Section 3 (Engine - 3.5L GTDI): Disassembly: Engine
WARNING: This page is about a different variant/trim than selected.
Special Tool(s)
| 3 Jaw Puller 303-D121 or equivalent | |
| Handle 205-153 (T80T-4000-W) | |
| 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) | |
| Tool, Camshaft Holding 303-1248 |
General Equipment
| 3/8" Spring Lock Coupling Disconnect Tool |
| Engine Stand |
| Hexagonal Screwdriver |
| Hose Clamp Remover/Installer |
| Lock Pin |
| Spreader Bar |
| Strap Wrench |
| Three Leg Puller |
Material
| Item | Specification |
| Motorcraft ® Metal Surface Prep ZC-31-B | - |
| Motorcraft ® Silicone Gasket Remover ZC-30-A | - |
WARNING:
Before beginning any service procedure in this article, refer to Safety Warnings in SERVICE INFORMATION
.
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:
Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.
NOTE:
A clean working environment is essential to prevent dirt or foreign material contamination into the fuel rails.
NOTE:
Refer to the exploded view under the Assembly procedure in this article.
- 3.
Install the General Equipment: Engine Stand.
NOTE:
Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.
- 5.
If equipped, disconnect the block heater electrical connector.- Remove the block heater wiring harness from the engine.
- 7.
Disconnect the LH turbocharger bypass valve electrical connector and turbocharger bypass valve hose.
- 8.
Remove the turbocharger wastegate regulating valve hoses from the RH CAC tube and turbocharger wastegate regulating valve.- Disconnect the turbocharger wastegate regulating valve electrical connector.
NOTE:
Index-mark the hoses for installation.
- 9.
Disconnect the RH turbocharger bypass valve electrical connector and turbocharger bypass valve hose.
- 10.
Loosen the clamp and remove the LH turbocharger intake tube from the LH turbocharger.
NOTE:
Index-mark the CAC tube position for reference during installation.
- 11.
Remove the nut from the RH valve cover stud bolt and remove the RH turbocharger intake tube.
NOTE:
The compression limiter bushing may fall out of the mounting bracket grommet on the turbocharger intake tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.
- 12.
Loosen the clamp and remove the RH CAC tube from the RH turbocharger.
NOTE:
Index-mark the CAC tube position for reference during installation.
- 13.
Remove the RH CAC tube nut from the intake manifold and remove the RH CAC tube and turbocharger intake tube as an assembly.
NOTE:
The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.
- 15.
Disconnect the 2 quick connect couplings and remove the PCV tube. REFER to Fuel System General Information .
- 16.
Remove the noise insulator shield for the fuel injection pump and remove the oil level indicator.
- 17.
Disconnect the Throttle Position (TP) sensor, electronic TB, LH Variable Camshaft Timing (VCT) solenoid and the 3 ignition coil-on-plugs electrical connectors.- Detach all the wiring harness retainers from the LH valve cover and stud bolts.
- 21.
Disconnect the Engine Oil Pressure (EOP) switch electrical connector.- Detach the EOP wiring harness retainer from the engine block.
- 26.
Disconnect the Manifold Absolute Pressure (MAP) /Intake Air Temperature 2 (IAT2) sensor electrical connector.- Detach and disconnect the 2 fuel injector wiring harness electrical connectors and the 2 wiring harness retainers.
- 27.
Remove the coolant tube and remove the fuel tube-to-engine front cover bracket bolt and position the fuel tube aside.
- 28.
Disconnect the 2 turbocharger coolant hoses from the intake manifold and disconnect the CMP sensor electrical connector.- Detach the wiring harness retainer.
- 29.
Disconnect the RH VCT solenoid and the 3 ignition coil-on-plug electrical connectors.- Detach all the wiring harness retainers.
- 30.
Remove the 2 bolts and the 2 ground wire from the RH cylinder head and the battery wiring harness.- Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
- 32.
Disconnect the LH CMP sensor electrical connector and remove the coolant tube retainer nut.- Detach the 2 wiring harness retainers.
- 34.
Remove the 12 bolts and the intake manifold.- Clean and inspect all sealing surfaces.
NOTE:
Note the routing of the 2 fuel rail wiring harnesses for installation.
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.
- 39.
