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Section 1990 (Engine - 3.0L (4V)): Disassembly: Engine

WARNING: This page is about a different car, the 2007 Mercury Mariner and 2007 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0024234
 Plate, Water Pump Pulley 303-456 (T94P-6312-AH1), part of 303-S455
GF0024235
 Protector, Water Pump Shaft 303-457 (T94P-6312-AH2), part of 303-S455
GF0000317
 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
GF0000385
 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
GF0000249
 Remover, Oil Seal 303-409 (T92C-6700CH)
GF0003558
 Slide Hammer 307-005 (T59L-100-B)
GF0000246
 Strap Wrench 303-D055 (D85L-6000-A)
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 bolts and the flexplate.
    2. Fig 1: Locating Flexplate & Bolts
    GF0024303Courtesy of FORD MOTOR CO.
  2. Using the special tools, remove and discard the crankshaft rear oil seal.
    3. Fig 2: Identifying Special Tools (307-005 And 303-519)
    G03898286Courtesy of FORD MOTOR CO.
  3. Mount the engine on a suitable stand.
  4. Detach the engine control sensor wiring connectors from the upper intake manifold.
    5. Fig 3: Locating Engine Control Sensor Wiring Connectors
    GF0024304Courtesy of FORD MOTOR CO.
  5. Detach the wiring retainer, remove the nut and the heated oxygen sensor (HO2S) electrical connector bracket.
    6. Fig 4: Locating Heated Oxygen Sensor (HO2S) Electrical Connector Bracket
    GF0024305Courtesy of FORD MOTOR CO.
  6. Disconnect the exhaust gas recirculation (EGR) vacuum regulator electrical connector and remove the nut. Detach the wiring harness retainer.
    7. Fig 5: Locating Exhaust Gas Recirculation (EGR) Vacuum Regulator Electrical Connector
    GF0024306Courtesy of FORD MOTOR CO.
  7. Disconnect the knock sensor (KS) electrical connector.
    8. Fig 6: Locating Knock Sensor (KS) Electrical Connector
    GF0024307Courtesy of FORD MOTOR CO.
  8. Remove the nuts and the engine control wire harness.
    9. Fig 7: Locating Engine Control Wiring Harness & Nuts
    GF0024308Courtesy of FORD MOTOR CO.
  9. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors, and detach the wiring retainer.
    10. Fig 8: Idle Air Control Valve & Throttle Position Sensor Electrical Connectors
    GF0024309Courtesy of FORD MOTOR CO.
  10. Remove the positive crankcase ventilation (PCV) tube.
    11. Fig 9: Locating Positive Crankcase Ventilation (PCV) Tube
    GF0024310Courtesy of FORD MOTOR CO.
  11. Disconnect the vacuum tube fittings from the EGR valve, EGR vacuum regulator and the intake manifold.
    12. Fig 10: Vacuum Tube Fittings At EGR Valve, EGR Vacuum Regulator & Intake Manifold
    GF0024311Courtesy of FORD MOTOR CO.
  12. Disconnect the throttle body coolant hose.
    13. Fig 11: Locating Throttle Body Coolant Hose
    GF0024312Courtesy of FORD MOTOR CO.
  13. Remove the bolts and upper intake manifold.
    • Discard the gaskets.
    14. Fig 12: Locating Upper Intake Manifold Bolts
    GF0024313Courtesy of FORD MOTOR CO.
  14. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    15. Fig 13: Locating Engine Coolant Temperature (ECT) Sensor Electrical Connector
    GF0024314Courtesy of FORD MOTOR CO.
  15. Disconnect the RH coil-on-plug electrical connectors and detach the wiring retainer.
    16. Fig 14: Coil-On-Plug Electrical Connectors & Wiring Retainers
    GF0024315Courtesy of FORD MOTOR CO.
  16. Disconnect the radio interference capacitor electrical connector and detach the wiring retainers.
    17. Fig 15: Locating Radio Interference Capacitor Electrical Connector
    GF0024316Courtesy of FORD MOTOR CO.
  17. Disconnect the LH coil-on-plug electrical connectors and detach the 2 wiring retainers.
    18. Fig 16: Coil-On-Plug Electrical Connectors & Wiring Retainers
    GF0024317Courtesy of FORD MOTOR CO.
