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Section 249 (Engine - 3.0L (4V)): Disassembly: Engine

WARNING: This page is about a different car, the 2005 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
ENGINE DISASSEMBLY SPECIAL TOOL CHART

G03984234
 3-Jaw Puller 303-D121
G03889585
 Strap Wrench 303-D055 (D85L-6000-A)
G03898751
 Remover, Oil Seal 303-409 (T92C-6700-CH)
G03990108
 Slide Hammer 307-005 (T59L-100-B)
G03886718
 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
  1. For additional information, refer to the exploded views under the engine assembly procedure in this article .
  2. Remove the 8 bolts and the flexplate.
    Fig 1: Removing Bolts And Flexplate
    G03995979Courtesy of FORD MOTOR CO.
  3. Detach the RH heated oxygen sensor (HO2S) wiring harness retainers from the spacer plate and the oil pan.
    Fig 2: Locating RH Heated Oxygen Sensor (HO2S) Wiring Harness Connector
    G03995980Courtesy of FORD MOTOR CO.
  4. Remove the spacer plate.
    Fig 3: Identifying Spacer Plate
    G03995981Courtesy of FORD MOTOR CO.
  5. Using the special tools, remove the crankshaft rear seal.
    Fig 4: Removing Crankshaft Rear Seal
    G03995982Courtesy of FORD MOTOR CO.
  6. Mount the engine on an engine stand.
  7. Disconnect the main engine vacuum harness from the fuel pressure sensor.
    Fig 5: Disconnecting Main Engine Vacuum Harness From Fuel Pressure Sensor
    G03995983Courtesy of FORD MOTOR CO.
  8. Disconnect the fuel vapor tube from the upper intake manifold, detach the retainer and remove the tube.
    Fig 6: Disconnecting Fuel Vapor Tube From Upper Intake Manifold
    G03995984Courtesy of FORD MOTOR CO.
  9. Remove the 2 bolts, the nut and the upper intake manifold support bracket.
    • Detach the wiring harness retainer from the bracket.
    Fig 7: Detaching Wiring Harness Retainer From Bracket
    G03995985Courtesy of FORD MOTOR CO.
  10. Remove the bolt and the RH accessory drive belt idler pulley.
    Fig 8: Removing Bolt And RH Accessory Drive Belt Idler Pulley
    G03995986Courtesy of FORD MOTOR CO.
  11. Remove the bolt and the LH accessory drive belt idler pulley.
    Fig 9: Removing Bolt And LH Accessory Drive Belt Idler Pulley
    G03995987Courtesy of FORD MOTOR CO.
  12. Remove the coolant bypass hose.
    Fig 10: Removing Coolant Bypass Hose
    G03995988Courtesy of FORD MOTOR CO.
  13. Remove the 2 stud bolts, the bolt and the coolant pump.
    Fig 11: Removing Stud Bolts, Bolt And Coolant Pump
    G03995989Courtesy of FORD MOTOR CO.
  14. Disconnect the 2 throttle body electrical connectors.
    Fig 12: Disconnecting Throttle Body Electrical Connectors
    G03995990Courtesy of FORD MOTOR CO.
  15. Disconnect the 2 intake manifold tuning (IMT) valve electrical connectors.
    Fig 13: Disconnecting Intake Manifold Tuning (IMT) Valve Electrical Connectors
    G03995991Courtesy of FORD MOTOR CO.
  16. Remove the RH upper intake manifold support bracket bolt.
    Fig 14: Removing RH Upper Intake Manifold Support Bracket Bolt
    G03995992Courtesy of FORD MOTOR CO.
  17. Remove the 2 nuts and the LH engine appearance cover bracket.
    Fig 15: Removing Nuts And LH Engine Appearance Cover Bracket
    G03995993Courtesy of FORD MOTOR CO.
  18. Remove the 6 bolts and the upper intake manifold.
    Fig 16: Removing Bolts And Upper Intake Manifold
    G03995994Courtesy of FORD MOTOR CO.
  19. Disconnect the fuel charging wiring harness connector.
    Fig 17: Locating Fuel Charging Wiring Harness Connector
    G03995995Courtesy of FORD MOTOR CO.
  20. Disconnect the 6 ignition coil electrical connectors.
    Fig 18: Disconnecting Ignition Coil Electrical Connectors
    G03995996Courtesy of FORD MOTOR CO.
