Section 324 (Engine - 3.0L (4V)): Disassembly: Engine
WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tool(s)
| Slide Hammer 307-005 (T59L-100-B) | |
| Strap Wrench 303-D055 (D85L-6000-A) | |
| Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) | |
| Installer, Connecting Rod 303-462 (T94P-6136-AH) | |
| Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) | |
| Remover, Oil Seal 303-409 (T92C-6700CH) | |
| Remover, Stretchy Belt 303-1419 | |
| Plate, Water Pump Pulley 303-456 (T94P-6312-AH1), part of 303-S455 | |
| Protector, Water Pump Shaft 303-457 (T94P-6312-AH2), part of 303-S455 |
Material
| Item | Specification |
| Motorcraft ® Metal Surface Prep ZC-31-A | - |
NOTE:
During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
NOTE:
For additional information, refer to the exploded view under the assembly procedure in this article.
NOTE:
Early build vehicles are equipped with the coolant pump drive pulley on the LH intake camshaft, late build vehicles are equipped with the coolant pump drive pulley on the LH exhaust camshaft.
All vehicles
- 5.
Detach the wiring retainer, remove the nut and the heated oxygen sensor (HO2S) electrical connector bracket.
- 6.
Disconnect the exhaust gas recirculation (EGR) vacuum regulator electrical connector and remove the nut. Detach the wiring harness retainer.
- 9.
Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors, and detach the wiring retainer.
- 11.
Disconnect the vacuum tube fittings from the EGR valve, EGR vacuum regulator and the intake manifold.
- 13.
Remove the bolts and 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.
- 16.
Disconnect the radio interference capacitor electrical connector and detach the wiring retainers.
- 18.
Disconnect the camshaft position sensor (CMP) and oil pressure sensor electrical connectors and detach the wiring retainers.
- 19.
Disconnect the crankshaft position (CKP) sensor electrical connector and detach the wiring retainers.
- 20.
Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.- Remove the engine vacuum harness.
- 22.
Remove the 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.
- 23.
Remove the bolts and the 6 coil-on-plugs.
NOTE:
LH shown, RH similar.
NOTE:
When removing the coil-on-plugs, a slight twisting motion will break the seal and ease removal.
Early build vehicles
Late build vehicles
4x2 vehicles
All vehicles
- 36.
Turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant pump pulley as shown below.
NOTE:
Feed the Stretchy Belt Remover onto the camshaft coolant pump pulley approximately 90 degrees.
- 37.
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.
- 54.
Remove the bolts, studs and the front cover.- Discard the gaskets.
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.
- 55.
Remove the ignition pulse wheel.
NOTE:
This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30RFF" (orange in color).
- 57.
Remove the LH and RH spark plugs.
NOTE:
LH shown, RH similar.
NOTE:
Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
- 58.
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.
- 59.
Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
- 61.
Remove the RH timing chain tensioner arm.- 1.
Remove the bolts.
- 2.
Remove the tensioner.
- 3.
Remove the tensioner arm.
- 1.
- 63.
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.
- 65.
Remove the LH timing chain and tensioner arm.- 1.
Remove the bolts.
- 2.
Remove the tensioner.
- 3.
Remove the tensioner arm.
- 1.
- 68.
Using the special tools, remove and discard the coolant pump pulley.
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.
NOTE:
On early build engines, the OEM pulley is pressed on 4.74 mm (0.18 in) past flush of the end of the camshaft. On late build engines, the OEM pulley is pressed on flush to the end of the camshaft. Service pulleys on all engines are pressed on flush to the end of the camshaft.
- 69.
Using the special tools, remove the camshaft oil seal and discard.
NOTE:
Early build shown, late build similar.
NOTE:
To make sure of correct sealing, do not scratch the camshaft.
- 70.
Remove the intake camshaft oil seal retainer and discard the press-in-place gasket.
NOTE:
Early build shown, late build similar.
- 71.
Loosen the bolts evenly in the sequence shown below.- 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.
- 1.
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:
Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If the numbers cannot be seen, mark the camshaft bearing caps prior to removing them.
Early build vehicles
- 72.
Loosen the bolts evenly in the sequence shown below.- 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.
- 1.
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:
Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If the numbers cannot be seen, mark the camshaft bearing caps prior to removing them.
Late build vehicles
- 73.
Loosen the bolts evenly in the sequence shown below.- 1.
Remove the camshaft bearing thrust caps (1L and 6L).
- 2.
Remove the remaining camshaft bearing caps.
- 3.
Remove the camshafts from the cylinder head.
- 1.
NOTE:
After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (1L and 6L) first, or damage to the thrust caps may occur.
NOTE:
Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If the numbers cannot be seen, mark the camshaft bearing caps prior to removing them.
All vehicles
- 74.
Remove the LH and RH camshaft roller followers.- Mark the location of the roller followers, using a permanent-type marker.
NOTE:
RH shown, LH similar.
NOTE:
The camshaft roller followers must be installed in their original positions.
- 75.
Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.- Discard the bolts and the gaskets.
NOTE:
RH shown, LH similar.
- 76.
Clean the cylinder head gasket surfaces with a plastic scraping tool and metal surface prep.
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.
- 77.
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 .
- 80.
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.
- 81.
Remove the connecting rod cap bolts and cap.- Discard the connecting rod cap bolts.
NOTE:
Clearly mark the position and orientation of the pistons, connecting rods, connecting rod caps and connecting rod bearings for reassembly.
- 82.
Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.- Repeat these 2 steps until all the piston/rod assemblies are removed from the engine block.
NOTE:
Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
- 84.
Remove the bolts and studs in the indicated sequence.- Discard the lower cylinder block bolts.
- Remove the lower cylinder block.
- 87.
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.
- 88.
Remove the crankshaft main bearings from the cylinder block.
NOTE:
If the main bearings are being reused, mark them for correct position and orientation for reassembly.
- 89.
Inspect the cylinder block, lower cylinder block, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .