Section 1034 (Engine - 3.5L GTDI): Disassembly: Engine
WARNING: This page is about a different car, the 2017 Lincoln Navigator and 2017 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.
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 Wipes ZC-31-B | - |
| Motorcraft ® Silicone Gasket Remover ZC-30-A | - |
| Motorcraft ® SAE 5W-30 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.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.
- 4.NOTE: This lift eye may have been installed on engines that did not come equipped with a factory lift eye.
Remove the bolts and the Right Front 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.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.
- 32.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.
- 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.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.
- 43.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 4 bolts, 7 stud bolts and remove the valve cover.
- 45.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 12 stud bolts and remove the valve cover.
- 47.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).
- 48.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).
- 49.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.
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)
- 56.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 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)
- 57.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 brushesNOTE: 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.
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)
- 58.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.
- 60.NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install the Camshaft Holding Tool.
- 62.NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install the Camshaft Holding Tool.
NOTE:
The following 3 steps are for primary timing chains that the colored links are not visible.
- 65.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.
- 69.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.
- 72.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.
- 73.NOTE: The VCT oil control solenoids are removed for clarity.
Install the Chain Tensioner Hold Down Tool.
- 78.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.
- 79.NOTE: The VCT oil control solenoids are removed for clarity.
Install the Chain Tensioner Hold Down Tool.
- 85.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.
- 86.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.
- 87.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.
- 90.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: 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: 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.
- 91.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.
Make sure that the mating faces of the cylinder head are clean and free of foreign material.
- 93.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.
- 95.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: 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.
- 96.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.
- 98.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.
- 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.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 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)
- 106.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.
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)
- 111.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.
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)
- 114.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.
- 115.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.
- 116.
Inspect the pistons. Refer to: Engine System General Information .
- 117.NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.
Remove and discard the bolts in the sequence shown.
- 118.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.
- 119.
Remove the lower crankshaft thrust washer from the back side of the No. 4 rear main bearing cap.
- 120.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.
- 121.NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
Remove the crankshaft.
- 123.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.
- 125.
Inspect the cylinder block distortion. Refer to: Engine System General Information .