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Material Specifications

WARNING: This page is about a different variant/trim than selected.
MATERIAL SPECIFICATIONS

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 may cause engine failure.
NOTE: For additional information, refer to the exploded view under the Assembly procedure in this service information.

All vehicles 

  1. Remove the bolts and the flexplate.
    Fig 1: Locating Flexplate Bolts
    G07441337Courtesy of FORD MOTOR CO.
  2. Remove the engine-to-transaxle separator plate.
    Fig 2: Locating Engine-To-Transaxle Separator Plate
    G07441338Courtesy of FORD MOTOR CO.
  3. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear oil seal.
    Fig 3: Removing Crankshaft Rear Oil Seal Using The Slide Hammer And The Crankshaft Rear Oil Seal Remover
    G07441339Courtesy of FORD MOTOR CO.
  4. Mount the engine on a suitable stand.
  5. Disconnect the engine block Knock Sensor (KS) electrical connector and detach the wire harness retainer, disconnect the Cylinder Head Temperature (CHT) sensor electrical connector and the cylinder head KS electrical connector.
    Fig 4: Locating Engine Block Knock Sensor And Cylinder Head Temperature (CHT) Electrical Connectors
    G07441340Courtesy of FORD MOTOR CO.
  6. Disconnect the electronic throttle control electrical connector.
    Fig 5: Locating Electronic Throttle Control Electrical Connector
    G07441341Courtesy of FORD MOTOR CO.
  7. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
    Fig 6: Locating Evaporative Emission Canister Purge Valve Electrical Connector
    G07441342Courtesy of FORD MOTOR CO.
  8. Disconnect the EGR regulator electrical connector and detach the wiring retainer.
    Fig 7: Locating EGR Regulator Electrical Connector And Wiring Retainer
    G07441343Courtesy of FORD MOTOR CO.
  9. Detach the wiring harness retainer from the upper intake manifold.
    Fig 8: Locating Wiring Harness Retainer Of Upper Intake Manifold
    G07441344Courtesy of FORD MOTOR CO.
  10. Disconnect the Manifold Absolute Pressure (MAP) electrical connector and detach the wiring retainer.
  11. Fig 9: Locating Manifold Absolute Pressure Electrical Connector And Wiring Retainer
    G07441345Courtesy of FORD MOTOR CO.
  12. Disconnect the RH coil-on-plug electrical connectors.
    • Detach the 2 wiring harness retainers.
    • Fig 10: Locating RH Coil-On-Plug Electrical Connectors And Wiring Harness Retainer
      G07441346Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

  13. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 11: Locating RH HO2S Electrical Connector
    G07441347Courtesy of FORD MOTOR CO.

