Engine - 3.0L ECOBOOST: Disassembly: Engine

For information on Ford Color Coded Illustrations refer to OEM Color Coding .

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	303-1246 Engine Spreader Bar TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1248 Camshaft holding tools TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1634 Lift Eyes (2) TKIT-2014D-ROW3 TKIT-2014D-FL_ROW
Courtesy of FORD MOTOR COMPANY	303-1696 Cam Comb Tool Study
Courtesy of FORD MOTOR COMPANY	303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH
Floor Crane
Mounting Stand
Plastic Scraper
Flat-Bladed Screwdriver

Materials 

1. Remove the bolts and the flexplate.

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2. Remove the crankshaft sensor ring.

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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.

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4. Remove the nut and the heat shield.

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5. 1. Disconnect the CKP sensor electrical connector.
   2. Remove the stud bolt and the CKP sensor.

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6. Remove the bolts and the crankshaft rear seal and retainer plate.
   • Discard the crankshaft rear seal and retainer plate.

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7. 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: Motorcraft® Metal Brake Parts cleaner / PM-4-A, PM-4-B

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

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8. 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

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9. • Remove the bolts and the LH engine mount.
   • Discard the bolts.

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10. Remove the bolts and the front axle disconnect actuator.

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11. Remove and discard the seal.

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12. • Remove and discard the nuts and bolts.
    • Remove the RH engine mount.

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13. Remove and discard the studs.

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14. Remove the bolts and the front axle assembly.

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15. Remove and discard the front axle assembly seal.

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16. Remove the oil level indicator.

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17. • Detach the fuel tube retainer.
    • Disconnect the quick release coupling and remove the fuel tube assembly. Refer to: QUICK RELEASE COUPLING - 3.0L
    • Disconnect the quick release coupling and remove the EVAP tube. Refer to: QUICK RELEASE COUPLING - 3.0L

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18. Remove the bolts and the A/C compressor.

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19. Remove the bolts and the air cleaner outlet pipe.

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20. Inspect the O-ring seal and replace as necessary.

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21. • Detach the wiring harness retainer.
    • Remove the bolt.
    • Loosen the clamp and remove the CAC inlet pipe.

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22. Disconnect the quick release couplings and remove the crankcase vent tube. Refer to: QUICK RELEASE COUPLING - 3.0L

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23. • Remove the stud bolt and the ground wire.
    • Slide the wiring harness insulator up.
    • Disconnect the CHT electrical connector.

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24. • Disconnect the wiring harness electrical connectors.
    • Detach the wiring harness retainers.

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25. • Disconnect the wiring harness electrical connectors.
    • Detach the wiring harness retainers.

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26. • Remove the stud bolt and the ground wire from the rear of the RH cylinder head.
    • Detach the wiring harness retainer.

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27. • Disconnect the wiring harness electrical connectors.
    • Detach the wiring harness retainers.

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28. • Disconnect the wiring harness electrical connectors.
    • Detach the wiring harness retainers.
    • Remove the wiring harness from the engine.

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29. • Release the clamp and disconnect the vacuum hose.
    • Detach the vacuum harness retainer.
    • Disconnect the vacuum harness quick release coupling. Refer to: QUICK RELEASE COUPLING - 3.0L

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30. • Remove the bolts.
    • Detach the vacuum harness retainers.
    • Remove the vacuum harness from the engine.

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31. Remove the bolts and the coolant pipe.

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32. Inspect the O-ring seal and replace as necessary.

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33. Loosen the bolts and remove the intake manifold.

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34. • Remove the insulator.
    • Remove and inspect the gaskets, replace as necessary.

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35. 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 fuel tube flare nut fittings.
    • Remove the nuts.
    • Remove and discard the fuel tube.

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

    Remove the nuts and the high-pressure fuel pump.

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37. Remove and discard the high-pressure fuel pump O-ring seal.

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38. Remove the high-pressure fuel pump tappet.

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39. 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.

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40. If damaged, remove and discard the studs.

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41. Remove the fasteners and the TC oil return tube.

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42. Remove and discard the TC oil return tube tube-to-engine block gasket.

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43. Remove and discard the TC oil return tube O-ring seal.

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44. NOTE: Inspect for blockage in the turbocharger tube. Check the tube, the sealing surfaces and the flange for flatness and damage. Ensure that the retaining bracket is not bent, check for square-ness of the retaining bracket to the O-ring area. Use brake cleaner and a NYLON brush to clean. DO NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.

