Section 1848 (Engine Mechanical - 3.5L): Disassembly: Engine

	3 Jaw Puller 303-D121 or equivalent
	Handle 205-153 (T80T-4000-W)
	Installer, Differential Bearing Cone 205-142 (T80T-4000-J)
	Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
	Remover, Oil Seal 303-409 (T92C-6700CH)
	Remover, VCT Spark Plug Tube Seal 303-1247/1
	Slide Hammer 307-005 (T59L-100-B)
	Strap Wrench 303-D055 (D85L-6000-A) or equivalent
	Tool, Camshaft Holding 303-1248

All vehicles 

1. Remove the 8 bolts and the flexplate.
   Fig 1: Locating Bolts And Flexplate

   Courtesy of FORD MOTOR CO.
2. Remove the crankshaft sensor ring.
   Fig 2: Locating Crankshaft Sensor Ring

   Courtesy of FORD MOTOR CO.
3. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.
   Fig 3: Removing Crankshaft Rear Seal Using Crankshaft Rear Oil Seal Remover And Slide Hammer

   Courtesy 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, remove the heat shield and disconnect the block heater electrical connector.
   • Detach all of the engine block heater harness retainers and remove the harness.
     Fig 4: Locating Heat Shield And Block Heater Electrical Connector

     Courtesy of FORD MOTOR CO.
6. Remove the 3 bolts and the accessory drive belt tensioner.
   Fig 5: Locating Bolts And Accessory Drive Belt Tensioner

   Courtesy of FORD MOTOR CO.
7. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
   • Discard the bolt.
     Fig 6: Identifying Crankshaft Pulley Bolt, Washer And Strap Wrench

     Courtesy of FORD MOTOR CO.
8. Using the 3 Jaw Puller, remove the crankshaft pulley.
   Fig 7: Removing Crankshaft Pulley Using 3 Jaw Puller

   Courtesy of FORD MOTOR CO.
9. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
   Fig 8: Removing Crankshaft Front Seal Using Oil Seal Remover

   Courtesy of FORD MOTOR CO.
10. Remove the crankcase vent tube. For additional information, refer to the quick connect coupling procedure in FUEL SYSTEM - GENERAL INFORMATION .
    Fig 9: Identifying Crankcase Vent Tube

    Courtesy of FORD MOTOR CO.
11. Disconnect the 3 LH coil-on-plug electrical connectors.
    Fig 10: Locating LH Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
12. Detach the wiring harness connector pin-type retainer from the LH valve cover.
    Fig 11: Locating Wiring Harness Connector Pin-Type Retainer Of LH Valve Cover

    Courtesy of FORD MOTOR CO.
13. Detach the 2 wiring harness retainers from the LH valve cover stud bolts and position the harness aside.
    Fig 12: Locating Wiring Harness Retainers And LH Valve Cover Stud Bolts

    Courtesy of FORD MOTOR CO.
14. Disconnect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors.
    • Detach the wiring harness pin-type retainer.
      Fig 13: Locating Variable Camshaft Timing Oil Control Solenoid Electrical Connectors And Pin-Type Retainer

      Courtesy of FORD MOTOR CO.
15. Detach the 2 wiring harness pin-type retainers.
    Fig 14: Locating Wiring Harness Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
16. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector.
    • Detach the wiring harness connector pin-type retainer from the LH valve cover.
      Fig 15: Locating LH Heated Oxygen Sensor Electrical Connector

      Courtesy of FORD MOTOR CO.
17. Disconnect the 3 fuel injector electrical connectors.
    • Detach the 2 wiring harness retainers from the LH valve cover stud bolts.
      Fig 16: Locating Fuel Injector Electrical Connectors And Retainers

      Courtesy of FORD MOTOR CO.
18. Detach the 2 wiring harness retainers and position the harness aside.
    Fig 17: Locating Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
19. Disconnect the 2 LH Camshaft Position (CMP) sensor electrical connectors.
    Fig 18: Locating LH Camshaft Position Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
20. Disconnect the LH Catalyst Monitor Sensor (CMS) electrical connector.
    • Remove the wiring harness retainer from the rear of the LH cylinder head.
      Fig 19: Locating LH Catalyst Monitor Sensor Electrical Connector And Retainer

      Courtesy of FORD MOTOR CO.
21. Detach the wiring harness retainer from the intake manifold.
    Fig 20: Locating Intake Manifold Wiring Harness Retainer

    Courtesy of FORD MOTOR CO.
22. Disconnect the Evaporative Emission (EVAP) canister vent solenoid and throttle body electrical connectors.
    • Detach the wiring harness pin-type retainer.
      Fig 21: Locating Evaporative Emission Canister Vent Solenoid, Throttle Body Electrical Connectors And Retainer

      Courtesy of FORD MOTOR CO.
23. Detach the 2 wiring harness/coolant tube retainers from the upper intake manifold.
    Fig 22: Locating Upper Intake Manifold Wiring Harness/Coolant Tube Retainers

    Courtesy of FORD MOTOR CO.
24. Disconnect the crankcase ventilation hose from the Positive Crankcase Ventilation (PCV) valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 23: Locating Crankcase Ventilation Hose And Positive Crankcase Ventilation Valve

    Courtesy of FORD MOTOR CO.
25. Remove the upper intake manifold support bracket bolt.
    Fig 24: Locating Upper Intake Manifold Support Bracket Bolt

    Courtesy of FORD MOTOR CO.
26. Remove the 7 bolts and the upper intake manifold.
    • Remove and discard the gasket.
    • Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
      Fig 25: Locating Bolts And Upper Intake Manifold

      Courtesy of FORD MOTOR CO.
27. Disconnect the 3 RH coil-on-plug electrical connectors.
    Fig 26: Locating RH Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
NOTE: On All-Wheel Drive (AWD) vehicles the Catalyst Monitor Sensor (CMS) electrical connector was disconnected during the engine removal procedure.
28. Disconnect the HO2S and CMS electrical connectors.
    • Detach the 2 wiring harness retainers from the RH valve cover.
      Fig 27: Locating HO2S Connector, CMS Connector And Retainers

      Courtesy of FORD MOTOR CO.
29. Disconnect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors.
    • Detach the 2 wiring harness retainers.
      Fig 28: Locating Variable Camshaft Timing Oil Control Solenoid Electrical Connectors And Retainers

      Courtesy of FORD MOTOR CO.
30. Disconnect the 3 fuel injector electrical connectors.
    • Detach the 2 wiring harness retainers.
      Fig 29: Locating Fuel Injector Electrical Connectors And Retainers

      Courtesy of FORD MOTOR CO.
31. Detach the wiring harness retainer.
    Fig 30: Locating Wiring Harness Retainer

    Courtesy of FORD MOTOR CO.
32. Disconnect the 2 RH Camshaft Position Camshaft Position (CMP) sensor electrical connectors.
    Fig 31: Locating RH Camshaft Position Camshaft Position Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
33. Disconnect the Knock Sensor (KS) electrical connector.
    Fig 32: Locating Knock Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
34. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
    Fig 33: Locating Cylinder Head Temperature Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
35. Remove the bolt and the ground cable from the RH cylinder.
    Fig 34: Locating Bolt And Ground Cable At RH Cylinder

    Courtesy of FORD MOTOR CO.
36. Remove the nut, the bolt and the heat shield.
    Fig 35: Locating Nut, Bolt And Heat Shield

    Courtesy of FORD MOTOR CO.
37. Remove the wiring harness retainer stud bolt.
    Fig 36: Locating Wiring Harness Retainer Stud Bolt

    Courtesy of FORD MOTOR CO.
38. Remove the wiring harness grommet.
    Fig 37: Locating Wiring Harness Grommet

    Courtesy of FORD MOTOR CO.
39. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 38: Locating Crankshaft Position (CKP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
40. Disconnect the A/C compressor electrical connector.
    Fig 39: Locating A/C Compressor Electrical Connector