  18. Disconnect the camshaft position sensor (CMP) and oil pressure sensor electrical connectors and detach the wiring retainers.
    19. Fig 17: Locating Camshaft Position Sensor (CMP) & Oil Pressure Sensor Electrical Connectors & Wiring Retainers
    GF0024318Courtesy of FORD MOTOR CO.
  19. Disconnect the crankshaft position (CKP) sensor electrical connector and detach the wiring retainers.
    20. Fig 18: Locating Crankshaft Position (CKP) Sensor Electrical Connector
    GF0024319Courtesy of FORD MOTOR CO.
  20. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
    • Remove the engine vacuum harness.
    21. Fig 19: Locating Fuel Rail Pressure & Temperature Sensor Electrical Connector
    GF0024320Courtesy of FORD MOTOR CO.
  21. Disconnect the fuel injector electrical connectors and remove the fuel charging wiring harness.
    22. Fig 20: Locating Fuel Injector Electrical Connectors
    GF0024321Courtesy of FORD MOTOR CO.
  22. Remove the bolts and the lower intake manifold.
    • Discard the gaskets.
    23. Fig 21: Locating Lower Intake Manifold Bolts
    GF0024322Courtesy of FORD MOTOR CO.
    CAUTION: When removing the coil-on-plugs, a slight twisting motion will break the seal and ease removal.
    NOTE: LH shown, RH similar.
  23. Remove the bolts and the 6 coil-on-plugs.
    24. Fig 22: Coil-On-Plug Bolts
    GF0024323Courtesy of FORD MOTOR CO.
  24. Remove the nut and the radio interference capacitor.
    25. Fig 23: Locating Radio Interference Capacitor Nut
    GF0024324Courtesy of FORD MOTOR CO.
  25. Remove the bolts and the RH valve cover.
    • Discard the gasket.
    26. Fig 24: Locating RH Valve Cover Bolts
    GF0024325Courtesy of FORD MOTOR CO.
  26. Remove the bolt and the engine lift bracket.
    27. Fig 25: Locating Lift Bracket & Bolt
    GF0024326Courtesy of FORD MOTOR CO.
  27. Remove the bolts and the LH valve cover.
    • Discard the gasket.
    28. Fig 26: Locating LH Valve Cover Bolts
    GF0024327Courtesy of FORD MOTOR CO.

    Front wheel drive (FWD) vehicles 

  28. Remove the nuts, the RH exhaust manifold and the gasket.
    • Discard the gasket and nuts.
    29. Fig 27: Locating Gasket & Nuts
    GF0024328Courtesy of FORD MOTOR CO.
  29. Remove and discard the 6 RH exhaust manifold studs.
    30. Fig 28: Locating Exhaust Manifold Studs
    G03898429Courtesy of FORD MOTOR CO.
  30. Remove the bolts and the halfshaft support bracket.
    31. Fig 29: Locating Halfshaft Support Bracket & Bolts
    GF0024329Courtesy of FORD MOTOR CO.

    All vehicles 

  31. Remove the nuts, the LH exhaust manifold and the gasket.
    • Discard the gasket and nuts.
    32. Fig 30: Locating LH Exhaust Manifold & Gasket
    GF0024330Courtesy of FORD MOTOR CO.
  32. Remove and discard the 6 LH exhaust manifold studs.
    33. Fig 31: Locating Exhaust Manifold Studs
    G03898429Courtesy of FORD MOTOR CO.
  33. Remove and discard the oil filter.
    34. Fig 32: Locating Oil Filter
    GF0024331Courtesy of FORD MOTOR CO.
  34. Cut and remove the coolant pump belt.
    35. Fig 33: Cutting Coolant Pump Belt
    GF0024332Courtesy of FORD MOTOR CO.
  35. Disconnect the hoses.
    36. Fig 34: Locating Hoses
    GF0024333Courtesy of FORD MOTOR CO.
  36. Remove the 3 bolts and the coolant pump.
    37. Fig 35: Locating Coolant Pump & Bolts
    GF0024334Courtesy of FORD MOTOR CO.
  37. Disconnect the hoses and remove the coolant tube.
    38. Fig 36: Locating Coolant Tube
    GF0024335Courtesy of FORD MOTOR CO.
