Section 2410 (Engine Mechanical - 3.0L (4V)): Disassembly: Engine: Material

All vehicles 

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

   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. Disconnect the engine block Knock Sensor (KS) electrical connector and detach the wire harness retainer, disconnect the Cylinder Head Temperature (CHT) sensor electrical connector and the cylinder head KS  electrical connector.
   Fig 4: Locating Engine Block Knock Sensor (KS) Electrical Connector And Wire Harness Retainer

   Courtesy of FORD MOTOR CO.
6. Disconnect the electronic throttle control electrical connector.
   Fig 5: Locating Electronic Throttle Control Electrical Connector

   Courtesy of FORD MOTOR CO.
7. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
   Fig 6: Locating Evaporative Emission (EVAP) Canister Purge Valve Electrical Connector

   Courtesy of FORD MOTOR CO.
8. Disconnect the EGR regulator electrical connector and detach the wiring retainer.
   Fig 7: Locating EGR Regulator Electrical Connector

   Courtesy of FORD MOTOR CO.
9. Detach the wiring harness retainer from the upper intake manifold.
   Fig 8: Locating Wiring Harness Retainer

   Courtesy of FORD MOTOR CO.
10. Disconnect the Manifold Absolute Pressure (MAP) electrical connector and detach the wiring retainer.
    Fig 9: Locating Manifold Absolute Pressure (MAP) Electrical Connector And Wiring Retainer

    Courtesy of FORD MOTOR CO.
11. Disconnect the RH coil-on-plug electrical connectors.
    • Detach the 2 wiring harness retainers.
      Fig 10: Locating RH Coil-On-Plug Electrical Connectors

      Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

12. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 11: Locating RH Heated Oxygen Sensor (HO2S) Electrical Connector

    Courtesy of FORD MOTOR CO.

    All vehicles 

13. Disconnect the RH Variable Camshaft Timing (VCT) electrical connector.
    Fig 12: Locating RH Variable Camshaft Timing (VCT) Electrical Connector

    Courtesy of FORD MOTOR CO.
14. Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the 2 wiring harness retainers.
    Fig 13: Locating Crankshaft Position (CKP) Sensor Electrical Connector And Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
15. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors and detach the wiring harness retainer from the engine front cover stud bolt.
    Fig 14: Locating Camshaft Position (CMP) Sensor Electrical Connectors And Wiring Harness Retainer

    Courtesy of FORD MOTOR CO.
16. Disconnect the fuel injector wiring harness electrical connector.
    Fig 15: Locating Fuel Injector Wiring Harness Electrical Connector

    Courtesy of FORD MOTOR CO.
17. Disconnect the LH VCT  electrical connector.
    Fig 16: Locating LH VCT Electrical Connector

    Courtesy of FORD MOTOR CO.
18. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wiring retainer.
    Fig 17: Locating Engine Oil Pressure (EOP) Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
19. Disconnect the LH HO2S  electrical connector.
    Fig 18: Locating LH HO2S Electrical Connector

    Courtesy of FORD MOTOR CO.
20. Disconnect the 3 LH coil-on-plug electrical connectors.
    • Detach the 2 wiring harness retainers.
      Fig 19: Locating LH Coil-On-Plug Electrical Connectors

      Courtesy of FORD MOTOR CO.
21. Remove the nut and the B+ wire from the generator.
    Fig 20: Locating Nut And B+ Wire

    Courtesy of FORD MOTOR CO.
22. Detach the 2 wiring harness retainers.
    • Remove the B+ harness from the engine.
      Fig 21: Locating Wiring Harness Retainers

      Courtesy of FORD MOTOR CO.
23. Remove the EGR tube fitting from the EGR valve.
    Fig 22: Locating EGR Tube Fitting

    Courtesy of FORD MOTOR CO.
24. Remove the 2 upper intake manifold bracket bolts (1 shown).
    Fig 23: Locating Upper Intake Manifold Bracket Bolt

    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.
25. Remove the 7 bolts and the upper intake manifold.
    • Remove and discard the gaskets.
      Fig 24: Locating Bolts And Upper Intake Manifold

      Courtesy of FORD MOTOR CO.
26. Remove the 4 bolts and the fuel rail and injectors as an assembly.
    Fig 25: Locating Bolts And Fuel Rail And Injectors

    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.
27. Remove the 8 lower intake manifold bolts and the lower intake manifold.
    • Remove and discard the gaskets.
      Fig 26: Locating Lower Intake Manifold Bolts

      Courtesy of FORD MOTOR CO.
NOTE: When removing the coil-on-plugs, a slight twisting motion will break the seal and ease removal.
NOTE: LH shown, RH similar.
Fig 27: Locating Bolts And Coil-On-Plugs
Courtesy of FORD MOTOR CO.
28. Remove the 6 bolts and the 6 coil-on-plugs.

    FWD vehicles 

29. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 28: Locating RH Heated Oxygen Sensor (HO2S) Electrical Connector

    Courtesy of FORD MOTOR CO.
30. Remove the 3 bolts and the RH heat shield.
    Fig 29: Locating Bolts And RH Heat Shield

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

      Courtesy of FORD MOTOR CO.

    All vehicles 

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

      Courtesy of FORD MOTOR CO.
33. Remove and discard the 6 RH exhaust manifold studs.
    Fig 32: Locating RH Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.
34. Remove the bolt, 2 nuts and the generator.
    Fig 33: Locating Bolt, Nuts And Generator

    Courtesy of FORD MOTOR CO.
35. Remove the 3 bolts and the A/C compressor bracket.
    Fig 34: Locating Bolts And A/C Compressor Bracket

    Courtesy of FORD MOTOR CO.
36. Remove the 3 bolts and the LH heat shield.
    Fig 35: Locating Bolts And LH Heat Shield

    Courtesy of FORD MOTOR CO.
37. Remove the stud bolt and the oil level indicator and tube.
    • Remove and discard the O-ring seal.
      Fig 36: Locating Stud Bolt And Oil Level Indicator And Tube

      Courtesy of FORD MOTOR CO.
38. Remove the 6 nuts, the LH catalytic converter and the gasket.
    • Discard the gasket and nuts.
      Fig 37: Locating Nuts And LH Catalytic Converter

      Courtesy of FORD MOTOR CO.
39. Remove and discard the 6 LH exhaust manifold studs.
    Fig 38: Locating LH Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.
40. Remove the EOP  switch and, if equipped, the block heater.
    Fig 39: Locating EOP Switch

    Courtesy of FORD MOTOR CO.
41. Remove and discard the oil filter.
    Fig 40: Locating Oil Filter

    Courtesy of FORD MOTOR CO.
42. Position the Stretchy Belt Remover under the coolant pump belt as shown.
    Fig 41: Locating Stretchy Belt Remover And Coolant Pump

    Courtesy of FORD MOTOR CO.
NOTE: Feed the Stretchy Belt Remover on to the camshaft coolant pump pulley approximately 90 degrees.
Fig 42: Identifying Stretchy Belt Remover
Courtesy of FORD MOTOR CO.
43. With the help of an assistant, turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant pump pulley as shown.
44. 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 43: Pulling Stretchy Belt Remover

      Courtesy of FORD MOTOR CO.
NOTE: 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.
Fig 44: Identifying Water Pump Pulley Plate, Water Pump Shaft Protector And Crankshaft Vibration Damper Remover
Courtesy of FORD MOTOR CO.
45. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.
46. Remove the 5 coolant pump housing bolts.
    Fig 45: Locating Coolant Pump Housing Bolts

    Courtesy of FORD MOTOR CO.
47. Loosen the clamp and detach the coolant hose. Remove the coolant pump housing.
    Fig 46: Locating Clamp And Coolant Hose

    Courtesy of FORD MOTOR CO.
48. Remove the nut and the radio interference capacitor.
    Fig 47: Locating Nut And Radio Interference Capacitor

    Courtesy of FORD MOTOR CO.
49. Remove the bolts and the RH valve cover.
    • Discard the gasket.
      Fig 48: Locating Bolts And RH Valve Cover

      Courtesy of FORD MOTOR CO.
50. Remove the bolts and the LH valve cover.
    • Discard the gasket.
      Fig 49: Locating Bolts And LH Valve Cover

      Courtesy of FORD MOTOR CO.
51. Remove the 15 bolts and the oil pan.
    • Discard the gasket.
      Fig 50: Locating Bolts And Oil Pan

