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Section 1034 (Engine): Disassembly: Engine

WARNING: This page is about a different car, the 2008 Lincoln MKZ. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000311Courtesy of FORD MOTOR CO.
 3-Jaw Puller 303-D121
GF0029191Courtesy of FORD MOTOR CO.
 Camshaft Alignment Tool 303-1248
GF0000811Courtesy of FORD MOTOR CO.
 Handle 205-153 (T80T-4000-W)
GF0000317Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
GF0000249Courtesy of FORD MOTOR CO.
 Remover, Oil Seal 303-409 (T92C-6700CH)
GF0029086Courtesy of FORD MOTOR CO.
 Remover, Seal 303-1247/1
GF0003558Courtesy of FORD MOTOR CO.
 Slide Hammer 307-005 (T59L-100-B)
GF0000246Courtesy of FORD MOTOR CO.
 Strap Wrench 303-D055 (D85L-6000-A)
Material

Item Specification
Motorcraft Metal Surface Prep
ZC-31-A		 -
Silicone Gasket Remover
ZC-30		 -
CAUTION: 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: For additional information, refer to the exploded view under the Assembly procedure.

All vehicles 

  1. Remove the 8 bolts and the flexplate.
    2. Fig 1: Identifying Flexplate & Bolts
    GF0029262Courtesy of FORD MOTOR CO.
  2. Remove the crankshaft sensor ring.
    3. Fig 2: Identifying Crankshaft Sensor Ring
    GF0029263Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove and discard the rear crankshaft seal.
    4. Fig 3: Removing Crankshaft Rear Seal Using Special Tools (303-519) & (307-005)
    GF0029110Courtesy of FORD MOTOR CO.
    NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.
  4. Mount the engine on a suitable engine stand.
  5. If equipped, detach the block heater wiring harness retainer from the upper intake manifold.
    6. Fig 4: Identifying Block Heater Wiring Harness Retainer From Upper Intake Manifold
    GF0029165Courtesy of FORD MOTOR CO.
  6. If equipped, remove the heat shield and disconnect the block heater electrical connector.
    7. Fig 5: Identifying Block Heater Wiring Harness
    GF0029221Courtesy of FORD MOTOR CO.
  7. If equipped, detach the block heater wiring harness retainer from the power steering reservoir hose and the power steering pressure (PSP) hose.
    • Remove the block heater wiring harness from the engine.
    8. Fig 6: Identifying Block Heater Wiring Harness From Engine
    GF0029166Courtesy of FORD MOTOR CO.
  8. If equipped, disconnect the heated PCV electrical connector.
    9. Fig 7: Identifying Positive Crankcase Ventilation (PCV) Fitting Electrical Connector
    GF0029167Courtesy of FORD MOTOR CO.
  9. Disconnect the PCV hose from the PCV valve.
    10. Fig 8: Identifying PCV Hose From PCV Valve
    GF0029168Courtesy of FORD MOTOR CO.
  10. Disconnect the throttle body (TB) electrical connector.
    11. Fig 9: Locating Throttle Body Electrical Connector
    GF0029169Courtesy of FORD MOTOR CO.
  11. Detach the wiring harness retainers from the upper intake manifold.
    12. Fig 10: Locating Wiring Harness Retainers From Upper Intake Manifold
    GF0029170Courtesy of FORD MOTOR CO.
  12. If equipped, remove the upper intake manifold long support bracket bolt.
    13. Fig 11: Locating Upper Intake Manifold Support Bracket Bolt
    GF0029171Courtesy of FORD MOTOR CO.
  13. Remove the upper intake manifold short support bracket bolt.
    14. Fig 12: Locating Upper Intake Manifold Support Bracket Bolt
    GF0029172Courtesy of FORD MOTOR CO.
  14. Remove the 6 bolts and the upper intake manifold.
    • Discard the gaskets.
    15. Fig 13: Identifying Upper Intake Manifold Bolts
    GF0029173Courtesy of FORD MOTOR CO.
  15. Disconnect the PSP switch electrical connector.
    16. Fig 14: Locating PSP Switch Electrical Connector
    GF0029174Courtesy of FORD MOTOR CO.