    Courtesy of FORD MOTOR CO.
41. Remove the nut and disconnect the generator B+ cable.
    Fig 40: Locating Nut And Generator B+ Cable

    Courtesy of FORD MOTOR CO.
42. Disconnect the generator electrical connector.
    Fig 41: Locating Generator Electrical Connector

    Courtesy of FORD MOTOR CO.
43. Detach the wiring harness retainer from the generator.
    Fig 42: Locating Wiring Harness Retainer At Generator

    Courtesy of FORD MOTOR CO.
44. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness pin-type retainer.
    • Remove the wiring harness from the engine.
      Fig 43: Locating Engine Oil Pressure Switch Electrical Connector And Pin-Type Retainer

      Courtesy of FORD MOTOR CO.
45. Remove the nut, 2 bolts and the A/C compressor.
    Fig 44: Locating Nut, Bolts And A/C Compressor

    Courtesy of FORD MOTOR CO.
46. Remove the A/C compressor mounting stud from the oil pan.
    Fig 45: Locating A/C Compressor Mounting Stud At Oil Pan

    Courtesy of FORD MOTOR CO.
47. Remove the nut, bolt and the generator.
    Fig 46: Locating Nut, Bolt And Generator

    Courtesy of FORD MOTOR CO.
48. Remove the 2 nuts and position aside the 2 power steering hose brackets.
    Fig 47: Locating Nuts And Power Steering Hose Brackets

    Courtesy of FORD MOTOR CO.
NOTE: Power steering hoses removed from graphic for clarity.
Fig 48: Locating Bolts And Power Steering Pump
Courtesy of FORD MOTOR CO.
49. Remove the 3 bolts and the power steering pump.
NOTE: If necessary, lubricate the Heated Oxygen Sensor (HO2S) with penetrating and lock lubricant to assist in removal.
Fig 49: Locating LH Heated Oxygen Sensor
Courtesy of FORD MOTOR CO.
50. Remove the LH Heated Oxygen Sensor (HO2S).
51. Remove the 3 bolts and the LH exhaust heat shield.
    Fig 50: Locating Bolts And LH Exhaust Heat Shield

    Courtesy of FORD MOTOR CO.
52. Remove the 6 nuts and the LH catalytic converter.
    • Discard the nuts and the gasket.
      Fig 51: Locating Nuts And LH Catalytic Converter

      Courtesy of FORD MOTOR CO.
53. Clean and inspect the catalytic converter flange. For additional information, refer to exhaust manifold cleaning and inspection in ENGINE SYSTEM - GENERAL INFORMATION .
54. Remove and discard the 6 LH exhaust manifold studs.
    Fig 52: Locating LH Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

55. Remove the 4 nuts and the RH catalytic converter.
    • Discard the nuts and the gasket.
      Fig 53: Locating Nuts And RH Catalytic Converter

      Courtesy of FORD MOTOR CO.

    All vehicles 

NOTE: Heat shield removed from graphic for clarity.
56. Remove the 6 nuts and the RH exhaust manifold.
    • Discard the nuts and exhaust manifold gaskets.
      Fig 54: Locating Nuts And RH Exhaust Manifold

      Courtesy of FORD MOTOR CO.
57. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
58. Remove and discard the 6 RH exhaust manifold studs.
    Fig 55: Locating RH Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.
59. Remove the RH cylinder block drain plug or, if equipped, the block heater.
    • Allow coolant to drain from the cylinder block.
      Fig 56: Locating RH Cylinder Block Drain Plug

      Courtesy of FORD MOTOR CO.
60. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
      Fig 57: Locating LH Cylinder Block Drain Plug

      Courtesy of FORD MOTOR CO.
61. Remove the pin-type retainer and the cover.
    Fig 58: Locating Pin-Type Retainer And Cover

    Courtesy of FORD MOTOR CO.
62. Remove the 2 bolts and the 2 LH CMP sensors.
    Fig 59: Locating Bolts And LH CMP Sensors

    Courtesy of FORD MOTOR CO.
63. Remove the 2 bolts and the 2 RH CMP sensors.
    Fig 60: Locating Bolts And RH CMP Sensors

    Courtesy of FORD MOTOR CO.
64. Remove the 2 thermostat housing-to-lower intake manifold bolts.
    Fig 61: Locating Thermostat Housing-To-Lower Intake Manifold Bolts

    Courtesy of FORD MOTOR CO.
NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
65. Remove the 10 bolts and the lower intake manifold.
    • Remove and discard the intake manifold and thermostat housing gaskets.
    • Clean and inspect all sealing surfaces.
      Fig 62: Locating Bolts And Lower Intake Manifold

      Courtesy of FORD MOTOR CO.
66. Remove the coolant inlet tube and thermostat assembly.
    • Remove and discard the O-ring seal.
      Fig 63: Locating Coolant Inlet Tube And Thermostat Assembly

      Courtesy of FORD MOTOR CO.
67. Disconnect and remove the CHT sensor jumper harness.
    Fig 64: Locating CHT Sensor Jumper Harness

    Courtesy of FORD MOTOR CO.
68. Remove the bolt and the CKP sensor.
    Fig 65: Locating Bolt And CKP Sensor

    Courtesy of FORD MOTOR CO.
69. Remove the EOP switch.
    Fig 66: Locating EOP Switch

    Courtesy of FORD MOTOR CO.
70. Remove the 3 bolts and the oil filter adapter.
    • Discard the gasket.
      Fig 67: Locating Bolts And Oil Filter Adapter

      Courtesy of FORD MOTOR CO.
71. Remove the 3 bolts and the 3 LH-coil-on-plugs.
    Fig 68: Locating Bolts And LH-Coil-On-Plugs

    Courtesy of FORD MOTOR CO.
NOTE: While removing the valve cover do not apply excessive force to the Variable Camshaft Timing (VCT) oil control solenoid or damage may occur.
NOTE: If the Variable Camshaft Timing (VCT) oil control solenoid sticks to the VCT seal, carefully wiggle the valve cover until the bond breaks free or damage to the VCT seal and VCT oil control solenoid may occur.
72. Loosen the 4 bolts and 7 stud bolts.
    • Remove the LH valve cover.
    • Discard the gasket.
      Fig 69: Locating LH Valve Cover Bolts And Stud Bolts

      Courtesy of FORD MOTOR CO.
73. Remove the 3 bolts and the 3 RH-coil-on-plugs.
    Fig 70: Locating Bolts And RH-Coil-On-Plugs

    Courtesy of FORD MOTOR CO.
NOTE: While removing the valve cover do not apply excessive force to the Variable Camshaft Timing (VCT) oil control solenoid or damage may occur.
NOTE: If the Variable Camshaft Timing (VCT) oil control solenoid sticks to the VCT seal, carefully wiggle the valve cover until the bond breaks free or damage to the VCT seal and VCT oil control solenoid may occur.
74. Loosen the 3 bolts and 8 stud bolts.
    • Remove the RH valve cover.
    • Discard the gasket.
      Fig 71: Locating RH Valve Cover Bolts And Stud Bolts

      Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
75. Inspect the VCT solenoid seals. Remove any damaged seals.
    • Using the Differential Bearing Cone Installer and Handle, remove and discard the seal(s).
      Fig 72: Removing VCT Solenoid Seals Using Differential Bearing Cone Installer And Handle

      Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
76. Inspect the spark plug tube seals. Remove any damaged seals.
    • Using the Spark Plug Tube Seal Remover and Handle, remove and discard the seal(s).
      Fig 73: Removing Spark Plug Tube Seals Using Spark Plug Tube Seal Remover And Handle