    Clean and inspect the TC oil return tube.

    Material: Motorcraft® Metal Brake Parts cleaner / PM-4-A, PM-4-B

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45. Remove the TC coolant return tube bolt.

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46. • Remove the TC oil supply tube bolt.
    • Remove the TC coolant supply tube bolt.

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47. Remove the fasteners and the TC.

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48. • Remove and discard the TC oil supply tube filter and O-ring seals.
    • Remove and discard the TC coolant supply tube O-ring seal.

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49. NOTE: Inspect the turbocharger tubes and the sealing surfaces. Ensure that the retaining brackets are not bent, check for square-ness of the retaining brackets to the O-ring areas. Use brake cleaner and a NYLON brush to clean. DO NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.
    • Clean and inspect the TC oil supply tube.

      Material: Motorcraft® Metal Brake Parts cleaner / PM-4-A, PM-4-B

    • Clean and inspect the TC coolant supply tube.

      Material: Motorcraft® Metal Brake Parts cleaner / PM-4-A, PM-4-B

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50. • Remove and discard the TC gasket.
    • If damaged, remove and discard the TC stud(s).

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51. • Remove the bolt.
    • Release the clamp and remove the TC coolant return tube.

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52. Remove and discard the O-ring seals.

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53. NOTE: Inspect the turbocharger tube and the sealing surfaces. Ensure that the retaining bracket is not bent, check for square-ness of the retaining brackets to the O-ring area. Use brake cleaner and a NYLON brush to clean. DO NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.

    Clean and inspect the TC coolant return tube fitting.

    Material: Motorcraft® Metal Brake Parts cleaner / PM-4-A, PM-4-B

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54. Remove the fasteners and the vacuum pump.

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55. • Remove the bolt.
    • Release the clamp and remove the TC coolant return tube.

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56. Remove and discard the O-ring seal.

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57. • Loosen the fuel tube flare nut fittings.
    • Remove and discard the fuel tube

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58. Remove the bolts and the oil cooler.

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59. Inspect the oil cooler. If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may cause engine failure. Refer to: Engine .

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60. Remove and discard the oil cooler gasket.

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61. • Remove the bolts and the coolant pump pulley.
    • Remove the bolt and the idler pulley.
    • Remove the bolt and the idler pulley.

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62. Remove the bolts and the coolant pump.

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63. Remove and discard the coolant pump gasket and seal.

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

    Remove the stud bolts and the LH ignition coil-on-plugs.

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

    Remove the stud bolts and the RH ignition coil-on-plugs.

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66. Remove the nuts and the bracket.

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67. Loosen the fasteners and remove the valve cover.

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68. 1. Remove and discard the gaskets.
    2. Clean the valve cover gasket groove with soap and water or a suitable solvent.

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69. 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.

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70. Loosen the fasteners and remove the valve cover.

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71. 1. Remove and discard the gaskets.
    2. Clean the valve cover gasket groove with soap and water or a suitable solvent.

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72. 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.

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73. Remove the crankshaft pulley bolt.

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74. NOTE: Use a universal puller (such as an OTC 6667, or equivalent).

    Using a universal puller, remove the crankshaft pulley.

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75. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
    1. Install the crankshaft pulley bolt.
    2. Using the special tool, remove and discard the crankshaft front oil seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.
    3. NOTE: Retain the original crankshaft pulley bolt for turning the crankshaft while the pulley is removed.

       Remove the crankshaft pulley bolt.

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76. Remove the bolts and the oil pan.

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77. Remove and discard the oil pan gasket.

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78. 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.

    Make sure that the mating faces of the engine block and engine front cover are clean and free of foreign material.

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79. NOTE: There are 5 different types of fasteners, note location of each fastener for assembly.

    Remove the engine front cover fasteners.

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80. 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

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81. Remove and discard the engine front cover gaskets.

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82. Remove and discard the oil gallery seal (6G068).

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83. 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: Motorcraft® Metal Brake Parts cleaner / PM-4-A, PM-4-B

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

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84. 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: Motorcraft® Metal Brake Parts cleaner / PM-4-A, PM-4-B

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

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85. NOTE: Rotate the crankshaft utilizing only the original crankshaft pulley bolt. Failure to follow this direction may cause damage to the crankshaft and result in engine failure.