    Front wheel drive (FWD) vehicles 

  16. Disconnect the RH catalyst monitor sensor electrical connector.
    17. Fig 15: Locating RH Catalyst Monitor Electrical Connector
    GF0029150Courtesy of FORD MOTOR CO.

    All vehicles 

  17. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
    18. Fig 16: Locating RH Heated Oxygen Sensor (HO2S) Electrical Connector
    GF0029222Courtesy of FORD MOTOR CO.
  18. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
    19. Fig 17: Locating RH Variable Camshaft Timing (VCT) Solenoid Electrical Connector
    GF0029175Courtesy of FORD MOTOR CO.
  19. Disconnect the 3 RH coil-on-plug electrical connectors.
    20. Fig 18: Locating RH Coil-On-Plug Electrical Connectors
    GF0029176Courtesy of FORD MOTOR CO.
  20. If equipped, disconnect the heated PCV valve electrical connector.
    21. Fig 19: Locating Heated PCV Valve Electrical Connector
    GF0029177Courtesy of FORD MOTOR CO.
  21. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
  22. Disconnect the coolant bypass hose from the thermostat housing.
    23. Fig 20: Identifying Coolant Bypass Hose From Thermostat Housing
    GF0041327Courtesy of FORD MOTOR CO.
  23. Disconnect the RH camshaft position (CMP) sensor electrical connector.
    24. Fig 21: Locating RH Camshaft Position (CMP) Sensor Electrical Connector
    GF0029224Courtesy of FORD MOTOR CO.
  24. Disconnect the knock sensor (KS) electrical connector.
    25. Fig 22: Locating Knock Sensor (KS) Electrical Connector
    GF0029274Courtesy of FORD MOTOR CO.
  25. Disconnect the 6 fuel injector electrical connectors (3 shown).
    26. Fig 23: Locating Fuel Injector Electrical Connectors
    GF0029226Courtesy of FORD MOTOR CO.
  26. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    27. Fig 24: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    GF0029227Courtesy of FORD MOTOR CO.
  27. Disconnect the LH CMP sensor electrical connector.
    28. Fig 25: Locating LH CMP Sensor Electrical Connector
    GF0029253Courtesy of FORD MOTOR CO.
  28. Disconnect the LH catalyst monitor sensor electrical connector.
    29. Fig 26: Identifying LH Catalyst Monitor Sensor Electrical Connector
    GF0041326Courtesy of FORD MOTOR CO.
  29. Disconnect the LH HO2S electrical connector.
    30. Fig 27: Locating LH Heated Oxygen Sensor (HO2S) Electrical Connector
    GF0029254Courtesy of FORD MOTOR CO.
  30. Disconnect the 3 LH coil-on-plug electrical connectors.
    31. Fig 28: Locating LH Coil-On-Plug Electrical Connectors
    GF0029179Courtesy of FORD MOTOR CO.
  31. Disconnect the LH VCT solenoid electrical connector.
    32. Fig 29: Locating LH VCT Solenoid Electrical Connector
    GF0029178Courtesy of FORD MOTOR CO.
  32. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
  33. Remove the wiring harness retainer bolt from the rear of the LH cylinder head.
    34. Fig 30: Identifying Wiring Harness Retainer Bolt From Rear Of LH Cylinder Head
    GF0029255Courtesy of FORD MOTOR CO.
  34. Remove the nut, the bolt and the heat shield.
    35. Fig 31: Identifying Heat Shield, Nut & Bolt
    GF0029275Courtesy of FORD MOTOR CO.
  35. Remove the wiring harness retainer stud bolt.
    36. Fig 32: Identifying Wiring Harness Retainer Stud Bolt
    GF0029276Courtesy of FORD MOTOR CO.
  36. Remove the wiring harness grommet.
    37. Fig 33: Identifying Wiring Harness Grommet
    GF0029277Courtesy of FORD MOTOR CO.
  37. Disconnect the crankshaft position (CKP) sensor electrical connector.
    38. Fig 34: Identifying Crankshaft Position (CKP) Sensor Electrical Connector
    GF0029270Courtesy of FORD MOTOR CO.
  38. Disconnect the A/C compressor electrical connector.
    39. Fig 35: Identifying A/C Compressor Electrical Connector
    GF0029246Courtesy of FORD MOTOR CO.
  39. Remove the nut and disconnect the generator B+ cable.
    40. Fig 36: Identifying Generator B+ Cable & Nut
    GF0029247Courtesy of FORD MOTOR CO.
  40. Disconnect the generator electrical connector.
    41. Fig 37: Identifying Generator Electrical Connector
    GF0029248Courtesy of FORD MOTOR CO.
  41. Detach the wiring harness retainer from the generator.
    42. Fig 38: Identifying Wiring Harness Retainer From Generator
    GF0029249Courtesy of FORD MOTOR CO.
  42. Disconnect the engine oil pressure (EOP) switch electrical connector and the wiring harness pin-type retainer.
    • Remove the wiring harness from the engine.
    43. Fig 39: Locating Engine Oil Pressure (EOP) Switch Electrical Connector & Wiring Harness Pin-Type Retainer
    GF0029278Courtesy of FORD MOTOR CO.
  43. Remove the bolt and the A/C manifold.
    • Discard the O-ring seals.
    44. Fig 40: Locating A/C Manifold Bolt
    GF0029279Courtesy of FORD MOTOR CO.
  44. Remove the nut, 2 bolts and the A/C compressor.
    45. Fig 41: Identifying A/C Compressor Nut & Bolts
    GF0029280Courtesy of FORD MOTOR CO.
  45. Remove the A/C compressor mounting stud from the oil pan.
    46. Fig 42: Locating A/C Compressor Mounting Stud
    GF0029281Courtesy of FORD MOTOR CO.
  46. Remove the bolt, nut and the generator.
    47. Fig 43: Locating Generator, Bolts & Nuts
    GF0029250Courtesy of FORD MOTOR CO.
  47. Detach the PSP hose retainer from the engine lifting eye.
    48. Fig 44: Locating PSP Hose Retainer From Engine Lifting Eye
    GF0029181Courtesy of FORD MOTOR CO.
  48. Remove the PSP hose bracket nut.
    49. Fig 45: Identifying PSP Hose Bracket Nut
    GF0029099Courtesy of FORD MOTOR CO.
  49. Remove the PSP tube bracket bolt from the RH cylinder head.
    50. Fig 46: Identifying Power Steering Pressure (PSP) Tube & Bracket Assembly
    GF0029225Courtesy of FORD MOTOR CO.
  50. Remove the 3 bolts and the power steering pump.
    51. Fig 47: Locating Power Steering Pump Bolts
    GF0029184Courtesy of FORD MOTOR CO.
  51. Remove the 3 bolts and the accessory drive belt tensioner.
    52. Fig 48: Locating Accessory Drive Belt Tensioner Bolts
    GF0029185Courtesy of FORD MOTOR CO.
  52. Remove the 4 nuts (3 shown) and the LH catalytic converter.
    • Discard the nuts and the gasket.
    53. Fig 49: Locating LH Catalytic Converter Nuts
    GF0029230Courtesy of FORD MOTOR CO.
  53. Remove the 3 bolts and the LH exhaust manifold heat shield.
    54. Fig 50: Locating LH Exhaust Manifold Heat Shield & Nuts
    GF0029256Courtesy of FORD MOTOR CO.
  54. Remove the 6 nuts and the LH exhaust manifold.
    • Discard the nuts and the exhaust manifold gasket.
    55. Fig 51: Locating LH Exhaust Manifold Nuts
    GF0029257Courtesy of FORD MOTOR CO.
  55. Clean and inspect the LH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
  56. Remove and discard the 6 LH exhaust manifold studs.
    57. Fig 52: Locating LH Exhaust Manifold Studs
    GF0029116Courtesy of FORD MOTOR CO.

    FWD vehicles 

  57. Remove the 4 nuts and the RH catalytic converter.
    • Discard the nuts and the gasket.
    58. Fig 53: Locating RH Catalytic Converter Nuts
    GF0029151Courtesy of FORD MOTOR CO.

    All vehicles 

  58. Remove the 3 bolts and the RH exhaust manifold heat shield.
    59. Fig 54: Locating RH Exhaust Manifold Heat Shield & Nuts
    GF0029233Courtesy of FORD MOTOR CO.
  59. Remove the 6 nuts and the RH exhaust manifold.
    • Discard the nuts and the exhaust manifold gasket.
    60. Fig 55: Locating RH Exhaust Manifold & Nuts
    GF0029234Courtesy of FORD MOTOR CO.
  60. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
  61. Remove and discard the 6 RH exhaust manifold studs.
    62. Fig 56: Locating RH Exhaust Manifold Studs
    GF0029119Courtesy of FORD MOTOR CO.
  62. Remove the RH cylinder block drain plug or, if equipped, the block heater.
    • Allow coolant to drain from the cylinder block.
    63. Fig 57: Locating RH Cylinder Block Drain Plug
    GF0029232Courtesy of FORD MOTOR CO.
  63. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
    64. Fig 58: Locating LH Cylinder Block Drain Plug
    GF0029231Courtesy of FORD MOTOR CO.
  64. Remove the pin-type retainer and the cover.
    65. Fig 59: Locating Pin-Type Retainer & Cover
    GF0029282Courtesy of FORD MOTOR CO.
  65. Remove the 2 bolts and the engine lifting eye.
    66. Fig 60: Locating Engine Lifting Eye & Bolts
    GF0029236Courtesy of FORD MOTOR CO.
  66. If equipped, remove the bolt and the upper intake manifold long support bracket.
    67. Fig 61: Locating Upper Intake Manifold Bracket & Bolt
    GF0029237Courtesy of FORD MOTOR CO.
  67. Remove the bolt and the upper intake manifold short support bracket.
    68. Fig 62: Locating Upper Intake Manifold Bracket & Bolt
    GF0029238Courtesy of FORD MOTOR CO.
  68. Remove the bolt and the RH CMP sensor.
    69. Fig 63: Locating RH CMP Sensor & Bolt
    GF0029239Courtesy of FORD MOTOR CO.

    All wheel drive (AWD) vehicles 

  69. Remove the 2 bolts and the catalytic converter bracket.
    70. Fig 64: Locating Catalytic Converter Bracket & Bolts
    GF0029283Courtesy of FORD MOTOR CO.

    All vehicles 

  70. Remove the 4 bolts and the fuel rail and injectors as an assembly.
    71. Fig 65: Locating Fuel Rail And Injectors & Bolts
    GF0029240Courtesy of FORD MOTOR CO.
  71. Remove the 2 thermostat housing-to-lower intake manifold bolts.
    • Remove the thermostat housing and discard the gasket.
    72. Fig 66: Locating Thermostat Housing-To-Lower Intake Manifold Bolts
    GF0041328Courtesy of FORD MOTOR CO.
  72. Remove the 10 bolts and the lower intake manifold.
    • Discard the gaskets.
    73. Fig 67: Locating Lower Intake Manifold Bolts
    GF0029242Courtesy of FORD MOTOR CO.
  73. Disconnect and remove the CHT sensor jumper harness.
    74. Fig 68: Identifying CHT Sensor Jumper Harness
    GF0029243Courtesy of FORD MOTOR CO.
  74. Remove the bolt and the LH CMP sensor.
    75. Fig 69: Locating LH CMP Sensor & Bolt
    GF0029258Courtesy of FORD MOTOR CO.
  75. Remove the bolt and the CKP sensor.
    76. Fig 70: Identifying CKP Sensor & Bolt
    GF0029271Courtesy of FORD MOTOR CO.
  76. Remove the EOP switch.
    77. Fig 71: Identifying EOP Switch
    GF0029284Courtesy of FORD MOTOR CO.
  77. Remove the 2 bolts and the oil filter adapter.
    • Discard the gasket and the O-ring seal.
    78. Fig 72: Locating Oil Filter Adapter & Bolts
    GF0029285Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  78. Remove the 6 bolts and the 6 coil-on-plugs.
    79. Fig 73: Locating Coil-On-Plugs & Bolts
    GF0029180Courtesy of FORD MOTOR CO.
  79. Remove the 2 nuts and the wiring harness retaining bracket.
    80. Fig 74: Identifying Wiring Harness Retaining Bracket & Nuts
    GF0029091Courtesy of FORD MOTOR CO.
  80. Remove the 11 stud bolts and the LH valve cover.
    • Discard the gasket.
    81. Fig 75: Locating LH Valve Cover Stud Bolts
    GF0029182Courtesy of FORD MOTOR CO.
  81. Remove the bolt, the 10 stud bolts and the RH valve cover.
    • Discard the gasket.
    82. Fig 76: Locating RH Valve Cover Stud Bolts
    GF0029183Courtesy of FORD MOTOR CO.
    NOTE: VCT solenoid seal removal shown, spark plug tube seal removal similar.
  82. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals.
    • Using the special tools, remove the seal(s).
    83. Fig 77: Removing Seals Using Special Tools (205-153) & (303-1247/1)
    GF0029092Courtesy of FORD MOTOR CO.
  83. Remove the crankshaft bolt and washer.
    • Discard the bolt.
    84. Fig 78: Removing Crankshaft Bolt & Washer Using Special Tool (303-D055)
    GF0029103Courtesy of FORD MOTOR CO.
  84. Using the special tool, remove the crankshaft pulley.
    85. Fig 79: Identifying Special Tools (303-D121) And Crankshaft Pulley
    GF0017017Courtesy of FORD MOTOR CO.
  85. Using the special tool, remove and discard the crankshaft front seal.
    86. Fig 80: Removing Crankshaft Front Seal Using Special Tool (303-409)
    GF0029106Courtesy of FORD MOTOR CO.
  86. Remove the 2 bolts and the engine mount bracket.
    87. Fig 81: Locating Engine Mount Bracket & Bolts
    GF0029186Courtesy of FORD MOTOR CO.
  87. Remove the 2 engine mount studs.
    88. Fig 82: Locating Engine Mount Studs
    GF0029187Courtesy of FORD MOTOR CO.
  88. Remove the 3 bolts and the engine mount bracket.
    89. Fig 83: Locating Engine Mount Bracket & Bolts
    GF0029188Courtesy of FORD MOTOR CO.
  89. Remove the 22 engine front cover bolts.
    90. Fig 84: Identifying Engine Front Cover Bolts
    GF0029189Courtesy of FORD MOTOR CO.
  90. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover in the following sequence.
    1. Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released.
    2. Remove the engine front cover.
    91. Fig 85: Identifying Engine Front Cover Bolts
    GF0029190Courtesy of FORD MOTOR CO.
  91. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown.
    92. Fig 86: Aligning Timing Marks On Variable Camshaft Timing (VCT) Assemblies
    GF0029192Courtesy of FORD MOTOR CO.
    NOTE: The special tool will hold the camshafts in the top dead center (TDC) position.
  92. Install the special tool onto the flats of the LH camshafts.
    93. Fig 87: Installing Special Tool (303-1248) Onto Flats Of LH Camshafts
    GF0029193Courtesy of FORD MOTOR CO.
    NOTE: The special tool will hold the camshafts in the TDC position.
  93. Install the special tool onto the flats of the RH camshafts.
    94. Fig 88: Installing Special Tool (303-1248) Onto Flats Of RH Camshafts
    GF0029194Courtesy of FORD MOTOR CO.
  94. Remove the 3 bolts and the RH VCT housing.
    95. Fig 89: Locating RH VCT Housing
    GF0029195Courtesy of FORD MOTOR CO.
  95. Remove the 3 bolts and the LH VCT housing.
    96. Fig 90: Locating LH VCT Housing
    GF0029196Courtesy of FORD MOTOR CO.
  96. Remove and discard the VCT housing seals.
    97. Fig 91: Locating VCT Housing Seals
    GF0029197Courtesy of FORD MOTOR CO.
  97. Remove the 2 bolts and the primary timing chain tensioner.
    98. Fig 92: Locating Primary Timing Chain Tensioner Bolts
    GF0029198Courtesy of FORD MOTOR CO.
  98. Remove the primary timing chain tensioner arm.
    99. Fig 93: Locating Primary Timing Chain Tensioner Arm
    GF0029199Courtesy of FORD MOTOR CO.
  99. Remove the 2 bolts and the lower LH primary timing chain guide.
    100. Fig 94: Locating Lower LH Primary Timing Chain Guide Bolts
    GF0029200Courtesy of FORD MOTOR CO.
  100. Remove the primary timing chain.
    101. Fig 95: Locating Primary Timing Chain
    GF0029201Courtesy of FORD MOTOR CO.
  101. Remove the crankshaft timing chain sprocket.
    102. Fig 96: Locating Crankshaft Timing Chain Sprocket
    GF0029202Courtesy of FORD MOTOR CO.
  102. Remove the 2 bolts and the upper LH primary timing chain guide.
    103. Fig 97: Locating Upper LH Primary Timing Chain Guide Bolts
    GF0029203Courtesy of FORD MOTOR CO.
  103. Compress the LH secondary timing chain tensioner and install a suitable lock pin to retain the tensioner in the collapsed position.
    104. Fig 98: Compressing LH Secondary Timing Chain Tensioner & Installing Suitable Lock Pin To Retain Tensioner In Collapsed Position
    GF0029204Courtesy of FORD MOTOR CO.
    NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
  104. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt.
    • Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
    105. Fig 99: Locating LH VCT Assembly Bolt & LH Exhaust Camshaft Sprocket Bolt
    GF0029205Courtesy of FORD MOTOR CO.
    NOTE: When the special tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.
  105. Remove the special tool from the LH camshafts.
    106. Fig 100: Removing Special Tool (303-1248) From LH Camshafts
    GF0029211Courtesy of FORD MOTOR CO.
    CAUTION: The camshafts must remain in the neutral position during removal or engine damage may occur.
  106. Verify the LH camshafts are in the neutral position.
    107. Fig 101: Verifying LH Camshafts Are In Neutral Position
    GF0029212Courtesy of FORD MOTOR CO.
  107. Remove the 2 bolts and the LH secondary timing chain tensioner.
    108. Fig 102: Locating LH Secondary Timing Chain Tensioner & Bolt
    GF0029259Courtesy of FORD MOTOR CO.
    NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
  108. Remove the bolts and the LH camshaft bearing caps.
    • Remove the LH camshafts.
    109. Fig 103: Identifying LH Camshafts Bolts
    GF0029213Courtesy of FORD MOTOR CO.
  109. Compress the RH secondary timing chain tensioner and install a suitable lock pin to retain the tensioner in the collapsed position.
    110. Fig 104: Compressing RH Secondary Timing Chain Tensioner & Installing Suitable Lock Pin To Retain Tensioner In Collapsed Position
    GF0029207Courtesy of FORD MOTOR CO.
    NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
  110. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt.
    • Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
    111. Fig 105: Locating RH VCT Assembly Bolt & RH Exhaust Camshaft Sprocket Bolt
    GF0029208Courtesy of FORD MOTOR CO.
  111. Remove the special tool from the RH camshafts.
    112. Fig 106: Removing Special Tool (303-1248) From RH Camshafts
    GF0029214Courtesy of FORD MOTOR CO.
    CAUTION: The camshafts must remain in the neutral position during removal or engine damage may occur.
  112. Rotate the RH camshafts counterclockwise to the neutral position.
    113. Fig 107: Rotating RH Camshafts Counterclockwise To Neutral Position
    GF0029215Courtesy of FORD MOTOR CO.
  113. Remove the 2 bolts and the RH secondary timing chain tensioner.
    114. Fig 108: Locating RH Secondary Timing Chain Tensioner & Bolts
    GF0029235Courtesy of FORD MOTOR CO.
  114. Remove the 2 bolts and the RH primary timing chain guide.
    115. Fig 109: Locating RH Primary Timing Chain Guide Lower Bolt
    GF0029210Courtesy of FORD MOTOR CO.
    NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
  115. Remove the bolts and the RH camshaft bearing caps.
    • Remove the RH camshafts.
    116. Fig 110: Identifying RH Camshafts Bolts
    GF0029216Courtesy of FORD MOTOR CO.
    NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
    NOTE: LH shown, RH similar.
  116. Remove the valve tappets from the cylinder heads.
    117. Fig 111: Identifying Valve Tappets From Cylinder Head
    GF0029217Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  117. Remove and discard the M6 bolt from each cylinder head.
    118. Fig 112: Identifying M6 Bolt
    GF0029260Courtesy of FORD MOTOR CO.
    CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
    CAUTION: Aluminum surfaces are soft and may be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield design and cannot be reused.
    NOTE: LH shown, RH similar.
  118. Remove and discard the 8 bolts from each cylinder head.
    • Remove the cylinder heads.
    • Discard the cylinder head gaskets.
    119. Fig 113: Identifying Cylinder Head Bolts
    GF0029261Courtesy of FORD MOTOR CO.
    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the gasket.
    NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
  119. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
  120. Support the cylinder heads on a bench with the head gasket side up.
    121. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
  121. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder heads must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
  122. Remove the coolant tube.
    • Remove and discard the O-ring seals.
    123. Fig 114: Identifying Coolant Tube
    GF0029286Courtesy of FORD MOTOR CO.
  123. Remove the 2 bolts and the knock sensor (KS).
    124. Fig 115: Locating Knock Sensor (KS) Bolts
    GF0029287Courtesy of FORD MOTOR CO.
  124. Remove the 8 bolts and the coolant pump.
    125. Fig 116: Locating Coolant Pump Bolts
    GF0029288Courtesy of FORD MOTOR CO.
  125. Remove the 16 oil pan bolts.
    126. Fig 117: Identifying Oil Pan Bolts
    GF0029265Courtesy of FORD MOTOR CO.
  126. Install 2 of the oil pan bolts (finger tight) into the 2 threaded holes in the oil pan in the following sequence.
    1. Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released.
    2. Remove the oil pan.
    127. Fig 118: Installing 2 Of Oil Pan Bolts (Finger Tight) Into 2 Threaded Holes In Oil Pan
    GF0029266Courtesy of FORD MOTOR CO.
  127. Remove the 3 bolts and the oil pump screen and pickup tube.
    • Discard the O-ring seal.
    128. Fig 119: Identifying Oil Pump Screen, Pickup Tube & Bolts
    GF0029267Courtesy of FORD MOTOR CO.
  128. Remove the 3 bolts and the oil pump.
    129. Fig 120: Identifying Oil Pump & Bolts
    GF0029289Courtesy of FORD MOTOR CO.
  129. Remove the 8 crankshaft rear seal retainer bolts.
    130. Fig 121: Locating Crankshaft Rear Seal Retainer Bolts
    GF0029272Courtesy of FORD MOTOR CO.
  130. Install the 2 M6 oil pan bolts (finger tight) into the 2 threaded holes in the crankshaft rear seal retainer in the following sequence.
    1. Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released.
    2. Remove the crankshaft rear seal retainer.
    131. Fig 122: Identifying M6 Oil Pan Bolts
    GF0029273Courtesy of FORD MOTOR CO.
    CAUTION: Only use a 3M Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.
  131. Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 RPM.
    • Thoroughly wash the engine front cover, oil pan and crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.
    132. CAUTION: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
    CAUTION: Do not use wire brushes, power abrasive discs or 3M Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.
  132. Clean all engine sealing surfaces of the cylinder block in the following sequence.
    1. Remove any large deposits of silicone or gasket material.
    2. Apply silicone gasket remover and allow to set for several minutes.
    3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
    5. Make sure the 2 engine front cover locating dowel pins are seated correctly in the cylinder block.
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