  21. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 19: Locating Cylinder Head Temperature Sensor Electrical Connector
    G03995997Courtesy of FORD MOTOR CO.
    22. NOTE: LH is shown, RH is similar.
    Fig 20: Disconnecting LH And RH Camshaft Position Sensor Electrical Connectors
    G03995998Courtesy of FORD MOTOR CO.
  22. Disconnect the LH and RH camshaft position (CMP) sensor electrical connectors.
  23. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 21: Disconnecting Crankshaft Position Sensor Electrical Connector
    G03995999Courtesy of FORD MOTOR CO.
  24. Disconnect the oil pressure switch and oil temperature sensor electrical connectors.
    • Detach the 3 wiring harness retainers.
    Fig 22: Detaching Wiring Harness Retainers
    G03996000Courtesy of FORD MOTOR CO.
  25. Detach the 3 wiring harness retainers from the LH valve cover stud bolts.
    Fig 23: Detaching Wiring Harness Retainers From LH Valve Cover Stud Bolts
    G03996001Courtesy of FORD MOTOR CO.
  26. Disconnect the generator electrical connector and detach the 2 wiring harness retainers.
    Fig 24: Disconnecting Generator Electrical Connector And Detach 2 Wiring Harness Retainers
    G03996002Courtesy of FORD MOTOR CO.
  27. Detach the wiring harness retainers from the RH upper intake manifold support bracket.
    Fig 25: Locating Wiring Harness Retainers At Upper Intake Manifold Support Bracket
    G03996003Courtesy of FORD MOTOR CO.
  28. Detach the 2 wiring harness retainers from the RH valve cover stud bolts.
    Fig 26: Detaching Wiring Harness Retainers From RH Valve Cover Stud Bolts
    G03996004Courtesy of FORD MOTOR CO.
  29. Remove the 2 bolts and detach the radio ignition interference capacitors.
    Fig 27: Identifying Radio Ignition Interference Capacitors And Bolts
    G03996005Courtesy of FORD MOTOR CO.
  30. Disconnect the knock sensor (KS) electrical connector and detach the retainer.
    Fig 28: Disconnecting Knock Sensor (KS) Electrical Connector And Detach Retainer
    G03996006Courtesy of FORD MOTOR CO.
  31. Remove the nut and detach the LH HO2S bracket.
    • Detach the wiring retainer from the LH engine mount bracket.
    Fig 29: Detaching Identifying Wiring Retainer From LH Engine Mount Bracket
    G03996007Courtesy of FORD MOTOR CO.
  32. Remove the 4 wiring conduit nuts and the main engine wiring harness.
    Fig 30: Identifying Main Engine Wiring Harness Nuts
    G03996008Courtesy of FORD MOTOR CO.
  33. Remove the 3 bolts and the LH exhaust manifold heat shield.
    Fig 31: Removing Bolts And LH Exhaust Manifold Heat Shield
    G03996009Courtesy of FORD MOTOR CO.
  34. Remove the 6 nuts and the LH exhaust manifold.
    • Discard the nuts.
    • Remove and discard the gasket.
    Fig 32: Removing Nuts And LH Exhaust Manifold
    G03929084Courtesy of FORD MOTOR CO.
  35. Clean and inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  36. Remove the 6 LH exhaust manifold studs and discard.
  37. Remove the stud bolt and the oil level indicator and tube.
    • Remove and discard the O-ring seal.
    Fig 33: Discarding O-Ring Seal
    G03996011Courtesy of FORD MOTOR CO.
  38. Remove the 3 bolts and the A/C compressor bracket.
    Fig 34: Removing Bolts And A/C Compressor Bracket
    G03996012Courtesy of FORD MOTOR CO.
  39. Using the special tool to hold the crankshaft pulley, remove and discard the bolt and washer.
    Fig 35: Removing And Discard Bolt And Washer
    G03995763Courtesy of FORD MOTOR CO.
    40. CAUTION: The special tool must grab the inside of the damper or damage to the damper can occur.
    Fig 36: Removing Crankshaft Pulley
    G03995764Courtesy of FORD MOTOR CO.
  40. Using the special tool, remove the crankshaft pulley.
    41. CAUTION: Use care not to scratch the crankshaft surface while removing the seal.
    Fig 37: Discarding Crankshaft Front Seal
    G03995770Courtesy of FORD MOTOR CO.