      Courtesy of FORD MOTOR CO.
52. Remove the 2 bolts and the oil pump screen and pickup tube.
    Fig 51: Locating Bolts Oil Pump Screen And Pickup Tube

    Courtesy of FORD MOTOR CO.
53. Remove and discard the O-ring seal.
    Fig 52: Locating O-Ring Seal

    Courtesy of FORD MOTOR CO.
54. Remove the oil pan baffle.
    1. Remove the 4 M6 oil pan baffle nuts.
    2. Remove the 4 M8 oil pan baffle nuts.
       Fig 53: Identifying Oil Pan Baffle Nuts

       Courtesy of FORD MOTOR CO.
55. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 54: Locating Bolts And Accessory Drive Belt Tensioner

    Courtesy of FORD MOTOR CO.
56. Remove the crankshaft pulley bolt and washer.
    • Discard the crankshaft pulley bolt.
      Fig 55: Locating Crankshaft Pulley Bolt

      Courtesy of FORD MOTOR CO.
57. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 56: Removing Crankshaft Pulley Using 3 Jaw Puller

    Courtesy of FORD MOTOR CO.
58. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 57: Removing Crankshaft Front Seal Using Oil Seal Remover

    Courtesy of FORD MOTOR CO.
NOTE: Note the position of the alignment dowel on the engine front cover.
Fig 58: Locating Bolts And LH VCT
Courtesy of FORD MOTOR CO.
59. Remove the 2 bolts and the LH VCT  .
NOTE: Note the position of the alignment dowel on the engine front cover.
Fig 59: Locating Bolts And RH VCT
Courtesy of FORD MOTOR CO.
60. Remove the 2 bolts and the RH VCT  .
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.
61. Remove the 14 bolts, 2 stud bolts and the engine front cover.
    • Discard the gaskets.
      Fig 60: Locating Engine Front Cover Bolts

      Courtesy of FORD MOTOR CO.
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 61: Locating Spark Plugs
Courtesy of FORD MOTOR CO.
62. Remove the LH and RH spark plugs.
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 62: Locating Ignition Pulse Wheel
Courtesy of FORD MOTOR CO.
63. Remove the ignition pulse wheel.
64. Install the crankshaft pulley bolt and washer.
    Fig 63: Locating Crankshaft Pulley Bolt And Washer

    Courtesy of FORD MOTOR CO.
65. 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 64: Locating Crankshaft Keyway

      Courtesy of FORD MOTOR CO.
66. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
    Fig 65: Locating Crankshaft Keyway

    Courtesy of FORD MOTOR CO.
67. Verify that the RH camshafts are in the neutral position.
    Fig 66: Locating RH Camshafts Marks

    Courtesy of FORD MOTOR CO.
68. Remove the RH timing chain tensioner arm.
    1. Remove the 2 bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
       Fig 67: Identifying Tensioner Arm And Bolts

       Courtesy of FORD MOTOR CO.
69. Remove the 2 bolts and the RH timing chain guide.
    • Remove the RH timing chain from the engine.
      Fig 68: Locating Bolts And RH Timing Chain Guide

      Courtesy of FORD MOTOR CO.
70. 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 69: Locating LH Camshafts Keywey

    Courtesy of FORD MOTOR CO.
71. Verify the LH camshafts are in the neutral position.
    Fig 70: Locating LH Camshafts Marks

    Courtesy of FORD MOTOR CO.
72. Remove the LH timing chain and tensioner arm.
    1. Remove the 2 bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
       Fig 71: Identifying Tensioner Arm And Bolts

       Courtesy of FORD MOTOR CO.
73. Remove the 2 bolts and the LH timing chain guide.
    • Remove the LH timing chain from the engine.
      Fig 72: Locating Bolts And LH Timing Chain Guide

      Courtesy of FORD MOTOR CO.
74. Remove the crankshaft pulley bolt and the crankshaft sprocket.
    Fig 73: Locating Crankshaft Pulley Bolt And Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
75. Remove the 4 bolts in the sequence shown.
    • Remove the oil pump.
      Fig 74: Identifying Oil Pump Bolts In Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Do not scratch the camshaft sealing surface while removing the camshaft oil seal. If scratched, camshaft oil seal leakage may occur.
Fig 75: Removing Camshaft Oil Seal Using Oil Seal Remover
Courtesy of FORD MOTOR CO.
76. Using the Oil Seal Remover, remove the camshaft oil seal and discard.
77. Remove the 2 bolts and the camshaft oil seal retainer.
    • Discard the press-in-place gasket.
      Fig 76: Locating Bolts And Camshaft Oil Seal Retainer

