Engine - 3.5L GTDI: Disassembly: Engine
Special Tool(s)
| Bar, Engine Spreader 303-1454 | |
| 3 Jaw Puller 303-D121 | |
| Brush, Fuel Injector 310-205 | |
| Handle 205-153 (T80T-4000-W) | |
| 2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent | |
| Hold Down, Secondary Chain 303-1530 | |
| Installer, Differential Bearing Cone 205-142 (T80T-4000-J) | |
| Installer, Spindle Bearing 205-150 (T80T-4000-S) | |
| Lift Eye, Right Front 303-1529 | |
| Remover, Fuel Injector 310-206 | |
| Remover, Oil Seal 303-409 (T92C-6700CH) | |
| Remover, VCT Spark Plug Tube Seal 303-1247/1 | |
| Slide Hammer 307-005 (T59L-100-B) | |
| Strap Wrench 303-D055 (D85L-6000-A) | |
| Tool, Camshaft Holding 303-1248 |
General Equipment
| Plastic Scraper |
Material
| Item | Specification |
| Motorcraft ® High Performance Engine RTV Silicone TA-357 | WSE-M4G323-A6 |
| Motorcraft ® Metal Surface Prep ZC-31-B | - |
| Motorcraft ® Silicone Gasket Remover ZC-30-A | - |
| Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft ® SAE 5W-30 Super Premium Motor Oil (Canada) XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada) | WSS-M2C946-A |
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, may cause engine failure.
NOTE:
Refer to: the exploded view under the Assembly procedure.
- 3.
Mount the engine to the mounting stand.
NOTE:
Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.
- 4.
Remove the bolts and the Right Front Lift Eye.
NOTE:
This lift eye may have been installed on engines that did not come equipped with a factory lift eye.
- 6.
Remove the bolts and the LH engine support insulator-to-cylinder block bracket.- Discard the bolts.
- 8.
- Disconnect the vacuum hoses from the turbochargers.
- Disconnect the electrical connector from the vacuum solenoid.
- Detach the vacuum hose retainers from the valve covers.
- 18.
- Remove and discard the bolt.
- Loosen the flare nuts and remove and discard the high-pressure fuel tube.
- 19.
Loosen the fitting and separate the RH turbocharger coolant supply tube and fitting from the cylinder head.
- 20.
- 1.
Remove the oil return tube bolt.
- 2.
Remove the coolant/oil tube assembly bolt.
- 3.
Remove the bolts and the RH turbocharger.
- 1.
- 22.
Loosen the fitting and separate the LH turbocharger coolant supply tube and fitting from the cylinder head.
- 23.
- 1.
Remove the oil return tube bolt.
- 2.
Remove the coolant/oil tube assembly bolt.
- 3.
Remove the bolts and the LH turbocharger.
- 1.
- 26.
- Remove the bolt and the oil cooler.
- Discard the oil cooler.
NOTE:
If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may cause engine failure.
- 32.
Inspect the gasket and the oil tube filter screen. Replace the gasket if necessary.
NOTE:
Make sure the oil tube filter screen is free of contaminants prior to installation.
- 33.
- Disconnect the CHT sensor electrical connector and wiring harness retainer.
- Remove the stud bolt and the ground wire.
- 34.
- Disconnect the KS electrical connector.
- Disconnect the fuel pressure sensor electrical connector.
- Disconnect the RH and LH fuel charge harness electrical connectors.
- 35.
- Disconnect the CMP sensor electrical connectors.
- Remove the nut and detach the wiring harness retainer.
- Remove the stud bolt and the ground wire.
- 38.
- Disconnect the CKP sensor electrical connector.
- Remove the bolt, the CKP sensor electrical connector and position the wiring harness aside.
- 39.
- Remove the oil level indicator.
- Disconnect the VCT sensor electrical connectors.
- Disconnect the coil-on-plug electrical connectors.
- Detach the wiring harness retainers.
- 40.
- 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.
- 41.
- Remove the bolts and the ignition coil-on-plugs.
- Remove the bolts and the CMP sensors.
NOTE:
When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
- 43.
Loosen the 4 bolts, 7 stud bolts and remove the valve cover.
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.
NOTE:
While removing the valve cover do not apply excessive force to the VCT oil control solenoid or damage may occur.
- 45.
Loosen the 12 stud bolts and remove the valve cover.
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.
NOTE:
While removing the valve cover do not apply excessive force to the VCT oil control solenoid or damage may occur.
- 47.
Using the special tools, remove and discard the seal(s).
NOTE:
Inspect the VCT solenoid seals. Remove any damaged seals.
NOTE:
RH shown, LH similar.
- 48.
Using the special tools, remove and discard the seal(s).
NOTE:
Inspect the spark plug tube seals. Remove any damaged seals.
NOTE:
RH shown, LH similar.
- 49.
Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation in Engine System General Information .- 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)
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.
- 56.
Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation in Engine System General Information .- 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)
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.
- 57.
Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation in Engine System General Information .- 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)
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.
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. Do not use wire brushes
- 58.
Rotate the crankshaft clockwise and align the timing marks on the intake VCT units as shown.
NOTE:
Rotate the crankshaft in a clockwise direction only.
- 60.
Install the Camshaft Holding Tool.
NOTE:
The Camshaft Holding Tool will hold the camshafts in the TDC position.
- 62.
Install the Camshaft Holding Tool.
NOTE:
The Camshaft Holding Tool will hold the camshafts in the TDC position.
NOTE:
The following 3 steps are for primary timing chains that the colored links are not visible.
- 65.
Mark the timing chain links that aligns with the timing mark on the crankshaft sprocket as shown.
NOTE:
The crankshaft sprocket timing mark should be between the colored links.
- 69.
Remove the bolts and the VCT oil control solenoids.
NOTE:
Keep the VCT oil control solenoid clean of dirt and debris.
NOTE:
A slight twisting motion will aid in the removal of the VCT oil control solenoids.
NOTE:
Removal of the VCT oil control solenoid will aid in the removal of the timing chain.
- 72.
Remove the bolt and the upper LH timing chain guide.
NOTE:
Do not use power tools to remove the bolt or damage to the LH primary timing chain guide may occur.
- 73.
Install the Chain Tensioner Hold Down Tool.
NOTE:
The VCT oil control solenoids are removed for clarity.
- 78.
Remove the bolts, camshaft caps and the camshafts.
NOTE:
Mark the exhaust and intake camshafts for installation into their original locations.
NOTE:
Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
- 79.
Install the Chain Tensioner Hold Down Tool.
NOTE:
The VCT oil control solenoids are removed for clarity.
- 85.
Remove the bolts, camshaft caps and the camshafts.
NOTE:
Mark the exhaust and intake camshafts for installation into their original locations.
NOTE:
Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
- 86.
Remove the bolt and the RH timing chain guide.
NOTE:
Do not use power tools to remove the bolt or damage to the RH primary timing chain guide may occur.
- 87.
Remove the valve tappets from the cylinder heads.
NOTE:
RH shown, LH similar.
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.
- 90.
- Remove and discard the bolts from the cylinder head.
- Remove the cylinder head.
NOTE:
The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
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:
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.
- 91.
Make sure that the mating faces of the cylinder head are clean and free of foreign material.
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.
- 93.
Make sure that the mating faces of the engine block are clean and free of foreign material.
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:
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.
- 95.
- Remove and discard the bolts from the cylinder head.
- Remove the cylinder head.
NOTE:
The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
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.
- 96.
Make sure that the mating faces of the cylinder head are clean and free of foreign material.
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.
- 98.
Make sure that the mating faces of the engine block are clean and free of foreign material.
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:
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.
- 99.
Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion. Refer to: Engine System General Information .
- 104.
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.
- 105.
Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation in Engine System General Information .- 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)
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.
- 106.
Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation in Engine System General Information .- 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)
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.
- 111.
Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation in Engine System General Information .- 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)
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.
- 114.
Remove the connecting rod cap bolts and caps.
NOTE:
Clearly mark the position and orientation of the connecting rods, connecting rod caps and connecting rod bearings for reassembly.
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.
- 115.
Remove the piston/rod assembly from the engine block.
NOTE:
Do not scratch the cylinder walls or crankshaft journals with the connecting rod while removing the pistons.
- 116.
Inspect the pistons. Refer to: Engine System General Information .
- 117.
Remove and discard the bolts in the sequence shown.
NOTE:
Clearly mark the position and orientation of the main bearing caps for reassembly.
- 118.
Remove the main bearing caps.
NOTE:
Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.
NOTE:
If the main bearings are being reused, mark them for correct position and orientation for reassembly.
- 119.
Remove the lower crankshaft thrust washer from the back side of the No. 4 rear main bearing cap.
- 120.
Remove the crankshaft main bearings from the main bearing caps.
NOTE:
If the main bearings are being reused, mark them for correct position and orientation for reassembly.
- 121.
Remove the crankshaft.
NOTE:
Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
- 123.
Remove the crankshaft main bearings from the cylinder block.
NOTE:
If the main bearings are being reused, mark them for correct position and orientation for reassembly.
- 125.
Inspect the cylinder block distortion. Refer to: Engine System General Information .