Lincoln Aviator: Engine - 3.0L EcoBoost / Disassembly and Assembly of Subassemblies - Cylinder Head
Special Tool(s) /
General Equipment
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303-1249 Valve Spring Compressor TKIT-2006UF-FLM TKIT-2006UF-ROW |
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303-1418 Compressor, Valve Spring TKIT-2008ET-FLM TKIT-2008ET-ROW |
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303-1567 Sizer, Teflon Seal TKIT-2010C-FLM |
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303-300
(T87C-6565-A)
Set, Valve Spring Compressor TKIT-1988-FESTIVA T88C-1000-ST TKIT-1988-TRACER TKIT-2009TC-F |
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303-350
(T89P-6565-A)
Compressor, Valve Spring TKIT-1990-LMH TKIT-1989-F TKIT-1989-FM TKIT-1989-FLM |
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307-005
(T59L-100-B)
Slide Hammer |
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310-205 Fuel Injector Brush |
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310-206 Remover, Fuel Injector TKIT-2009A-FLM |
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310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM |
DISASSEMBLY
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 the oil pan, can cause engine failure.
NOTE:
If the components are to be reinstalled, they must be
installed in their original locations. Mark the components for
installation into their original locations.
LH cylinder heads
-
NOTE:
Do not reuse the CHT sensor, install a new sensor.
Remove and discard the CHT sensor.
All cylinder heads
-
Using the special tools, remove the keys, retainer and spring.
Use Special Service Tool: 303-300
(T87C-6565-A)
Set, Valve Spring Compressor.
, 303-350
(T89P-6565-A)
Compressor, Valve Spring.
, 303-1249
Valve Spring Compressor.
, 303-1418
Compressor, Valve Spring.
-
Remove and discard the valve stem seal.
-
Remove the valve from the cylinder head.
-
Repeat the previous steps for each of the remaining valves.
-
NOTE:
LH shown, RH similar.
Detach the wiring harness retainer.
-
NOTICE:
Pull out the fuel rails in the direction of the
fuel injector axis or damage may occur to the fuel injectors.
NOTE:
Use compressed air and remove any dirt or
foreign material from the cylinder head, and general surrounding area of
the fuel rail and injectors.
NOTE:
When removing the fuel rails, the fuel injectors
may remain in the cylinder heads and require the use of a Fuel Injector
Remover tool to extract. Wiggling the injector by hand to break it
loose may allow the injector to be removed by hand.
NOTE:
Should any of the fuel injectors remain in the
head, then the fuel injector electrical connectors will need to be
disconnected as the fuel rail is being removed.
NOTE:
LH shown, RH similar.
Remove the bolts and the fuel rails.
-
NOTE:
LH shown, RH similar.
Disconnect the fuel injector electrical connectors.
-
NOTE:
LH shown, RH similar.
Remove the fuel injectors from the fuel rail.
-
Remove and discard the fuel injector clips.
-
NOTICE:
Use minimal force to remove the fuel injectors
that remained in the cylinder head with the Fuel Injector Remover tool
or damage to the fuel injector assembly may occur. Wiggling the injector
by hand to break it loose may allow the injector to be removed by hand.
NOTE:
LH shown, RH similar.
Using the special tools, remove any of the fuel injectors that remained in the cylinder head.
Use Special Service Tool: 307-005
(T59L-100-B)
Slide Hammer.
, 310-206
Remover, Fuel Injector.
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-
-
Remove and discard the fuel injector O-ring seals.
-
NOTE:
Note the correct orientation of the fuel
injector support rings for correct installation of the NEW fuel injector
support rings.
Remove and discard the fuel injector support rings.
-
Inspect the inlet stopper, if it is damaged or
comes off then discard the inlet stopper. The inlet stopper is not
necessary for proper function. Ensure that any debris from the inlet
stopper are removed. If the inlet stopper is intact and undamaged do not
remove the inlet stopper from the fuel injector.
-
NOTICE:
Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.
NOTICE:
Do not attempt to cut the lower Teflon® seal
without first pulling it away from the fuel injector or damage to the
injector may occur.
-
Pull the lower Teflon® seal away from the injector.
-
Carefully cut and discard the lower fuel injector Teflon® seals.
-
NOTICE:
Make sure to thoroughly clean any residual fuel
or foreign material from the cylinder head, block and the general
surrounding area of the fuel rails and injectors.
NOTICE:
Do not use compressed air to clean the tip of the fuel injector.
NOTICE:
Do not use a brush to clean the tip of the fuel injector.
NOTE:
LH shown, RH similar.
Using the special tool, clean the cylinder head fuel injector bores.
Use Special Service Tool: 310-205
Fuel Injector Brush.
-
NOTICE:
If a spark plug is dropped, internal damage may
result and the spark plug must be discarded. The use of a damaged spark
plug may cause cylinder misfire resulting in engine damage.
