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Section 3190 (Engine - 2.7L ECOBOOST (238KW/324PS)): Disassembly: Engine

WARNING: This page is about a different car, the 2017 Ford Edge. However, it is still accessible from the selected car via links, so may be relevant.

Special Tool(s) / General Equipment 

GFD16095Courtesy of FORD MOTOR COMPANY
 205-153 (T80T-4000-W) Handle
GFD16773Courtesy of FORD MOTOR COMPANY
 303-1246 Engine Spreader Bar

TKIT-2006UF-FLM

TKIT-2006UF-ROW
GFD16096Courtesy of FORD MOTOR COMPANY
 303-1247 VCT Spark Plug Tube Seal Remover and Installer

TKIT-2006UF-FLM

TKIT-2006UF-ROW
GFD16444Courtesy of FORD MOTOR COMPANY
 303-1248 Camshaft holding tools

TKIT-2006UF-FLM

TKIT-2006UF-ROW
GFD16774Courtesy of FORD MOTOR COMPANY
 303-1634 Lift Eyes (2)

TKIT-2014D-FL_ROW

TKIT-2014D-ROW3
GFD15952Courtesy of FORD MOTOR COMPANY
 303-409 (T92C-6700-CH) Remover, Crankshaft Seal

TKIT-1992-FH/FMH/FLMH

TKIT-1993-LMH/MH
Floor Crane
Three Leg Puller
Mounting Stand
Plastic Scraper
Hose Clamp Remover/Installer
Flat-Bladed Screwdriver

Materials 

Name Specification
Motorcraft® Silicone Gasket Remover ZC-30-A -
Motorcraft® Metal Surface Prep ZC-31-B -
Metal Brake Parts Cleaner (U.S.) PM-4-A, PM-4-B (U.S.) -
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 .

  1. 1.

    Remove the bolts and the flexplate.
GFD16745Courtesy of FORD MOTOR COMPANY

  1. 2.

    Remove the crankshaft sensor ring.
GFD16648Courtesy of FORD MOTOR COMPANY

  1. 3.

    Inspect the crankshaft sensor ring for damage. If the crankshaft sensor ring has been dropped or has any visual damage, it must be discarded.
GFD16649Courtesy of FORD MOTOR COMPANY

  1. 4.

    1. 1.

      Disconnect the CKP sensor electrical connector.

    1. 2.

      Remove the bolt and the CKP sensor.
GFD16650Courtesy of FORD MOTOR COMPANY

  1. 5.

    Remove the bolts and the crankshaft rear seal and retainer plate.
    • Discard the crankshaft rear seal and retainer plate.
GFD16651Courtesy of FORD MOTOR COMPANY

  1. 6.

    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. Use a plastic scraping tool to remove all traces of old sealant.

    Clean and inspect the mating surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

    Material

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

    Material

    : Metal Brake Parts Cleaner (U.S.) / PM-4-A, PM-4-B (U.S.)

    Material

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

GFD16652Courtesy of FORD MOTOR COMPANY

  1. 7.

    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 Crane

    Use the General Equipment: Mounting Stand

GFD16800Courtesy of FORD MOTOR COMPANY

  1. 8.

    • Remove the bolts and the accessory drive belt tensioner.
    • Remove the bolt and the idler pulley.
    • Remove the bolts and the coolant pump pulley.
    • Remove the generator stud.
    • Remove the bolt and the generator.
GFD16801Courtesy of FORD MOTOR COMPANY

  1. 9.

    • Disconnect the oil pressure control solenoid electrical connector.
    • Remove the retainer and the oil pressure control solenoid.
GFD16802Courtesy of FORD MOTOR COMPANY

  1. 10.

    Detach the wiring harness retainers.
GFD16496Courtesy of FORD MOTOR COMPANY

  1. 11.

    • Disconnect the KS electrical connector.
    • Detach the wiring harness retainer.
    • Remove the nut, the bolt and the bracket.
GFD16803Courtesy of FORD MOTOR COMPANY

  1. 12.

    Remove the stud bolt and the ground wire.
GFD16804Courtesy of FORD MOTOR COMPANY

  1. 13.

    • Disconnect the high pressure fuel pump electrical connector.
    • Detach the wiring harness retainers.
    • Remove the stud bolt and the ground wire.
GFD16805Courtesy of FORD MOTOR COMPANY

  1. 14.

    • Disconnect the PCV tube quick release couplings and remove the tube. Refer to: QUICK RELEASE COUPLING - 2.7L EcoBoost (238kW/324PS).

    1. 1.

      Disconnect the throttle body electrical connector and detach the wiring harness retainer.
GFD16806Courtesy of FORD MOTOR COMPANY

  1. 15.

    • Disconnect the crankcase pressure sensor electrical connector.
    • Detach the PCV tube retainer.
    • Disconnect the PCV tube quick release coupling and remove the tube. Refer to: QUICK RELEASE COUPLING - 2.7L EcoBoost (238kW/324PS).
GFD16485Courtesy of FORD MOTOR COMPANY

  1. 16.

    Disconnect the EVAP tube quick release coupling and remove the tube. Refer to: QUICK RELEASE COUPLING - 2.7L EcoBoost (238kW/324PS).
GFD16807Courtesy of FORD MOTOR COMPANY

  1. 17.

    1. 1.

      Disconnect the EVAP tube quick release coupling. Refer to: QUICK RELEASE COUPLING - 2.7L EcoBoost (238kW/324PS).

    1. 2.

      Disconnect the EVAP purge valve electrical connector.

    1. 3.

      Lift the EVAP purge valve off of the intake manifold mounting tab and remove the valve from the engine.
GFD16808Courtesy of FORD MOTOR COMPANY

  1. 18.

    Disconnect the engine wiring harness electrical connectors and retainers.
GFD16487Courtesy of FORD MOTOR COMPANY

  1. 19.

    1. 1.

      Remove the vacuum harness pressure sensor bolt.

    1. 2.

      Disconnect the MAP sensor electrical connector.

    1. 3.

      Detach the wiring harness and vacuum harness retainers.
GFD16488Courtesy of FORD MOTOR COMPANY

  1. 20.

    • Slide the insulator up to access the CHT electrical connector.
    • Disconnect the engine wiring harness electrical connectors and detach the wiring harness retainers.
GFD16809Courtesy of FORD MOTOR COMPANY

  1. 21.

    • Disconnect the engine wiring harness electrical connectors.
    • Detach the wiring harness retainers and remove the harness from the engine.
GFD16810Courtesy of FORD MOTOR COMPANY

  1. 22.

    Detach the vacuum hose retainers.
    • Release the clamp and disconnect the vacuum hose from the TC.
GFD16811Courtesy of FORD MOTOR COMPANY

  1. 23.

    1. 1.

      Release the clamp and disconnect the vacuum hose from the TC.

    1. 2.

      Remove the vacuum control solenoid bolts.

    1. 3.

      Disconnect the vacuum tube quick release coupling. Refer to: QUICK RELEASE COUPLING - 2.7L EcoBoost (238kW/324PS).

    1. 4.

      Detach the retainers and remove the vacuum tube assembly from the engine.
GFD16812Courtesy of FORD MOTOR COMPANY

  1. 24.

    NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

    Remove the bolts and the coil-on-plug assemblies.

GFD16502Courtesy of FORD MOTOR COMPANY

  1. 25.

    Remove the oil level indicator.
GFD16493Courtesy of FORD MOTOR COMPANY

  1. 26.

    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 if found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

    Loosen the bolts and remove the intake manifold.

GFD16813Courtesy of FORD MOTOR COMPANY

  1. 27.

    Inspect the gaskets and replace as necessary.
GFD16751Courtesy of FORD MOTOR COMPANY

  1. 28.

    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.
    • Loosen the high-pressure fuel pump-to-fuel rail high-pressure fuel tube flare nuts.
    • Remove and discard the high-pressure fuel tube.
GFD16615Courtesy of FORD MOTOR COMPANY

  1. 29.

    NOTE: Alternately loosen the high-pressure fuel pump nuts one revolution at a time.

    Remove the nuts and the high-pressure fuel pump.

GFD16616Courtesy of FORD MOTOR COMPANY

  1. 30.

    Remove and discard the high-pressure fuel pump O-ring seal.
GFD16617Courtesy of FORD MOTOR COMPANY

  1. 31.

    Remove the high-pressure fuel pump tappet.
GFD16618Courtesy of FORD MOTOR COMPANY

  1. 32.

    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.
GFD16619Courtesy of FORD MOTOR COMPANY

  1. 33.

    Remove the stud bolts and the high-pressure fuel pump drive unit.
GFD16620Courtesy of FORD MOTOR COMPANY

  1. 34.

    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. Use a plastic scraping tool to remove all traces of old sealant.

    Clean and inspect the mating surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

    Use the General Equipment: Plastic Scraper

    Material

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

    Material

    : Metal Brake Parts Cleaner (U.S.) / PM-4-A, PM-4-B (U.S.)

    Material

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

GFD16621Courtesy of FORD MOTOR COMPANY

  1. 35.

    • Loosen the fuel rail-to-fuel rail high-pressure fuel tube flare nuts.
    • Remove and discard the high-pressure fuel tube.
GFD16677Courtesy of FORD MOTOR COMPANY

  1. 36.

    Remove the bolts and the brake vacuum pump.
GFD16814Courtesy of FORD MOTOR COMPANY

  1. 37.

    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. Use a plastic scraping tool to remove all traces of old sealant.

    Clean and inspect the mating surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

    Material

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

    Material

    : Metal Brake Parts Cleaner (U.S.) / PM-4-A, PM-4-B (U.S.)

    Material

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

GFD16520Courtesy of FORD MOTOR COMPANY

  1. 38.

    Remove the bolts and the coolant pump.
GFD16517Courtesy of FORD MOTOR COMPANY

  1. 39.

    Remove and discard the coolant pump gasket and seal.
GFD16518Courtesy of FORD MOTOR COMPANY

  1. 40.

    Remove the bolts and the TC oil supply tube.
GFD16666Courtesy of FORD MOTOR COMPANY

  1. 41.

    Remove and discard the TC oil supply tube oil filter and the O-ring seals.
GFD16667Courtesy of FORD MOTOR COMPANY

  1. 42.

    Remove the bolts and the TC oil return tube.
GFD16668Courtesy of FORD MOTOR COMPANY

  1. 43.

    Remove and discard the TC oil return tube O-ring seal.
GFD16669Courtesy of FORD MOTOR COMPANY

  1. 44.

    Remove and discard the TC oil return tube tube-to-engine block gasket.
GFD16670Courtesy of FORD MOTOR COMPANY

  1. 45.

    Release the clamp and disconnect the TC coolant return hose.

    Use the General Equipment: Hose Clamp Remover/Installer

GFD16671Courtesy of FORD MOTOR COMPANY

  1. 46.

    NOTE: Remove the TC coolant supply tube from the engine block while removing the TC.
    • Remove the TC coolant supply tube bolt.
    • Remove the TC bolt.
    • Remove the nuts and the TC.
GFD16672Courtesy of FORD MOTOR COMPANY

  1. 47.

    Remove and discard the TC coolant supply tube O-ring seal.
GFD16673Courtesy of FORD MOTOR COMPANY

  1. 48.

    • Remove and discard the TC gasket.
    • Remove and discard the TC mounting studs.
GFD16674Courtesy of FORD MOTOR COMPANY

  1. 49.

    Remove the bolts and the TC oil supply tube.
GFD16703Courtesy of FORD MOTOR COMPANY

  1. 50.

    Remove and discard the TC oil supply tube O-ring seals and the TC oil supply tube oil filter.
GFD16704Courtesy of FORD MOTOR COMPANY

  1. 51.

    Remove the bolt and disconnect the TC coolant return tube.
GFD16705Courtesy of FORD MOTOR COMPANY

  1. 52.

    Remove and discard the TC coolant return tube O-ring seal.
GFD16706Courtesy of FORD MOTOR COMPANY

  1. 53.

    NOTE: AWD shown in illustration FWD is similar.

    Remove the bolts and the TC oil return tube.

GFD16708Courtesy of FORD MOTOR COMPANY

  1. 54.

    Remove and discard the TC oil return tube O-ring seal.
GFD16669Courtesy of FORD MOTOR COMPANY

  1. 55.

    Remove and discard the TC oil return tube tube-to-engine block gasket.
GFD16670Courtesy of FORD MOTOR COMPANY

  1. 56.

    Remove the TC coolant supply tube bolt.
GFD16709Courtesy of FORD MOTOR COMPANY

  1. 57.

    NOTE: Remove the TC coolant supply tube from the engine block while removing the TC.

    Remove the retainers and the TC.

GFD16710Courtesy of FORD MOTOR COMPANY

  1. 58.

    Remove and discard the TC coolant supply tube O-ring seal.
GFD16673Courtesy of FORD MOTOR COMPANY

  1. 59.

    Remove and discard the TC gasket.
GFD16711Courtesy of FORD MOTOR COMPANY

  1. 60.

    Remove and discard the TC mounting studs.
GFD16712Courtesy of FORD MOTOR COMPANY

  1. 61.

    Remove the oil pan bolts.
GFD16473Courtesy of FORD MOTOR COMPANY

  1. 62.

    Using a large flat-bladed screwdriver and the indicated pry pads, release the sealer and remove the oil pan.

    Use the General Equipment: Flat-Bladed Screwdriver

GFD16474Courtesy of FORD MOTOR COMPANY

  1. 63.

    Inspect the oil pickup for cracks.
    • Discard the oil pan if cracks are present in the oil pickup.
GFD16757Courtesy of FORD MOTOR COMPANY

  1. 64.

    Remove and discard the oil pump seal.
GFD16476Courtesy of FORD MOTOR COMPANY

  1. 65.

    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. Use a plastic scraping tool to remove traces of sealant.
    NOTE: Do not use metal cleaner on the plastic oil pan.

    Make sure that the oil pan mating faces of the cylinder block, engine front cover and oil pan are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .

    Use the General Equipment: Plastic Scraper

    Material

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

    Material

    : Metal Brake Parts Cleaner (U.S.) / PM-4-A, PM-4-B (U.S.)

    Material

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

GFD16477Courtesy of FORD MOTOR COMPANY

  1. 66.

    Loosen the fasteners and remove the valve cover.
GFD16503Courtesy of FORD MOTOR COMPANY

  1. 67.

    Remove and discard the gasket.
    • Clean the valve cover gasket groove with soap and water or a suitable solvent.
GFD16504Courtesy of FORD MOTOR COMPANY

  1. 68.

    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.

GFD16505Courtesy of FORD MOTOR COMPANY

  1. 69.

    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. Use a plastic scraping tool to remove all traces of old sealant.

    Clean the valve cover mating surface of the cylinder head and engine front cover. Refer to: RTV Sealing Surface Cleaning and Preparation .

    Use the General Equipment: Plastic Scraper

    Material

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

    Material

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

    Material

    : Metal Brake Parts Cleaner (U.S.) / PM-4-A, PM-4-B (U.S.)

GFD16506Courtesy of FORD MOTOR COMPANY

  1. 70.

    Remove the oil level indicator.
GFD16493Courtesy of FORD MOTOR COMPANY

  1. 71.

    Loosen the fasteners and remove the valve cover.
GFD16507Courtesy of FORD MOTOR COMPANY

  1. 72.

    Remove and discard the gasket.
    • Clean the valve cover gasket groove with soap and water or a suitable solvent.
GFD16508Courtesy of FORD MOTOR COMPANY

  1. 73.

    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.

GFD16509Courtesy of FORD MOTOR COMPANY

  1. 74.

    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. Use a plastic scraping tool to remove all traces of old sealant.

    Clean the valve cover mating surface of the cylinder head and engine front cover. Refer to: RTV Sealing Surface Cleaning and Preparation .

    Use the General Equipment: Plastic Scraper

    Material

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

    Material

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

    Material

    : Metal Brake Parts Cleaner (U.S.) / PM-4-A, PM-4-B (U.S.)

GFD16510Courtesy of FORD MOTOR COMPANY

  1. 75.

    Remove and discard the crankshaft pulley bolt.
GFD16513Courtesy of FORD MOTOR COMPANY

  1. 76.

    Using the 3 Leg Puller and a step plate, remove the crankshaft pulley.

    Use the General Equipment: Three Leg Puller

GFD16514Courtesy of FORD MOTOR COMPANY

  1. 77.

    NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

    Using the special tool, remove and discard the crankshaft front oil seal.

    Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.

GFD16515Courtesy of FORD MOTOR COMPANY

  1. 78.

    NOTE: There are 4 different types of fasteners, note location of each fastener for assembly.

    Remove the engine front cover fasteners.

GFD16521Courtesy of FORD MOTOR COMPANY

  1. 79.

    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

GFD16522Courtesy of FORD MOTOR COMPANY

  1. 80.

    Remove and discard the engine front cover gaskets.
GFD16523Courtesy of FORD MOTOR COMPANY

  1. 81.

    Remove and discard the oil gallery seal.
GFD16524Courtesy of FORD MOTOR COMPANY

  1. 82.

    NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean front cover.
    • Clean the engine front cover 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. 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.

      Material

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

      Material

      : Metal Brake Parts Cleaner (U.S.) / PM-4-A, PM-4-B (U.S.)

