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Engine Mechanical - 2.0L ECOBOOST: Disassembly: Engine

SPECIAL TOOL/GENERAL EQUIPMENT DESCRIPTION

G09600055
 205-153  (T80T-4000-W)
Handle
G09600056
 300-OTC1819E 
2, 200# Floor Crane, Fold Away
G09600057
 303-103  (T74P-6375-A)
Holding Tool, Flywheel
TKIT-2009TC-F
T74P-77000-A
G09600058
 303-1247 
VCT Spark Plug Tube Seal Remover and Installer
TKIT-2006UF-FLM
TKIT-2006UF-ROW
G08062335
 303-1565 
Alignment Tool, Camshaft
TKIT-2010C-FLM
TKIT-2010C-FLM
G08062359
 303-409  (T92C-6700-CH)
Remover, Crankshaft Seal
TKIT-1992-FH/FMH/FLMH
TKIT-1993-LMH/MH
G08062627
 303-507 
Timing Peg, Crankshaft TDC
TKIT-2001N-FLM
TKIT-2001N-ROW
G09600062
 307-005  (T59L-100-B)
Slide Hammer
G09371878
 310-206 
Remover, Fuel Injector
TKIT-2009A-FLM
Strap Wrench
MATERIALS SPECIFICATION

Name Specification
Motorcraft® Metal Surface Prep
ZC-31-A		 -
NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
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.
  1. Loosen each bolt 2 turns at a time until all bolts are removed.
    G08064504
  2. Discard the specified component. Follow local disposal regulations.

    Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel  .

    G08062281
  3. Install.
    G08063275
  4. Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away  .
    G08063258
  5. Loosen.
    G08063277
  6. G08062995
  7. G08063279
  8. G08063053
  9. Discard the specified component. Follow local disposal regulations.
    G08063802
  10. G08063282
  11. Discard the specified component. Follow local disposal regulations.
    G08063283
  12. Discard the specified component. Follow local disposal regulations.
    G08063806
  13. Discard the specified component. Follow local disposal regulations.
    G08063285
  14. G08063286
  15. Discard the specified component. Follow local disposal regulations.
    G08063809
  16. Discard the specified component. Follow local disposal regulations.
    G08063288
  17. G08063289
  18. G08063290
  19. Loosen.
    G08063291
  20. Refer to: AIR CONDITIONING (A/C) COMPRESSOR BELT .
  21. G08063292
  22. G08063293
  23. G09600085
  24. G08063295
  25. G08063296
  26. G08063297
  27. G08063298
  28. G08063299
  29. NOTE: A new oil cooler must be installed or severe damage to the engine can occur.

    Discard the specified component. Follow local disposal regulations.

    G08063300
  30. Discard the specified component. Follow local disposal regulations.
    G08063301
    1. Refer to: QUICK RELEASE COUPLING .
      G08063302
  32. G08063303
  33. G08063304
  34. G08063305
  35. G08062982
  36. G08063307
  37. G08063308
  38. G08063309
  39. G08063310
  40. G08063311
  41. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel during the loosening of the fuel injection pump flare nut.

    Discard the specified component. Follow local disposal regulations.

    G08063312
  42. NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
    NOTE: Use compressed air 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 fuel rails but normally remain in the cylinder head and require the use of a Fuel Injector Remover tool to extract.

    Discard the specified component. Follow local disposal regulations.

    G08063313
  43. Remove any of the fuel injectors that remained in the fuel rail.
    G08063314
  44. Remove any of the fuel injectors that remained in the fuel rail.

    Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer  ., 310-206 Remover, Fuel Injector  .

    G08063315
  45. Discard the specified component. Follow local disposal regulations.
    G08063316
  46. Discard the specified component. Follow local disposal regulations.
    G08063317
  47. NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.
    NOTE: Be very careful when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.
    1. Pull the lower Teflon® seal away from the injector. Long-nosed pliers.
    2. Carefully cut and discard the lower fuel injector Teflon® seals. Cutting knife.
    3. Discard the specified component. Follow local disposal regulations.
      G08063318
  48. G08063319
  49. G08063320
  50. G08056167
  51. G08063322
  52. G08063323
  53. Discard the specified component. Follow local disposal regulations.
    G08056205
  54. G08063325
  55. NOTE: The fuel injection cam lobe must be positioned at zero lift before removing the fuel injection pump housing.

    Turn the component clockwise.

    G08063062
  56. G08063327
  57. G08063328
  58. G08063329
    1. Early build vehicles equipped with metal vacuum tubes.
    2. Late build vehicles equipped with nylon vacuum tubes.
      G08063330
  60. G08063001
  61. Discard the specified component. Follow local disposal regulations.
    G08063002
  62. NOTE: The VCT  solenoid seals should only be replaced if they are damaged upon inspection.

    Visual check. Discard the specified component. Follow local disposal regulations.

    Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer  ., 205-153 (T80T-4000-W) Handle  .

    G08063003
  63. 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.

    Clean the specified component with the specified material.

    Material  : Motorcraft® Metal Surface Prep/ZC-31-A

    G08063004
  64. G08028552
  65. G09599804
  66. Turn the crankshaft clockwise until the No. 1 piston is 45 degrees BTDC  using the guide holes on the engine front cover and the crankshaft pulley.
    G08063962
  67. G08063963
  68. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC  .
    G08063964
  69. NOTE: The Crankshaft TDC  Timing Peg will contact the crankshaft and prevent it from turning past TDC  . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC  position during the crankshaft pulley removal and installation.
    NOTE: The engine front cover is removed from graphic for clarity.

    Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC  .

    G08063965
  70. NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Tool cannot be installed, remove the TDC  Timing Peg and rotate the crankshaft three-fourths of a revolution clockwise and repeat the previous 2 steps of this procedure.

    Tighten the retainer.

    Install Special Service Tool: 303-1565 Alignment Tool, Camshaft  .

    G09599178
  71. NOTE: The crankshaft must remain in the TDC  position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Strap Wrench and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
    NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley.

    Discard the specified component. Follow local disposal regulations.

    Use the General Equipment: Strap Wrench

    G08063342
  72. NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur.

    If the diamond washer did not come off with the crankshaft pulley, remove the diamond washer.

    G08063032
  73. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

    Discard the specified component. Follow local disposal regulations.

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

    G08063050
  74. G08063345
  75. G08063054
  76. Loosen.
    G08062698
  77. Loosen.
    G08062699
    1. Using a small pick, release and hold the ratchet mechanism.
    2. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.
    3. Insert a holding pin into the hole to retain the tensioner.
      G08063068
  79. G08063069
  80. G08063070
  81. Discard the specified component. Follow local disposal regulations.
    G08062559
  82. NOTE: Washers are not required for installation of the VCT  units.

    If equipped, discard the washers.

    G08063209
  83. Remove Special Service Tool: 303-1565 Alignment Tool, Camshaft  .
    G09599178
  84. G08062407
  85. G08062708
  86. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
    NOTE: Note the location and orientation of each camshaft bearing cap and the position of the camshaft lobes on the No. 1 cylinder for installation reference.

    Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.

    G08063087
  87. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.
    G08063358
  88. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.

    Visual check.

    G08062416
  89. Discard the specified component. Follow local disposal regulations.
    G08063106
  90. Discard the specified component. Follow local disposal regulations.
    G08063107
  91. G08062714
  92. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the metal surface prep.
    NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.

    Clean the specified component with the specified material.

    Material  : Motorcraft® Metal Surface Prep/ZC-31-A

    G08063108
  94. G08063364
  95. 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.

    Plastic scraper.

    G08063133
  96. Discard the specified component. Follow local disposal regulations.
    G08063194
  97. Discard the specified component. Follow local disposal regulations.
    G08063159
  98. G08062718
  99. G08062719
  100. NOTE: The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur.

    Remove the diamond washer.

    G08063370
  101. G08063161
  102. G08063162
  103. Clean the specified component with the specified material.

    Material  : Motorcraft® Metal Surface Prep/ZC-31-A

    G08063163
  104. NOTE: Make sure the Crankshaft TDC  Timing Peg is still installed and the engine is still at TDC  .

    Visual check.

    G08063374
  105. NOTE: Mark the balance shaft assembly front shafts on the top for reference that the balance shaft assembly is at TDC  .

    Marker.

    G08063375
  106. NOTE: Due to the precision interior construction of the balance shaft assembly, it should not be disassembled.
    G08062967
  107. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC  .
    G08063964
    1. Visual check.
    2. Abrasive pad.
      G08062723
  109. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
    G08063379
  110. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    G08063380
  111. NOTE: Mark the position of the parts, so they can be installed in their original positions.

    Refer to: PISTON INSPECTION .

    G08063381
  112. Remove in the sequence shown in illustration below.
    G08063382
  113. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
    G08062727
  114. G08063384
  115. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
    NOTE: The center bulkhead has the thrust bearing.
    G08063385
  116. G08063386
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