Special Tool(s)

Courtesy of FORD MOTOR CO.	3 Jaw Puller 303-D121
Courtesy of FORD MOTOR CO.	Installer, Connecting Rod 303-462 (T94P-6136-AH)
Courtesy of FORD MOTOR CO.	Plate, Water Pump Pulley 303-456 (T94P-6312-AH1), part of 303-S455
Courtesy of FORD MOTOR CO.	Protector, Water Pump Shaft 303-457 (T94P-6312-AH2), part of 303-S455
Courtesy of FORD MOTOR CO.	Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
Courtesy of FORD MOTOR CO.	Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
Courtesy of FORD MOTOR CO.	Remover, Oil Seal 303-409 (T92C-6700CH)
Courtesy of FORD MOTOR CO.	Remover, Stretchy Belt 303-1419
Courtesy of FORD MOTOR CO.	Slide Hammer 307-005 (T59L-100-B)

All engines 

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

   Courtesy of FORD MOTOR CO.
2. Remove the engine-to-transaxle separator plate.
   Fig 2: Locating Engine-To-Transaxle Separator Plate

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

   Courtesy of FORD MOTOR CO.
4. Mount the engine on a suitable stand.
5. Detach the 2 B+ wiring harness retainers from the valve cover stud bolts.
   Fig 4: Locating B+ Wiring Harness Retainers From Valve Cover Stud Bolts

   Courtesy of FORD MOTOR CO.
6. Disconnect the A/C compressor clutch electrical connector.
   Fig 5: Locating A/C Compressor Clutch Electrical Connector

   Courtesy of FORD MOTOR CO.
7. Disconnect the generator electrical connector.
   Fig 6: Locating Generator Electrical Connector

   Courtesy of FORD MOTOR CO.
8. Remove the nut and the B+ wire from the generator.
   • Remove the B+ harness from the engine.
   Fig 7: Locating Generator Bolt & Nuts

   Courtesy of FORD MOTOR CO.
9. Disconnect the 3 engine wiring connectors.
   • Disconnect the engine block Knock Sensor (KS) electrical connector.
   • Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
   • Disconnect the cylinder head KS  electrical connector.
   Fig 8: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.
10. Disconnect the electronic throttle control electrical connector.
    Fig 9: Locating Electronic Throttle Control Electrical Connector

    Courtesy of FORD MOTOR CO.
11. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
    Fig 10: Locating Evaporative Emission Canister Purge Valve Electrical Connector

    Courtesy of FORD MOTOR CO.
12. Disconnect the EGR regulator electrical connector and detach the wiring retainer.
    Fig 11: Locating EGR Regulator Electrical Connector & Wiring Retainer

    Courtesy of FORD MOTOR CO.
13. Disconnect the PCV valve electrical connector.
    Fig 12: Locating PCV Valve Electrical Connector

    Courtesy of FORD MOTOR CO.
14. Detach the wiring harness retainer from the upper intake manifold.
    Fig 13: Locating Wiring Harness Retainer From Upper Intake Manifold

    Courtesy of FORD MOTOR CO.
15. Disconnect the Manifold Absolute Pressure (MAP) electrical connector and detach the wiring retainer.
    Fig 14: Locating MAP Electrical Connector & Wiring Retainer

    Courtesy of FORD MOTOR CO.
16. Disconnect the RH coil-on-plug electrical connectors.
    • Detach the 2 wiring harness retainers.
    Fig 15: Locating RH Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
17. Disconnect the RH Variable Camshaft Timing (VCT) electrical connector and detach the wiring harness retainer from the valve cover stud bolt.
    Fig 16: Locating RH VCT Electrical Connector & Wiring Harness Retainer From Valve Cover Stud Bolt

    Courtesy of FORD MOTOR CO.
18. Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the 2 wiring harness retainers.
    Fig 17: Locating Crankshaft Position (CKP) Sensor Electrical Connector & Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
19. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors and detach the wiring harness retainer from the engine front cover stud bolt.
    Fig 18: Locating Camshaft Position Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
20. Disconnect the fuel injector wiring harness electrical connector and detach the wiring harness retainer.
    Fig 19: Locating Fuel Injector Wiring Harness Electrical Connector & Wiring Harness Retainer

    Courtesy of FORD MOTOR CO.
21. Disconnect the LH VCT  electrical connector.
    Fig 20: Locating LH VCT Electrical Connector

    Courtesy of FORD MOTOR CO.
22. Remove the nut and the radio frequency interference capacitor.
    Fig 21: Locating Radio Frequency Interference Capacitor & Nut

    Courtesy of FORD MOTOR CO.
23. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wiring retainer from the oil indicator tube.
    Fig 22: Locating EOP Switch Electrical Connector & Wiring Retainer From Oil Indicator Tube

    Courtesy of FORD MOTOR CO.
24. Disconnect the 3 LH coil-on-plug electrical connectors.
    • Detach the 2 wiring harness retainers.
    Fig 23: Locating LH Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
25. Remove the 2 upper intake manifold bracket bolts (1 shown).
    Fig 24: Locating Upper Intake Manifold Bracket Bolts

    Courtesy of FORD MOTOR CO.
26. Remove the 7 bolts and the upper intake manifold.
    • Remove and discard the gaskets.
    Fig 25: Locating Upper Intake Manifold & Bolts

    Courtesy of FORD MOTOR CO.
27. Remove the 4 bolts and the fuel rail and injectors as an assembly.
    Fig 26: Locating Fuel Rail & Injectors Assembly Bolts

    Courtesy of FORD MOTOR CO.
28. Remove the 8 lower intake manifold bolts and the lower intake manifold.
    • Remove and discard the gaskets.
    Fig 27: Locating Lower Intake Manifold Bolts
    Courtesy of FORD MOTOR CO.

    FWD vehicles 

29. Remove the 3 bolts and the RH heat shield.
    Fig 28: Locating RH Heat Shield Bolts

    Courtesy of FORD MOTOR CO.
30. Remove the 3 nuts and the RH catalytic converter.
    • Discard the nuts and gasket.
    Fig 29: Locating RH Catalytic Converter Nut

    Courtesy of FORD MOTOR CO.

    All engines 

31. Remove the 6 RH exhaust manifold nuts and the manifold.
    • Discard the nuts and gasket.
    Fig 30: Locating RH Exhaust Manifold Nuts

    Courtesy of FORD MOTOR CO.
32. Clean and inspect the RH catalytic converter manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
33. Remove and discard the 6 RH catalytic converter manifold studs.
    Fig 31: Locating Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.
34. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
    Fig 32: Locating Accessory Drive Belt

    Courtesy of FORD MOTOR CO.
35. Remove the 3 bolts and the A/C compressor.
    Fig 33: Locating A/C Compressor & Bolts

    Courtesy of FORD MOTOR CO.
36. Remove the bolt, 2 nuts and the generator.
    Fig 34: Locating Generator With Bolt & Nuts

    Courtesy of FORD MOTOR CO.
37. Remove the 3 bolts and the A/C compressor bracket.
    Fig 35: Locating A/C Compressor Bracket & Bolts

    Courtesy of FORD MOTOR CO.
38. Position the Stretchy Belt Remover under the coolant pump belt as shown.
    Fig 36: Positioning Stretchy Belt Remover

    Courtesy of FORD MOTOR CO.
39. Turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant pump pulley as shown.
    NOTE: Feed the Stretchy Belt Remover on to the camshaft coolant pump pulley 90 degrees.
    Fig 37: Identifying Stretchy Belt Remover

    Courtesy of FORD MOTOR CO.
40. Remove the coolant pump belt.
    • Fold the Stretchy Belt Remover over the top of the coolant pump belt.
    • In one quick motion, pull the Stretchy Belt Remover up and toward the front of the engine removing the coolant pump belt.
    Fig 38: Removing Coolant Pump Belt