  41. Using the special tool, remove the crankshaft front seal.
    • Discard the crankshaft front seal.
  42. Remove the bolt and the accessory drive belt tensioner.
    Fig 38: Removing Bolt And Accessory Drive Belt Tensioner
    G03996016Courtesy of FORD MOTOR CO.
    43. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
    Fig 39: Discarding Oil Cooler And Gasket
    G03996017Courtesy of FORD MOTOR CO.
  43. If equipped, remove the bolt and the oil cooler.
    • Discard the oil cooler and gasket.
  44. Remove and discard the oil filter.
  45. Remove the 2 bolts, the stud bolt, the banjo bolt and the oil filter adapter.
    • Remove and discard the banjo bolt O-ring seal.
    Fig 40: Discarding Banjo Bolt O-Ring Seal
    G03996018Courtesy of FORD MOTOR CO.
  46. Remove the 3 bolts and the RH exhaust manifold heat shield.
    Fig 41: Removing Bolts And RH Exhaust Manifold Heat Shield
    G03996019Courtesy of FORD MOTOR CO.
  47. Remove the 6 nuts and the RH exhaust manifold.
    • Discard the nuts.
    • Remove and discard the gasket.
    Fig 42: Removing Nuts And RH Exhaust Manifold
    G03996020Courtesy of FORD MOTOR CO.
  48. Clean and inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  49. Remove the 6 RH exhaust manifold studs and discard.
  50. Remove the 3 bolts and the RH engine mount bracket.
    Fig 43: Removing Bolts And RH Engine Mount Bracket
    G03996021Courtesy of FORD MOTOR CO.
  51. Remove the 3 bolts and the generator.
    Fig 44: Removing Bolts And Generator
    G03996022Courtesy of FORD MOTOR CO.
  52. Remove the oil pressure switch and oil temperature sensor.
    Fig 45: Removing Oil Pressure Switch And Oil Temperature Sensor
    G03996023Courtesy of FORD MOTOR CO.
    53. NOTE: RH shown, LH similar.
    NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease removal.
    Fig 46: Removing Ignition Coil Bolts And Ignition Coils
    G03996024Courtesy of FORD MOTOR CO.
  53. Remove the 6 ignition coil bolts and 6 ignition coils.
  54. Remove and discard the CHT sensor.
    Fig 47: Discarding CHT Sensor
    G03996025Courtesy of FORD MOTOR CO.
  55. Remove the 2 nuts and the engine appearance cover bracket.
    Fig 48: Removing Nuts And Engine Appearance Cover Bracket
    G03996026Courtesy of FORD MOTOR CO.
  56. Remove the 12 stud bolts and the LH valve cover.
    • Remove and discard the gaskets.
    Fig 49: Removing Stud Bolts And The LH Valve Cover
    G03996027Courtesy of FORD MOTOR CO.
  57. Remove the 2 nuts and the upper intake manifold support bracket.
    Fig 50: Removing Nuts And Upper Intake Manifold Support Bracket
    G03996028Courtesy of FORD MOTOR CO.
  58. Disconnect the crankcase vent tube from the RH valve cover and remove the tube.
    Fig 51: Disconnecting Crankcase Vent Tube From RH Valve Cover And Remove Tube
    G03996029Courtesy of FORD MOTOR CO.
  59. Remove the 12 stud bolts and the RH valve cover.
    • Remove and discard the gaskets.
    Fig 52: Removing Stud Bolts And The RH Valve Cover
    G03996030Courtesy of FORD MOTOR CO.
  60. Remove the fuel tube bracket bolt.
    Fig 53: Removing Fuel Tube Bracket Bolt
    G03995780Courtesy of FORD MOTOR CO.
  61. Remove the bolts and the lower intake manifold.
    Fig 54: Removing Bolts And Lower Intake Manifold
    G03996032Courtesy of FORD MOTOR CO.
  62. Remove the 14 bolts, the stud bolt and the o pan.
    • Remove and discard the gasket.
    Fig 55: Discarding Gasket
    G03996033Courtesy of FORD MOTOR CO.
  63. Remove the 2 bolts and the oil pump screen pickup tube.
    • Remove and discard the O-ring seal.
    Fig 56: Removing Bolts And The Oil Pump Screen Pickup Tube
    G03996034Courtesy of FORD MOTOR CO.