Remove the spark plugs.
ASSEMBLY
All cylinder heads
-
NOTICE:
If a spark plug is dropped, internal damage may
result and the spark plug must be discarded. The use of a damaged spark
plug may cause cylinder misfire resulting in engine damage.
Install the spark plugs.
Torque:
133 lb.in (15 Nm)
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-
NOTICE:
Do not lubricate the new lower Teflon® fuel injector seals.
-
Install the Arbor on the fuel injector tips.
Use Special Service Tool: 310-207
Installer, Fuel Injector Seal Assembly.
-
NOTICE:
Once the Teflon® seal is installed on the
Teflon® Seal Guide, it should immediately be installed onto the fuel
injector to avoid excessive expansion of the Teflon® seal.
NOTE:
Make sure that new lower fuel injector Teflon® seals are installed.
Install the new Teflon® seals onto the Arbor,
using the Pusher Tool (part of the Fuel Injector Seal Installer), slide
the Teflon® seals along the Arbor.
-
Using the Pusher Tool, slide the Teflon® seals
off of the Teflon® Seal Guide and into the groove on the fuel injectors.
Use Special Service Tool: 310-207
Installer, Fuel Injector Seal Assembly.
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NOTE:
Make sure the Teflon® seal is fully seated in
the groove on the fuel injector before sizing the Teflon® seal.
-
Some Teflon® seal massaging with your fingers
before the Teflon® seal sizer tool is installed will aid in installing
the Teflon® seal sizer tool.
-
Position the Teflon® seal sizer tool with the
larger opening towards the Teflon® seal. Push while turning the Teflon®
seal sizer tool 180 degrees.
Use Special Service Tool: 303-1567
Sizer, Teflon Seal.
-
Once the Teflon® seal sizer tool is installed,
check and make sure the Teflon® seal is in the sizing portion of the
Teflon® seal sizer tool.
-
After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.
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-
NOTE:
Make sure that NEW fuel injector support rings and NEW fuel injector O-ring seals are installed.
-
Install the new fuel injector O-rings. The
O-rings are pre-lubricated, NO ADDITIONAL lubricant is required.
-
NOTICE:
The NEW the fuel injector support rings must
be installed in the correct orientation with the wide surface area
facing up against the fuel injector O-ring seals. Improperly installed
support rings may cause the fuel system to leak.
Install the NEW the fuel injector support rings.
-
Inspect the inlet stopper, if it is damaged or
comes off then discard the inlet stopper. The inlet stopper is not
needed for proper function. Ensure that any debris from the inlet
stopper are removed. If the inlet stopper is intact and undamaged do not
remove the inlet stopper from the fuel injector.
-
The upper side of the support ring has the wide surface area.
-
Fuel injector support ring.
-
The lower side of the support ring has the narrow surface area.
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NOTE:
Make sure that new fuel injector clips are installed.
Install the new the fuel injector clips.
-
NOTICE:
The FRP sensor must be replaced if it is removed from the fuel rail.
NOTE:
The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.
LH shown, RH similar.
Install the fuel injectors to the fuel rail.
-
NOTE:
LH shown, RH similar.
Connect the fuel injector electrical connectors.
-
NOTE:
Do not lubricate the new lower Teflon® fuel injector seals.
NOTE:
LH shown, RH similar.
Install the fuel rail, push down on the fuel rail
above the fuel injectors, apply an even force to ensure that the fuel
rail seats parallel to the cylinder head mounting bosses. Install the
bolts and hand tighten until snug.
Torque:
Stage 1:
Tighten the bolts one revolution at the
time, in the sequence shown, until all of the fuel rail mounting
brackets are seated flat on the cylinder head mounting bosses: :
1 turn(s)
Stage 2:
Tighten in the sequence shown to: :
18 lb.ft (24 Nm)
-
NOTE:
LH shown, RH similar.
Attach the wiring harness retainer.
-
NOTE:
Lubricate the new valve stem seal with clean engine oil.
Install the new valve stem seal.
Refer to: Specifications (303-01A Engine - 3.0L EcoBoost, Specifications).
-
NOTE:
Lubricate the valve stem with clean engine oil.
Install the valve into the cylinder head.
Refer to: Specifications (303-01A Engine - 3.0L EcoBoost, Specifications).
-
-
Using the special tools, install the spring, retainer and keys.
Use Special Service Tool: 303-300
(T87C-6565-A)
Set, Valve Spring Compressor.
, 303-350
(T89P-6565-A)
Compressor, Valve Spring.
, 303-1249
Valve Spring Compressor.
, 303-1418
Compressor, Valve Spring.
-
Repeat the previous steps for each of the remaining valves.
LH cylinder heads
-
NOTE:
Do not reuse the CHT sensor, install a new sensor.
Install a new CHT sensor.
Torque:
106 lb.in (12 Nm)
Special Tool(s) /
General Equipment
205-153
(T80T-4000-W)
Handle
303-1246Engine Spreader BarTKIT-2006UF-FLMTKIT-2006UF-ROW
303-1247VCT Spark Plug Tube Seal Remover and InstallerTKIT-2006UF-FLMTKIT-2006UF-ROW
303-1248Camshaft holding toolsTKIT-2006UF-FLMTKIT-2006UF-ROW
303-1634Lift Eyes (2)TKIT-2014D-ROW3TKIT-2014D-FL_ROW
303-1696Camshaft holding fixture
303-409
(T92C-6700-CH)
Remover, Crankshaft SealTKIT-1992-FH/FMH/FLMHTKIT-1993-LMH/MH
Floor Crane
Mounting Stand
Plastic Scraper
Flat-Bladed Screwdriver
Materials
Name
Specification
Motorcraft® Silicone Gasket RemoverZC-30-A
-
Motorcraft® Metal Surface Prep WipesZC-31-B
-
Motorcraft® Metal Brake Parts CleanerPM-4-A, PM-4-B
-
NOTICE:
During engine repair procedures, cleanliness is extremely
important...
DISASSEMBLY
NOTICE:
The RH and LH pistons are similar in appearance but differ
in design specifications. The pistons must be installed in the correct
cylinder bank or serious damage to the engine will occur...
Other information:
M..
Diagnostic Trouble Code (DTC) Chart
Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
Diagnostic Trouble Code Chart
Module
DTC
Description
Action
CCM
B142E:78
Forward Looking Sensor Horizontal Alignment: Alignment or Adjustment Incorrect
GO to Pinpoint Test C
CCM
B1433:54
Forward Looking Sensor Horizontal Alignment: Missing Calibration
GO to Pinpoint Test C
CCM
C1001:08
Vision System Camera: Bus Signal/Message Failure
GO to Pinpoint Test D
CCM
C1A67:96
Forward Looking Sensor: Component Internal Failure
GO to Pinpoint Test F
CCM
C1A67:97
Forward Looking Sensor: Component Or System Operation Obstructed Or Blocked
GO to Pinpoint Test G
CCM
U2100:00
Initial Configuration Not Complete: No Sub Type Information
GO to Pinpoint Test H
CCM
U2300:55
Central Configuration Not Complete: No Sub Type Information
GO to Pinpoint Test H
CCM
U3000:41
Control Module: General Checksum Failure
GO to Pinpoint Test I
CCM
U3000:42
Control Module: General Memory Failure
GO to Pinpoint Test I
CCM
U3000:44
Control Module: Data Memory Failure
GO to Pinpoint Test I
CCM
U3000:49
Control Module: Internal Electronic Failure
GO to Pinpoint Test I
CCM
U3002:62
Vehicle Identification Number: Signal Compare Failure
GO to Pinpoint Test J
CCM
U3003:16
Battery Voltage: Circuit Voltage Below Threshold
GO to Pinpoint Test K
CCM
U3003:17
Battery Voltage: Circuit Voltage Above Threshold
GO to Pinpoint Test L
IPMA
C1A67:08
Forward Looking Sensor: Bus Signal/Message Failure
GO to Pinpoint Test E
PCM
P0504:00
Brake Switch A / B Correlation: No Sub Type Information
GO to Pinpoint Test B
PCM
P0572:00
Brake Switch "A" Circuit Low: No Sub Type Information
GO to Pinpoint Test B
PCM
P0573:00
Brake Switch "A" Circuit High: No Sub Type Information
GO to Pinpoint Test B
PCM
P1703:00
Brake Switch Out Of Self - Test Range: No Sub Type Information
GO to Pinpoint Test B
PCM
P1935:00
Brake Switch/Sensor Signal: No Sub Type Information
GO to Pinpoint Test B
SIMA
P0564:11
Cruise Control Multi-Function Input "A" Circuit: Circuit Short To Ground
GO to Pinpoint Test A
SIMA
P0564:12
Cruise Control Mulit-Function Input "A" Circuit: Circuit Short To Battery
GO to Pinpoint Test A
SIMA
P0564:13
Cruise Control Mulit-Function Input "A" Circuit: Circuit Open
GO to Pinpoint Test A
SIMA
P0589:11
Cruise Control Multi-Function Input "B" Circuit: Circuit Short To Ground
GO to Pinpoint Test A
SIMA
P0589:12
Cruise Control Mulit-Function Input "B" Circuit: Circuit Short To Battery
GO to Pinpoint Test A
SIMA
P0589:13
Cruise Control Mulit-Function Input "B" Circuit: Circuit Open
GO to Pinpoint Test A
Global Customer Symptom Code (GCSC) Chart
Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices...