Section 2294 (Engine Mechanical - 3.5L): Disassembly: Engine: Material

All vehicles 

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

   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: Identifying Crankshaft Rear Oil Seal Remover And Slide Hammer

   Courtesy of FORD MOTOR CO.
4. Mount the engine on a suitable engine stand.
   NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.
5. If equipped, detach the block heater wiring harness retainer from the upper intake manifold.
   Fig 4: Locating Block Heater Wiring Harness Retainer From Upper Intake Manifold

   Courtesy of FORD MOTOR CO.
6. If equipped, remove the heat shield and disconnect the block heater electrical connector.
   Fig 5: Locating Block Heater Electrical Connector

   Courtesy 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.
   Fig 6: Locating Block Heater Wiring Harness

   Courtesy of FORD MOTOR CO.
8. Disconnect the PCV hose from the PCV valve.
   Fig 7: Locating PCV Hose

   Courtesy of FORD MOTOR CO.
9. Disconnect the Throttle Body (TB) electrical connector.
   Fig 8: Locating Throttle Body (TB) Electrical Connector

   Courtesy of FORD MOTOR CO.
10. Detach the wiring harness retainers from the upper intake manifold.
    Fig 9: Locating Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
11. Remove the upper intake manifold support bracket bolt.
    Fig 10: Locating Upper Intake Manifold Support Bracket Bolt

    Courtesy of FORD MOTOR CO.
12. Remove the 6 bolts and the upper intake manifold.
    • Discard the gaskets.
    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.
    Fig 11: Locating Upper Intake Manifold Bolts

    Courtesy of FORD MOTOR CO.
13. Disconnect the PSP  switch electrical connector.
    Fig 12: Locating PSP Switch Electrical Connector

    Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

14. Disconnect the RH Catalyst Monitor Sensor (CMS) sensor electrical connector.
    Fig 13: Locating RH Catalyst Monitor Sensor (CMS) Electrical Connector

    Courtesy of FORD MOTOR CO.

    All vehicles 

15. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 14: Locating RH Heated Oxygen Sensor (HO2S) Electrical Connector

    Courtesy of FORD MOTOR CO.
16. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
    Fig 15: Locating RH Variable Camshaft Timing (VCT) Solenoid Electrical Connector

    Courtesy of FORD MOTOR CO.
17. Disconnect the 3 RH coil-on-plug electrical connectors.
    Fig 16: Locating RH Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
18. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
19. Disconnect the coolant bypass hose from the thermostat housing.
    Fig 17: Locating Coolant Bypass Hose To Thermostat Housing

    Courtesy of FORD MOTOR CO.
20. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.
    Fig 18: Locating RH Camshaft Position (CMP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
21. Disconnect the Knock Sensor (KS) electrical connector.
    Fig 19: Locating Knock Sensor (KS) Electrical Connector

    Courtesy of FORD MOTOR CO.
22. Disconnect the 6 fuel injector electrical connectors (3 shown in illustration).
    Fig 20: Locating Fuel Injector Electrical Connectors

    Courtesy of FORD MOTOR CO.
23. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
    Fig 21: Identifying Cylinder Head Temperature (CHT) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
24. Disconnect the LH CMP  sensor electrical connector.
    Fig 22: Locating LH CMP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
25. Disconnect the LH CMS  sensor electrical connector.
    Fig 23: Locating LH Catalyst Monitor Sensor (CMS) Electrical Connector

    Courtesy of FORD MOTOR CO.
26. Disconnect the LH HO2S  electrical connector.
    Fig 24: Locating LH Heated Oxygen Sensor (HO2S) Electrical Connector

    Courtesy of FORD MOTOR CO.
27. Disconnect the 3 LH coil-on-plug electrical connectors.
    Fig 25: Locating LH Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
28. Disconnect the LH VCT  solenoid electrical connector.
    Fig 26: Locating LH VCT Solenoid Electrical Connector

    Courtesy of FORD MOTOR CO.
29. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
30. Remove the wiring harness retainer bolt from the rear of the LH cylinder head.
    Fig 27: Locating Wiring Harness Retainer Bolt

    Courtesy of FORD MOTOR CO.
31. Remove the nut, the bolt and the heat shield.
    Fig 28: Locating Nut, Bolt & Heat Shield

    Courtesy of FORD MOTOR CO.
32. Remove the wiring harness retainer stud bolt.
    Fig 29: Locating Wiring Harness Retainer Stud Bolt

    Courtesy of FORD MOTOR CO.
33. Remove the wiring harness grommet.
    Fig 30: Locating Wiring Harness Grommet

    Courtesy of FORD MOTOR CO.
34. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 31: Identifying Crankshaft Position (CKP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
35. Disconnect the A/C compressor electrical connector.
    Fig 32: Locating A/C Compressor Electrical Connector

    Courtesy of FORD MOTOR CO.
36. Remove the nut and disconnect the generator B+ cable.
    Fig 33: Locating Generator B+ Cable Nut

    Courtesy of FORD MOTOR CO.
37. Disconnect the generator electrical connector.
    Fig 34: Locating Electronic Automatic Temperature Control Hose

    Courtesy of FORD MOTOR CO.
38. Detach the wiring harness retainer from the generator.
    Fig 35: Locating Wiring Harness Retainer To Generator

    Courtesy of FORD MOTOR CO.
39. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness pin-type retainer.
    • Remove the wiring harness from the engine.
    Fig 36: Locating Engine Oil Pressure (EOP) Switch Electrical Connector & Wiring Harness Pin-Type Retainer

    Courtesy of FORD MOTOR CO.
40. Remove the bolt and the A/C manifold.
    • Discard the O-ring seals.
    Fig 37: Locating O-Ring Seals

    Courtesy of FORD MOTOR CO.
41. Remove the nut, 2 bolts and the A/C compressor.
    Fig 38: Locating A/C Compressor, Bolt & Nut

    Courtesy of FORD MOTOR CO.
42. Remove the A/C compressor mounting stud from the oil pan.
    Fig 39: Locating A/C Compressor Mounting Stud

    Courtesy of FORD MOTOR CO.
43. Remove the bolt, nut and the generator.
    Fig 40: Locating Nut, Bolt & Generator

    Courtesy of FORD MOTOR CO.
44. Detach the PSP  hose retainer from the engine lifting eye.
    Fig 41: Locating PSP Hose Retainer

    Courtesy of FORD MOTOR CO.
45. Remove the PSP  hose bracket nut.
    Fig 42: Locating PSP Hose Bracket Nut

    Courtesy of FORD MOTOR CO.
46. Remove the PSP  tube bracket bolt from the RH cylinder head.
    Fig 43: Locating Power Steering Pressure Tube & Bracket Assembly

    Courtesy of FORD MOTOR CO.
47. Remove the 3 bolts and the power steering pump.
    Fig 44: Locating Power Steering Pump & Bolts

    Courtesy of FORD MOTOR CO.
48. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 45: Locating Accessory Drive Belt Tensioner Bolts

    Courtesy of FORD MOTOR CO.
49. Remove the 4 nuts (3 shown in illustration) and the LH catalytic converter.
    • Discard the nuts and the gasket.
    Fig 46: Locating LH Catalytic Converter Nuts

    Courtesy of FORD MOTOR CO.
50. Remove the 3 bolts and the LH exhaust manifold heat shield.
    Fig 47: Locating LH Exhaust Manifold Heat Shield Bolts

    Courtesy of FORD MOTOR CO.
51. Remove the 6 nuts and the LH exhaust manifold.
    • Discard the nuts and the exhaust manifold gasket.
    Fig 48: Locating Exhaust Manifold Gasket Nuts

    Courtesy of FORD MOTOR CO.
52. Clean and inspect the LH exhaust manifold. For additional information, refer to EXHAUST MANIFOLD CLEANING AND INSPECTION .
53. Remove and discard the 6 LH exhaust manifold studs.
    Fig 49: Locating LH Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.

    FWD vehicles 

54. Remove the 4 nuts and the RH catalytic converter.
    • Discard the nuts and the gasket.
    Fig 50: Locating RH Catalytic Converter & Nuts

    Courtesy of FORD MOTOR CO.

    All vehicles 

55. Remove the 3 bolts and the RH exhaust manifold heat shield.
    Fig 51: Locating RH Exhaust Manifold Heat Shield Bolts

    Courtesy of FORD MOTOR CO.
56. Remove the 6 nuts and the RH exhaust manifold.
    • Discard the nuts and the exhaust manifold gasket.
    Fig 52: Locating RH Exhaust Manifold & Nuts

    Courtesy of FORD MOTOR CO.
57. Clean and inspect the RH exhaust manifold. For additional information, refer to EXHAUST MANIFOLD CLEANING AND INSPECTION .
58. Remove and discard the 6 RH exhaust manifold studs.
    Fig 53: 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 54: Locating RH Cylinder Block Drain Plug & Block Heater

    Courtesy of FORD MOTOR CO.
60. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
    Fig 55: Locating LH Cylinder Block Drain Plug

    Courtesy of FORD MOTOR CO.
61. Remove the pin-type retainer and the cover.
    Fig 56: Locating Pin-Type Retainer & Cover

    Courtesy of FORD MOTOR CO.
62. Remove the 2 bolts and the engine lifting eye.
    Fig 57: Locating Engine Lifting Eye & Bolts

    Courtesy of FORD MOTOR CO.
63. Remove the bolt and the upper intake manifold support bracket.
    Fig 58: Locating Upper Intake Manifold Support Bracket & Bolt

    Courtesy of FORD MOTOR CO.
64. Remove the bolt and the RH CMP  sensor.
    Fig 59: Locating RH CMP Sensor & Bolt

    Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

65. Remove the 2 bolts and the catalytic converter bracket.
    Fig 60: Locating Catalytic Converter Bracket & Bolt

    Courtesy of FORD MOTOR CO.

    All vehicles 

66. Remove the 4 bolts and the fuel rail and injectors as an assembly.
    Fig 61: Locating Fuel Rail & Injectors Assembly Bolts

    Courtesy of FORD MOTOR CO.
67. Remove the 2 thermostat housing-to-lower intake manifold bolts.
    • Remove the thermostat housing and discard the gasket.
    Fig 62: Locating Thermostat Housing-To-Lower Intake Manifold Bolts

    Courtesy of FORD MOTOR CO.
68. Remove the 10 bolts and the lower intake manifold.
    • Discard the gaskets.
    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.
    Fig 63: Locating Lower Intake Manifold Bolts

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

    Courtesy of FORD MOTOR CO.
70. Remove the bolt and the LH CMP  sensor.
    Fig 65: Locating LH CMP Sensor And Bolt

    Courtesy of FORD MOTOR CO.
71. Remove the bolt and the CKP  sensor.
    Fig 66: Locating CKP Sensor & Bolt

    Courtesy of FORD MOTOR CO.
72. Remove the EOP  switch.
    Fig 67: Locating EOP Switch

    Courtesy of FORD MOTOR CO.

    Early build vehicles 

73. Remove the 2 bolts and the oil filter adapter.
    • Discard the gasket and the O-ring seal.
    Fig 68: Locating Oil Filter Adapter, O-Ring Seal & Bolts

    Courtesy of FORD MOTOR CO.

    Late build vehicles 

74. Remove the 3 bolts and the oil filter adapter.
    • Discard the gasket.
    Fig 69: Locating Oil Filter Adapter & Bolts

    Courtesy of FORD MOTOR CO.

    All vehicles 

75. Remove the 6 bolts and the 6 coil-on-plugs.
    NOTE: LH shown in illustration, RH similar.
    Fig 70: Locating Bolts And Coil-On-Plug Assemblies

    Courtesy of FORD MOTOR CO.
76. Remove the 2 nuts and the wiring harness retaining bracket.
    Fig 71: Locating Wiring Harness Retaining Bracket & Bolt

    Courtesy of FORD MOTOR CO.

    Early build vehicles 

77. Loosen the 11 stud bolts and remove the LH valve cover.
    • Discard the gasket.
    Fig 72: Locating Stud Bolts & Valve Cover

    Courtesy of FORD MOTOR CO.
78. Loosen the bolt, the 10 stud bolts and remove the RH valve cover.
    • Discard the gasket.
    Fig 73: Locating Stud Bolts & Valve Cover

    Courtesy of FORD MOTOR CO.

    Late build vehicles 

79. Loosen the 9 stud bolts and remove the LH valve cover.
    • Discard the gasket.
    Fig 74: Locating Stud Bolts & Valve Cover

    Courtesy of FORD MOTOR CO.
80. Loosen the 9 stud bolts and remove the RH valve cover.
    • Discard the gasket.
    Fig 75: Locating Stud Bolts & RH Valve Cover

    Courtesy of FORD MOTOR CO.

    All vehicles 

81. Inspect the VCT  solenoid seals and the spark plug tube seals. Remove any damaged seals.
    • Using the VCT  Spark Plug Tube Seal Remover and Handle, remove the seal(s).
    NOTE: VCT  solenoid seal removal shown in illustration, spark plug tube seal removal similar.
    Fig 76: Identifying VCT Spark Plug Tube Seal Remover And Handle

    Courtesy of FORD MOTOR CO.
82. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
    • Discard the bolt.
    Fig 77: Locating Crankshaft Pulley Bolt & Washer

    Courtesy of FORD MOTOR CO.
83. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 78: Identifying Jaw Puller

    Courtesy of FORD MOTOR CO.
84. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 79: Identifying Oil Seal Remover

    Courtesy of FORD MOTOR CO.
85. Remove the 2 bolts and the engine mount bracket.
    Fig 80: Locating Engine Mount Bracket & Bolts

    Courtesy of FORD MOTOR CO.
86. Remove the 2 engine mount studs.
    NOTE: Only use hand tools to remove the studs.
    Fig 81: Locating Engine Mount Studs

    Courtesy of FORD MOTOR CO.
87. Remove the 3 bolts and the engine mount bracket.
    Fig 82: Locating Engine Mount Bracket & Bolts

    Courtesy of FORD MOTOR CO.
88. Remove the 22 engine front cover bolts.
    Fig 83: Locating Engine Front Cover Bolts

    Courtesy of FORD MOTOR CO.
89. 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 crisscross pattern until the engine front cover-to-cylinder block seal is released.
    2. Remove the engine front cover.
    Fig 84: Identifying Engine Front Cover Bolt

    Courtesy of FORD MOTOR CO.

    Engines equipped with early build RH timing chain guides 

90. Rotate the crankshaft clockwise and align the timing marks on the VCT  assemblies as shown in illustration.
    Fig 85: Locating Timing Marks On Variable Camshaft Timing (VCT)

    Courtesy of FORD MOTOR CO.

    Engines equipped with late build/replacement RH timing chain guides 

91. Rotate the crankshaft clockwise and align the timing marks on the VCT  assemblies as shown in illustration.
    Fig 86: Locating Timing Marks On VCT Assemblies

    Courtesy of FORD MOTOR CO.

    All vehicles 

92. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
    NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.
    Fig 87: Identifying Camshaft Holding Tool

    Courtesy of FORD MOTOR CO.
93. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
    NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC  position.
    Fig 88: Identifying Camshaft Holding Tool

    Courtesy of FORD MOTOR CO.
94. Remove the 3 bolts and the RH VCT  housing.
    Fig 89: Locating VCT Housing Bolts

    Courtesy of FORD MOTOR CO.
95. Remove the 3 bolts and the LH VCT  housing.
    Fig 90: Locating VCT Housing Bolts

    Courtesy of FORD MOTOR CO.
96. Remove the 2 bolts and the primary timing chain tensioner.
    Fig 91: Locating Primary Timing Chain Tensioner Bolts

    Courtesy of FORD MOTOR CO.
97. Remove the primary timing chain tensioner arm.
    Fig 92: Locating Primary Timing Chain Tensioner Arm

    Courtesy of FORD MOTOR CO.
98. Remove the 2 bolts and the lower LH primary timing chain guide.
    Fig 93: Locating Lower LH Primary Timing Chain Guide & Bolts

    Courtesy of FORD MOTOR CO.
99. Remove the primary timing chain.
    Fig 94: Locating Primary Timing Chain

    Courtesy of FORD MOTOR CO.
100. Remove the crankshaft timing chain sprocket.
     Fig 95: Locating Crankshaft Timing Chain Sprocket

     Courtesy of FORD MOTOR CO.
101. Remove the 2 bolts and the upper LH primary timing chain guide.
     Fig 96: Locating Upper LH Primary Timing Chain Guide & Bolts

     Courtesy of FORD MOTOR CO.
102. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
     Fig 97: Compressing LH Secondary Timing Chain Tensioner

     Courtesy of FORD MOTOR CO.
103. 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.
     NOTE: The VCT  bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
     Fig 98: Locating VCT Bolt & Exhaust Camshaft Bolt

     Courtesy of FORD MOTOR CO.
104. Remove the Camshaft Holding Tool from the LH camshafts.
     NOTE: When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.
     Fig 99: Identifying Camshaft Holding Tool

     Courtesy of FORD MOTOR CO.
105. Verify the LH camshafts are in the neutral position.
     NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.
     Fig 100: Positioning Camshafts Onto LH Cylinder Head In Neutral Position

     Courtesy of FORD MOTOR CO.
106. Remove the 2 bolts and the LH secondary timing chain tensioner.
     Fig 101: Locating LH Secondary Timing Chain Tensioner & Bolts

     Courtesy of FORD MOTOR CO.
107. Remove the bolts and the LH camshaft bearing caps.
     • Remove the LH camshafts.
     NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
     Fig 102: Locating LH Camshaft Bearing Caps Bolts

     Courtesy of FORD MOTOR CO.
108. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
     Fig 103: Compressing RH Secondary Timing Chain Tensioner

     Courtesy of FORD MOTOR CO.
109. 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.
     NOTE: The VCT  bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
     Fig 104: Locating VCT Assembly Bolt & RH Exhaust Camshaft Sprocket Bolt

     Courtesy of FORD MOTOR CO.
110. Remove the Camshaft Holding Tool from the RH camshafts.
     Fig 105: Identifying Camshaft Holding Tool

     Courtesy of FORD MOTOR CO.
111. Rotate the RH camshafts counterclockwise to the neutral position.
     NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.
     Fig 106: Positioning Of Camshafts In Neutral Position

     Courtesy of FORD MOTOR CO.
112. Remove the 2 bolts and the RH secondary timing chain tensioner.
     Fig 107: Locating RH Secondary Timing Chain Tensioner & Bolts

     Courtesy of FORD MOTOR CO.

     Engines equipped with early build RH timing chain guides 

113. Remove the 2 bolts and the RH primary timing chain guide.
     Fig 108: Locating RH Primary Timing Chain Guide Bolts

     Courtesy of FORD MOTOR CO.

     Engines equipped with late build/replacement RH timing chain guides 

114. Remove the 2 bolts and the RH primary timing chain guide.
     Fig 109: Locating RH Primary Timing Chain Guide & Bolts

     Courtesy of FORD MOTOR CO.

