remove and discard the upper TC oil tube assembly gasket.

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Remove and discard the upper TC oil tube assembly gasket.

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NOTE: Use a 3/8" Jiffy-Tite® quick disconnect tool, close the tool around the tube, press the tool into the fitting and rotate until the tool is fully seated into the fitting.

Disconnect the TC coolant supply tube from the TC fitting and remove the TC coolant supply tube. Remove the TC.

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Remove and discard the turbocharger gasket.

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Remove the turbocharger exhaust flange studbolts and the turbocharger exhaust flange. Discard the turbocharger exhaust flange studbolts.

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Remove and discard the turbocharger exhaust flange gasket.

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NOTE: Whenever the turbocharger is removed or replaced, always install a new turbocharger fitting and oil filter assembly.

Remove the lower turbocharger oil tube assembly bolt and the turbocharger oil tube assembly.

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Remove and discard the O-ring seal.

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Remove and discard the turbocharger fitting and oil filter assembly.

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Remove the coolant tube fitting.

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Inspect the coolant tube fitting and replace as needed.

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Loosen the fitting and separate the LH turbocharger coolant supply tube and fitting from the cylinder head.

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Position the cover aside and disconnect the electrical connector from the oil pressure switch.

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Remove the bolt for the turbocharger coolant supply tube and the turbocharger oil feed tube.

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Remove the upper turbocharger oil tube manifold assembly bolts at the turbocharger oil tube manifold assembly.

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Remove and discard the upper turbocharger oil tube assembly gasket.

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1. Remove and discard the turbocharger fasteners, remove the turbocharger coolant supply tube from the block fitting while removing the turbocharger and position the turbocharger aside.
NOTE: Use a commercially available tool such as a 3/8" Jiffy-Tite® or equivalent quick disconnect tool, close the tool around the tube, press the tool into the fitting and rotate until the tool is fully seated into the fitting.

Disconnect the turbocharger coolant supply tube from the turbocharger fitting and remove the turbocharger coolant supply tube. Remove the turbocharger.

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Remove and discard the turbocharger gasket.

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Remove the turbocharger exhaust flange stud bolts if they need to be removed.

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Remove the lower turbocharger oil manifold assembly bolt and the turbocharger oil manifold assembly.

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Remove and discard the turbocharger oil manifold assembly O-ring seal and gasket.

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NOTE: Whenever the turbocharger is removed or replaced, always install a new turbocharger fitting and oil filter assembly.

Remove and discard the turbocharger fitting and oil filter assembly.

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Remove the coolant tube fitting.

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Inspect the coolant tube fitting and replace as needed.

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Discard the gasket and O-ring seal.

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Remove the bolts and the generator.

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Remove the generator stud bolt.

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1. Slide the insulator off of the CHT sensor electrical connector.
2. Disconnect the CHT sensor electrical connector.
3. Detach the wiring harness retainer and position the harness aside.
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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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Remove the bolt and coolant hose bracket.

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Remove the bolts and the oil filter adapter.

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Inspect the gasket and replace if necessary.

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

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

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- Remove the bolts and the brake vacuum pump.
- Remove the nut, bolt and the heat shield.
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NOTE: Make sure the oil tube filter screen is free of contaminants prior to installation.

Inspect the gasket and the oil tube filter screen. Replace the gasket if necessary.

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- Disconnect the CHT sensor electrical connector and wiring harness retainer.
- Remove the stud bolt and the ground wire.
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- Disconnect the KS electrical connector.
- Disconnect the fuel pressure sensor electrical connector.
- Disconnect the RH and LH fuel charge harness electrical connectors.
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- Disconnect the CMP sensor electrical connectors.
- Detach the wiring harness retainer.
- Remove the stud bolt and the ground wire.
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Remove the nut, bolt and the heat shield.

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- Remove the stud bolt.
- Detach the wiring harness grommet from the cylinder block.
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- Disconnect the CKP sensor electrical connector.
- Remove the bolt, the CKP sensor electrical connector and position the wiring harness aside.
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Disconnect the electrical connector and detach the pin-type retainer.

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- Remove the oil level indicator.
- Disconnect the VCT sensor electrical connectors.
- Disconnect the coil-on-plug electrical connectors.
- Detach the wiring harness retainers.
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- Disconnect the VCT sensor electrical connectors.
- Disconnect the CMP sensor electrical connectors.
- Disconnect the coil-on-plug electrical connectors.
- Detach the wiring harness retainers and remove the engine wiring harness.
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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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Inspect the coil seals for rips, nicks or tears.

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Remove the nuts and cabin pump.
Torque: 5 Nm

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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 bolts and remove the valve cover.

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Discard the gasket.

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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 bolts and remove the valve cover.

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Discard the gasket.

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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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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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Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .

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Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .

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Remove the bolts and the CMP sensors.

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Remove the bolts and the coolant pump.

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

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Vehicles without dual alternators shown, with dual alternators similiar.Remove the bolts.

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

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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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NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 rpm, to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean front cover.
- Make sure that the mating faces of the front cover are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .
- Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
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Make sure that the mating faces of the engine block and oil pan are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .

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NOTE: Rotate the crankshaft in a clockwise direction only.

Rotate the crankshaft clockwise and align the timing marks on the intake VCT units as shown.

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Remove the bolts and the LH oil tube.

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

Install Special Service Tool: 303-1248 Camshaft holding tools.

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Remove the bolts and the RH oil tube.

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

Install Special Service Tool: 303-1248 Camshaft holding tools.

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NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.
Mark the timing chain link that aligns with the timing mark on the LH intake VCT unit as shown.

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Mark the timing chain link that aligns with the timing mark on the RH intake VCT unit as shown.

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NOTE: The crankshaft sprocket timing mark should be between the colored links.

Mark the timing chain links that aligns with the timing mark on the crankshaft sprocket as shown.

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Remove the bolts and the timing chain tensioner.

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Remove the timing chain tensioner arm.

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Remove the bolts and the lower LH timing chain guide.

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NOTE: Removal of the VCT oil control solenoid will aid in the removal of the timing chain.

NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoids.

NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

Remove the bolts and the VCT oil control solenoids.

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Remove the timing chain.

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Remove the crankshaft sprocket.

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NOTE: Do not use power tools to remove the bolt or damage to the LH primary timing chain guide may occur.

Remove the bolt and the upper LH timing chain guide.

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NOTE: The VCT oil control solenoids are removed for clarity.

Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

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Remove and discard the LHVCT unit bolts.

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Remove the LHVCT units and secondary timing chain.

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Remove Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

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Remove Special Service Tool: 303-1248 Camshaft holding tools.

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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, camshaft caps and the camshafts.

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NOTE: The VCT oil control solenoids are removed for clarity.

Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

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Remove and discard the RHVCT unit bolts.

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Remove the RHVCT units and secondary timing chain.

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Remove Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

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Remove Special Service Tool: 303-1248 Camshaft holding tools.

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Remove the bolts and the camshaft bearing cap.

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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, camshaft caps and the camshafts.

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NOTE: Do not use power tools to remove the bolt or damage to the RH primary timing chain guide may occur.

Remove the bolt and the RH timing chain guide.

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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.

Remove the valve tappets from the cylinder heads.

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Inspect and install new components as necessary.

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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: When removing the fuel rails remove the left side fuel rail first.

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 cylinder heads and require the use of a Fuel Injector Remover tool to extract. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.

NOTE: Should any of the fuel injectors remain in the head, then the fuel injector electrical connectors will need to be disconnected as the fuel rail is being removed.

Remove the fuel rail bolts and remove the fuel rails. Discard the fuel rail bolts.

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Remove the fuel rail bolts and remove the fuel rails. Discard the fuel rail bolts.

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Remove the fuel injectors from the fuel rail.

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Remove and discard the fuel injector clips.

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NOTE: Use minimal force to remove the fuel injectors that remained in the cylinder head with the Fuel Injector Remover tool or damage to the fuel injector assembly may occur. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.

NOTE: Commercially available OTC 5028 8-1/2" long slide hammer may be substituted for 307-005 where there are clearance concerns.

Using the special tool, clean the cylinder head fuel injector bores.Use Suggested Tool: 310-205 Fuel Injector Brush. Tool shown or a commercially available equivalent can be used.

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NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.

NOTE: Do not use compressed air to clean the tip of the fuel injector.

NOTE: Do not use a brush to clean the tip of the fuel injector.

Using the special tool, clean the cylinder head fuel injector bores.Use Suggested Tool: 310-205 Fuel Injector Brush. Tool shown or a commercially available equivalent can be used.

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Vehicles with cast iron exhaust manifold
Remove the nuts and the LH exhaust manifold. Discard the nuts.

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Remove the studs and the LH exhaust manifold gasket and discard.

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Vehicles with stainless steel exhaust manifold
Remove the nuts and the LH exhaust manifold. Discard the nuts.

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Remove the studs and the LH exhaust manifold gasket and discard.

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All vehicles
Remove the bolts and the LH lift eye.

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Remove and discard the M6 bolt.

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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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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.

Make sure that the mating faces of the cylinder head are clean and free of foreign material.

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Remove and discard the cylinder head gasket.

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Remove the LH water jacket spacer.Use the General Equipment: Long Nose Pliers

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NOTE: Place clean, lint-free 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: 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.

Make sure that the mating faces of the engine block are clean and free of foreign material.

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Vehicles with cast iron exhaust manifold
Remove the nuts and the RH exhaust manifold. Discard the nuts.

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Remove the studs and the RH exhaust manifold gasket and discard.

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Vehicles with stainless steel exhaust manifold
Remove the nuts and the RH exhaust manifold. Discard the nuts.

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Remove the studs and the RH exhaust manifold gasket and discard.

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All vehicles
Remove the bolts and the RH lift eye.

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Remove and discard the M6 bolt.

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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 cylinder head.
- Remove the cylinder head.
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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.

Make sure that the mating faces of the cylinder head are clean and free of foreign material.

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Remove and discard the cylinder head gasket.

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Remove the RH water jacket spacer.Use the General Equipment: Long Nose Pliers

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NOTE: Place clean, lint-free 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: 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.

Make sure that the mating faces of the engine block are clean and free of foreign material.

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

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Remove the bolts and the channel cover plate.

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Inspect and replace if necessary.

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Removethe stud bolt.

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Remove the oil pan bolts.

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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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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.
- Make sure that the mating faces of the oil pan are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .
  Material: Gasket Remover
  
  Material: Brake Cleaner
  
  Material: Metal Cleaner
- Thoroughly wash the oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.
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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 of the engine block are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation

(303-00 Engine System - General Information, General Procedures).Use the General Equipment: Plastic Scraper

Material: Gasket Remover

Material: Brake Cleaner

Material: Metal Cleaner

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

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

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Remove the bolts and the oil pump.

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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 is clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation

(303-00 Engine System - General Information, General Procedures).Use the General Equipment: Plastic Scraper

Material: Gasket Remover

Material: Brake Cleaner

Material: Metal Cleaner

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Inspect and clean the specified component with a abrasive pad.

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- Remove and discard the bolts in the sequence shown.
- Remove the main bearing cap support brace.
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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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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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Inspect the pistons. Refer to: Piston Inspection .
NOTE: Early build engines have a 13 mm bolt head with coarse threads for the main bearing caps. Late build engines have a 15 mm bolt head with fine threads for the main bearing caps. The main bearing cap side bolts remain the same.

NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.

Remove and discard the bolts in the sequence shown.

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

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

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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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Using a hexagonal screwdriver, remove the piston oil cool valves.

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Inspect the cylinder block distortion. Refer to: Cylinder Block Distortion .
NOTE: Place clean, lint-free 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: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.

Make sure that the mating faces of the cylinder block are clean and free of foreign material.

Material: Gasket Remover

Material: Metal Cleaner