  64. Remove the 5 nuts and the oil pan baffle.
    Fig 57: Removing Nuts And Oil Pan Baffle
    G03996035Courtesy of FORD MOTOR CO.
  65. Remove the 2 bolts and the RH and LH CMP sensors.
    Fig 58: Removing Bolts And RH And LH CMP Sensors
    G03996036Courtesy of FORD MOTOR CO.
  66. Remove the bolt and the CKP sensor.
    Fig 59: Removing Bolt And CKP Sensor
    G03996037Courtesy of FORD MOTOR CO.
  67. Remove the 15 bolts and the engine front cover.
    • Remove and discard the gaskets.
    Fig 60: Discarding Gaskets
    G03996038Courtesy of FORD MOTOR CO.
    CAUTION: This pulse wheel is used with several different engines. Install the pulse wheel with the keyway in the slot stamped "20-25-30 DAMB 30 RFF" only. This slot is also marked with an orange paint mark and aligns with the missing tooth in the trigger wheel.
  68. Remove the ignition pulse wheel.
    Fig 61: Identifying Ignition Pulse Wheel
    G03995784Courtesy of FORD MOTOR CO.
  69. Install the crankshaft damper bolt and washer.
    Fig 62: Identifying Crankshaft Damper Bolt And Washer
    G03995785Courtesy of FORD MOTOR CO.
  70. Rotate the crankshaft clockwise to position the crankshaft keyway to the 9 o'clock position.
    Fig 63: Positioning Crankshaft Keyway To 9 O'Clock Position
    G03995786Courtesy of FORD MOTOR CO.
  71. Rotate the crankshaft clockwise to position the crankshaft keyway to the 3 o'clock position.
    Fig 64: Positioning Crankshaft Keyway To 3 O'Clock Position
    G03995787Courtesy of FORD MOTOR CO.
  72. Verify that the front 2 intake camshaft lobes are pointing up.
    Fig 65: Verifying Front Intake Camshaft Lobes Are Pointing Up
    G03995788Courtesy of FORD MOTOR CO.
  73. Compress the timing chain tensioner.
    1. Release the racheting pawl.
    2. Compress the timing chain tensioner and install a stiff wire or paper clip.
    Fig 66: Compressing Timing Chain Tensioner
    G03995789Courtesy of FORD MOTOR CO.
  74. Remove the bolts and the RH timing chain tensioner.
    Fig 67: Removing Bolts And RH Timing Chain Tensioner
    G03995790Courtesy of FORD MOTOR CO.
    75. CAUTION: If the RH timing chain tensioner arm is to be reused, mark the position to make sure that it is installed on the correct side when reassembled.
    Fig 68: Removing RH Timing Chain Tensioner Arm
    G03995791Courtesy of FORD MOTOR CO.
  75. Remove the RH timing chain tensioner arm.
  76. Remove the RH timing chain.
    Fig 69: Removing RH Timing Chain
    G03995792Courtesy of FORD MOTOR CO.
  77. Remove the bolts and the RH variable camshaft timing (VCT) solenoid housing assembly.
    Fig 70: Removing Bolts And RH Variable Camshaft Timing (VCT) Solenoid Housing Assembly
    G03995793Courtesy of FORD MOTOR CO.
  78. Rotate the crankshaft counterclockwise to position the crankshaft keyway to the 11 o'clock position.
    Fig 71: Positioning Crankshaft Keyway To 11 O'Clock Position
    G03995794Courtesy of FORD MOTOR CO.
  79. Compress the timing chain tensioner.
    1. Release the racheting pawl.
    2. Compress the timing chain tensioner and install a stiff wire or paper clip.
    Fig 72: Compressing Timing Chain Tensioner
    G03995795Courtesy of FORD MOTOR CO.
  80. Remove the bolts and the LH timing chain tensioner.
    Fig 73: Removing Bolts And LH Timing Chain Tensioner
    G03995796Courtesy of FORD MOTOR CO.
    81. CAUTION: If the LH timing chain tensioner arm is to be reused, mark the position to make sure that it is installed on the correct side when reassembled.
    Fig 74: Removing LH Timing Chain Tensioner Arm
    G03995797Courtesy of FORD MOTOR CO.
  81. Remove the LH timing chain tensioner arm.
  82. Remove the LH timing chain.
    Fig 75: Removing LH Timing Chain
    G03995798Courtesy of FORD MOTOR CO.
  83. Remove the LH VCT solenoid housing assembly.
    Fig 76: Removing LH VCT Solenoid Housing Assembly
    G03995799Courtesy of FORD MOTOR CO.
  84. Using a wrench on the flats of the camshaft, hold the camshaft in position and remove the bolt and the RH VCT actuator.
    • Discard the bolt.
    Fig 77: Removing Bolt And RH VCT Actuator
    G03995800Courtesy of FORD MOTOR CO.
  85. Using a wrench on the flats of the camshaft, hold the camshaft in position and remove the bolt and the RH exhaust camshaft sprocket.
    • Discard the bolt.
    Fig 78: Removing Bolt And RH Exhaust Camshaft Sprocket
    G03995801Courtesy of FORD MOTOR CO.
  86. Using a wrench on the flats of the camshaft, hold the camshaft in position and remove the bolt and the LH VCT actuator.
    • Discard the bolt.
    Fig 79: Removing Bolt And LH VCT Actuator
    G03995802Courtesy of FORD MOTOR CO.
  87. Using a wrench on the flats of the camshaft, hold the camshaft in position and remove the bolt and the LH exhaust camshaft sprocket.
    • Discard the bolt.
    Fig 80: Removing Bolt And LH Exhaust Camshaft Sprocket
    G03995803Courtesy of FORD MOTOR CO.
  88. Remove the crankshaft sprockets.
    Fig 81: Removing Crankshaft Sprockets
    G03995804Courtesy of FORD MOTOR CO.
    89. CAUTION: Remove the camshaft journal thrust caps prior to loosening other camshaft journal cap bolts. Damage to the camshaft journal thrust cap can occur if not removed first.
    CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered for assembly in their original positions. Keep camshaft journal caps with the cylinder head from which they were removed. Do not mix with camshaft journal caps from another cylinder head.
    Fig 82: Removing Bolts
    G03996060Courtesy of FORD MOTOR CO.
  89. Remove the bolts.
    90. NOTE: The camshaft journal thrust caps have alignment dowels.
    Fig 83: Removing Camshaft Journal Thrust Caps
    G03996061Courtesy of FORD MOTOR CO.
  90. Using a soft-faced mallet, gently loosen and remove the camshaft journal thrust caps.
  91. Remove the remaining camshaft journal cap bolts.
    Fig 84: Removing Remaining Camshaft Journal Cap Bolts
    G03996062Courtesy of FORD MOTOR CO.
  92. Using a soft-faced mallet, gently loosen and remove the remaining camshaft journal caps.
    Fig 85: Removing Remaining Camshaft Journal Caps
    G03996063Courtesy of FORD MOTOR CO.
  93. Carefully lift out the camshafts.
    Fig 86: Lifting Out Camshafts
    G03996064Courtesy of FORD MOTOR CO.
  94. Remove the 16 bolts and the RH and LH cylinder heads.
    • Discard the bolts and the gaskets.
    Fig 87: Removing Bolts And The RH And LH Cylinder Heads
    G03996065Courtesy of FORD MOTOR CO.
    95. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
  95. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.0001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.0001 in).
  96. Remove the 2 bolts and the coolant bypass tube.
    • Discard the O-ring seal.
    Fig 88: Removing Bolts And Coolant Bypass Tube
    G03996066Courtesy of FORD MOTOR CO.
  97. Remove the 2 bolts and the coolant inlet tube.
    • Discard the O-ring seal.
    Fig 89: Removing Bolts And Coolant Inlet Tube
    G03996067Courtesy of FORD MOTOR CO.
  98. Remove the bolt and the KS.
    • Detach the wiring retainer from the oil separator cover.
    Fig 90: Detaching Wiring Retainer From Oil Separator Cover
    G03996068Courtesy of FORD MOTOR CO.
  99. Remove the 2 bolts and the oil separator cover.
    • Discard the gasket.
    Fig 91: Removing Bolts And Oil Separator Cover
    G03996069Courtesy of FORD MOTOR CO.
  100. Remove the 4 oil pump bolts in the sequence shown.
    • Remove the oil pump.
    Fig 92: Removing Oil Pump Bolts In Sequence Shown
    G03955868Courtesy of FORD MOTOR CO.
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