     All vehicles 

115. Remove the bolts and the RH camshaft bearing caps.
     • Remove the RH camshafts.
     NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
     Fig 110: Locating RH Camshaft Bearing Caps And Bolts

     Courtesy of FORD MOTOR CO.
116. Remove the valve tappets from the cylinder heads.
     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 111: Locating Valve Tappets

     Courtesy of FORD MOTOR CO.
117. Remove and discard the M6 bolt from each cylinder head.
     NOTE: LH shown in illustration, RH similar.
     Fig 112: Locating M6 Bolt

     Courtesy of FORD MOTOR CO.
118. Remove and discard the 8 bolts from each cylinder head.
     • Remove the cylinder heads.
     • Discard the cylinder head gaskets.
     NOTE: 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.
     NOTE: 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 a tighten-to-yield design and cannot be reused.
     NOTE: LH shown in illustration, RH similar.
     Fig 113: Installing Valve Spring, Retainer & Key Using Valve Spring Compressors

     Courtesy of FORD MOTOR CO.
119. 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.
     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 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.
120. 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 CYLINDER HEAD DISTORTION and CYLINDER BLOCK DISTORTION .
121. Remove the coolant inlet tube.
     • Remove and discard the O-ring seals.
     Fig 114: Locating Coolant Tube

     Courtesy of FORD MOTOR CO.
122. Remove the 2 bolts and the Knock Sensor (KS).
     Fig 115: Locating Knock Sensor Bolts

     Courtesy of FORD MOTOR CO.
123. Remove the 8 bolts and the coolant pump.
     Fig 116: Locating Coolant Pump Bolts

     Courtesy of FORD MOTOR CO.
124. Remove the 16 oil pan bolts.
     Fig 117: Locating Oil Pan Bolts

     Courtesy of FORD MOTOR CO.
125. 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.
     Fig 118: Locating Oil Pan Bolts

     Courtesy of FORD MOTOR CO.
126. Remove the 2 bolts and the oil pump screen and pickup tube.
     • Discard the O-ring seal.
     Fig 119: Locating Oil Pump Screen, Pickup Tube & Bolts

     Courtesy of FORD MOTOR CO.
127. Remove the 3 bolts and the oil pump.
     Fig 120: Locating Oil Pump & Bolts

     Courtesy of FORD MOTOR CO.
128. Remove the 8 crankshaft rear seal retainer bolts.
     Fig 121: Locating Oil Pump Screen, Pickup Tube & Bolts

     Courtesy of FORD MOTOR CO.
129. 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.
     Fig 122: Locating M6 Oil Pan Bolts

     Courtesy of FORD MOTOR CO.
130. 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.
     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.
131. 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.
132. Remove the bolts in the sequence shown in illustration below.
     • Remove the main bearing cap support brace.
     • Discard the bolts.
     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.
     Fig 123: Identifying Main Bearing Cap Support Brace Bolt Tighten Sequence

     Courtesy of FORD MOTOR CO.
133. Remove the connecting rod cap bolts and cap.
     NOTE: The connecting rod cap bolts are torque to yield. 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 124: Locating Connecting Rod Cap Bolts & Cap

     Courtesy of FORD MOTOR CO.
134. Remove the piston/rod assembly from the engine block.
     NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
     Fig 125: Removing Piston & Rod Assembly

     Courtesy of FORD MOTOR CO.
135. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
136. Remove the 8 main bearing cap side bolts and the 8 main bearing cap bolts in the sequence shown in illustration below.
     • Discard the bolts.
     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.
     Fig 126: Identifying Main Bearing Cap Side Bolt Remove Sequence

     Courtesy of FORD MOTOR CO.
137. Remove the 4 main bearing caps.
     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 127: Locating Main Bearing Caps

     Courtesy of FORD MOTOR CO.
138. Remove the crankshaft.
     NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
     Fig 128: Locating Crankshaft

     Courtesy of FORD MOTOR CO.
139. Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.
     NOTE: Inside shown in illustration, outside similar.
     Fig 129: Locating Heater Coolant Hose

     Courtesy of FORD MOTOR CO.
140. 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 130: Locating Crankshaft Main Bearings To Cylinder Block

     Courtesy of FORD MOTOR CO.
141. Remove the 4 crankshaft main bearings from the main bearing caps.
     NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
     Fig 131: Locating Main Bearings

     Courtesy of FORD MOTOR CO.
142. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
143. 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.
     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.