Ford Explorer Quiz
Powertrain

Disassembly - Engine

In this manual: Powertrain
General Information — 41Chassis — 173Powertrain — 250Electrical — 303Body and Paint — 331
148steps
~933min
5/5difficulty
9special tools
Done 0 of 148

Special Service Tools / General Equipment

205-153 (T80T-4000-W)
Handle
303-050 (T70P-6000)
Engine Lift Bracket
303-1685
Camshaft Alignment Tool
303-1687
VCT Solenoid Seal Installer
303-1689
Crankshaft Damper Holding Tool
303-409 (T92C-6700-CH)
Remover, Crankshaft Seal
TKIT-1992-FX/FMX/FLMX
TKIT-1993-LMX/MX
303-507
Timing Pin, Crankshaft TDC
TKIT-2001N-FLM
TKIT-2001N-RYAD
307-005 (T59L-100-B)
Slide Hammer
310-206
Puller, Fuel Injector
TKIT-2009A-FLM
Mounting Stand
Plastic Scraper
Hose Clamp Removal/Installation Tool

Materials

Name Specification
Motorcraft® Silicone Gasket Remover
ZK-30-A		 -
Motorcraft® Metal Surface Preparation Wipes
ZC-31-B		 -
Motorcraft® Brake Parts Cleaner
PM-4-A, PM-4-B		 -

Left Full-Time 4WD/Left Rear-Wheel Drive

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as specified in this procedure. The crankshaft pulley and crankshaft sprocket are not keyed to the crankshaft. The crankshaft, crankshaft sprocket and pulley are connected to each other by friction. For this reason the crankshaft sprocket can also come loose 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 with the special service tools, otherwise serious engine damage may occur.

NOTICE: 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 oil pan may cause engine failure.

NOTICE: Turbocharger compressor blades can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, make sure that no debris enters the system. Failure to do so may result in damage to the turbocharger.

    • Remove the bolts and the flexplate.
    • Discard the bolts.
  2. Install the engine on the engine stand.
    Use general equipment: Engine stand.
  3. Remove the engine lifting equipment.
  4. Remove the Special Service Tool: 303-050 (T70P-6000) Engine Lift Bracket.
  5. If equipped, disconnect the engine block heater electrical connector and disconnect the wire harness clips.
  6. Disconnect and remove the transmission vent tube.
  7. Cut and discard the A/C belt.
  8. Loosen the coolant pump pulley bolts.
    1. Install the tool and loosen the accessory drive belt tensioner tension.
    1. Remove the accessory drive belt.
    1. Release the tension and remove the tool.
    • Remove the ground bolt.
    • Disconnect the wiring harness electrical connectors.
    • Disconnect the wiring harness clips.
    • Remove the bolts and the left engine mount.
    • Discard the bolts.
    • Disconnect the wiring harness electrical connectors.
    • Disconnect the wiring harness clips.
    • Disconnect the wiring harness electrical connectors.
    • Disconnect the wiring harness clips.
    • Disconnect the wiring harness electrical connectors.
    • Disconnect the wiring harness clips.
    • Disconnect the wiring harness electrical connectors.
    • Disconnect the wiring harness clips.
    • Disconnect the wiring harness electrical connectors.
    • Disconnect the wiring harness clips.
  17. Disconnect the wire harness clips and remove the engine wire harness.
    • Disconnect the coolant hose bracket and remove the nut.
    • Remove the bolts and the thermostat housing.
    • Disconnect the coolant hose clip.
    • Release the clamps and remove the coolant hose.
      Use common shop equipment: hose clamp removal/installation tool.
  20. Remove the bolt and set the turbocharger coolant tube aside.
  21. Remove and discard the turbocharger coolant tube O-ring.
    1. Remove the bolt from the coolant tube support bracket.
    1. Remove the bolt and the coolant tube support bracket.
    1. Remove the nut from the EGR valve bracket.
    1. Remove the bolt and the EGR valve bracket.
  24. Remove the bolts and the coolant tube.
  25. Inspect the coolant tube O-ring. Replace if damaged.
  26. Remove the bolt, nuts and EGR valve.
  27. Remove and discard the EGR valve O-ring.
  28. Remove and discard the EGR valve gasket.
  29. Remove the bolt, stud and EGR cooler bracket.
  30. Remove the bolts and the EGR cooler.
  31. Remove and discard the EGR cooler gaskets.
  32. Remove the bolts and the coolant tube.
  33. Discard the coolant tube O-ring.
    • Loosen the clamps and remove the EGR sensor hoses.
      Use common shop equipment: hose clamp removal/installation tool.
    • Remove the stud and the EGR sensor assembly.
  35. Remove the nuts, bolts and the Exhaust Gas Recirculation (EGR) intake pipe assembly.
  36. Remove and discard the EGR tube assembly gasket.
  37. Remove the bolts and the air cleaner bracket.
  38. Remove the coolant pump bolts and pulley.
  39. Remove the bolts and the accessory drive belt tensioner.
  40. Remove the studs and the generator.
  41. Remove the studs, the bolt and the air conditioning (A/C) compressor.
  42. Remove the bolts and the A/C bracket.
    • Remove the nut, bolts and the right engine mount.
    • Discard the nut and bolts.