    Courtesy of FORD MOTOR CO.
41. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.
    NOTE: Failure to use the correct special tools, assembled as shown below, will result in damage to the coolant pump pulley and/or special tools.
    Fig 39: Removing Coolant Pump Pulley

    Courtesy of FORD MOTOR CO.
42. Remove the 5 coolant pump housing bolts.
    Fig 40: Identifying Coolant Pump Housing Bolts

    Courtesy of FORD MOTOR CO.
43. Loosen the clamp and detach the coolant hose.
    • Remove the coolant pump housing.
    Fig 41: Identifying Coolant Hose Clamp

    Courtesy of FORD MOTOR CO.
44. Remove the stud bolt and the oil level indicator and tube.
    • Remove and discard the O-ring seal.
    Fig 42: Locating Oil Level Indicator & Tube With Stud Bolt

    Courtesy of FORD MOTOR CO.
45. Remove the EOP  switch and, if equipped, the block heater.
    Fig 43: Locating EOP Switch

    Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
Fig 44: Locating Coil-On-Plugs And Bolts
Courtesy of FORD MOTOR CO.
46. Remove the bolts and the 6 coil-on-plugs.
47. Remove the bolts and the RH valve cover.
    • Discard the gasket.
    Fig 45: Locating RH Valve Cover With Bolts

    Courtesy of FORD MOTOR CO.
48. Remove the bolts and the LH valve cover.
    • Discard the gasket.
    Fig 46: Locating LH Valve Cover With Bolts

    Courtesy of FORD MOTOR CO.
49. Remove the 15 bolts and the oil pan.
    • Discard the gasket.
    Fig 47: Locating LH Valve Cover With Bolts

    Courtesy of FORD MOTOR CO.
50. Remove the 2 bolts and the oil pump screen and pickup tube.
    Fig 48: Locating Oil Pump Screen & Pickup Tube With Bolts

    Courtesy of FORD MOTOR CO.
51. Remove and discard the O-ring seal.
    Fig 49: Locating O-Ring Seal

    Courtesy of FORD MOTOR CO.
52. Remove the oil pan baffle.
    1. Remove the 4 M6 oil pan baffle nuts.
    2. Remove the 4 M8 oil pan baffle nuts.
    Fig 50: Identifying Oil Pan Baffle Nuts

    Courtesy of FORD MOTOR CO.
53. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 51: Locating Accessory Drive Belt Tensioner With Bolts

    Courtesy of FORD MOTOR CO.
54. Remove the crankshaft pulley bolt and washer.
    • Discard the crankshaft pulley bolt.
    Fig 52: Locating Crankshaft Pulley Bolt

    Courtesy of FORD MOTOR CO.
55. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 53: Identifying 3-Jaw Puller (303-D121) On Crankshaft Pulley

    Courtesy of FORD MOTOR CO.
56. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 54: Removing Crankshaft Front Seal

    Courtesy of FORD MOTOR CO.
57. Remove the 2 bolts and the LH VCT  .
    NOTE: Note the position of the alignment dowel on the engine front cover.
    Fig 55: Locating LH VCT Connector With Bolts

    Courtesy of FORD MOTOR CO.
58. Remove the 2 bolts and the RH VCT  .
    NOTE: Note the position of the alignment dowel on the engine front cover.
    Fig 56: Locating RH VCT With Bolts

    Courtesy of FORD MOTOR CO.
59. Remove the 14 bolts, 2 stud bolts and the engine front cover.
    • Discard the gaskets.
    NOTE: 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.
    NOTE: Note the location of all bolts and stud bolts for installation.
    Fig 57: Identifying Engine Front Cover & Stud Bolts

    Courtesy of FORD MOTOR CO.
60. Remove the LH and RH spark plugs.
    NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
    NOTE: LH shown, RH similar.
    Fig 58: Locating Spark Plugs

    Courtesy of FORD MOTOR CO.
61. Remove the ignition pulse wheel.
    NOTE: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30RFF" (orange in color).
    Fig 59: Locating Ignition Pulse Wheel

    Courtesy of FORD MOTOR CO.
62. Install the crankshaft pulley bolt and washer.
    Fig 60: Identifying Crankshaft Pulley Bolt & Washer