      Courtesy of FORD MOTOR CO.
NOTE: The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
Fig 77: Locating LH Camshafts Marks
Courtesy of FORD MOTOR CO.
78. Verify the LH camshafts are in the neutral position.
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 78: Locating LH Camshaft Phaser And Sprocket Bolts
Courtesy of FORD MOTOR CO.
79. Remove the 3 bolts and the LH camshaft phaser and sprocket.
80. Remove and discard the VCT  system oil filter screen from the LH camshaft.
    Fig 79: Locating VCT System Oil Filter Screen

    Courtesy of FORD MOTOR CO.
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 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 positions may result in severe engine damage.
Fig 80: Locating Camshaft Bearing Cap
Courtesy of FORD MOTOR CO.
81. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
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.
82. Loosen the bolts evenly in the sequence shown.
    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.
       Fig 81: Identifying Camshaft Bearing Cap Bolts In Sequence

       Courtesy of FORD MOTOR CO.
NOTE: The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
Fig 82: Locating RH Camshafts Marks
Courtesy of FORD MOTOR CO.
83. Verify the RH camshafts are in the neutral position.
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 83: Locating RH Camshaft Phaser And Sprocket Bolts
Courtesy of FORD MOTOR CO.
84. Remove the 3 bolts and the RH camshaft phaser and sprocket.
85. Remove and discard the VCT  system oil filter screen from the RH camshaft.
    Fig 84: Locating VCT System Oil Filter

    Courtesy of FORD MOTOR CO.
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 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 positions may result in severe engine damage.
Fig 85: Locating Camshaft Bearing Cap
Courtesy of FORD MOTOR CO.
86. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
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.
87. 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.
       Fig 86: Identifying Camshaft Bearing Caps Bolts In Sequence

       Courtesy of FORD MOTOR CO.
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.
88. Remove the LH and RH camshaft roller followers.
    • Mark the location of the roller followers, using a permanent-type marker.
      Fig 87: Locating Camshaft Roller Followers

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

      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 which make leak paths.
91. Clean the cylinder head gasket surfaces with a plastic scraping tool and metal surface prep.
92. 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 ENGINE SYSTEM - GENERAL INFORMATION .
93. Remove the bolts and the oil separator cover.
    • Discard the gasket.
      Fig 89: Locating Bolts And Oil Separator Cover

      Courtesy of FORD MOTOR CO.
94. Remove the crankshaft key.
    Fig 90: Locating Crankshaft Key

    Courtesy of FORD MOTOR CO.
95. 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: Clearly mark the position and orientation of the pistons, connecting rods, connecting rod caps and connecting rod bearings for reassembly.
96. Remove the connecting rod cap bolts and cap.
    • Discard the connecting rod cap bolts.
      Fig 91: Locating Connecting Rod Cap Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Fig 92: Identifying Connecting Rod Installer
Courtesy of FORD MOTOR CO.
97. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
98. Repeat the previous 2 steps until all of the piston/rod assemblies are removed from the engine block.
99. Remove the engine block from the stand and place on a workbench.
100. Remove the bolts and studs in the indicated sequence.
     • Discard the lower cylinder block bolts.
     • Remove the lower cylinder block.
       Fig 93: Identifying Lower Cylinder Block Bolts In Sequence

       Courtesy of FORD MOTOR CO.
101. Remove the crankshaft rear main seal.
     • Remove the crankshaft.
       Fig 94: Locating Crankshaft And Crankshaft Rear Main Seal

       Courtesy of FORD MOTOR CO.
102. Remove the crankshaft thrust bearing from the cylinder block.
     Fig 95: Locating Crankshaft Thrust Bearing

     Courtesy of FORD MOTOR CO.
NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Fig 96: Locating Bearings
Courtesy of FORD MOTOR CO.
103. 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 97: Locating Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
104. Remove the crankshaft main bearings from the cylinder block.
105. Inspect the cylinder block, lower cylinder block, pistons and connecting rods. For additional information, refer to GENERAL PROCEDURES .