      Material

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

GFD16525Courtesy of FORD MOTOR COMPANY

  1. 83.

    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 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 engine block are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .

    Use the General Equipment: Plastic Scraper

    Material

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

    Material

    : Metal Brake Parts Cleaner (U.S.) / PM-4-A, PM-4-B (U.S.)

    Material

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

GFD16526Courtesy of FORD MOTOR COMPANY

  1. 84.

    Install the crankshaft pulley bolt.
GFD16527Courtesy of FORD MOTOR COMPANY

  1. 85.

    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. 1.

      Rotate the crankshaft clockwise.

    1. 2.

      Position the crankshaft sprocket keyway at the 11 o'clock position.

    1. 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).
GFD16528Courtesy of FORD MOTOR COMPANY

  1. 86.

    Remove the bolts and the RH timing chain tensioner.
GFD16529Courtesy of FORD MOTOR COMPANY

  1. 87.

    Remove the RH timing chain tensioner arm.
GFD16530Courtesy of FORD MOTOR COMPANY

  1. 88.

    Remove the bolts and the RH timing chain guide.
GFD16531Courtesy of FORD MOTOR COMPANY

  1. 89.

    Remove the RH timing chain.
GFD16532Courtesy of FORD MOTOR COMPANY

  1. 90.

    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. 1.

      Rotate the crankshaft clockwise one revolution (360 degrees).

    1. 2.

      Position the crankshaft sprocket keyway at the 11 o'clock position.

    1. 3.

      The circle  timing marks on the VCT units will be at the 10 o'clock (intake) and 12:30 (exhaust) positions.
GFD16536Courtesy of FORD MOTOR COMPANY

  1. 91.

    Remove the crankshaft pulley bolt.
GFD16535Courtesy of FORD MOTOR COMPANY

  1. 92.

    Remove the timing chain sprocket.
GFD16534Courtesy of FORD MOTOR COMPANY

  1. 93.

    1. 1.

      Rotate the oil pump drive chain tensioner counterclockwise.

    1. 2.

      Insert a small hex wrench or pin into the holes of the tensioner to secure the end of the spring.
GFD16537Courtesy of FORD MOTOR COMPANY

  1. 94.

    Remove the bolt and oil pump drive chain tensioner.
GFD16538Courtesy of FORD MOTOR COMPANY

  1. 95.

    Remove the bolts and oil pump drive chain guide.
GFD16539Courtesy of FORD MOTOR COMPANY

  1. 96.

    Remove the oil pump drive chain.
GFD16540Courtesy of FORD MOTOR COMPANY

  1. 97.

    Remove the bolts and the LH timing chain tensioner.
GFD16541Courtesy of FORD MOTOR COMPANY

  1. 98.

    Remove the LH timing chain tensioner arm.
GFD16542Courtesy of FORD MOTOR COMPANY

  1. 99.

    Remove the bolts and the LH timing chain guide.
GFD16543Courtesy of FORD MOTOR COMPANY

  1. 100.

    Remove the LH timing chain.
GFD16544Courtesy of FORD MOTOR COMPANY

  1. 101.

    Remove the timing chain sprocket.
GFD16765Courtesy of FORD MOTOR COMPANY

  1. 102.

    Remove the bolts and the oil pump.
GFD16815Courtesy of FORD MOTOR COMPANY

  1. 103.

    1. 1.

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

    1. 2.

      Remove and discard the VCT unit bolts.

    1. 3.

      Remove the VCT units.
GFD16622Courtesy of FORD MOTOR COMPANY

  1. 104.

    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.

GFD16623Courtesy of FORD MOTOR COMPANY

  1. 105.

    Remove the bolts and the camshaft bearing caps.
GFD16624Courtesy of FORD MOTOR COMPANY

  1. 106.

    Remove the intake and exhaust camshafts.
GFD16625Courtesy of FORD MOTOR COMPANY

  1. 107.

    1. 1.

      Remove the camshaft roller follower and hydraulic lash adjuster assemblies.

    1. 2.

      Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.

    1. 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.
GFD16626Courtesy of FORD MOTOR COMPANY

  1. 108.

    1. 1.

      Release the clamp and disconnect the coolant hose.

      Use the General Equipment: Hose Clamp Remover/Installer

    1. 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.

GFD16714Courtesy of FORD MOTOR COMPANY

  1. 109.

    • Remove and discard the cylinder head bolts.
    • Remove the cylinder head.
GFD16715Courtesy of FORD MOTOR COMPANY

  1. 110.

    Remove and discard the cylinder head gasket.
GFD16716Courtesy of FORD MOTOR COMPANY

  1. 111.

    • Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
GFD16717Courtesy of FORD MOTOR COMPANY

  1. 112.

    1. 1.

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

    1. 2.

      Remove and discard the VCT unit bolts.

    1. 3.

      Remove the VCT units.
GFD16545Courtesy of FORD MOTOR COMPANY

  1. 113.

    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.

GFD16546Courtesy of FORD MOTOR COMPANY

  1. 114.

    Remove the bolts and the camshaft bearing caps.
GFD16547Courtesy of FORD MOTOR COMPANY

  1. 115.

    Remove the intake and exhaust camshafts.
GFD16548Courtesy of FORD MOTOR COMPANY

  1. 116.

    1. 1.

      Remove the camshaft roller follower and hydraulic lash adjuster assemblies.

    1. 2.

      Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.

    1. 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.
GFD16549Courtesy of FORD MOTOR COMPANY

  1. 117.

    1. 1.

      Release the clamp and disconnect the coolant hose.

      Use the General Equipment: Hose Clamp Remover/Installer

    1. 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.

GFD16675Courtesy of FORD MOTOR COMPANY

  1. 118.

    • Remove and discard the cylinder head bolts.
    • Remove the cylinder head.
GFD16678Courtesy of FORD MOTOR COMPANY

  1. 119.

    Remove and discard the cylinder head gasket.
GFD16679Courtesy of FORD MOTOR COMPANY

  1. 120.

    • Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
GFD16680Courtesy of FORD MOTOR COMPANY

  1. 121.

    1. 1.

      Detach the wiring harness retainer from the stud bolt.

    1. 2.

      Remove the stud bolt, the nuts and the coolant outlet connector pipe.
GFD16816Courtesy of FORD MOTOR COMPANY

  1. 122.

    1. 1.

      Disconnect the ECT sensor electrical connector.

    1. 2.

      Remove the bolts and the KS assembly.
GFD16817Courtesy of FORD MOTOR COMPANY

  1. 123.

    NOTE: Do not reuse the ECT sensor, install a new sensor.

    Remove and discard the ECT sensor.

GFD16818Courtesy of FORD MOTOR COMPANY

  1. 124.

    Remove the engine block skirt stiffener bolts.
GFD16819Courtesy of FORD MOTOR COMPANY

  1. 125.

    Using a suitable pry bar at the 4 pry pad locations, release the engine block skirt stiffener-to-engine block seal.
GFD16820Courtesy of FORD MOTOR COMPANY

  1. 126.

    • Remove the engine block skirt stiffener.
    • Remove and discard the oil seal.
GFD16821Courtesy of FORD MOTOR COMPANY

  1. 127.

    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. Use a plastic scraping tool to remove all traces of old sealant.

    Clean and inspect the mating surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation .

    Use the General Equipment: Plastic Scraper

    Material

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

    Material

    : Metal Brake Parts Cleaner (U.S.) / PM-4-A, PM-4-B (U.S.)

    Material

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

GFD16822Courtesy of FORD MOTOR COMPANY

  1. 128.

    • 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.
GFD16823Courtesy of FORD MOTOR COMPANY

  1. 129.

    Remove the bolts and the connecting rod cap.
GFD16824Courtesy of FORD MOTOR COMPANY

  1. 130.

    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.
    • Remove the piston through the top of the cylinder block
    • Repeat the steps for each of the remaining pistons.
GFD16825Courtesy of FORD MOTOR COMPANY

  1. 131.

    • Remove the connecting rod bearings.
GFD16826Courtesy of FORD MOTOR COMPANY

  1. 132.

    Remove and discard the main bearing cap bolts.
GFD16827Courtesy of FORD MOTOR COMPANY

  1. 133.

    1. 1.

      Remove the main bearing caps.

    1. 2.

      Remove the lower thrust washer.

    1. 3.

      Remove the lower main bearings.
GFD16828Courtesy of FORD MOTOR COMPANY

  1. 134.

    1. 1.

      Remove the crankshaft.

    1. 2.

      Remove the lower main bearings.

    1. 3.

      Remove the lower thrust bearing.
GFD16829Courtesy of FORD MOTOR COMPANY

  1. 135.

    Remove the bolts and the piston cooling jets from the cylinder block.
GFD16830Courtesy of FORD MOTOR COMPANY
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