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Home›Repair guides›Service procedure for WSG1068 Sec. 02-B Engine.pdf

Ford — Service procedure for WSG1068 Sec. 02-B Engine.pdf

A Ford service procedure — check it applies to your exact model before use.

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Procedure

  1. CAUTION: Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant. Failure to follow this procedure can cause future oil leakage. • Use silicone gasket and sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE- M4G323-A6. NOTE: Sealant must be removed and area cleaned with solvent if above instructions are not followed. • Use metal surface cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE- M5B292-A.
  2. Using the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter, install the crankshaft rear oil seal.
  3. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer and the Rear Crankshaft Seal Replacer to install the rear main seal slinger.
  4. Install the flywheel; refer to Flywheel in this section.
  5. Connect the battery ground cable. !
  6. Disconnect the battery ground cable (14301). Remove the flywheel (6375); refer to Flywheel in this section.
  7. Use the Rear Crankshaft Slinger Remover and the Impact Slide Hammer to remove the crankshaft oil slinger (6310). Special Service Tools called for by the procedures can be obtained by calling: 1-800-ROTUNDA (1-800-768-8632).
  8. Use the Rear Crankshaft Seal Remover and the Impact Slide Hammer to remove the crankshaft rear oil seal (6701).
  9. Remove the oil pan; refer to Oil Pan in this section.
  10. Remove the crankcase bolts and the crankshaft rear oil seal retainer plate. Crankshaft Rear Oil Seal (with retainer plate) - Installation
  11. CAUTION: Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant. Failure to follow this procedure can cause future oil leakage. • Use silicone gasket and sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE- M4G323-A6. NOTE: Sealant must be removed and area cleaned with solvent if above instructions are not followed. • Use metal surface cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE- M5B292-A.
  12. Apply a bead of silicone around the rear oil seal retainer sealing surface. • Use Silicone Gasket and Sealant F6AZ-19562-A or equivalent meeting Ford specification WSE- M4G323-A6. !
  13. NOTE: If the rear main oil seal is still in place and being reinstalled, be sure the lip is not folded over or wrinkled during the retainer plate installation. The seal lip must start squarely on the crankshaft journal. Position the crankshaft rear oil seal and retainer (6K301), install the bolts. Then install the oil pan and the two bolts. Tighten in two stages. • Stage 1: Tighten retainer plate bolts to 8-12 Nm (71-107 lb/in). • Stage 2: Tighten oil pan bolts to 14-20 Nm 10-15 lb/ft) then tighten an additional 90°.
  14. Use the Rear Crankshaft Seal Replacer and Rear Crankshaft Seal Adapter to install the crankshaft rear oil seal.
  15. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer and Rear Crankshaft Seal Replacer to install the crankshaft oil slinger.
  16. Install the flywheel; refer to Flywheel in this section.
  17. Connect the battery ground cable.
  18. Disconnect the battery ground cable (14301).
  19. Remove the intake manifold (9424); refer to Intake Manifold – Variable Resonance Induction System (VRIS) in this section.
  20. Remove the radiator upper and lower radiator supports (16138).
  21. Remove the radiator (8005), fan shroud (8146) and engine cooling fan.
  22. Remove the drive belt (8620); refer to Section 05. Engine - Removal Special Service Tools called for by the procedures can be obtained by calling: 1-800-ROTUNDA (1-800-768-8632).
  23. Remove exhaust pipe nuts.
  24. Drain engine oil and remove the oil bypass filter (6714).
  25. Remove the starter motor (11002); refer to Section
  26. 6. At the oil cooler water inlet, disconnect and set aside the lower radiator hose (8286).
  27. Disconnect the engine harness.
  28. Remove the engine from the equipment.
  29. Install the Modular Lifting Bar.
  30. Remove the engine support insulator nuts.
  31. Remove the bolts, and remove the flywheel.
  32. Use the Rear Crankshaft Slinger Remover and the Impact Slide Hammer to remove the crankshaft oil slinger (6310).
  33. Use the Rear Crankshaft Seal Remover and the Impact Slide Hammer to remove the crankshaft rear oil seal (6701).
  34. Remove the bolts and remove the crankshaft rear oil seal retainer plate.
  35. Mount the engine on an engine stand.
  36. Remove the Modular Lifting Bar.
  37. With the engine on the engine stand, remove the engine wiring harness. Special Service Tools called for by the procedures can be obtained by calling: 1-800-ROTUNDA (1-800-768-8632).
  38. Remove the two bolts and nut retaining the oil pump screen cover and tube (6622) and remove the oil pump screen cover and tube.
  39. Remove the bolts, the oil pan (6675), and the oil pan gasket (6710).
  40. NOTE: The bolts are a part of the valve cover (6582) and are not to be removed. LH is shown; RH is similar. • Fully loosen the sixteen bolts, and remove the valve cover gasket (6584).
  41. Remove the drive belt.
  42. Remove the water pump pulley (8509).
  43. Remove the four bolts.
  44. Remove the water pump pulley.
  45. Remove the four bolts from the water pump.
  46. Remove the (A) water pump (8501) from the (B) cylinder block (6010).
  47. Remove the crankshaft pulley bolt (6A340). Use the Crankshaft Damper Remover to remove the crankshaft pulley (6312).
  48. Use the (A) Front Cover Seal Remover to remove the (B) crankshaft front seal (6700).
  49. Remove the engine front cover fasteners.
  50. Remove the engine front cover (6019) from the front cover to cylinder block dowels (6C002).
  51. Remove the crankshaft sensor ring from the crankshaft (6303).
  52. Remove the balancing shaft bearing caps.
  53. Remove balancing shaft.
  54. CAUTION: Unless otherwise instructed, at no time when the timing chains (6268) are removed and the cylinder heads (6049) are installed is the crankshaft or camshaft (6250) to be rotated. Severe piston (6108) and valve damage will occur. Position the crankshaft with the Crankshaft Holding Tool as shown.
  55. Install the Camshaft Holding Tools on the camshafts (2). !
  56. Remove the bolts and the timing chain tensioners (6L266). Remove the timing chain tensioner arms (6L253) from the dowel pins.
  57. CAUTION: Unless otherwise instructed, at no time when the timing chain are removed and the cylin
  58. Remove the timing chain guides (6K297). • Remove the bolts. • Remove the timing chain guides.
  59. Remove the ten nuts, the LH exhaust manifold and the exhaust manifold gaskets. Discard the exhaust manifold gasket.
  60. Remove the ten nuts and the RH exhaust manifold (9430) and exhaust manifold gasket (9448). Discard the exhaust manifold gasket.
  61. Remove the oil level dipstick, the bolt and the oil level indicator tube (6754).
  62. Install the Lifting Handles on both ends of the cylinder head.
  63. CAUTION: These bolts must be replaced with new bolts. They are tighten-to-yield designed and cannot be reused. Remove the bolts, cylinder head, and head gasket. • Discard the head gasket (6051), cylinder head bolts and clean the engine block surface. • LH is shown; RH is similar. !
  64. Use silicone gasket and sealant F6AZ-19562-AA equivalent meeting Ford specification WSE-M4G323- A6. NOTE: Sealant must be removed and area cleaned with solvent if above instructions are not followed. • Use metal surface cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE- M5B292-A.
  65. Remove the bolts and remove the engine mounts.
  66. Remove the bolts and nut retaining the oil filter adapter (6881) to the cylinder block. Remove the oil filter adapter and clean the gasket surface.
  67. Remove the bolts and the oil pump (6600).
  68. Remove the twelve bolts and the two lower crankshaft bearing supports.
  69. CAUTION: Make sure connecting rods (6200) and rod caps are numbered, to keep in proper orientation. Remove the bolts and the connecting rod caps. • Rotate the crankshaft so that the connecting rod is at bottom dead center. • Remove the bolts and discard them. !
  70. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod. Remove the piston and rod assembly. • Use the Connecting Rod Guide Tools to guide the piston and rod assembly out of the cylinder.
  71. Repeat the previous steps until all ten piston and rod assemblies have been removed from the cylinder block. !
  72. Remove the main bearing cap dowel pins.
  73. Remove the main bearing bolts and discard the bolts.
  74. Remove and discard the twelve cross-mounted bolts.
  75. Remove the crankshaft and the crankshaft main bearings from the cylinder block.
  76. Remove the main bearing caps, the lower crankshaft main bearings (6333) and the thrust washer.
  77. Remove the Camshaft Holding Tool from the camshaft (6250). Cylinder Head - Disassembly Special Tool(s) Special Service Tools called for by the procedures can be obtained by calling: 1-800-ROTUNDA (1-800-768-8632).

Source: manual:WSG1068 Sec. 02-B Engine.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.