left rear

  1. Remove the right-hand engine mount bracket.

Left Full-Time 4WD

  1. Remove the bolts and the left axle connector.
  2. Remove and discard the axle connector seal.
  3. Remove the bolts and the front axle assembly.
  4. Remove and discard the front axle assembly seal.

Left Full-Time 4WD/Left Rear-Wheel Drive

    • Disconnect the fuel rail wiring harness electrical connector from the intake manifold.
    • Disconnect and separate the KS electrical connectors.
    • Disconnect the crankcase ventilation oil separator quick-connect coupling from the intake manifold.
      Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 2.3 L EcoBoost (201 kW/273 L hp), General Procedures).
    • Remove the bolts and the intake manifold.
    • If equipped, remove the bolt and the oil cooler.
    • If equipped, discard the oil cooler.
  4. Remove the bolts and the oil filter adapter assembly.
    • Remove and discard the engine mount stud.
    • Remove the transmission bolt.
  6. Release the clamps and remove the coolant hose.
    Use common shop equipment: hose clamp removal/installation tool.
  7. Disconnect the crankcase ventilation oil separator tube and remove it.
    Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 2.3 L EcoBoost (201 kW/273 L hp), General Procedures).
  8. Remove the bolts and the KS.
  9. Remove the bolts and the crankcase ventilation separator.
  10. Remove the bolts and the coolant pump adapter assembly.
  11. Remove and discard the coolant pump adapter assembly gasket.
    • Remove the high-pressure fuel line bolts.
    • Loosen the flare nuts, then remove and discard the high-pressure fuel line.
    • Remove and discard the bolts.
    • Remove the high-pressure fuel pump.
  14. Remove and discard the high-pressure fuel pump O-ring.
  15. Remove the high-pressure fuel pump tappet.
  16. Remove the coolant hose attaching bolt.
  17. Remove and discard the bolts and the oil return tube from the turbocharger to the cylinder block.
  18. Remove the nuts, the bolt and the heat shield.
  19. Remove the bolts and the oil supply tube from the cylinder block to the turbocharger.
  20. Remove and discard the oil supply filter and the O-rings.
  21. Remove the bolt and the coolant outlet tube.
  22. Remove and discard the coolant outlet tube O-ring.
  23. Remove the nuts and the turbocharger.
  24. Remove and discard the coolant outlet tube seal and the O-ring.
    • Remove and discard the gasket.
    • Inspect and replace the studs if damaged.
  26. Remove the studs, bolts and the coolant pipe.
    • Remove the spark plug studs and the spark plug coil.
    • Remove the oil level indicator.
  28. Loosen the fasteners and remove the valve cover.
  29. Discard the valve cover gaskets.
    • Inspect the VCT seals for damage.
    • If damaged, using the special service tools, remove and discard the VCT oil control solenoid seals.
      Use the special service tool: 303-1687 Installer, VCT Solenoid Seal, and 205-153 (T80T-4000-H) Handle.
  31. Clean the valve cover.

  32. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools leave scratches and gouges that create leak paths.

    Make sure the mating surfaces are clean and free of foreign material.
    • Disconnect the fuel rail harness electrical connectors.
    • Disconnect the fuel rail wiring harness retainers and remove the harness.
  34. Remove the fuel rail insulator.

  35. NOTICE: Pull the fuel rails straight off along the injector axis, otherwise the fuel injectors may be damaged.

    Remove and discard the bolts, then remove the fuel rail.
  36. Remove all fuel injectors remaining in the fuel rail.
  37. Remove all fuel injectors remaining in the cylinder head.
    Use the special service tools: 307-005 (T59L-100-B) Slide Hammer, and 310-206 Puller, Fuel Injector.
  38. Remove and discard the fuel injector clamp.

  39. NOTICE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector, otherwise damage to the injector may occur.

    1. Pull the lower Teflon seal away from the injector.
    1. Carefully cut and discard the lower fuel injector Teflon seals.
  40. Remove and discard the fuel injector seal and the O-ring.
    • Remove the CHT sensor and the heat shield.
    • Discard the CHT sensor.
  42. Remove the bolts and the CKP sensor.
  43. Rotate the crankshaft clockwise until the No. 1 piston is 45 degrees before TDC, using the access holes in the front engine cover and the crankshaft pulley.
  44. Remove the engine plug bolt.
  45. Install the special service tool: 303-507 Timing Pin, Crankshaft TDC.
  46. Rotate the crankshaft clockwise until it contacts the special tool.
    Use the special service tool: 303-507 Timing Pin, Crankshaft TDC.
  47. Remove the bolts and the high-pressure fuel pump drive assembly.

  48. NOTICE: The camshaft alignment tool is for alignment only. Using this tool to prevent engine rotation may result in engine damage.

    Install the special service tool: 303-1685 Camshaft Timing Tool.

  49. NOTICE: The crankshaft must remain at the TDC position while removing the pulley bolt or engine damage may occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt must be removed with an impact wrench (1/2 inch drive minimum).

    • Using the special tools, remove the crankshaft pulley bolt and pulley.
      Use the special service tool: 303-1689 Holding Tool, Crankshaft Damper.
    • Discard the bolt.
  50. Install the original crankshaft pulley bolt and washer.

  51. NOTICE: Take care not to damage the front engine cover or the crankshaft when removing the seal.

    Using the crankshaft seal puller, remove the front crankshaft seal and discard it.
    Use the special service tool: 303-409 (T92C-6700-CH) Puller, Crankshaft Seal.
  52. Remove the original crankshaft pulley bolt and washer.
  53. Remove the bolts and the front engine cover.

  54. NOTICE: Use only a 3M™ Roloc® bristle disc (2 in, white, part number 07528) in a suitable rotary tool at the recommended speed of 15,000 rpm to clean the front engine cover. Do not use metal scrapers, wire brushes or any other aggressive abrasive disc for cleaning. These tools cause scratches and gouges that create leak paths.

    • Make sure the mating surfaces of the front engine cover are clean and free of foreign material.
      Refer to: RTV Sealant Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
      Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
      Material: Motorcraft® Metal Surface Preparation Wipes / ZS-31-B
    • Thoroughly wash the front engine cover to remove foreign material, including any abrasive particles generated during the cleaning process.

  55. NOTICE: Place clean, lint-free shop towels over the open engine cavities. Carefully remove the towels to prevent foreign material from falling into the engine. Any foreign material (including any material generated during gasket surface cleaning) that enters the oil galleries or oil pan may cause engine failure.

    NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or the 3M™ Roloc® Bristle Disk (white, 2 inch, part number 07528) to clean sealing surfaces. These tools cause scratches and gouges that create leak paths. They also generate contamination that will cause premature engine failure. Remove all traces of gasket material.

    Make sure the mating surfaces of the cylinder block and oil pan are clean and free of foreign material.
    Refer to: RTV Sealant Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
    Use common shop 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 Preparation Wipes / ZS-31-B

  56. NOTICE: Use an open-end wrench on the camshaft flats to prevent the component from rotating.

    Loosen the exhaust VCT bolt.

  57. NOTICE: Use an open-end wrench on the camshaft flats to prevent the component from rotating.

    Loosen the intake VCT bolt.
  58. Remove the bolts and the timing chain tensioner.
  59. Remove the bolts and remove the timing chain guide, timing chain and tensioner lever.
    • Remove the bolts and the VCT units.
    • Discard the bolts.
  61. Special Service Tool Removal: 303-1685 Camshaft Alignment Tool.
  62. Remove the bolts and the VCT oil control solenoids.
  63. Remove the bolts and the front camshaft bearing cap.

  64. NOTICE: Failure to follow the camshaft loosening procedure may damage the camshafts.

    • Loosen the camshaft bearing caps sequentially by 2 turns each, one at a time, until all tension is released from the camshaft bearing caps. Remove the camshaft bearing caps and the camshafts.
    • Inspect the camshaft bores for scratches that can be felt with a finger.
  65. Remove the valve lifters.
  66. Inspect the valve lifters.
  67. If equipped, remove the heater core.
  68. Remove the bolts, stud and cylinder head cover assembly.
  69. Remove and discard the cylinder head cover gasket.
    • Remove the bolts and the cylinder head.
    • Discard the bolts.
  71. Remove and discard the cylinder head gasket.
  72. Remove the cylinder block plugs.

  73. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools leave scratches and gouges that create leak paths. Use a plastic scraper to remove all traces of the cylinder head gasket.

    Clean the cylinder head sealing surfaces.

  74. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools leave scratches and gouges that create leak paths. Use a plastic scraper to remove all traces of the cylinder head gasket.

    Clean the cylinder block sealing surfaces.
    • Check the cylinder block for distortion.
      Refer to: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures).
    • Check the cylinder head for distortion.
      Refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).

  76. NOTICE: Do not strike the oil pan on the side to remove it. The oil pan is secured with dowels and will damage the oil pan and engine block.

    Remove the bolts and the oil pan.
  77. Remove the bolts, oil pump pick-up tube and screen.
  78. Discard the oil pump pick-up tube and screen O-ring.

  79. NOTICE: Do not use wire brushes, mechanical abrasive discs or 3M™ Roloc® bristle disc (white, 2 inch, part number 07528) to clean the cylinder block sealing surfaces. These tools cause scratches and gouges that create leak paths. They also cause contamination that leads to premature engine failure. Remove all traces of gasket.

    Make sure that the cylinder block mating surfaces are clean and free of foreign material.
    Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
    Use 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 Preparation Pads / ZS-31-B

  80. NOTICE: Use only a 3M™ Roloc® bristle disc (2 inch, white, part number 07528) in a suitable rotary tool at the recommended speed of 15,000 rpm to clean the oil pan. Do not use metal scrapers, wire brushes or any other aggressive abrasive disc for cleaning. These cause scratches and gouges that create leak paths.

    • Make sure that the oil pan mating surfaces are clean and free of foreign material.
      Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
      Use 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 Preparation Pads / ZS-31-B
    • Thoroughly clean the oil pan to remove all foreign material, including any abrasive particles generated during the cleaning process.
    • Remove the bolts and the rear crankshaft seal.
    • Discard the rear crankshaft seal.
  82. Remove the crankshaft sprocket.
  83. Rotate the crankshaft until it contacts the special tool.
  84. Mark the balance shaft module.
  85. Remove the bolts and the oil outlet tube.
  86. Inspect the outlet oil tube O-rings and replace if damaged.
    1. Remove the bolt securing the oil supply tube to the bracket.
    1. Remove the bolt and the oil supply tube bracket.
    1. Remove the bolts and the oil supply tube.
  88. Inspect the inlet oil tube O-rings and replace if damaged.
  89. Remove the bolts and the balance shaft assembly.
  90. Remove the special service tool: 303-507 Camshaft/Crankshaft TDC Pin.
    1. Inspect the ridge.
    1. Clean with an abrasive pad.
  92. Remove the bolts and the connecting rod caps.

  93. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

    Remove the pistons.
  94. Remove the connecting rod bearings.
    Refer to: Engine (Engine 303-01A - 2.3 L EcoBoost (201 kW/273 L PS), Disassembly).
  95. Remove the bolts and the main bearing beam.
  96. Remove the main bearing beam bearings.
  97. Remove the crankshaft.
  98. Remove the crankshaft main bearings.
  99. Remove the bolts and the engine piston oil cooler valves.
  100. If necessary, remove and discard the front cylinder block plug.
  101. If necessary, remove and discard the rear cylinder block plug.

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