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Section 1957 (Engine Mechanical - 3.5L): Disassembly: Engine: Material

WARNING: This page is about a different car, the 2010 Lincoln MKX and 2010 Ford Edge. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL SPECIFICATION

Item Specification
Motorcraft® Metal Surface Prep
ZC-31-A		 -
Silicone Gasket Remover
ZC-30		 -
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: Early build engines have 11 fastener valve covers, late build engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.
NOTE: On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.
NOTE: For additional information, refer to the exploded view under the ASSEMBLY  procedure.

All vehicles 

  1. Remove the 8 bolts and the flexplate.
    Fig 1: Locating Flexplate Bolts
    G06062358Courtesy of FORD MOTOR CO.
  2. Remove the crankshaft sensor ring.
    Fig 2: Locating Crankshaft Sensor Ring
    G06062359Courtesy of FORD MOTOR CO.
  3. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.
    Fig 3: Identifying Crankshaft Rear Oil Seal Remover And Slide Hammer
    G06061951Courtesy of FORD MOTOR CO.
    4. 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, remove the heat shield and disconnect the block heater electrical connector.
    • Detach all of the engine block heater harness retainers and remove the harness.
      Fig 4: Locating Heat Shield
      G06062307Courtesy of FORD MOTOR CO.
  6. Disconnect the PCV hose from the PCV valve.
    Fig 5: Locating PCV Hose
    G06062361Courtesy of FORD MOTOR CO.
  7. Disconnect the Throttle Body (TB) electrical connector.
    Fig 6: Locating Throttle Body Electrical Connector
    G06062242Courtesy of FORD MOTOR CO.
  8. Detach the wiring harness retainers from the upper intake manifold.
    Fig 7: Locating Wiring Harness Retainers
    G06501328Courtesy of FORD MOTOR CO.
  9. Remove the upper intake manifold support bracket bolt.
    Fig 8: Locating Upper Intake Manifold Support Bracket Bolt
    G06062244Courtesy of FORD MOTOR CO.
    10. 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 if found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
  10. Remove the 6 bolts and the upper intake manifold in the following sequence.
    • Discard the gaskets.
      Fig 9: Identifying Upper Intake Manifold Bolts Tightening Sequence
      G06500974Courtesy of FORD MOTOR CO.
  11. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
    Fig 10: Locating PSP Switch Electrical Connector
    G06501332Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

  12. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 11: Locating RH Catalyst Monitor Sensor Electrical Connector
    G06062161Courtesy of FORD MOTOR CO.

    All vehicles 

  13. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 12: Locating RH Heated Oxygen Sensor Electrical Connector
    G06074178Courtesy of FORD MOTOR CO.
  14. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
    Fig 13: Locating RH Variable Camshaft Timing Solenoid Electrical Connector
    G06062248Courtesy of FORD MOTOR CO.
  15. Disconnect the 3 RH coil-on-plug electrical connectors.
    Fig 14: Locating RH Coil-On-Plug Electrical Connectors
    G06062249Courtesy of FORD MOTOR CO.
  16. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
  17. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.
    Fig 15: Locating RH Camshaft Position (CMP) Sensor Electrical Connector
    G06062433Courtesy of FORD MOTOR CO.
  18. Disconnect the Knock Sensor (KS) electrical connector.
    Fig 16: Locating Knock Sensor (KS) Electrical Connector
    G06062434Courtesy of FORD MOTOR CO.
  19. Remove the bolt and the ground cable from the RH cylinder.
    Fig 17: Locating Ground Cable Bolts
    G06501382Courtesy of FORD MOTOR CO.
  20. Disconnect the 6 fuel injector electrical connectors (3 shown in illustration).
    Fig 18: Locating Fuel Injector Electrical Connectors
    G06062300Courtesy of FORD MOTOR CO.
  21. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
    Fig 19: Locating Cylinder Head Temperature Sensor Electrical Connector
    G06062301Courtesy of FORD MOTOR CO.
  22. Disconnect the LH CMP  sensor electrical connector.
    Fig 20: Locating LH Camshaft Position Sensor Electrical Connector
    G06062949Courtesy of FORD MOTOR CO.
  23. Disconnect the LH CMS  electrical connector.
    Fig 21: Locating LH Catalyst Monitor Sensor Electrical Connector
    G06062302Courtesy of FORD MOTOR CO.
  24. Disconnect the LH HO2S  electrical connector.
    Fig 22: Locating LH Heated Oxygen Sensor Electrical Connector
    G06062328Courtesy of FORD MOTOR CO.
  25. Disconnect the 3 LH coil-on-plug electrical connectors.
    Fig 23: Locating LH Coil-On-Plug Electrical Connectors
    G06062251Courtesy of FORD MOTOR CO.
  26. Disconnect the LH VCT  solenoid electrical connector.
    Fig 24: Locating LH VCT Solenoid Electrical Connector
    G06062250Courtesy of FORD MOTOR CO.
  27. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
  28. Remove the wiring harness retainer bolt from the rear of the LH cylinder head.
    Fig 25: Locating Wiring Harness Retainer Bolt
    G06270076Courtesy of FORD MOTOR CO.
  29. Remove the nut, the bolt and the heat shield.
    Fig 26: Locating Heat Shield Nut And Bolt
    G06062443Courtesy of FORD MOTOR CO.
  30. Remove the wiring harness retainer stud bolt.
    Fig 27: Locating Wiring Harness Retainer Stud Bolt
    G06062444Courtesy of FORD MOTOR CO.
  31. Remove the wiring harness grommet.
    Fig 28: Locating Wiring Harness Grommet
    G06062445Courtesy of FORD MOTOR CO.
  32. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 29: Locating Crankshaft Position Sensor Electrical Connector
    G06062446Courtesy of FORD MOTOR CO.
  33. Disconnect the A/C compressor electrical connector.
    Fig 30: Locating A/C Compressor Electrical Connector
    G06501415Courtesy of FORD MOTOR CO.
  34. Remove the nut and disconnect the generator B+ cable.
    Fig 31: Locating Generator B+ Cable
    G06062331Courtesy of FORD MOTOR CO.
  35. Disconnect the generator electrical connector.
    Fig 32: Locating Generator Electrical Connector
    G06062332Courtesy of FORD MOTOR CO.
  36. Detach the wiring harness retainer from the generator.
    Fig 33: Locating Wiring Harness Retainer
    G06270068Courtesy of FORD MOTOR CO.
  37. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness pin-type retainer.
    • Remove the wiring harness from the engine.
      Fig 34: Locating Engine Oil Pressure Switch Electrical Connector
      G06252462Courtesy of FORD MOTOR CO.
  38. Remove the nut, 2 bolts and the A/C compressor.
    Fig 35: Locating A/C Compressor Bolts And Nut
    G06062451Courtesy of FORD MOTOR CO.
  39. Remove the A/C compressor mounting stud from the oil pan.
    Fig 36: Locating A/C Compressor Mounting Stud
    G06062452Courtesy of FORD MOTOR CO.
  40. Remove the nut, bolt and the generator.
    Fig 37: Locating Generator Bolt And Nut
    G06062453Courtesy of FORD MOTOR CO.
  41. Remove the 3 bolts and the power steering pump.
    Fig 38: Locating Power Steering Pump Bolts
    G06501343Courtesy of FORD MOTOR CO.
  42. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 39: Locating Accessory Drive Belt Tensioner Bolts
    G06062657Courtesy of FORD MOTOR CO.
  43. Remove the 4 nuts (3 shown in illustration) and the LH catalytic converter.
    • Discard the nuts and the gasket.
      Fig 40: Locating LH Catalytic Converter Nuts
      G06062304Courtesy of FORD MOTOR CO.
  44. Remove the 3 bolts and the LH exhaust manifold heat shield.
    Fig 41: Locating LH Exhaust Manifold Heat Shield Bolts
    G06062337Courtesy of FORD MOTOR CO.
  45. Remove the 6 nuts and the LH exhaust manifold.
    • Discard the nuts and exhaust manifold gaskets.
      Fig 42: Locating LH Exhaust Manifold Nuts
      G06062338Courtesy of FORD MOTOR CO.
  46. Clean and inspect the LH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  47. Remove and discard the 6 LH exhaust manifold studs.
    Fig 43: Locating LH Exhaust Manifold Studs
    G06073883Courtesy of FORD MOTOR CO.

    FWD vehicles 

  48. Remove the 4 nuts and the RH catalytic converter.
    • Discard the nuts and the gasket.
      Fig 44: Locating RH Catalytic Converter Nuts
      G06269875Courtesy of FORD MOTOR CO.

    All vehicles 

  49. Remove the 3 bolts and the RH exhaust manifold heat shield.
    Fig 45: Locating RH Exhaust Manifold Heat Shield Bolts
    G06074271Courtesy of FORD MOTOR CO.
  50. Remove the 6 nuts and the RH exhaust manifold.
    • Discard the nuts and exhaust manifold gaskets.
      Fig 46: Locating RH Exhaust Manifold Nuts
      G06251778Courtesy of FORD MOTOR CO.
  51. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  52. Remove and discard the 6 RH exhaust manifold studs.
    Fig 47: Locating RH Exhaust Manifold Studs
    G06074273Courtesy of FORD MOTOR CO.
  53. Remove the RH cylinder block drain plug or, if equipped, the block heater.
    • Allow coolant to drain from the cylinder block.
      Fig 48: Locating RH Cylinder Block Drain Plug
      G06062308Courtesy of FORD MOTOR CO.
  54. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
      Fig 49: Locating LH Cylinder Block Drain Plug
      G06062305Courtesy of FORD MOTOR CO.
  55. Remove the pin-type retainer and the cover.
    Fig 50: Locating Pin-Type Retainer
    G06062469Courtesy of FORD MOTOR CO.
  56. Remove the 2 bolts and the engine lifting eye.
    Fig 51: Locating Engine Lifting Eye With Bolts
    G06062470Courtesy of FORD MOTOR CO.
  57. Remove the bolt and the upper intake manifold bracket.
    Fig 52: Locating Upper Intake Manifold Bracket Bolt
    G06062471Courtesy of FORD MOTOR CO.
  58. Remove the bolt and the RH CMP  sensor.
    Fig 53: Locating RH CMP Sensor Bolt
    G06062472Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

  59. Remove the 2 bolts and the catalytic converter bracket.
    Fig 54: Locating Catalytic Converter Bracket Bolts
    G06270442Courtesy of FORD MOTOR CO.

    All vehicles 

  60. Remove the 4 bolts and the fuel rail and injectors as an assembly.
    Fig 55: Locating Fuel Rail Bolts
    G06062317Courtesy of FORD MOTOR CO.
  61. Remove the 3 thermostat housing-to-lower intake manifold bolts.
    • Remove the thermostat housing and discard the gasket.
      Fig 56: Locating Thermostat Housing-To-Lower Intake Manifold Bolts
      G06062318Courtesy of FORD MOTOR CO.
    62. 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 if found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
  62. Remove the 10 bolts and the lower intake manifold.
    • Discard the gaskets.
      Fig 57: Locating Lower Intake Manifold Bolts
      G06062319Courtesy of FORD MOTOR CO.
  63. Disconnect and remove the CHT  sensor jumper harness.
    Fig 58: Locating CHT Sensor Jumper Harness
    G06062320Courtesy of FORD MOTOR CO.
  64. Remove the bolt and the LH CMP  sensor.
    Fig 59: Locating LH CMP Sensor
    G06062327Courtesy of FORD MOTOR CO.
  65. Remove the bolt and the CKP  sensor.
    Fig 60: Locating CKP Sensor
    G06062406Courtesy of FORD MOTOR CO.
  66. Remove the EOP  switch.
    Fig 61: Locating EOP Switch
    G06062480Courtesy of FORD MOTOR CO.
  67. Remove the 3 bolts and the oil filter adapter.
    • Discard the gasket.
      Fig 62: Locating Oil Filter Adapter Bolts
      G06062483Courtesy of FORD MOTOR CO.
    68. NOTE: LH shown in illustration, RH similar.
    Fig 63: Locating Coil-On-Plugs Bolts
    G06062252Courtesy of FORD MOTOR CO.
  68. Remove the 6 bolts and the 6 coil-on-plugs.

    Early build vehicles 

  69. Loosen the 11 stud bolts and remove the LH valve cover.
    • Discard the gasket.
      Fig 64: Locating LH Valve Cover Stud Bolts
      G06251724Courtesy of FORD MOTOR CO.
  70. Loosen the bolt, the 10 stud bolts and remove the RH valve cover.
    • Discard the gasket.
      Fig 65: Locating RH Valve Cover Stud Bolts
      G06251725Courtesy of FORD MOTOR CO.

    Late build vehicles 

  71. Loosen the 9 stud bolts and remove the LH valve cover.
    • Discard the gasket.
      Fig 66: Locating LH Valve Cover Stud Bolts
      G06251726Courtesy of FORD MOTOR CO.
  72. Loosen the 9 stud bolts and remove the RH valve cover.
    • Discard the gasket.
      Fig 67: Locating RH Valve Cover Stud Bolts
      G06251727Courtesy of FORD MOTOR CO.

    All vehicles 

    73. NOTE: VCT  solenoid seal removal shown in illustration, spark plug tube seal similar.
  73. 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).
      Fig 68: Identifying VCT Spark Plug Tube Seal Remover And Handle
      G06061919Courtesy of FORD MOTOR CO.
  74. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
    • Discard the bolt.
      Fig 69: Locating Crankshaft Bolt And Washer
      G06062261Courtesy of FORD MOTOR CO.
  75. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 70: Removing Crankshaft Pulley
    G06061968Courtesy of FORD MOTOR CO.
  76. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 71: Removing Crankshaft Front Seal
    G06061944Courtesy of FORD MOTOR CO.
  77. Remove the 2 bolts and the engine mount bracket.
    Fig 72: Locating Engine Mount Bracket Bolts
    G06061983Courtesy of FORD MOTOR CO.
    78. NOTE: Only use hand tools to remove the studs.
    Fig 73: Locating Engine Mount Studs
    G06061984Courtesy of FORD MOTOR CO.
  78. Remove the 2 engine mount studs.
  79. Remove the 3 bolts and the engine mount bracket.
    Fig 74: Locating Engine Mount Bracket Bolts
    G06074073Courtesy of FORD MOTOR CO.
  80. Remove the 22 engine front cover bolts.
    Fig 75: Locating Engine Front Cover Bolts
    G06061990Courtesy of FORD MOTOR CO.
  81. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover.
    • Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.
      • Remove the engine front cover.
        Fig 76: Locating Engine Front Cover Bolts
        G06061991Courtesy of FORD MOTOR CO.

    Engines equipped with early build RH timing chain guides 

  82. Rotate the crankshaft clockwise and align the timing marks on the VCT  assemblies as shown in illustration.
    Fig 77: Identifying Timing Marks Location
    G06063036Courtesy of FORD MOTOR CO.

    Engines equipped with late build/replacement RH timing chain guides 

  83. Rotate the crankshaft clockwise and align the timing marks on the VCT  assemblies as shown in illustration.
    Fig 78: Aligning Timing Marks On VCT Assemblies
    G06251738Courtesy of FORD MOTOR CO.

    All vehicles 

    84. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.
    Fig 79: Identifying Camshaft Holding Tool
    G06063037Courtesy of FORD MOTOR CO.
  84. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
    85. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC  position.
    Fig 80: Identifying Camshaft Holding Tool
    G06062026Courtesy of FORD MOTOR CO.
  85. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
  86. Remove the 3 bolts and the RH VCT  housing.
    Fig 81: Locating RH VCT Housing Bolts
    G06063039Courtesy of FORD MOTOR CO.
  87. Remove the 3 bolts and the LH VCT  housing.
    Fig 82: Locating LH VCT Housing Bolts
    G06062028Courtesy of FORD MOTOR CO.
  88. Remove the 2 bolts and the primary timing chain tensioner.
    Fig 83: Locating Primary Timing Chain Tensioner Bolts
    G06063042Courtesy of FORD MOTOR CO.
  89. Remove the primary timing chain tensioner arm.
    Fig 84: Locating Primary Timing Chain Tensioner Arm
    G06062031Courtesy of FORD MOTOR CO.
  90. Remove the 2 bolts and the lower LH primary timing chain guide.
    Fig 85: Locating Primary Timing Chain Tensioner Arm
    G06062032Courtesy of FORD MOTOR CO.
  91. Remove the primary timing chain.
    Fig 86: Locating Primary Timing Chain
    G06073847Courtesy of FORD MOTOR CO.
  92. Remove the crankshaft timing chain sprocket.
    Fig 87: Locating Crankshaft Timing Chain Sprocket
    G06062034Courtesy of FORD MOTOR CO.
  93. Remove the 2 bolts and the upper LH primary timing chain guide.
    Fig 88: Locating Upper LH Primary Timing Chain Guide With Bolts
    G06063046Courtesy of FORD MOTOR CO.
  94. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
    Fig 89: Compressing LH Secondary Timing Chain Tensioner
    G06062036Courtesy of FORD MOTOR CO.
    95. NOTE: The VCT  bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
  95. 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.
      Fig 90: Locating Secondary Timing Chain And LH Exhaust Camshaft Sprocket
      G06062037Courtesy of FORD MOTOR CO.
    96. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.
    Fig 91: Identifying Camshaft Holding Tool
    G06074088Courtesy of FORD MOTOR CO.
  96. Remove the Camshaft Holding Tool from the LH camshafts.
    97. NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.
    Fig 92: Identifying LH Camshafts Neutral Position
    G06062511Courtesy of FORD MOTOR CO.
  97. Verify the LH camshafts are in the neutral position.
  98. Remove the 2 bolts and the LH secondary timing chain tensioner.
    Fig 93: Locating LH Secondary Timing Chain Tensioner Bolts
    G06062349Courtesy of FORD MOTOR CO.
    99. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If not reassembled in their original position, severe engine damage may occur.
  99. Remove the bolts and the LH camshaft bearing caps.
    • Remove the LH camshafts.
      Fig 94: Locating LH Camshaft Bearing Caps Bolts
      G06062283Courtesy of FORD MOTOR CO.
  100. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
    Fig 95: Compressing RH Secondary Timing Chain Tensioner
    G06062039Courtesy of FORD MOTOR CO.
    101. NOTE: The VCT  bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
  101. 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.
      Fig 96: Locating Secondary Timing Chain And RH Exhaust Camshaft Sprocket
      G06062040Courtesy of FORD MOTOR CO.
  102. Remove the Camshaft Holding Tool from the RH camshafts.
    Fig 97: Identifying Camshaft Holding Tool
    G06062286Courtesy of FORD MOTOR CO.
    103. NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.
    Fig 98: Identifying RH Camshafts Neutral Position
    G06062287Courtesy of FORD MOTOR CO.
  103. Rotate the RH camshafts counterclockwise to the neutral position.
  104. Remove the 2 bolts and the RH secondary timing chain tensioner.
    Fig 99: Locating RH Secondary Timing Chain Tensioner Bolts
    G06062313Courtesy of FORD MOTOR CO.

    Engines equipped with early build RH timing chain guides 

  105. Remove the 2 bolts and the RH primary timing chain guide.
    Fig 100: Locating RH Primary Timing Chain Guide Bolts
    G06063051Courtesy of FORD MOTOR CO.

    Engines equipped with late build/replacement RH timing chain guides 

  106. Remove the 2 bolts and the RH primary timing chain guide.
    Fig 101: Locating RH Primary Timing Chain Guide Bolts
    G06501602Courtesy of FORD MOTOR CO.

    All vehicles 

    107. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If not reassembled in their original position, severe engine damage may occur.
  107. Remove the bolts and the RH camshaft bearing caps.
    • Remove the RH camshafts.
      Fig 102: Locating RH Camshaft Bearing Caps Bolts
      G06062288Courtesy of FORD MOTOR CO.
    108. 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 103: Locating Valve Tappets
    G06062321Courtesy of FORD MOTOR CO.
  108. Remove the valve tappets from the cylinder heads.
    109. NOTE: LH shown in illustration, RH similar.
    Fig 104: Locating M6 Bolt
    G06062351Courtesy of FORD MOTOR CO.
  109. Remove and discard the M6 bolt from each cylinder head.
    110. 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: Aluminum surfaces are soft and can 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 tighten-to-yield designed and cannot be reused.
    NOTE: LH shown in illustration, RH similar.
  110. Remove and discard the 8 bolts from each cylinder head.
    • Remove the cylinder heads.
    • Discard the cylinder head gaskets.
      Fig 105: Locating Cylinder Head Bolts
      G06062352Courtesy of FORD MOTOR CO.
    111. 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 head 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.
  111. 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.
    5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
  112. 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 .
  113. Remove the coolant inlet tube.
    • Remove and discard the O-ring seals.
      Fig 106: Locating Coolant Inlet Tube
      G06062524Courtesy of FORD MOTOR CO.
  114. Remove the 2 bolts and the KS  .
    Fig 107: Locating KS Bolt
    G06062525Courtesy of FORD MOTOR CO.
  115. Remove the 8 bolts and the coolant pump.
    Fig 108: Locating Coolant Pump Bolts
    G06063049Courtesy of FORD MOTOR CO.
  116. Remove the 16 oil pan bolts.
    Fig 109: Locating Oil Pan Bolts
    G06062396Courtesy of FORD MOTOR CO.
  117. Install 2 of the oil pan bolts (finger tight) into the 2 threaded holes in the oil pan.
    • Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released.
      • Remove the oil pan.
        Fig 110: Locating Oil Pan Bolts
        G06062397Courtesy of FORD MOTOR CO.
  118. Remove the 2 bolts and the oil pump screen and pickup tube.
    • Discard the O-ring seal.
      Fig 111: Locating Oil Pump Screen And Pickup Tube
      G06063010Courtesy of FORD MOTOR CO.
  119. Remove the 3 bolts and the oil pump.
    Fig 112: Locating Oil Pump Bolts
    G06062093Courtesy of FORD MOTOR CO.
  120. Remove the 8 crankshaft rear seal retainer bolts.
    Fig 113: Locating Crankshaft Rear Seal Retainer Bolts
    G06062408Courtesy of FORD MOTOR CO.
  121. Install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal retainer.
    • Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released.
      • Remove the crankshaft rear seal retainer.
        Fig 114: Locating M6 Oil Pan Bolts
        G06062409Courtesy of FORD MOTOR CO.
    122. 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.
  122. Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M™ Roloc® Bristle Disk (2 inch, 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.
  123. 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.
    124. 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.
  124. Remove the bolts in the sequence shown in illustration.
    • Remove the main bearing cap support brace.
    • Discard the bolts.
      Fig 115: Identifying Main Bearing Cap Bolts
      G06252004Courtesy of FORD MOTOR CO.
    125. NOTE: The connecting rod cap bolts are a torque-to-yield design. 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 116: Locating Connecting Rod Cap Bolts
    G06252005Courtesy of FORD MOTOR CO.
  125. Remove the connecting rod cap bolts and cap.
    126. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 117: Removing Piston/Rod Assembly From Engine Block
    G06252006Courtesy of FORD MOTOR CO.
  126. Remove the piston/rod assembly from the engine block.
  127. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
    128. 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.
  128. Remove the 8 main bearing cap side bolts and the 8 main bearing cap bolts in the sequence shown in illustration.
    • Discard the bolts.
      Fig 118: Identifying Main Bearing Cap Bolts
      G06252007Courtesy of FORD MOTOR CO.
    129. 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 119: Locating Main Bearing Caps
    G06252008Courtesy of FORD MOTOR CO.
  129. Remove the 4 main bearing caps.
    130. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
    Fig 120: Locating Crankshaft
    G06252009Courtesy of FORD MOTOR CO.
  130. Remove the crankshaft.
    131. NOTE: Inside shown in illustration, outside similar.
    Fig 121: Locating Crankshaft Thrust Bearings
    G06279911Courtesy of FORD MOTOR CO.
  131. Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.
    132. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
    Fig 122: Locating Crankshaft Main Bearings
    G06252011Courtesy of FORD MOTOR CO.
  132. Remove the 4 crankshaft main bearings from the cylinder block.
    133. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
    Fig 123: Locating Crankshaft Main Bearings
    G06252012Courtesy of FORD MOTOR CO.
  133. Remove the 4 crankshaft main bearings from the main bearing caps.
  134. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
    135. 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.
  135. Clean the 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 locating dowel pins are seated correctly in the cylinder block.
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