    All vehicles 

  14. Disconnect the RH Variable Camshaft Timing (VCT) electrical connector.
    Fig 12: Locating RH Variable Camshaft Timing Electrical Connector
    G07441348Courtesy of FORD MOTOR CO.
  15. Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the 2 wiring harness retainers.
    Fig 13: Locating Crankshaft Position Sensor Electrical Connector And Wiring Harness Retainers
    G07441349Courtesy of FORD MOTOR CO.
  16. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors and detach the wiring harness retainer from the engine front cover stud bolt.
    Fig 14: Locating Camshaft Position Sensor Electrical Connectors
    G07441350Courtesy of FORD MOTOR CO.
  17. Disconnect the fuel injector wiring harness electrical connector.
    Fig 15: Locating Fuel Injector Wiring Harness Electrical Connector
    G07441351Courtesy of FORD MOTOR CO.
  18. Disconnect the LH VCT  electrical connector.
    Fig 16: Locating LH VCT Electrical Connector
    G07441352Courtesy of FORD MOTOR CO.
  19. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wiring retainer.
    Fig 17: Locating Engine Oil Pressure Switch Electrical Connector
    G07441353Courtesy of FORD MOTOR CO.
  20. Disconnect the LH HO2S  electrical connector.
    Fig 18: Locating LH HO2S Electrical Connector
    G07441354Courtesy of FORD MOTOR CO.
  21. Disconnect the 3 LH coil-on-plug electrical connectors.
    • Detach the 2 wiring harness retainers.
      Fig 19: Locating LH Coil-On-Plug Electrical Connectors
      G07441355Courtesy of FORD MOTOR CO.
  22. Remove the nut and the B+ wire from the generator.
    Fig 20: Locating Generator B+ Wire And Nut
    G07441356Courtesy of FORD MOTOR CO.
  23. Detach the 2 wiring harness retainers.
    • Remove the B+ harness from the engine.
      Fig 21: Locating Wiring Harness Retainers And Engine B+ Harness
      G07441357Courtesy of FORD MOTOR CO.
  24. Remove the EGR tube fitting from the EGR valve.
    Fig 22: Locating EGR Tube Fitting
    G07441358Courtesy of FORD MOTOR CO.
  25. Remove the 2 upper intake manifold bracket bolts (1 shown in illustration).
    Fig 23: Locating Upper Intake Manifold Bracket Bolts
    G07441359Courtesy of FORD MOTOR CO.
  26. 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.
  27. Remove the 7 bolts and the upper intake manifold.
    • Remove and discard the gaskets.
      Fig 24: Locating Upper Intake Manifold Bolts
      G07441360Courtesy of FORD MOTOR CO.
  28. Remove the 4 bolts and the fuel rail and injectors as an assembly.
    Fig 25: Locating Fuel Rail And Injectors Assembly Bolts
    G07441361Courtesy of FORD MOTOR CO.
  29. 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.
  30. Remove the 8 lower intake manifold bolts and the lower intake manifold.
    • Remove and discard the gaskets.
      Fig 26: Locating Lower Intake Manifold Bolts
      G07441362Courtesy of FORD MOTOR CO.
  31. NOTE: When removing the coil-on-plugs, a slight twisting motion will break the seal and ease removal.
    NOTE: LH shown in illustration, RH similar.
    Fig 27: Locating Coil-On-Plugs Bolts
    G07441363Courtesy of FORD MOTOR CO.
  32. Remove the 6 bolts and the 6 coil-on-plugs.

    FWD  vehicles

  33. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 28: Locating RH Heated Oxygen Sensor Electrical Connector
    G07441364Courtesy of FORD MOTOR CO.
  34. Remove the 3 bolts and the RH heat shield.
    Fig 29: Locating RH Heat Shield Bolts
    G07441365Courtesy of FORD MOTOR CO.
  35. Remove the 3 nuts and the RH catalytic converter.
    • Discard the nuts and gasket.
      Fig 30: Locating RH Catalytic Converter Nuts
      G07441366Courtesy of FORD MOTOR CO.

    All vehicles 

  36. Remove the 6 RH exhaust manifold nuts and the manifold.
    • Discard the nuts and gasket.
      Fig 31: Locating RH Exhaust Manifold Nuts
      G07441367Courtesy of FORD MOTOR CO.
  37. Remove and discard the 6 RH exhaust manifold studs.
    Fig 32: Locating RH Exhaust Manifold Studs
    G07441368Courtesy of FORD MOTOR CO.
  38. Remove the bolt, 2 nuts and the generator.
    Fig 33: Locating Generator Nuts And Bolts
    G07441369Courtesy of FORD MOTOR CO.
  39. Remove the 3 bolts and the A/C compressor bracket.
    Fig 34: Locating A/C Compressor Bracket Bolts
    G07441370Courtesy of FORD MOTOR CO.
  40. Remove the 3 bolts and the LH heat shield.
    Fig 35: Locating LH Heat Shield Bolts
    G07441371Courtesy of FORD MOTOR CO.
  41. Remove the stud bolt and the oil level indicator and tube.
    • Remove and discard the O-ring seal.
      Fig 36: Locating Stud Bolt
      G07441372Courtesy of FORD MOTOR CO.
  42. Remove the 6 nuts, the LH catalytic converter and the gasket.
    • Discard the gasket and nuts.
      Fig 37: Locating LH Catalytic Converter Nuts
      G07441373Courtesy of FORD MOTOR CO.
  43. Remove and discard the 6 LH exhaust manifold studs.
    Fig 38: Locating RH Exhaust Manifold Studs
    G07441374Courtesy of FORD MOTOR CO.
  44. Remove the EOP  switch and, if equipped, the block heater.
    Fig 39: Locating EOP Switch And Block Heater
    G07441375Courtesy of FORD MOTOR CO.
  45. Remove and discard the oil filter.
    Fig 40: Locating Oil Filter
    G07441376Courtesy of FORD MOTOR CO.
  46. Position the Stretchy Belt Remover under the coolant pump belt as shown in illustration.
    Fig 41: Positioning Stretchy Belt Remover Under The Coolant Pump Belt
    G07441377Courtesy of FORD MOTOR CO.
  47. NOTE: Feed the Stretchy Belt Remover on to the camshaft coolant pump pulley approximately 90 degrees.
    Fig 42: Turning Crankshaft And Feeding The Stretchy Belt Remover Evenly On The Camshaft Coolant Pump Pulley
    G07441378Courtesy of FORD MOTOR CO.
  48. With the help of an assistant, turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant pump pulley as shown in illustration.
  49. 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.
      Fig 43: Removing Coolant Pump Belt Using Stretchy Belt Remover
      G07441379Courtesy of FORD MOTOR CO.
  50. 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.
    Fig 44: Removing Coolant Pump Pulley Using Special Tools
    G07441380Courtesy of FORD MOTOR CO.
  51. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.
  52. Remove the 5 coolant pump housing bolts.
    Fig 45: Locating Coolant Pump Housing Bolts
    G07441381Courtesy of FORD MOTOR CO.
  53. Loosen the clamp and detach the coolant hose. Remove the coolant pump housing.
    Fig 46: Locating Coolant Pump Housing And Cooling Hose
    G07441382Courtesy of FORD MOTOR CO.
  54. Remove the nut and the radio interference capacitor.
    Fig 47: Locating Radio Interference Capacitor With Nut
    G07441383Courtesy of FORD MOTOR CO.
  55. Remove the bolts and the RH valve cover.
    • Discard the gasket.
      Fig 48: Locating RH Valve Cover Bolts
      G07441384Courtesy of FORD MOTOR CO.
  56. Remove the bolts and the LH valve cover.
    • Discard the gasket.
      Fig 49: Locating LH Valve Cover Bolts
      G07441385Courtesy of FORD MOTOR CO.
  57. Remove the 15 bolts and the oil pan.
    • Discard the gasket.
      Fig 50: Locating Oil Pan Bolts
      G07441386Courtesy of FORD MOTOR CO.
  58. Remove the 2 bolts and the oil pump screen and pickup tube.
    Fig 51: Locating Oil Pump Screen And Pickup Tube Bolts
    G07441387Courtesy of FORD MOTOR CO.
  59. Remove and discard the O-ring seal.
    Fig 52: Locating O-Ring Seal
    G07441388Courtesy of FORD MOTOR CO.
  60. Remove the oil pan baffle.
    1. Remove the 4 M6 oil pan baffle nuts.
    2. Remove the 4 M8 oil pan baffle nuts.
      Fig 53: Identifying Oil Pan Baffle Nuts Removing Sequence
      G07441389Courtesy of FORD MOTOR CO.
  61. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 54: Locating Accessory Drive Belt Tensioner And Bolts
    G07441390Courtesy of FORD MOTOR CO.
  62. Remove the crankshaft pulley bolt and washer.
    • Discard the crankshaft pulley bolt.
      Fig 55: Locating Crankshaft Pulley Bolt
      G07441391Courtesy of FORD MOTOR CO.
  63. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 56: Removing Crankshaft Pulley Using The 3 Jaw Puller
    G07441392Courtesy of FORD MOTOR CO.
  64. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 57: Removing Crankshaft Front Seal Using The Oil Seal Remover
    G07441393Courtesy of FORD MOTOR CO.
  65. NOTE: Note the position of the alignment dowel on the engine front cover.
    Fig 58: Locating LH VCT With Bolts
    G07441394Courtesy of FORD MOTOR CO.
  66. Remove the 2 bolts and the LH VCT  .
  67. NOTE: Note the position of the alignment dowel on the engine front cover.
    Fig 59: Locating RH VCT With Bolts
    G07441395Courtesy of FORD MOTOR CO.
  68. Remove the 2 bolts and the RH VCT  .
  69. 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.
    NOTE: Note the location of all bolts and stud bolts for installation.
  70. Remove the 14 bolts, 2 stud bolts and the engine front cover.
    • Discard the gaskets.
      Fig 60: Identifying Engine Front Cover And Stud Bolts
      G07441396Courtesy of FORD MOTOR CO.
  71. NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
    NOTE: LH shown in illustration, RH similar.
    Fig 61: Locating Spark Plugs
    G07441397Courtesy of FORD MOTOR CO.
  72. Remove the LH and RH spark plugs.
  73. NOTE: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30RFF" (orange in color).
    Fig 62: Locating Ignition Pulse Wheel
    G07441398Courtesy of FORD MOTOR CO.
  74. Remove the ignition pulse wheel.
  75. Install the crankshaft pulley bolt and washer.
    Fig 63: Locating Crankshaft Pulley Bolt
    G07441399Courtesy of FORD MOTOR CO.
  76. 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 No. 1 cylinder at Top Dead Center (TDC).
    • Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
      Fig 64: Locating Marking On Timing Chain
      G07441400Courtesy of FORD MOTOR CO.
  77. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
    Fig 65: Locating Crankshaft Position
    G07441401Courtesy of FORD MOTOR CO.
  78. Verify that the RH camshafts are in the neutral position.
    Fig 66: Locating RH Camshafts Neutral Position
    G07441402Courtesy of FORD MOTOR CO.
  79. Remove the RH timing chain tensioner arm.
    1. Remove the 2 bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
      Fig 67: Identifying RH Timing Chain Tensioner Arm With Bolts
      G07441403Courtesy of FORD MOTOR CO.
  80. Remove the 2 bolts and the RH timing chain guide.
    • Remove the RH timing chain from the engine.
      Fig 68: Locating RH Timing Chain Guide And Bolts
      G07441404Courtesy of FORD MOTOR CO.
  81. Rotate the crankcase clockwise 600 degrees (one and two-thirds turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
    Fig 69: Locating Crankcase Keyway
    G07441405Courtesy of FORD MOTOR CO.
  82. Verify the LH camshafts are in the neutral position.
    Fig 70: Locating LH Camshafts Neutral Position
    G07441406Courtesy of FORD MOTOR CO.
  83. Remove the LH timing chain and tensioner arm.
    1. Remove the 2 bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
      Fig 71: Identifying LH Timing Chain And Tensioner Arm With Bolts
      G07441407Courtesy of FORD MOTOR CO.
  84. Remove the 2 bolts and the LH timing chain guide.
    • Remove the LH timing chain from the engine.
      Fig 72: Locating LH Timing Chain Guide With Bolts
      G07441408Courtesy of FORD MOTOR CO.
  85. Remove the crankshaft pulley bolt and the crankshaft sprocket.
    Fig 73: Locating Crankshaft Pulley Bolt And Crankshaft Sprocket
    G07441409Courtesy of FORD MOTOR CO.
  86. Remove the 4 bolts in the sequence shown in illustration.
    • Remove the oil pump.
      Fig 74: Oil Pump Bolts Removing Order
      G07441410Courtesy of FORD MOTOR CO.
  87. NOTE: Do not scratch the camshaft sealing surface while removing the camshaft oil seal. If scratched, camshaft oil seal leakage may occur.
    Fig 75: Removing Camshaft Oil Seal Using The Oil Seal Remover
    G07441411Courtesy of FORD MOTOR CO.
  88. Using the Oil Seal Remover, remove the camshaft oil seal and discard.
  89. Remove the 2 bolts and the camshaft oil seal retainer.
    • Discard the press-in-place gasket.
      Fig 76: Locating Camshaft Oil Seal Retainer With Bolts
      G07441412Courtesy of FORD MOTOR CO.
  90. NOTE: The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
    Fig 77: Identifying LH Camshafts Are In The Neutral Position
    G07441413Courtesy of FORD MOTOR CO.
  91. Verify the LH camshafts are in the neutral position.
  92. NOTE: Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket or damage to the engine may occur.
    NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the camshaft phaser and sprocket bolts.
    Fig 78: Remove/Install LH Camshaft Phaser And Sprocket Bolt
    G07441414Courtesy of FORD MOTOR CO.
  93. Remove the 3 bolts and the LH camshaft phaser and sprocket.
  94. Remove and discard the VCT  system oil filter screen from the LH camshaft.
    Fig 79: Locating VCT System Oil Filter Screen
    G07441415Courtesy of FORD MOTOR CO.
  95. NOTE: Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in illustration). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original positions may result in severe engine damage.
    Fig 80: Locating Camshaft Bearing Cap Position And Orientation
    G07441416Courtesy of FORD MOTOR CO.
  96. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
  97. 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: Make sure the camshaft bearing caps are marked as instructed in the previous step.
  98. Loosen the bolts evenly in the sequence shown in illustration.
    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.
      Fig 81: Identifying Camshaft Bearing Cap Bolts Removing Sequence
      G07441417Courtesy of FORD MOTOR CO.
  99. NOTE: The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
    Fig 82: Identifying RH Camshafts Positions
    G07441418Courtesy of FORD MOTOR CO.
  100. Verify the RH camshafts are in the neutral position.
  101. NOTE: Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket or damage to the engine may occur.
    NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the camshaft phaser and sprocket bolts.
    Fig 83: Remove/Install RH Camshaft Phaser And Sprocket Bolt
    G07441419Courtesy of FORD MOTOR CO.
  102. Remove the 3 bolts and the RH camshaft phaser and sprocket.
  103. Remove and discard the VCT  system oil filter screen from the RH camshaft.
    Fig 84: Locating Variable Camshaft Timing (VCT) System Oil Filter
    G07441420Courtesy of FORD MOTOR CO.
  104. NOTE: Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in illustration). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original positions may result in severe engine damage.
    Fig 85: Locating Camshaft Bearing Cap Position And Orientation
    G07441421Courtesy of FORD MOTOR CO.
  105. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
  106. 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: Make sure the camshaft bearing caps are marked as instructed in the previous step.
  107. Loosen the bolts evenly in the sequence shown in illustration.
    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.
      Fig 86: Camshaft Bearing Caps Bolts Loosening Sequence
      G07441422Courtesy of FORD MOTOR CO.
  108. NOTE: The camshaft roller followers must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
    NOTE: RH shown in illustration, LH similar.
  109. Remove the LH and RH camshaft roller followers.
    • Mark the location of the roller followers, using a permanent-type marker.
      Fig 87: Locating Roller Follower
      G07441423Courtesy of FORD MOTOR CO.
  110. NOTE: The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
  111. Remove the hydraulic lash adjusters.
  112. NOTE: RH shown in illustration, LH similar.
  113. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
    • Discard the bolts and the gaskets.
      Fig 88: Cylinder Heads Bolts Loosening Sequence
      G07441424Courtesy of FORD MOTOR CO.
  114. 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.
  115. Clean the cylinder head gasket surfaces with a plastic scraping tool and metal surface prep.
  116. Support the cylinder heads 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 MECHANICAL SYSTEM - GENERAL INFORMATION article.
  117. Remove the bolts and the oil separator cover.
    • Discard the gasket.
      Fig 89: Locating Oil Separator Cover Bolts
      G07441425Courtesy of FORD MOTOR CO.
  118. Remove the crankshaft key.
    Fig 90: Locating Crankshaft Key
    G07441426Courtesy of FORD MOTOR CO.
  119. 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.
  120. NOTE: Clearly mark the position and orientation of the pistons, connecting rods, connecting rod caps and connecting rod bearings for reassembly.
  121. Remove the connecting rod cap bolts and cap.
    • Discard the connecting rod cap bolts.
      Fig 91: Locating Connecting Rod Cap Bolts
      G07441427Courtesy of FORD MOTOR CO.
  122. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 92: Removing Piston/Rod Assembly Using The Connecting Rod Installer
    G07441428Courtesy of FORD MOTOR CO.
  123. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
  124. Repeat the previous 2 steps until all of the piston/rod assemblies are removed from the engine block.
  125. Remove the engine block from the stand and place on a workbench.
  126. Remove the bolts and studs in the indicated sequence.
    • Discard the lower cylinder block bolts.
    • Remove the lower cylinder block.
      Fig 93: Identifying Lower Cylinder Block Bolts
      G07441429Courtesy of FORD MOTOR CO.
  127. Remove the crankshaft rear main seal.
    • Remove the crankshaft.
      Fig 94: Locating Crankshaft With Rear Main Seal
      G07441430Courtesy of FORD MOTOR CO.
  128. Remove the crankshaft thrust bearing from the cylinder block.
    Fig 95: Locating Crankshaft Thrust Bearing
    G07441431Courtesy of FORD MOTOR CO.
  129. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
    Fig 96: Locating Bearings On Lower Cylinder Block
    G07441432Courtesy of FORD MOTOR CO.
  130. Remove the bearings from the lower cylinder block.
  131. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
    Fig 97: Locating Crankshaft Main Bearings
    G07441433Courtesy of FORD MOTOR CO.
  132. Remove the crankshaft main bearings from the cylinder block.
  133. Inspect the cylinder block, lower cylinder block, pistons and connecting rods. For additional information, refer to ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION article.