    Install the original crankshaft pulley bolt.

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86. 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. Rotate the crankshaft clockwise.
    2. Position the crankshaft sprocket keyway at the 11 o'clock position.
    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).

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87. Remove the bolts and the RH timing chain tensioner.

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88. Remove the RH timing chain tensioner arm.

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89. Remove the bolts and the RH timing chain guide.

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90. Remove the RH timing chain.

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91. NOTE: The crankshaft must be rotated clockwise one revolution (360 degrees). Failure to do so will result in incorrect camshaft timing.
    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. Rotate the crankshaft clockwise one revolution (360 degrees).
    2. Position the crankshaft sprocket keyway at the 11 o'clock position.
    3. The circle  timing marks on the VCT units will be at the 10 o'clock (intake) and 12:30 (exhaust) positions.

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92. Remove the original crankshaft pulley bolt.

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93. Remove the timing chain sprocket.

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94. Remove the bolts and the splash shield.

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95. Slide the oil pump drive belt off of the crankshaft sprocket and remove the belt.

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96. Remove the crankshaft sprocket.

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97. Remove the bolts and the LH timing chain tensioner.

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98. Remove the LH timing chain tensioner arm.

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99. Remove the bolts and the LH timing chain guide.

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100. Remove the LH timing chain.

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101. Remove the timing chain sprocket.

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102. • Remove the bolts and the oil return tube,
     • Remove the bolt and the oil control solenoid.

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103. Remove and discard the O-ring seals.

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104. Remove the bolts and the oil pump.

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105. 1. Install Special Service Tool: 303-1696 Cam Comb Tool Study.
     2. Remove and discard the VCT unit bolts.
     3. Remove the VCT units.
     4. Remove Special Service Tool: 303-1696 Cam Comb Tool Study.

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106. 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.

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107. Remove the bolts and the camshaft bearing caps.

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108. Remove the intake and exhaust camshafts.

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109. 1. Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
     2. Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
     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.

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110. • Remove and discard the cylinder head bolts.
     • Remove the cylinder head.

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111. Remove and discard the cylinder head gasket.

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112. • Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
     • Refer to: Cylinder Head Distortion .
     • Refer to: Cylinder Block Distortion .

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113. 1. Install Special Service Tool: 303-1248 Camshaft holding tools.
     2. Remove and discard the VCT unit bolts.
     3. Remove the VCT units.
     4. Remove Special Service Tool: 303-1248 Camshaft holding tools.

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114. 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.

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115. Remove the bolts and the camshaft bearing caps.

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116. Remove the intake and exhaust camshafts.

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117. 1. Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
     2. Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
     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.

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118. • Remove and discard the cylinder head bolts.
     • Remove the cylinder head.

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119. Remove and discard the cylinder head gasket.

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120. • Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
     • Refer to: Cylinder Head Distortion .
     • Refer to: Cylinder Block Distortion .

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121. 1. Detach the wiring harness retainer from the stud bolt
     2. Remove the stud bolt, the nuts and the coolant outlet connector pipe.

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122. Remove and discard the coolant outlet connector pipe gasket.

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123. 1. Disconnect the ECT sensor electrical connector.
     2. Remove the bolts and the KS assembly.

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

     Remove and discard the ECT sensor.

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125. Remove the engine block skirt stiffener bolts.

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126. Using a suitable pry bar at the pry pad locations, release the engine block skirt stiffener-to-engine block seal.

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127. • Remove the engine block skirt stiffener.
     • Remove and discard the oil seal.

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128. 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: Motorcraft® Metal Brake Parts cleaner / PM-4-A, PM-4-B

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

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129. • 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.

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130. Remove the bolts and the main bearing cap support braces.

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131. Remove the bolts and the connecting rod cap.

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132. 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.

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133. • Remove the connecting rod bearings.
     • Disassemble and inspect the pistons. Refer to: Piston . Refer to: Piston Inspection .

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134. Remove and discard the main bearing cap bolts.

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135. 1. Remove the main bearing caps.
     2. Remove the lower thrust washer.
     3. Remove the lower main bearings.

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136. 1. Remove the crankshaft.
     2. Remove the lower main bearings.
     3. Remove the lower thrust bearing.

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137. Remove the bolts and the piston cooling jets from the cylinder block.

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