    Courtesy of FORD MOTOR CO.
63. 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 No. 1 cylinder at Top Dead Center (TDC).
    • Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
    Fig 61: Identifying Timing Mark Location

    Courtesy of FORD MOTOR CO.
64. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
    Fig 62: Identifying Crankshaft Keyway

    Courtesy of FORD MOTOR CO.
65. Verify that the RH camshafts are in the neutral position.
    Fig 63: Identifying Timing Mark On RH Camshafts

    Courtesy of FORD MOTOR CO.
66. Remove the RH timing chain tensioner arm.
    1. Remove the 2 bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
    Fig 64: Identifying RH Timing Chain Tensioner Arm With Bolts

    Courtesy of FORD MOTOR CO.
67. Remove the 2 bolts and the RH timing chain guide.
    • Remove the RH timing chain from the engine.
    Fig 65: Locating RH Timing Chain Guide & Bolts

    Courtesy of FORD MOTOR CO.
68. Rotate the crankcase clockwise 600 degrees (one and two-thirds turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
    Fig 66: Locating Crankcase Keyway

    Courtesy of FORD MOTOR CO.
69. Verify the LH camshafts are in the neutral position.
    Fig 67: Identifying Timing Mark On LH Camshafts

    Courtesy of FORD MOTOR CO.
70. Remove the LH timing chain and tensioner arm.
    1. Remove the 2 bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
    Fig 68: Identifying LH Timing Chain & Tensioner Arm

    Courtesy of FORD MOTOR CO.
71. Remove the 2 bolts and the LH timing chain guide.
    • Remove the LH timing chain from the engine.
    Fig 69: Locating LH Timing Chain Guide With Bolts

    Courtesy of FORD MOTOR CO.
72. Remove the crankshaft pulley bolt and the crankshaft sprocket.
    Fig 70: Locating Crankshaft Pulley Bolt & Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
73. Remove the 4 bolts in the sequence shown below.
    • Remove the oil pump.
    Fig 71: Identifying Oil Pump Bolts

    Courtesy of FORD MOTOR CO.
74. Using the Oil Seal Remover, remove the camshaft oil seal and discard.
    NOTE: Do not scratch the camshaft sealing surface while removing the camshaft oil seal. If scratched, camshaft oil seal leakage may occur.
    Fig 72: Removing Camshaft Oil Seal

    Courtesy of FORD MOTOR CO.
75. Remove the 2 bolts and the camshaft oil seal retainer.
    • Discard the press-in-place gasket.
    Fig 73: Locating Camshaft Oil Seal Retainer With Bolts

    Courtesy of FORD MOTOR CO.
76. Verify the LH camshafts are in the neutral position.
    NOTE: The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
    Fig 74: Locating LH Camshafts In Neutral Position

    Courtesy of FORD MOTOR CO.
77. Remove the 3 bolts and the LH camshaft phaser and sprocket.
    NOTE: Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket or damage to the engine may occur.
    NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the camshaft phaser and sprocket bolts.
    Fig 75: Locating LH Camshaft Phaser & Sprocket With Bolts

    Courtesy of FORD MOTOR CO.
78. Remove and discard the VCT  system oil filter screen from the LH camshaft.
    Fig 76: Locating Oil Filter Screen

    Courtesy of FORD MOTOR CO.
79. If necessary, mark the camshaft bearing cap position and orientation as shown below.
    NOTE: Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown below). 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 positions may result in severe engine damage.
    Fig 77: Locating Mark Camshaft Bearing Cap Position & Orientation

    Courtesy of FORD MOTOR CO.
80. Loosen the bolts evenly in the sequence shown below.
    1. Remove the camshaft bearing thrust caps (1L and 5L).
    2. Remove the remaining camshaft bearing caps.
    3. Remove the camshafts from the cylinder head.
    NOTE: After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (1L and 5L) first, or damage to the thrust caps may occur.
    NOTE: Make sure the camshaft bearing caps are marked as instructed in the previous step.
    Fig 78: Identifying Camshaft Bearing Cap Bolts In Tightening Sequence

    Courtesy of FORD MOTOR CO.
81. Verify the RH camshafts are in the neutral position.
    NOTE: The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
    Fig 79: Locating RH Camshafts Correctly Position

    Courtesy of FORD MOTOR CO.
82. Remove the 3 bolts and the RH camshaft phaser and sprocket.
    NOTE: Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket or damage to the engine may occur.
    NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the camshaft phaser and sprocket bolts.
    Fig 80: Locating RH Camshaft Phaser & Sprocket Bolts

    Courtesy of FORD MOTOR CO.
83. Remove and discard the VCT  system oil filter screen from the RH camshaft.
    Fig 81: Locating VCT System Oil Filter Screen From RH Camshaft

    Courtesy of FORD MOTOR CO.
84. If necessary, mark the camshaft bearing cap position and orientation as shown below.
    NOTE: Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown below). 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 positions may result in severe engine damage.
    Fig 82: Locating Mark Camshaft Bearing Cap Position & Orientation

    Courtesy of FORD MOTOR CO.
85. Loosen the bolts evenly in the sequence shown below.
    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.
    NOTE: 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.
    Fig 83: Identifying Camshaft Bearing Caps Bolts In Tightening Sequence

    Courtesy of FORD MOTOR CO.
86. Remove the LH and RH camshaft roller followers.
    • Mark the location of the roller followers, using a permanent-type marker.
    NOTE: The camshaft roller followers must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
    NOTE: RH shown, LH similar.
    Fig 84: Locating Camshaft Roller Followers

    Courtesy of FORD MOTOR CO.
87. Remove the hydraulic lash adjusters.
    NOTE: The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
88. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
    • Discard the bolts and the gaskets.
    NOTE: RH shown, LH similar.
    Fig 85: Locating LH & RH Cylinder Heads Bolts In Loosening Sequence

    Courtesy of FORD MOTOR CO.
89. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to CYLINDER HEAD DISTORTION and CYLINDER BLOCK DISTORTION .
90. Remove the bolts and the oil separator cover.
    • Discard the gasket.
    Fig 86: Locating Crankcase Cover Bolts

    Courtesy of FORD MOTOR CO.
91. Remove the crankshaft key.
    Fig 87: Locating Crankshaft Key

    Courtesy of FORD MOTOR CO.
92. 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.
93. Remove the connecting rod cap bolts and cap.
    • Discard the connecting rod cap bolts.
    NOTE: Clearly mark the position and orientation of the pistons, connecting rods, connecting rod caps and connecting rod bearings for reassembly.
    Fig 88: Locating Connecting Rod Cap Bolts

    Courtesy of FORD MOTOR CO.
94. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
    • Repeat these 2 steps until all the piston/rod assemblies are removed from the engine block.
    NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 89: Removing Piston/Rod Assembly

    Courtesy of FORD MOTOR CO.
95. Remove the engine block from the stand and place on a workbench.
96. Remove the bolts and studs in the indicated sequence.
    • Discard the lower cylinder block bolts.
    • Remove the lower cylinder block.
    Fig 90: Identifying Lower Cylinder Block Bolts & Studs In Sequence

    Courtesy of FORD MOTOR CO.
97. Remove the crankshaft rear main seal.
    • Remove the crankshaft.
    Fig 91: Locating Crankshaft Rear Main Seal

    Courtesy of FORD MOTOR CO.
98. Remove the crankshaft thrust bearing from the cylinder block.
    Fig 92: Locating Crankshaft Thrust Bearing

    Courtesy of FORD MOTOR CO.
99. Remove the bearings from the lower cylinder block.
    NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
    Fig 93: Identifying Main Bearings Installation Position

    Courtesy of FORD MOTOR CO.
100. Remove the 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 94: Locating Crankshaft Main Bearings From Cylinder Block

     Courtesy of FORD MOTOR CO.
101. Inspect the cylinder block, lower cylinder block, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .