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Section 458 (Engine - 3.0L 4V): Disassembly: Engine

WARNING: This page is about a different car, the 2003 Mercury Sable and 2003 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tools
G01593021Courtesy of FORD MOTOR CO.
  1. Mount the engine to a suitable stand.
  2. Remove the accessory drive belt.
  3. Remove the generator.
    1. Disconnect the electrical connector.
    2. Remove the bolt.
    3. Remove the studs.
    4. Remove the generator.
    Fig 2: Removing Generator
    G01593022Courtesy of FORD MOTOR CO.
  4. Remove the bolts and the power steering pump.
    Fig 3: Removing Bolts And Power Steering Pump
    G01593023Courtesy of FORD MOTOR CO.
  5. Disconnect the A/C compressor.
    1. Disconnect the compressor electrical connector.
    2. Disconnect the pressure sensor electrical connector.
    3. Disconnect the harness from the bracket.
    Fig 4: Disconnecting A/C Compressor
    G01593024Courtesy of FORD MOTOR CO.
  6. Remove the bolts and the A/C compressor.
    Fig 5: Removing Bolts And A/C Compressor
    G01593025Courtesy of FORD MOTOR CO.
  7. Remove the bolts and the A/C compressor bracket.
    Fig 6: Removing Bolts And A/C Compressor Bracket
    G01593026Courtesy of FORD MOTOR CO.
  8. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 7: Disconnecting Camshaft Position Sensor Electrical Connector
    G01593027Courtesy of FORD MOTOR CO.
  9. Disconnect the harness from the front LH valve cover studs.
    Fig 8: Disconnecting Harness From Front LH Valve Cover Studs
    G01593028Courtesy of FORD MOTOR CO.
  10. Disconnect the oil pressure sensor.
    Fig 9: Disconnecting Oil Pressure Sensor
    G01593029Courtesy of FORD MOTOR CO.
  11. Install the special tool to hold the flywheel.
    Fig 10: Installing Special Tool To Hold Flywheel
    G01593030Courtesy of FORD MOTOR CO.
    12. NOTE: The pulley has LH threads.
    Fig 11: Removing Crankshaft Pulley
    G01593031Courtesy of FORD MOTOR CO.
  12. Remove the crankshaft pulley.
  13. Remove the crankshaft damper bolt and washer.
    Fig 12: Removing Crankshaft Damper Bolt And Washer
    G01593032Courtesy of FORD MOTOR CO.
  14. Using the special tool, remove the crankshaft vibration damper.
    Fig 13: Removing Crankshaft Vibration Damper
    G01593033Courtesy of FORD MOTOR CO.
  15. Remove the special tool.
    Fig 14: Removing Special Tool
    G01593034Courtesy of FORD MOTOR CO.
  16. Remove the crankshaft position (CKP) sensor.
    1. Disconnect the electrical connector.
    2. Remove the bolt.
    3. Remove the sensor.
    Fig 15: Removing Crankshaft Position Sensor
    G01593035Courtesy of FORD MOTOR CO.
  17. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) system electrical connector.
    Fig 16: Disconnecting Differential Pressure Feedback Exhaust Gas Recirculation System Electrical Connector
    G01593036Courtesy of FORD MOTOR CO.
  18. Loosen and disconnect the EGR tube from the manifold.
    Fig 17: Loosening And Disconnecting EGR Tube From Manifold
    G01593037Courtesy of FORD MOTOR CO.
  19. Disconnect the throttle position sensor (TPS) and idle air control (IAC) valve electrical connectors.
    Fig 18: Disconnecting Throttle Position Sensor And Idle Air Control Valve Electrical Connectors
    G01593038Courtesy of FORD MOTOR CO.
  20. Disconnect the positive crankcase ventilation (PCV) and evaporative emissions (EVAP) hoses from the upper intake.
    Fig 19: Disconnecting Positive Crankcase Ventilation And Evaporative Emissions Hoses From Upper Intake
    G01593039Courtesy of FORD MOTOR CO.
  21. Disconnect the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical connector.
    Fig 20: Disconnecting Exhaust Gas Recirculation Vacuum Regulator Solenoid Electrical Connector
    G01593040Courtesy of FORD MOTOR CO.
  22. Remove the bolts and the upper intake manifold.
    • Inspect the gaskets. Discard if damaged.
    Fig 21: Removing Bolts And Upper Intake Manifold
    G01593041Courtesy of FORD MOTOR CO.
  23. Disconnect the RH radio ignition interference capacitor, heated oxygen sensor (HO2S) electrical connectors and ignition coil electrical connector.
    Fig 22: Disconnecting RH Radio Ignition Interference Capacitor, HO2S Electrical Connectors And Ignition Coil Electrical Connector
    G01593042Courtesy of FORD MOTOR CO.
  24. Remove the bolt and the knock sensor (KS).
    Fig 23: Removing Bolt And Knock Sensor
    G01593043Courtesy of FORD MOTOR CO.
  25. Disconnect and unclip the LH HO2S electrical connector from the coolant tube.
    Fig 24: Disconnecting LH HO2S Electrical Connector From Coolant Tube
    G01593044Courtesy of FORD MOTOR CO.
    26. NOTE: LH shown, RH similar.
    NOTE: When removing the spark plug wires, a slight twisting motion will break the seals and ease removal.
    Fig 25: Disconnecting Spark Plug Wires
    G01593045Courtesy of FORD MOTOR CO.
  26. Disconnect the LH and RH spark plug wires.
  27. Remove the nut and the ground strap from the ignition coil stud.
    Fig 26: Removing Nut And Ground Strap From Ignition Coil Stud
    G01593046Courtesy of FORD MOTOR CO.
  28. Remove the stud nuts, and the ignition coil.
    Fig 27: Removing Stud Nuts, And Ignition Coil
    G01593047Courtesy of FORD MOTOR CO.
  29. Disconnect the fuel injector electrical connectors.
    Fig 28: Disconnecting Fuel Injector Electrical Connectors
    G01593048Courtesy of FORD MOTOR CO.
  30. Remove the bolts and the lower intake manifold. Remove and discard the gaskets.
    Fig 29: Removing Bolts And Lower Intake Manifold
    G01593049Courtesy of FORD MOTOR CO.
  31. Disconnect the heater hose and the water temperature sensor electrical connectors from the coolant crossover tube.
    Fig 30: Disconnecting Heater Hose And Water Temperature Sensor Electrical Connectors From Coolant Crossover Tube
    G01593050Courtesy of FORD MOTOR CO.
  32. Disconnect the two hose clamps and remove the coolant tube assembly.
    Fig 31: Disconnecting Hose Clamps And Removing Coolant Tube Assembly
    G01593051Courtesy of FORD MOTOR CO.
  33. Remove the fuel charging harness.
    • Disconnect the harness from the stud.
    • Remove the harness nut.
    Fig 32: Removing Fuel Charging Harness
    G01593052Courtesy of FORD MOTOR CO.
  34. Remove the nuts and the LH exhaust manifold.
    • Discard the gasket.
    Fig 33: Removing Nuts And LH Exhaust Manifold
    G01593053Courtesy of FORD MOTOR CO.
  35. Remove the nuts and the RH exhaust manifold.
    • Discard the gasket.
    Fig 34: Removing Nuts And RH Exhaust Manifold
    G01593054Courtesy of FORD MOTOR CO.
  36. Remove the nuts and the EVAP tube from the RH valve cover.
    Fig 35: Removing Nuts And EVAP Tube From RH Valve Cover
    G01593055Courtesy of FORD MOTOR CO.
  37. Remove the water pump drive belt cover.
    Fig 36: Removing Water Pump Drive Belt Cover
    G01593056Courtesy of FORD MOTOR CO.
  38. Rotate the drive belt tensioner clockwise and remove the water pump belt.
    Fig 37: Removing Water Pump Belt
    G01593057Courtesy of FORD MOTOR CO.
  39. Disconnect the water pump outlet hose.
    Fig 38: Disconnecting Water Pump Outlet Hose
    G01593058Courtesy of FORD MOTOR CO.
  40. Disconnect the heater hose from the water pump and remove the heater hose assembly.
    Fig 39: Disconnecting Heater Hose From Water Pump And Removing Heater Hose Assembly
    G01593059Courtesy of FORD MOTOR CO.
  41. Remove the bolts and the water pump.
    Fig 40: Removing Bolts And Water Pump
    G01593060Courtesy of FORD MOTOR CO.
    42. NOTE: RH shown, LH similar.
    Fig 41: Removing Bolts And Studs And Valve Cover
    G01593061Courtesy of FORD MOTOR CO.
  42. Remove the bolts and studs and the RH and LH valve cover.
    • Remove and discard the gaskets.
  43. Remove the bolt and stud and the coolant tube.
    Fig 42: Removing Bolt And Stud And Coolant Tube
    G01593062Courtesy of FORD MOTOR CO.
  44. Remove the bolts and studs and the oil pan.
    • Discard the gasket.
    Fig 43: Removing Bolts And Studs And Oil Pan
    G01593063Courtesy of FORD MOTOR CO.
  45. Remove the bolts, nut and the oil pick-up tube and screen.
    Fig 44: Removing Bolts, Nut And Oil Pick-Up Tube And Screen
    G01593064Courtesy of FORD MOTOR CO.
  46. Remove the nuts and the oil pan baffle.
    Fig 45: Removing Nuts And Oil Pan Baffle
    G01593065Courtesy of FORD MOTOR CO.
  47. Remove and discard the oil filter.
    Fig 46: Removing Oil Filter
    G01593066Courtesy of FORD MOTOR CO.
  48. Remove the stud and the oil level indicator and tube.
    Fig 47: Removing Stud And Oil Level Indicator And Tube
    G01593067Courtesy of FORD MOTOR CO.
  49. Remove the oil pressure sensor.
    Fig 48: Removing Oil Pressure Sensor
    G01593068Courtesy of FORD MOTOR CO.
  50. Remove the bolts, studs and the front cover.
    • Remove and discard the front cover gaskets.
    Fig 49: Removing Bolts, Studs And Front Cover
    G01593069Courtesy of FORD MOTOR CO.
  51. Remove the crankshaft front seal from the front cover and discard.
    Fig 50: Removing Crankshaft Front Seal From Front Cover
    G01593070Courtesy of FORD MOTOR CO.
    52. CAUTION: This pulse wheel is used with several difference engines. Install the pulse wheel with the keyway in the slot stamped 30 or 30 RFF only (orange in color).
    Fig 51: Removing Ignition Pulse Wheel
    G01593071Courtesy of FORD MOTOR CO.
  52. Remove the ignition pulse wheel.
  53. Install the damper bolt.
    Fig 52: Installing Damper Bolt
    G01593072Courtesy of FORD MOTOR CO.
    54. NOTE: LH shown, RH similar.
    Fig 53: Removing Spark Plugs
    G01593073Courtesy of FORD MOTOR CO.
  54. Remove the LH and RH spark plugs.
  55. 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 number one cylinder at top dead center (TDC).
    • Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
    Fig 54: Positioning Crankshaft Keyway In 11 O'Clock Position
    G01593074Courtesy of FORD MOTOR CO.
  56. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.
    Fig 55: Rotating Crankshaft Clockwise 120 Degrees To 3 O'Clock Position
    G01593075Courtesy of FORD MOTOR CO.
  57. Verify that the RH camshafts are in the neutral position.
    Fig 56: Verifying That RH Camshafts Are In Neutral Position
    G01593076Courtesy of FORD MOTOR CO.
  58. Remove the RH timing chain tensioner arm.
    1. Remove the bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
    Fig 57: Removing RH Timing Chain Tensioner Arm
    G01593077Courtesy of FORD MOTOR CO.
  59. Remove the bolts, RH timing chain guide and the timing chain.
    Fig 58: Removing Bolts, RH Timing Chain Guide And Timing Chain
    G01593078Courtesy of FORD MOTOR CO.
  60. Rotate the crankcase clockwise 600 degrees (1-2/3 turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
    Fig 59: Positioning Crankcase Keyway In 11 O'Clock Position
    G01593079Courtesy of FORD MOTOR CO.
  61. Verify the left hand camshafts are in the neutral position.
    Fig 60: Verifying Left Hand Camshafts Are In Neutral Position
    G01593080Courtesy of FORD MOTOR CO.
  62. Remove the LH timing chain and tensioner arm.
    1. Remove the bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
    Fig 61: Removing LH Timing Chain And Tensioner Arm
    G01593081Courtesy of FORD MOTOR CO.
  63. Remove the LH timing chain and timing chain guide.
    Fig 62: Removing LH Timing Chain And Timing Chain Guide
    G01593082Courtesy of FORD MOTOR CO.
  64. Remove the damper bolt and the crankshaft sprockets.
    Fig 63: Removing Damper Bolt And Crankshaft Sprockets
    G01593083Courtesy of FORD MOTOR CO.
    65. CAUTION: The OEM pulley is pressed on 4.74 mm (0.18 in) past flush of the end of the camshaft. The service pulley gets pressed on flush to the end of the camshaft.
    Fig 64: Removing Water Pump Drive Pulley
    G01593084Courtesy of FORD MOTOR CO.
  65. Using the special tools, remove the water pump drive pulley and discard.
    66. NOTE: In order to make sure of correct sealing, do not scratch the camshaft.
    Fig 65: Removing Camshaft Oil Seal
    G01593085Courtesy of FORD MOTOR CO.
  66. Using the special tools, remove the camshaft oil seal and discard.
  67. Remove the intake camshaft oil seal retainer and discard the press-in-place gasket.
    Fig 66: Removing Intake Camshaft Oil Seal Retainer
    G01593086Courtesy of FORD MOTOR CO.
    68. CAUTION: Record camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientations or engine damage can occur.
    Fig 67: Removing LH Camshaft Caps
    G01593087Courtesy of FORD MOTOR CO.
  68. Loosen the LH camshaft cap bolts in the indicated sequence and remove the camshaft caps.
    • Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.
    69. CAUTION: Record camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientations or engine damage can occur.
    Fig 68: Removing RH Camshaft Caps
    G01593088Courtesy of FORD MOTOR CO.
  69. Loosen the RH camshaft cap bolts in the indicated sequence and remove the camshaft caps.
    • Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.
  70. Remove the LH and RH camshafts.
    71. CAUTION: The camshaft followers must be installed in their original position.
    NOTE: LH shown, RH similar.
    Fig 69: Removing Camshaft Followers
    G01593089Courtesy of FORD MOTOR CO.
  71. Remove the LH and RH camshaft followers.
    • Mark the location of the followers using a permanent-type marker.
    72. NOTE: LH shown, RH similar.
    Fig 70: Removing Cylinder Head
    G01593090Courtesy of FORD MOTOR CO.
  72. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
    • Discard the gaskets.
  73. Remove the bolts and the oil separator.
    • Discard the gaskets.
    Fig 71: Removing Bolts And Oil Separator
    G01593091Courtesy of FORD MOTOR CO.
  74. Remove the bolts in the indicated sequence and remove the oil pump.
    Fig 72: Removing Oil Pump
    G01593092Courtesy of FORD MOTOR CO.
  75. Using the special tool, remove the cylinder ridge.
    Fig 73: Removing Cylinder Ridge
    G01593093Courtesy of FORD MOTOR CO.
  76. Remove the connecting rod cap bolts. Hold the piston/rod assembly to keep it from falling from the engine block.
    Fig 74: Removing Connecting Rod Cap Bolts
    G01593094Courtesy of FORD MOTOR CO.
  77. Using the special tool, remove the piston/rod assembly from the engine block.
    Fig 75: Removing Piston/Rod Assembly From Engine Block
    G01593095Courtesy of FORD MOTOR CO.
  78. Remove the engine block from the stand and place on a workbench.
  79. Remove the bolts and the flexplate.
    Fig 76: Removing Bolts And Flexplate
    G01593096Courtesy of FORD MOTOR CO.
  80. Remove the bolts and studs in the indicated sequence and remove the lower cylinder block.
    Fig 77: Removing Lower Cylinder Block
    G01593097Courtesy of FORD MOTOR CO.
  81. Remove the crankshaft rear main seal and remove the crankshaft.
    Fig 78: Removing Crankshaft Rear Main Seal And Crankshaft
    G01593098Courtesy of FORD MOTOR CO.
  82. Remove the crankshaft key.
    Fig 79: Removing Crankshaft Key
    G01593099Courtesy of FORD MOTOR CO.
  83. Remove the crankshaft thrust bearing from the cylinder block.
    Fig 80: Removing Crankshaft Thrust Bearing From Cylinder Block
    G01593100Courtesy of FORD MOTOR CO.
  84. Remove the bearings from the lower cylinder block.
    Fig 81: Removing Bearings From Lower Cylinder Block
    G01593101Courtesy of FORD MOTOR CO.
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