      Courtesy of FORD MOTOR CO.
77. Clean the valve covers, cylinder heads and engine front cover sealing surfaces with metal surface prep.
78. Remove the 26 front cover bolts.
    Fig 74: Identifying Engine Front Cover Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
79. Using a suitable pry tool, locate the 7 pry pads shown in illustration and pry the engine front cover loose and remove.
    Fig 75: Locating Engine Front Cover Pry Pads

    Courtesy of FORD MOTOR CO.
80. Rotate the crankshaft clockwise and align the timing marks on the intake Variable Camshaft Timing (VCT) assemblies as shown in illustration.
    Fig 76: Locating Timing Marks On Intake Variable Camshaft Timing Assemblies

    Courtesy of FORD MOTOR CO.
81. Remove the 3 bolts and the LH valve train oil tube.
    Fig 77: Locating Bolts And LH Valve Train Oil Tube

    Courtesy of FORD MOTOR CO.
NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.
Fig 78: Identifying LH Camshaft Holding Tool
Courtesy of FORD MOTOR CO.
82. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
83. Remove the 3 bolts and the RH valve train oil tube.
    Fig 79: Locating Bolts And RH Valve Train Oil Tube

    Courtesy of FORD MOTOR CO.
NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Fig 80: Identifying RH Camshaft Holding Tool
Courtesy of FORD MOTOR CO.
NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.
84. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
85. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown in illustration.
    Fig 81: Locating Timing Mark On LH Intake VCT Assembly And Timing Chain Link

    Courtesy of FORD MOTOR CO.
86. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown in illustration.
    Fig 82: Locating Timing Mark On RH Intake VCT Assembly And Timing Chain Link

    Courtesy of FORD MOTOR CO.
NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Fig 83: Locating Marked Timing Chain Links With Timing Mark On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
87. Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown in illustration.
88. Remove the 2 bolts and the primary timing chain tensioner.
    Fig 84: Locating Bolts And Primary Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
89. Remove the primary timing chain tensioner arm.
    Fig 85: Locating Primary Timing Chain Tensioner Arm

    Courtesy of FORD MOTOR CO.
90. Remove the 2 bolts and the lower LH primary timing chain guide.
    Fig 86: Locating Bolts And Lower LH Primary Timing Chain Guide

    Courtesy of FORD MOTOR CO.
NOTE: Removal of the VCT oil control solenoid will aid in the removal of the primary timing chain.
NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.
NOTE: Keep the VCT oil control solenoid clean of dirt and debris.
Fig 87: Locating Bolt And LH Intake VCT Oil Control Solenoid
Courtesy of FORD MOTOR CO.
91. Remove the bolt and the LH intake VCT oil control solenoid.
NOTE: Removal of the VCT oil control solenoid will aid in the removal of the primary timing chain.
NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.
NOTE: Keep the VCT oil control solenoid clean of dirt and debris.
Fig 88: Locating Bolt And RH Intake VCT Oil Control Solenoid
Courtesy of FORD MOTOR CO.
92. Remove the bolt and the RH intake VCT oil control solenoid.
93. Remove the primary timing chain.
    Fig 89: Locating Primary Timing Chain

    Courtesy of FORD MOTOR CO.
NOTE: Do not use power tools to remove the bolt or damage to the LH primary timing chain guide may occur.
Fig 90: Locating Bolt And Upper LH Primary Timing Chain Guide
Courtesy of FORD MOTOR CO.
94. Remove the bolt and the upper LH primary timing chain guide.
95. Remove the crankshaft timing chain sprocket.
    Fig 91: Locating Crankshaft Timing Chain Sprocket

    Courtesy of FORD MOTOR CO.
NOTE: The 2 VCT oil control solenoids are removed for clarity.
NOTE: The Secondary Chain Hold Down is inserted through a hole in the top of the mega cap.
Fig 92: Locating Secondary Chain Hold Down And Secondary Timing Chain Tensioner Guide
Courtesy of FORD MOTOR CO.
96. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.
97. Remove and discard the 2 LH VCT assembly bolts.
    Fig 93: Locating LH VCT Assembly Bolts

    Courtesy of FORD MOTOR CO.
98. Remove the 2 LH VCT assemblies and secondary timing chain.
    • Remove the Secondary Chain Hold Down.
      Fig 94: Locating LH VCT Assemblies And Secondary Timing Chain

      Courtesy of FORD MOTOR CO.
NOTE: When the Camshaft Holding Tool is removed, valve spring pressure may rotate the LH camshafts approximately 3 degrees to a neutral position.
Fig 95: Identifying Camshaft Holding Tool
Courtesy of FORD MOTOR CO.
99. Remove the Camshaft Holding Tool from the LH camshafts.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
NOTE: Mark the exhaust and intake camshafts for installation into their original locations.
Fig 96: Locating Bolts, Camshaft Caps, Mega Cap And LH Camshafts
Courtesy of FORD MOTOR CO.
100. Remove the 12 bolts, 6 camshaft caps, mega cap and the LH camshafts.
NOTE: The 2 VCT oil control solenoids are removed for clarity.
NOTE: The Secondary Chain Hold Down is inserted through a hole in the top of the mega cap.
Fig 97: Locating Secondary Chain Hold Down And Secondary Timing Chain Tensioner Guide
Courtesy of FORD MOTOR CO.
101. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.
102. Remove and discard the 2 RH VCT assembly bolts.
     Fig 98: Locating RH VCT Assembly Bolts

     Courtesy of FORD MOTOR CO.
103. Remove the 2 RH VCT assemblies and secondary timing chain.
     • Remove the Secondary Chain Hold Down.
       Fig 99: Locating RH VCT Assemblies And Secondary Timing Chain

       Courtesy of FORD MOTOR CO.
NOTE: Do not use power tools to remove the bolt or damage to the RH primary timing chain guide may occur.
Fig 100: Locating Bolt And RH Primary Timing Chain Guide
Courtesy of FORD MOTOR CO.
104. Remove the bolt and the RH primary timing chain guide.
NOTE: When the Camshaft Holding Tool is removed, valve spring pressure may rotate the RH camshafts approximately 3 degrees to a neutral position.
Fig 101: Identifying Camshaft Holding Tool
Courtesy of FORD MOTOR CO.
105. Remove the Camshaft Holding Tool from the RH camshafts.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
NOTE: Mark the exhaust and intake camshafts for installation into their original locations.
Fig 102: Locating Bolts, Camshaft Caps, Mega Cap And RH Camshafts
Courtesy of FORD MOTOR CO.
106. Remove the 12 bolts, 6 camshaft caps, mega cap and the RH camshafts.
107. Remove the 2 bolts and the engine lifting eye.
     Fig 103: Locating Bolts And Engine Lifting Eye

     Courtesy of FORD MOTOR CO.
NOTE: Index-mark the location of the bracket on the cylinder head for installation.
Fig 104: Locating Bolt And Upper Intake Manifold Bracket
Courtesy of FORD MOTOR CO.
108. Remove the bolt and the upper intake manifold bracket.
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 in illustration, RH similar.
Fig 105: Locating Valve Tappets
Courtesy of FORD MOTOR CO.
109. Remove the valve tappets from the cylinder heads.
NOTE: LH shown in illustration, RH similar.
Fig 106: Locating M6 Bolt
Courtesy of FORD MOTOR CO.
110. Remove and discard the M6 bolt from each cylinder head.
NOTE: 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.
NOTE: Aluminum surfaces are soft and can 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 designed and cannot be reused.
NOTE: LH shown in illustration, RH similar.
111. Remove and discard the 8 bolts from each cylinder head.
     • Remove the cylinder heads.
     • Discard the cylinder head gaskets.
       Fig 107: Locating Cylinder Head Bolts

       Courtesy of FORD MOTOR CO.
NOTE: 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 head 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.
112. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence.
     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.
     5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
113. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
114. Remove the 2 bolts and the KS.
     Fig 108: Locating Bolts And Knock Sensor

     Courtesy of FORD MOTOR CO.
115. Remove the 8 bolts and the coolant pump.
     Fig 109: Locating Bolts And Coolant Pump

     Courtesy of FORD MOTOR CO.
116. Remove the 16 oil pan bolts.
     Fig 110: Locating Oil Pan Bolts

     Courtesy of FORD MOTOR CO.
NOTE: Oil pan shown in illustration removed from engine for clarity.
Fig 111: Locating Oil Pan Pry Pads
Courtesy of FORD MOTOR CO.
117. Using a suitable pry tool, locate the 5 pry pads shown in illustration and pry the oil pan loose and remove.
118. Remove the 2 bolts and the oil pump screen and pickup tube.
     • Discard the O-ring seal.
       Fig 112: Locating Bolts, Oil Pump Screen And Pickup Tube

       Courtesy of FORD MOTOR CO.
119. Remove the 3 bolts and the oil pump.
     Fig 113: Locating Oil Pump Bolts

     Courtesy of FORD MOTOR CO.
120. Remove the 8 crankshaft rear seal retainer bolts.
     Fig 114: Locating Crankshaft Rear Seal Retainer Bolts

     Courtesy of FORD MOTOR CO.
121. Install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal retainer.
     • Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released.
       • Remove the crankshaft rear seal retainer.
         Fig 115: Locating M6 Oil Pan Bolts

         Courtesy of FORD MOTOR CO.
NOTE: 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.
122. Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M™ Roloc® Bristle Disk (2 inch, 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.
123. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
NOTE: The main bearing cap support brace bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
124. Remove the bolts in the sequence shown in illustration.
     • Remove the main bearing cap support brace.
     • Discard the bolts.
       Fig 116: Identifying Main Bearing Cap Support Brace Bolts Removing Sequence

       Courtesy of FORD MOTOR CO.
NOTE: The connecting rod cap bolts are a torque-to-yield design. The original connecting rod cap bolts will be used when measuring the connecting rod large end bore during assembly. The connecting rod cap bolts will be discarded after measurement.
NOTE: Clearly mark the position and orientation of the connecting rods, connecting rod caps and connecting rod bearings for reassembly.
Fig 117: Locating Connecting Rod Cap Bolts And Cap
Courtesy of FORD MOTOR CO.
125. Remove the connecting rod cap bolts and cap.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Fig 118: Removing Piston/Rod Assembly From Engine Block
Courtesy of FORD MOTOR CO.
126. Remove the piston/rod assembly from the engine block.
127. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
NOTE: The 8 main bearing cap side bolts and the 8 main bearing cap bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.
128. Remove the 8 main bearing cap side bolts and the 8 main bearing cap bolts in the sequence shown in illustration.
     • Discard the bolts.
       Fig 119: Identifying Main Bearing Cap Side Bolts And Main Bearing Cap Bolts Removing Sequence

       Courtesy of FORD MOTOR CO.
NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.
Fig 120: Locating Main Bearing Caps
Courtesy of FORD MOTOR CO.
129. Remove the 4 main bearing caps.
NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
Fig 121: Locating Crankshaft
Courtesy of FORD MOTOR CO.
130. Remove the crankshaft.
NOTE: Inside shown in illustration, outside similar.
Fig 122: Locating Crankshaft Thrust Bearing In Rear Main Bearing Bulkhead
Courtesy of FORD MOTOR CO.
131. Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.
NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Fig 123: Locating Crankshaft Main Bearings In Cylinder Block
Courtesy of FORD MOTOR CO.
132. Remove the 4 crankshaft main bearings from the cylinder block.
NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Fig 124: Locating Crankshaft Main Bearings In Main Bearing Caps
Courtesy of FORD MOTOR CO.
133. Remove the 4 crankshaft main bearings from the main bearing caps.
134. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
NOTE: 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.
NOTE: 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.
135. Clean the 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 locating dowel pins are seated correctly in the cylinder block.