  38. Remove the nut, bolt and the coolant bypass tube.
    39. Fig 37: Locating Coolant Bypass Tube Bolt & Nut
    GF0024336Courtesy of FORD MOTOR CO.
  39. Remove the stud bolt and the oil level indicator and tube.
    • Remove and discard the O-ring seal.
    40. Fig 38: Positioning Oil Level Indicator Tube
    GF0024337Courtesy of FORD MOTOR CO.
  40. Remove the bolts, studs and the oil pan.
    • Discard the gasket.
    41. Fig 39: Locating Oil Pan Gasket Bolts & Stud Bolts
    GF0024338Courtesy of FORD MOTOR CO.
  41. Remove the bolts, nut and the oil pump screen and pickup tube.
    42. Fig 40: Locating Oil Pump Screen & Pickup Tube Bolts
    GF0024256Courtesy of FORD MOTOR CO.
  42. Remove and discard the O-ring seal.
    43. Fig 41: Locating O-Ring Seal
    GF0024339Courtesy of FORD MOTOR CO.
  43. Remove the nuts and the oil pan baffle.
    44. Fig 42: Locating Oil Pan Baffle Nuts
    GF0024340Courtesy of FORD MOTOR CO.
  44. Remove the oil pressure sender and, if equipped, the block heater.
    45. Fig 43: Locating Oil Pressure Sender
    GF0024341Courtesy of FORD MOTOR CO.
  45. Remove the bolt and the KS.
    46. Fig 44: Locating Knock Sensor (KS) & Bolt
    GF0024342Courtesy of FORD MOTOR CO.
  46. Use the special tool to hold the crankshaft damper and remove the bolt.
    47. Fig 45: Locating Special Tool (303-D055) And Crankshaft Pulley Bolt
    GF0024221Courtesy of FORD MOTOR CO.
  47. Using the special tool, remove the crankshaft damper.
    48. Fig 46: Removing Crankshaft Pulley Using Special Tool (303-009)
    GF0024222Courtesy of FORD MOTOR CO.
  48. Remove and discard the crankshaft front seal from the front cover.
    49. Fig 47: Removing Crankshaft Front Seal Using Special Tool (303-409)
    GF0024224Courtesy of FORD MOTOR CO.
  49. Remove the bolt and the idler pulley.
    50. Fig 48: Locating Idler Pulley & Bolt
    GF0024343Courtesy of FORD MOTOR CO.
  50. Remove the bolt and the belt tensioner.
    51. Fig 49: Locating Belt Tensioner & Bolt
    GF0024344Courtesy of FORD MOTOR CO.
    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
  51. Remove the bolts, studs and the front cover.
    • Discard the gaskets.
    52. Fig 50: Locating Engine Front Cover Bolts
    GF0024345Courtesy of FORD MOTOR CO.
    CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30RFF" (orange in color).
  52. Remove the ignition pulse wheel.
    53. Fig 51: Identifying Ignition Pulse Wheel
    G03898322Courtesy of FORD MOTOR CO.
  53. Install the damper bolt.
    54. Fig 52: Identifying Damper Bolt
    G03898296Courtesy of FORD MOTOR CO.
    CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
    NOTE: LH shown, RH similar.
  54. Remove the LH and RH spark plugs.
    55. Fig 53: Spark Plugs
    GF0024346Courtesy of FORD MOTOR CO.
  55. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number one cylinder at top dead center (TDC).
    • Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
    56. Fig 54: Identifying Crankshaft Keyway In 11 O'Clock Position
    G03898298Courtesy of FORD MOTOR CO.
  56. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
    57. Fig 55: Identifying Crankshaft Keyway
    G03898299Courtesy of FORD MOTOR CO.
  57. Verify that the RH camshafts are in the neutral position.
    58. Fig 56: Locating Camshafts Align Marks
    G03898496Courtesy of FORD MOTOR CO.
  58. Remove the RH timing chain tensioner arm.
    1. Remove the bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
    59. Fig 57: Identifying RH Timing Chain Tensioner Arm & Bolts
    GF0017028Courtesy of FORD MOTOR CO.
  59. Remove the bolts, RH timing chain guide and the timing chain.
    60. Fig 58: Locating Timing Chain Guide & Bolts
    G03898302Courtesy of FORD MOTOR CO.
  60. Rotate the crankcase clockwise 600 degrees (1-2/3 turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
    61. Fig 59: Positioning Crankcase Key Way In 11 O'Clock Position
    G03898303Courtesy of FORD MOTOR CO.
  61. Verify the LH camshafts are in the neutral position.
    62. Fig 60: Locating Camshafts Aligning Marks
    G03955709Courtesy of FORD MOTOR CO.
  62. Remove the LH timing chain and tensioner arm.
    1. Remove the bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
    63. Fig 61: Locating LH Timing Chain & Tensioner Arm
    GF0017029Courtesy of FORD MOTOR CO.
  63. Remove the LH timing chain and timing chain guide.
    64. Fig 62: Locating Timing Chain & Timing Chain Guide
    G03898306Courtesy of FORD MOTOR CO.
  64. Remove the damper bolt and the crankshaft sprockets.
    65. Fig 63: Locating Damper Bolt & Crankshaft Sprockets
    G03898307Courtesy of FORD MOTOR CO.
    CAUTION: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
  65. Using the special tools, remove the coolant pump pulley.
    66. Fig 64: Removing Coolant Pump Pulley
    GF0024237Courtesy of FORD MOTOR CO.
    CAUTION: To make sure of correct sealing, do not scratch the camshaft.
  66. Using the special tools, remove the camshaft oil seal and discard.
    67. Fig 65: Identifying Special Tools (303-409)
    GF0024238Courtesy of FORD MOTOR CO.
  67. Remove the 2 bolts and the camshaft oil seal retainer.
    • Discard the press-in-place gasket.
    68. Fig 66: Locating Camshaft Oil Seal Retainer And Bolts
    GF0024347Courtesy of FORD MOTOR CO.
    CAUTION: Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in illustration). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original position may result in severe engine damage.
  68. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
    69. Fig 67: Marking Camshaft Bearing Caps
    GF0024240Courtesy of FORD MOTOR CO.
    CAUTION: After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (1L and 6L) first, or damage to the thrust caps may occur.
    NOTE: Make sure the camshaft bearing caps are marked as instructed in the previous step.
  69. Loosen the bolts evenly in the sequence shown.
    1. Remove the camshaft bearing thrust caps (1L and 6L).
    2. Remove the remaining camshaft bearing caps.
    3. Remove the camshafts from the cylinder head.
    70. Fig 68: Camshaft Bearing Cap Bolts Loosening Sequence
    GF0024348Courtesy of FORD MOTOR CO.
    CAUTION: Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in illustration). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original position may result in severe engine damage.
  70. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
    71. Fig 69: Marking Camshaft Bearing Cap Positions
    GF0024247Courtesy of FORD MOTOR CO.
    CAUTION: After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (5R and 1R) first, or damage to the thrust caps may occur.
    NOTE: Make sure the camshaft bearing caps are marked as instructed in the previous step.
  71. Loosen the bolts evenly in the sequence shown.
    1. Remove the camshaft bearing thrust caps (5R and 1R).
    2. Remove the remaining camshaft bearing caps.
    3. Remove the camshafts from the cylinder head.
    72. Fig 70: Camshaft Bearing Cap Bolts Loosening Sequence
    GF0024349Courtesy of FORD MOTOR CO.
    CAUTION: The camshaft roller followers must be installed in their original positions.
    NOTE: RH shown, LH similar.
  72. Remove the LH and RH camshaft roller followers.
    • Mark the location of the roller followers, using a permanent-type marker.
    73. Fig 71: Locating Camshaft Roller Followers
    G03898508Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  73. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
    • Discard the bolts and the gaskets.
    74. Fig 72: Identifying Cylinder Heads Bolts Loosening Sequence
    GF0017189Courtesy of FORD MOTOR CO.
  74. Support the cylinder head on a bench with the head gasket side up.
    75. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
  75. 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 (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
  76. Remove the bolts and the oil separator cover.
    • Discard the gasket.
    77. Fig 73: Locating Oil Separator Cover Bolts
    G03898510Courtesy of FORD MOTOR CO.
  77. Remove the crankshaft key.
    78. Fig 74: Locating Crankshaft Key
    G03898511Courtesy of FORD MOTOR CO.
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