Section 2616 (Engine Mechanical - 3.5L): Disassembly: Engine

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

All engines 

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

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

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

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

   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 Retainers At PSP Hose And Power Steering Reservoir Hose

   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 At Upper Intake Manifold

    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.
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.
12. Remove the 6 bolts and the upper intake manifold.
    • Discard the gaskets.
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: Identifying RH Catalyst Monitor Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.

    All engines 

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

    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: Locating 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 On Rear Of LH Cylinder Head

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

    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: Locating 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 Generator Electrical Connector

    Courtesy of FORD MOTOR CO.
38. Detach the wiring harness retainer from the generator.
    Fig 35: Locating Wiring Harness Retainer At 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 And 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 A/C Manifold Bolt

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

    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: Identifying Generator And Fasteners

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

    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 PSP Tube Bracket Bolt At RH Cylinder Head

    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 And 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 LH Exhaust Manifold Nuts

    Courtesy of FORD MOTOR CO.
52. Clean and inspect the LH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
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 engines 

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 ENGINE SYSTEM - GENERAL INFORMATION article.
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 And 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 And Cover

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

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

    Courtesy of FORD MOTOR CO.

    All engines 

66. Remove the 4 bolts and the fuel rail and injectors as an assembly.
    Fig 61: Identifying Fuel Rail And 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.
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.
68. Remove the 10 bolts and the lower intake manifold.
    • Discard the gaskets.
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 And Bolt

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

    Courtesy of FORD MOTOR CO.
73. Remove the 3 bolts and the oil filter adapter.
    • Discard the gasket.
    Fig 68: Locating Oil Filter Adapter And Bolts

    Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
Fig 69: Locating Coil-On-Plugs And Bolts
Courtesy of FORD MOTOR CO.
74. Remove the 6 bolts and the 6 coil-on-plugs.
75. Remove the 2 nuts and the wiring harness retaining bracket.
    Fig 70: Locating Nuts And Wiring Harness Retaining Bracket

    Courtesy of FORD MOTOR CO.
76. Loosen the 9 stud bolts and remove the LH valve cover.
    • Discard the gasket.
    Fig 71: Locating LH Valve Cover Stud Bolts

    Courtesy of FORD MOTOR CO.
77. Loosen the bolt, 8 stud bolts and remove the RH valve cover.
    • Discard the gasket.
    Fig 72: Locating RH Valve Cover Bolts

    Courtesy of FORD MOTOR CO.
NOTE: VCT solenoid seal removal shown in illustration, spark plug tube seal removal similar.
Fig 73: Removing Seal Using VCT Spark Plug Tube Seal Remover And Handle
Courtesy of FORD MOTOR CO.
78. 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).
79. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
    • Discard the bolt.
    Fig 74: Identifying Crankshaft Pulley Bolt And Washer With Strap Wrench

    Courtesy of FORD MOTOR CO.
80. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 75: Removing Crankshaft Pulley Using Jaw Puller

    Courtesy of FORD MOTOR CO.
81. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 76: Removing Crankshaft Front Seal Using Oil Seal Remover

    Courtesy of FORD MOTOR CO.
82. Remove the 2 bolts and the engine mount bracket.
    Fig 77: Locating Engine Mount Bracket And Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Only use hand tools to remove the studs.
Fig 78: Locating Engine Mount Studs
Courtesy of FORD MOTOR CO.
83. Remove the 2 engine mount studs.
84. Remove the 3 bolts and the engine mount bracket.
    Fig 79: Locating Engine Mount Bracket And Bolts

    Courtesy of FORD MOTOR CO.
85. Remove the 22 engine front cover bolts.
    Fig 80: Locating Engine Front Cover Bolts

    Courtesy of FORD MOTOR CO.
86. 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 81: Identifying Engine Front Cover Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Engine equipped with roller timing chain and stamped steel RH timing chain guide shown in illustration, other applications similar.
Fig 82: Locating Timing Marks On Variable Camshaft Timing Assemblies
Courtesy of FORD MOTOR CO.
87. Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown in illustration.
NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.
Fig 83: Identifying Camshaft Holding Tool On Flats Of LH Camshafts
Courtesy of FORD MOTOR CO.
88. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Fig 84: Identifying Camshaft Holding Tool On Flats Of RH Camshafts
Courtesy of FORD MOTOR CO.
89. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
90. Remove the 3 bolts and the RH VCT housing.
    Fig 85: Locating VCT Housing Bolts - RH

    Courtesy of FORD MOTOR CO.
91. Remove the 3 bolts and the LH VCT housing.
    Fig 86: Locating VCT Housing Bolts - LH

    Courtesy of FORD MOTOR CO.

    Engines equipped with a roller timing chain 

    NOTE: The following 3 steps are for primary timing chains when the colored links are not visible.
92. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown in illustration.
    Fig 87: Aligning Timing Chain Link Mark With Timing Mark On RH Intake VCT Assembly

    Courtesy of FORD MOTOR CO.
93. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown in illustration.
    Fig 88: Aligning Timing Chain Link Mark With Timing Mark On LH Intake VCT Assembly

    Courtesy of FORD MOTOR CO.
94. Mark the timing chain link that aligns with the timing mark on the crankshaft sprocket as shown in illustration.
    Fig 89: Aligning Timing Chain Link Mark With Timing Mark On Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
95. Remove the 2 bolts and the primary timing chain tensioner.
    Fig 90: Locating Primary Timing Chain Tensioner And Bolts

    Courtesy of FORD MOTOR CO.
96. Remove the primary timing chain tensioner arm.
    Fig 91: Identifying Primary Timing Chain Tensioner Arm

    Courtesy of FORD MOTOR CO.
97. Remove the 2 bolts and the lower LH primary timing chain guide.
    Fig 92: Locating Lower LH Primary Timing Chain Guide And Bolts

    Courtesy of FORD MOTOR CO.
98. Remove the primary timing chain.
    Fig 93: Identifying Primary Timing Chain

    Courtesy of FORD MOTOR CO.
99. Remove the crankshaft timing chain sprocket.
    Fig 94: Locating Crankshaft Timing Chain Sprocket

    Courtesy of FORD MOTOR CO.
100. Remove the 2 bolts and the upper LH primary timing chain guide.
     Fig 95: Locating Upper LH Primary Timing Chain Guide And Bolts

     Courtesy of FORD MOTOR CO.

     Engines equipped with an inverted tooth timing chain 

     NOTE: The following 3 steps are for primary timing chains when the colored links are not visible.
101. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown in illustration.
     Fig 96: Aligning Timing Chain Link Mark With Timing Mark On RH Intake VCT Assembly

     Courtesy of FORD MOTOR CO.
102. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown in illustration.
     Fig 97: Aligning Timing Chain Link Mark With Timing Mark On LH Intake VCT Assembly

     Courtesy of FORD MOTOR CO.
NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Fig 98: Aligning Timing Chain Links Mark With Timing Mark On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
103. Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown in illustration.
104. Remove the 2 bolts and the primary timing chain tensioner.
     Fig 99: Locating Bolts And Primary Timing Chain Tensioner

     Courtesy of FORD MOTOR CO.
105. Remove the primary timing chain tensioner arm.
     Fig 100: Locating Primary Timing Chain Tensioner Arm

     Courtesy of FORD MOTOR CO.
106. Remove the 2 bolts and the lower LH primary timing chain guide.
     Fig 101: Locating Bolts And Lower LH Primary Timing Chain Guide

     Courtesy of FORD MOTOR CO.
107. Remove the primary timing chain.
     Fig 102: Identifying Primary Timing Chain

     Courtesy of FORD MOTOR CO.
108. Remove the crankshaft timing chain sprocket.
     Fig 103: Locating Crankshaft Timing Chain Sprocket

     Courtesy of FORD MOTOR CO.
109. Remove the bolt and the upper LH primary timing chain guide.
     Fig 104: Locating Bolt And Upper LH Primary Timing Chain Guide

     Courtesy of FORD MOTOR CO.

     All engines 

110. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
     Fig 105: Compressing LH Secondary Timing Chain Tensioner

     Courtesy of FORD MOTOR CO.
NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
Fig 106: Locating LH VCT Assembly Bolt And LH Exhaust Camshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
111. 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: When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.
Fig 107: Identifying Camshaft Holding Tool On LH Camshafts
Courtesy of FORD MOTOR CO.
112. Remove the Camshaft Holding Tool from the LH camshafts.
NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.
Fig 108: Locating LH Camshafts Neutral Position
Courtesy of FORD MOTOR CO.
113. Verify the LH camshafts are in the neutral position.
114. Remove the 2 bolts and the LH secondary timing chain tensioner.
     Fig 109: Locating LH Secondary Timing Chain Tensioner And Bolts

     Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Fig 110: Locating LH Camshaft Bearing Caps Bolts
Courtesy of FORD MOTOR CO.
115. Remove the bolts and the LH camshaft bearing caps.
     • Remove the LH camshafts.
116. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
     Fig 111: Compressing RH Secondary Timing Chain Tensioner

     Courtesy of FORD MOTOR CO.
NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
Fig 112: Identifying RH VCT Assembly Bolt And RH Exhaust Camshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
117. 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.
118. Remove the Camshaft Holding Tool from the RH camshafts.
     Fig 113: Identifying Camshaft Holding Tool On RH Camshafts

     Courtesy of FORD MOTOR CO.
NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.
Fig 114: Locating RH Camshafts Neutral Position
Courtesy of FORD MOTOR CO.
119. Rotate the RH camshafts counterclockwise to the neutral position.
120. Remove the 2 bolts and the RH secondary timing chain tensioner.
     Fig 115: Locating RH Secondary Timing Chain Tensioner And Bolts

     Courtesy of FORD MOTOR CO.
NOTE: The engine comes equipped with either a roller primary timing chain or an inverted tooth primary timing chain. The roller timing chain engine comes equipped with either a composite RH timing chain guide requiring the timing chain to ride on the outer side of the guide or a stamped steel RH timing chain guide requiring the timing chain to ride on the inner side of the guide. All roller timing chain engine replacement RH timing chain guides will be the stamped steel design.
Fig 116: Locating Bolts And RH Timing Chain Guide
Courtesy of FORD MOTOR CO.
121. Remove the bolt(s) and the RH timing chain guide.
     1. Roller timing chain stamped steel RH guide.
     2. Roller timing chain composite RH guide.
     3. Inverted tooth timing chain RH guide.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Fig 117: Locating RH Camshaft Bearing Caps Bolts
Courtesy of FORD MOTOR CO.
122. Remove the bolts and the RH camshaft bearing caps.
     • Remove the RH camshafts.
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 118: Locating Valve Tappets
Courtesy of FORD MOTOR CO.
123. Remove the valve tappets from the cylinder heads.
NOTE: LH shown in illustration, RH similar.
Fig 119: Locating M6 Bolt
Courtesy of FORD MOTOR CO.
124. Remove and discard the M6 bolt from each cylinder head.
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 120: Locating Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
125. Remove and discard the 8 bolts from each cylinder head.
     • Remove the cylinder heads.
     • Discard the cylinder head gaskets.
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.
126. 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.
127. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
128. Remove the coolant inlet tube.
     • Remove and discard the O-ring seals.
     Fig 121: Locating Coolant Inlet Tube

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

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

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

     Courtesy of FORD MOTOR CO.
132. 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 125: Locating Oil Pan Bolts

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

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

     Courtesy of FORD MOTOR CO.
135. Remove the 8 crankshaft rear seal retainer bolts.
     Fig 128: Locating Crankshaft Rear Seal Retainer Bolts

     Courtesy of FORD MOTOR CO.
136. 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 129: Locating M6 Oil Pan Bolts

     Courtesy of FORD MOTOR CO.
NOTE: Only use a 3M Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.
137. 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.
138. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
NOTE: The main bearing cap support brace bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
Fig 130: Identifying Main Bearing Cap Support Brace Bolts Removing Sequence
Courtesy of FORD MOTOR CO.
139. Remove the bolts in the sequence shown in illustration.
     • Remove the main bearing cap support brace.
     • Discard the bolts.
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 131: Locating Connecting Rod Cap Bolts
Courtesy of FORD MOTOR CO.
140. Remove the connecting rod cap bolts and cap.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Fig 132: Locating Piston/Rod Assembly
Courtesy of FORD MOTOR CO.
141. Remove the piston/rod assembly from the engine block.
142. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
NOTE: The 8 main bearing cap side bolts and the 8 main bearing cap bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.
Fig 133: Identifying Main Bearing Cap Side Bolts And Main Bearing Cap Bolts Removing Sequence
Courtesy of FORD MOTOR CO.
143. Remove the 8 main bearing cap side bolts and the 8 main bearing cap bolts in the sequence shown in illustration.
     • Discard the bolts.
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 134: Locating Main Bearing Caps
Courtesy of FORD MOTOR CO.
144. Remove the 4 main bearing caps.
NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
Fig 135: Identifying Crankshaft
Courtesy of FORD MOTOR CO.
145. Remove the crankshaft.
NOTE: Inside shown in illustration, outside similar.
Fig 136: Locating Crankshaft Thrust Bearings
Courtesy of FORD MOTOR CO.
146. Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.
NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Fig 137: Locating Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
147. 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 138: Identifying Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
148. Remove the 4 crankshaft main bearings from the main bearing caps.
149. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
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.
150. 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.