Lincoln Aviator: Engine - 3.0L EcoBoost / Disassembly and Assembly of Subassemblies - Cylinder Head

Special Tool(s) / General Equipment

	303-1249 Valve Spring Compressor TKIT-2006UF-FLM TKIT-2006UF-ROW
	303-1418 Compressor, Valve Spring TKIT-2008ET-FLM TKIT-2008ET-ROW
	303-1567 Sizer, Teflon Seal TKIT-2010C-FLM
	303-300 (T87C-6565-A) Set, Valve Spring Compressor TKIT-1988-FESTIVA T88C-1000-ST TKIT-1988-TRACER TKIT-2009TC-F
	303-350 (T89P-6565-A) Compressor, Valve Spring TKIT-1990-LMH TKIT-1989-F TKIT-1989-FM TKIT-1989-FLM
	307-005 (T59L-100-B) Slide Hammer
	310-205 Fuel Injector Brush
	310-206 Remover, Fuel Injector TKIT-2009A-FLM
	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

1. NOTE: Do not reuse the CHT sensor, install a new sensor.

   Remove and discard the CHT sensor.
   

All cylinder heads

1. 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.

1. Remove and discard the valve stem seal.
   

1. Remove the valve from the cylinder head.
   
   • Repeat the previous steps for each of the remaining valves.
     

1. NOTE: LH shown, RH similar.

   Detach the wiring harness retainer.
   

1. 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.
   

1. NOTE: LH shown, RH similar.

   Disconnect the fuel injector electrical connectors.
   

1. NOTE: LH shown, RH similar.

   Remove the fuel injectors from the fuel rail.
   

1. Remove and discard the fuel injector clips.
   

1. 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.

1. 1. Remove and discard the fuel injector O-ring seals.
      

   2. 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.
      
   3. 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.
      

1. 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.

   1. Pull the lower Teflon® seal away from the injector.
      
   2. Carefully cut and discard the lower fuel injector Teflon® seals.
      

1. 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.

1. 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

1. 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)

1. NOTICE: Do not lubricate the new lower Teflon® fuel injector seals.

   1. Install the Arbor on the fuel injector tips.
      Use Special Service Tool: 310-207  Installer, Fuel Injector Seal Assembly.

   2. 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.
      
   3. 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.

1. NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.

   1. Some Teflon® seal massaging with your fingers before the Teflon® seal sizer tool is installed will aid in installing the Teflon® seal sizer tool.
      
   2. 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.
   3. 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.
      
   4. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.
      

1. NOTE: Make sure that NEW fuel injector support rings and NEW fuel injector O-ring seals are installed.

   1. Install the new fuel injector O-rings. The O-rings are pre-lubricated, NO ADDITIONAL lubricant is required.
      

   2. 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.
      
   3. 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.
      
   4. The upper side of the support ring has the wide surface area.
      
   5. Fuel injector support ring.
      
   6. The lower side of the support ring has the narrow surface area.
      

1. NOTE: Make sure that new fuel injector clips are installed.

   Install the new the fuel injector clips.
   

1. 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.
   

1. NOTE: LH shown, RH similar.

   Connect the fuel injector electrical connectors.
   

1. 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)

1. NOTE: LH shown, RH similar.

   Attach the wiring harness retainer.
   

1. 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).
   

1. 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).
   

1. • 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

1. NOTE: Do not reuse the CHT sensor, install a new sensor.

   Install a new CHT sensor.
   Torque: 106 lb.in (12 Nm)