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Section 462 (Engine - 3.0L (2V)): Disassembly: Engine: Disassembly

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

    VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION 

    CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring will occur resulting in complete clutch release.
    NOTE: If the parts are to be reused, index-mark the clutch pressure plate to the flywheel.
    Fig 1: Removing Clutch Pressure Plate And Clutch Disc
    G03274188Courtesy of FORD MOTOR CO.
  1. Remove the bolts, the clutch pressure plate and the clutch disc.

    2. ALL VEHICLES 

  2. Remove the flywheel or flexplate.
    Fig 2: Removing Flywheel Or Flexplate
    G03274189Courtesy of FORD MOTOR CO.
  3. Remove the engine-to-transmission spacer plate.
  4. Mount the engine to a suitable engine stand and remove the lifting equipment and Lifting Eyes.
    5. CAUTION: Do not pull on the spark plug wires. Twist the boot while pulling upwards.
    Fig 3: Disconnecting Spark Plug Wires
    G03274190Courtesy of FORD MOTOR CO.
  5. Disconnect the spark plug wires.
  6. Disconnect the ignition coil electrical connector.
    Fig 4: Disconnecting Ignition Coil Electrical Connector
    G03274191Courtesy of FORD MOTOR CO.
  7. Remove the bolts and the ignition coil assembly.
    Fig 5: Removing Ignition Coil Assembly
    G03274192Courtesy of FORD MOTOR CO.
  8. Remove the bolts and the generator mounting bracket.
    Fig 6: Removing Generator Mounting Bracket
    G03274193Courtesy of FORD MOTOR CO.
  9. Remove the four bolts and the coolant pump pulley.
    Fig 7: Removing Coolant Pump Pulley
    G03274194Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the crankshaft pulley.
    Fig 8: Removing Crankshaft Pulley
    G03274195Courtesy of FORD MOTOR CO.
  11. Remove the crankshaft damper bolt.
    Fig 9: Removing Crankshaft Damper Bolt
    G03274196Courtesy of FORD MOTOR CO.
  12. Using a Crankshaft Vibration Damper Remover, remove the crankshaft damper.
    Fig 10: Removing Crankshaft Damper
    G03274197Courtesy of FORD MOTOR CO.
  13. Disconnect the engine control sensor wiring from:
    • The engine coolant temperature (ECT) sensor.
    • The water temperature indicator sender unit.
    • The fuel injectors.
    • The camshaft position (CMP) sensor.
      Fig 11: Disconnecting Engine Control Sensor Wiring
      G03274198Courtesy of FORD MOTOR CO.
    14. NOTE: To prevent stretching the valve cover gasket, loosen silicone gasket and sealant from the cylinder head by sliding a flat knife between the valve cover gasket and cylinder head.
    Fig 12: Removing Valve Covers
    G03274199Courtesy of FORD MOTOR CO.
  14. Remove the valve covers.
  15. If necessary, remove the valve cover gaskets.
    Fig 13: Removing Valve Cover Gaskets
    G03274200Courtesy of FORD MOTOR CO.
  16. Clean the sealing surfaces.
    Fig 14: Identifying Sealing Surfaces
    G03274201Courtesy of FORD MOTOR CO.
  17. Remove the rocker arms and the push rods.
    Fig 15: Removing Rocker Arms And Push Rods
    G03274202Courtesy of FORD MOTOR CO.
  18. Remove the lower intake manifold.
    • Remove the eight bolts.
    • Remove the lower intake manifold.
      Fig 16: Removing Lower Intake Manifold
      G03274203Courtesy of FORD MOTOR CO.
  19. Remove and discard the intake manifold gaskets and end seals.
    Fig 17: Removing Intake Manifold Gaskets And End Seals
    G03274204Courtesy of FORD MOTOR CO.
  20. Clean the sealing surfaces.
    Fig 18: Cleaning Sealing Surfaces
    G03274205Courtesy of FORD MOTOR CO.
  21. Remove the screws and the camshaft position (CMP) sensor.
    Fig 19: Removing CMP Sensor
    G03274206Courtesy of FORD MOTOR CO.
  22. Remove the camshaft synchronizer bolt.
    Fig 20: Removing Camshaft Synchronizer Bolt
    G03274207Courtesy of FORD MOTOR CO.
    23. NOTE: In some cases the oil pump intermediate shaft may not come out with the synchronizer assembly. If so, retrieve the intermediate shaft before proceeding.
    Fig 21: Removing Camshaft Synchronizer
    G03274208Courtesy of FORD MOTOR CO.
  23. Remove the camshaft synchronizer.
  24. Remove the oil pan.
    • Remove the bolts.
      Fig 22: Removing Oil Pan
      G03274209Courtesy of FORD MOTOR CO.
  25. Remove the oil pan baffle.
    Fig 23: Removing Oil Pan Baffle
    G03274210Courtesy of FORD MOTOR CO.
  26. Remove the oil pan gasket.
    Fig 24: Removing Oil Pan Gasket
    G03274211Courtesy of FORD MOTOR CO.
  27. Clean the surfaces.
    Fig 25: Cleaning Surfaces
    G03274212Courtesy of FORD MOTOR CO.
  28. Remove the crankshaft position (CKP) sensor.
    Fig 26: Removing CKP Sensor
    G03274213Courtesy of FORD MOTOR CO.
  29. Remove the engine front cover.
    • Remove the ten bolts.
      Fig 27: Removing Engine Front Cover
      G03274214Courtesy of FORD MOTOR CO.
  30. Remove the engine front cover gasket.
    Fig 28: Removing Engine Front Cover Gasket
    G03274215Courtesy of FORD MOTOR CO.
  31. Clean the sealing surfaces.
    Fig 29: Cleaning Sealing Surfaces
    G03274216Courtesy of FORD MOTOR CO.
  32. Remove the oil level indicator tube.
    Fig 30: Removing Oil Level Indicator Tube
    G03274217Courtesy of FORD MOTOR CO.
  33. Remove the oil filter.
    Fig 31: Removing Oil Filter
    G03274218Courtesy of FORD MOTOR CO.
  34. Remove the bolts.
    Fig 32: Removing Cylinder Heads Bolts
    G03274219Courtesy of FORD MOTOR CO.
  35. Remove the cylinder heads.
    Fig 33: Removing Cylinder Heads
    G03274220Courtesy of FORD MOTOR CO.
  36. Remove the head gaskets.
    Fig 34: Removing Head Gaskets
    G03274221Courtesy of FORD MOTOR CO.
  37. Remove the valve tappet guide plate retainer.
    Fig 35: Removing Valve Tappet Guide Plate Retainer
    G03274222Courtesy of FORD MOTOR CO.
  38. Remove the valve tappet guide plates.
    Fig 36: Removing Valve Tappet Guide Plates
    G03274223Courtesy of FORD MOTOR CO.
    39. NOTE: The valve tappets are positional. Identify each valve tappet for installation in the original position.
    Fig 37: Removing Valve Tappets
    G03274224Courtesy of FORD MOTOR CO.
  39. Remove the valve tappets.
  40. Align the timing marks.
    Fig 38: Aligning Timing Marks
    G03274225Courtesy of FORD MOTOR CO.
  41. Remove the bolt.
    Fig 39: Removing Cam Gear Bolt
    G03274226Courtesy of FORD MOTOR CO.
  42. Remove the timing sprockets and the timing chain as an assembly.
    Fig 40: Removing Timing Sprockets And Timing Chain As An Assembly
    G03274227Courtesy of FORD MOTOR CO.
  43. Remove the camshaft retainer.
    Fig 41: Removing Camshaft Retainer
    G03274228Courtesy of FORD MOTOR CO.
  44. Remove the camshaft.
    Fig 42: Removing Camshaft
    G03274229Courtesy of FORD MOTOR CO.
  45. If required, remove the camshaft bearings.
    • Use the Camshaft Service Set.
      Fig 43: Removing Camshaft Bearings
      G03274230Courtesy of FORD MOTOR CO.
  46. Remove the oil pump.
    Fig 44: Removing Oil Pump
    G03274231Courtesy of FORD MOTOR CO.
    47. NOTE: Before removing the piston and connecting rod assemblies, inspect the top of the cylinder bores. If necessary remove the cylinder ridge. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  47. Remove the piston and connecting rod assemblies one at a time.
    • Remove the connecting rod nuts in pairs.
    • Remove the connecting rod cap.
    • Remove the piston and connecting rod assembly.
      Fig 45: Removing Piston And Connecting Rod Assemblies
      G03274232Courtesy of FORD MOTOR CO.
  48. Remove the bolts.
    Fig 46: Removing Main Bearing Caps Bolts
    G03274233Courtesy of FORD MOTOR CO.
  49. Remove the main bearing caps.
    Fig 47: Removing Main Bearing Caps
    G03274234Courtesy of FORD MOTOR CO.
  50. Remove the lower crankshaft main bearings.
    Fig 48: Removing Lower Crankshaft Main Bearings
    G03274235Courtesy of FORD MOTOR CO.
  51. Remove the crankshaft rear oil seal.
    Fig 49: Removing Crankshaft Rear Oil Seal
    G03274236Courtesy of FORD MOTOR CO.
  52. Remove the crankshaft.
    Fig 50: Removing Crankshaft
    G03274237Courtesy of FORD MOTOR CO.
  53. Remove the crankshaft upper main bearings.
    Fig 51: Removing Crankshaft Upper Main Bearings
    G03274238Courtesy of FORD MOTOR CO.
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