Remove the 3 banjo bolts and the LH turbocharger coolant tubes and oil tube.- Disconnect the turbocharger wastegate regulating valve hose from the LH turbocharger assembly.
- 46.
Remove the 8 LH exhaust manifold nuts and the exhaust manifold and turbocharger as an assembly.- Discard the nuts.
- Clean and inspect the LH exhaust manifold. REFER to Engine System General Information .
- 47.
Remove the 8 LH exhaust manifold studs and exhaust manifold gasket.- Discard the studs and gasket.
- Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
NOTE:
Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.
- 50.
Disconnect the CKP sensor electrical connector and remove the stud bolt and the engine wiring harness.
- 56.
Remove the 3 banjo bolts and the RH turbocharger coolant tubes and oil tube.- Disconnect the turbocharger wastegate regulating valve hose from the RH turbocharger assembly.
- 62.
Remove the 8 nuts and the RH exhaust manifold and turbocharger as an assembly.- Discard the nuts.
- Clean and inspect the RH exhaust manifold. REFER to Engine System General Information .
- 63.
Remove and the 8 RH studs and exhaust manifold gasket.- Discard the studs and gasket.
- Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
NOTE:
Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.
- 67.
Remove the RH cylinder block drain plug or, if equipped, the block heater.- Allow coolant to drain from the cylinder block.
- 68.
Remove the nut for from the LH valve cover stud bolt and remove the high pressure fuel tube flare nuts from the fuel injection pump and fuel rail.- Discard the tube and nut.
NOTE:
To release the fuel pressure in the high pressure fuel tube, wrap the flare nut with a shop towel to absorb any residual fuel pressure during the loosening of the flare nut.
- 73.
Inspect the fuel injection pump roller tappet. FUEL CHARGING AND CONTROLS - 3.5L TI-VCT .
- 74.
Carefully cut and remove the fuel rail wire harness tie straps and disconnect the Fuel Rail Pressure (FRP) sensor electrical connector.
NOTE:
Use compressed air to remove any dirt or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.
NOTE:
It is very important to note the routing of the wiring harness on the fuel rails and index-mark the locations of the tie straps prior to removal or damage may occur to the wire harnesses during installation. The illustration details the correct wire harness routing and tie strap positioning for installation.
- 75.
Remove the 6 bolts and the LH fuel rail.- Discard the bolts.
NOTE:
When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain lodged in the cylinder heads and require the use of a Fuel Injector Remover to extract.
NOTE:
Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
- 77.
Disconnect the 6 fuel injector electrical connectors and remove the 2 fuel injector wire harnesses.
NOTE:
RH shown, LH similar.
- 80.
Special Tool(s): Slide Hammer 307-005 (T59L-100-B) and Remover, Fuel Injector 310-206. Remove any fuel injectors that did not come out with the fuel rail.
- 81.
Remove the 3 bolts and the 3 RH ignition coils-on-plugs.
NOTE:
When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
- 82.
Remove the 3 bolts and the 3 LH ignition coils-on-plugs.
NOTE:
When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
- 83.
Loosen the bolt and the 10 stud bolts. Remove the LH valve cover.- Discard the gasket.
NOTE:
When removing the valve cover do not apply excessive force to the VCT oil control solenoid. If the VCT solenoid seal sticks to the VCT oil control solenoid carefully wiggle the valve cover until the seal breaks free. After the valve cover is removed, inspect and replace the VCT solenoid if damaged.
- 85.
Loosen the 5 bolts and the 6 stud bolts. Remove the RH valve cover.- Discard the gasket.
NOTE:
When removing the valve cover do not apply excessive force to the VCT oil control solenoid. If the VCT solenoid seal sticks to the VCT oil control solenoid carefully wiggle the valve cover until the seal breaks free. After the valve cover is removed, inspect and replace the VCT solenoid if damaged.
- 87.
Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged.- Special Tool(s): Remover, VCT Spark Plug Tube Seal 303-1247/1 and Handle 205-153 (T80T-4000-W).
NOTE:
VCT solenoid seal removal shown, spark plug tube seal removal similar.
- 89.
Using a three leg puller, remove the crankshaft pulley.
NOTE:
Use a three leg puller (such as Matco Tools ® MST9740D, or equivalent).
- 93.
Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover.- Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.
- Remove the engine front cover.
- Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.
- 94.
Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown.
- 95.
Install the Special Tool(s): Tool, Camshaft Holding 303-1248.
NOTE:
The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.
- 96.
Install the Special Tool(s): Tool, Camshaft Holding 303-1248.
NOTE:
The Camshaft Holding Tool will hold the camshafts in the TDC position.
NOTE:
The following 3 steps are for primary timing chains when the colored links are not visible.
- 99.
Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown.
- 100.
Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown.
- 101.
Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown.
NOTE:
The crankshaft sprocket timing mark should be between the 2 colored links.
- 108.
Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
- 109.
Remove the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt.- Discard the bolts.
- Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
NOTE:
The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
- 111.
Remove the Special Tool(s): Tool, Camshaft Holding 303-1248.
NOTE:
When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.
- 112.
Verify the LH camshafts are in the neutral position.
NOTE:
The camshafts must remain in the neutral position during removal or engine damage may occur.
- 114.
Remove the bolts and the LH camshaft bearing caps.- Remove the LH camshafts.
NOTE:
Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
- 115.
Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
- 116.
Remove the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt. Discard the specified component. Follow local disposal regulations.- Discard the bolts.
- Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
NOTE:
The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
- 118.
Rotate the RH camshafts counterclockwise to the neutral position.
NOTE:
The camshafts must remain in the neutral position during removal or engine damage may occur.
- 121.
Remove the bolts and the RH camshaft bearing caps.- Remove the RH camshafts.
NOTE:
Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
- 122.
Remove the 24 valve tappets from the cylinder heads.
NOTE:
LH shown, RH 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.
- 123.
Inspect the valve tappets. REFER to Engine System General Information .
- 125.
Remove the 8 bolts from each cylinder head.- Discard the bolts.
- Remove the cylinder heads.
NOTE:
LH shown, RH similar.
NOTE:
The cylinder head bolts must be discarded and new bolts must be installed. They are a torque-to-yield design and cannot be reused.
NOTE:
Aluminum surfaces are soft and may be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
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.
- 126.
Remove the cylinder head gasket from each cylinder head and discard.
NOTE:
LH shown, RH similar.
- 127.
Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence.- 1.
Remove any large deposits of silicone or gasket material with a plastic scraper.
- 2.
Apply silicone gasket remover, following package directions, and allow to set for several minutes.
- 3.
Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
- 4.
Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
- 1.
NOTE:
If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
NOTE:
Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
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.
- 128.
Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. REFER to Engine System General Information .
- 138.
Remove the 8 bolts and the crankshaft rear seal retainer plate.- Discard the plate and seal assembly.
- 139.
Clean the engine front cover and oil pan using a 3M™ Roloc ® Bristle Disk (2 inch, white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 RPM.- Thoroughly wash the engine front cover and oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.
NOTE:
Only use a 3M™ Roloc ® Bristle Disk (2-in white, part number 07528) to clean the engine front cover and oil pan. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover and oil pan. These tools cause scratches and gouges that make leak paths.
- 140.
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 or equivalent, following manufacturer's instructions.
- 141.
Remove the bolts in the sequence shown.- Discard the bolts.
- Remove the main bearing cap support brace.
NOTE:
The main bearing cap support brace bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
- 142.
Remove the 12 connecting rod cap bolts and 6 cap.
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.
- 143.
Remove the piston/rod assembly from the engine block.
NOTE:
Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
- 145.
Remove the 8 main bearing cap side bolts and the 8 main bearing cap bolts in the sequence shown.- Discard the bolts.
NOTE:
Clearly mark the position and orientation of the main bearing caps for reassembly.
NOTE:
The 8 main bearing cap side bolts and the 8 main bearing cap bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
- 146.
Remove the 4 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.
- 147.
Remove the lower crankshaft thrust washer from the back side of the No. 4 rear main bearing cap.
- 148.
Remove the 4 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.
- 149.
Remove the crankshaft.
NOTE:
Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
- 151.
Remove the 4 crankshaft main bearings from the cylinder block.
NOTE:
If the main bearings are being reused, mark them for correct position and orientation for reassembly.
- 153.
Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. REFER to Engine System General Information .
- 154.
Clean the sealing surfaces of the cylinder block in the following sequence.- 1.
Remove any large deposits of silicone or gasket material.
- 2.
Apply silicone gasket remover and allow to set for several minutes.
- 3.
Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
- 4.
Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
- 5.
Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
- 1.
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.
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.