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Section 176 (Engine Mechanical - 3.7L): Disassembly: Engine

WARNING: This page is about a different car, the 2013 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G06061933
 3 Jaw Puller
303-D121
G07958493
 Handle
205-153 (T80T-4000-W)
G08640624
 2, 200# Floor Crane, Fold Away
300-OTC1819E
G07410362
 Hold Down, Secondary Chain
303-1530
G07397878
 Installer, Differential Bearing Cone
205-142 (T80T-4000-J)
G07410344
 Installer, Spindle Bearing
205-150 (T80T-4000-S)
G06061949
 Remover, Crankshaft Rear Oil Seal
303-519 (T95P-6701-EH)
G07441694
 Remover, Oil Seal
303-409 (T92C-6700CH)
G06061916
 Remover, VCT Spark Plug Tube Seal
303-1247/1
G06062402
 Slide Hammer
307-005 (T59L-100-B)
G06251558
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G07958537
 Strap Wrench
303-D055 (D85L-6000-A)
G07958571
 Tool, Camshaft Holding
303-1248
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® Metal Surface Prep
ZC-31-A		 -
Motorcraft® Silicone Gasket Remover
ZC-30		 -
WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.
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: The engine is equipped with a cast aluminum (early build) or stamped steel (late build) crankshaft rear seal retainer plate. If the engine is equipped with a stamped steel plate, the seal and plate must be removed as an assembly and discarded.
NOTE: For additional information, refer to the exploded view under the ASSEMBLY  procedure.

Engines with automatic transmission 

  1. Remove the 8 bolts and the flexplate.
    Fig 1: Locating Flexplate Bolts
    G07959029Courtesy of FORD MOTOR CO.

    Engines with manual transmission 

  2. NOTE: Loosen the bolts evenly to prevent clutch pressure plate damage.
    NOTE: If the parts are to be reused, index-mark the pressure plate to the flywheel.

    Remove the 6 pressure plate bolts, remove the pressure plate and the clutch disc.

    • Discard the pressure plate bolts.
      Fig 2: Locating Pressure Plate Bolts
      G07488581Courtesy of FORD MOTOR CO.
  3. NOTE: The dual mass flywheel normally has up to a total of 14 degrees (6.5 ring gear teeth) maximum rotational freeplay between the primary (bolted to crankshaft) and the secondary mass (clutch disc face).

    Remove the 8 bolts and the dual mass flywheel.

    Fig 3: Locating Dual Mass Flywheel Bolts
    G07986578Courtesy of FORD MOTOR CO.

    All engines 

  4. Remove the spacer plate.
    Fig 4: Locating Spacer Plate
    G07959030Courtesy of FORD MOTOR CO.
  5. Remove the crankshaft sensor ring.
    Fig 5: Locating Crankshaft Sensor Ring
    G08640639Courtesy of FORD MOTOR CO.

    Cast aluminum (early build) crankshaft rear seal retainer plates 

  6. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.
    G08029523

    All engines 

  7. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.

    Using the Floor Crane and Spreader Bar, mount the engine on a suitable engine stand.

    Fig 6: Mounting/Removing Engine Using Floor Crane And Spreader Bar
    G07987271Courtesy of FORD MOTOR CO.
  8. Remove the LH and RH engine lift eyes.
  9. Remove the crankcase vent tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 7: Locating Crankcase Vent Tube
    G07987272Courtesy of FORD MOTOR CO.
  10. Remove the engine oil level indicator.
    G07960000
  11. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
    • Detach the EVAP canister purge valve electrical connector wiring harness pin-type retainer.
      Fig 8: Locating EVAP Canister Purge Valve Electrical Connector Wiring Harness Pin-Type Retainer
      G07987274Courtesy of FORD MOTOR CO.
  12. Disconnect the Throttle Body (TB) electrical connector.
    • Detach the TB electrical connector wiring harness pin-type retainer from the TB.
      Fig 9: Locating TB Electrical Connector Wiring Harness Pin-Type Retainer
      G07987275Courtesy of FORD MOTOR CO.
  13. Disconnect the PCV tube quick connect couplings from the PCV valve and intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 10: Locating PCV Tube Quick Connect Couplings
    G07987276Courtesy of FORD MOTOR CO.
  14. Detach the wiring harness pin-type retainer from the rear of the upper intake manifold.
    Fig 11: Locating Wiring Harness Pin-Type Retainer
    G07987277Courtesy of FORD MOTOR CO.
  15. Remove the LH fuel rail insulator.
    Fig 12: Locating LH Fuel Rail Insulator
    G07987278Courtesy of FORD MOTOR CO.
  16. Remove the upper intake manifold support bracket bolt from the front of the RH cylinder head.
    Fig 13: Locating Upper Intake Manifold Support Bracket Bolt
    G07987279Courtesy of FORD MOTOR CO.
  17. 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.

    Loosen the 7 bolts and remove the upper intake manifold.

    • Remove and discard the gaskets.
    • Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
      Fig 14: Locating Upper Intake Manifold Bolts
      G07987280Courtesy of FORD MOTOR CO.
  18. Remove the RH fuel rail insulator.
    G07960002
  19. Disconnect the 3 RH ignition coil-on-plug electrical connectors.
    G07960003
  20. Disconnect the Cylinder Head Temperature (CHT) sensor wiring harness jumper electrical connector.
    G07960004
  21. Disconnect the 3 RH fuel rail electrical connectors.
    G07960005
  22. Disconnect the 2 RH Variable Camshaft Timing (VCT) solenoid electrical connectors.
    G07960006
  23. Disconnect the 2 RH Camshaft Position (CMP) sensors electrical connectors.
    G07960007
  24. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
  25. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
    • Detach the EOP switch wiring harness retainer from the cylinder head.
      G07960008
  26. Disconnect the 3 LH ignition coil-on-plug electrical connectors.
    G07960009
  27. Disconnect the 3 LH fuel rail electrical connectors.
    G07960010
  28. Disconnect the 2 LH VCT solenoid electrical connectors.
    G07960011
  29. Disconnect the Knock Sensor (KS) sensor electrical connector.
    G07960012
  30. Disconnect the 2 LH CMP sensors electrical connectors.
    • Detach the wiring harness retainer from the rear of the cylinder head.
      G07960013
  31. Remove the nut, the bolt and the heat shield.
    Fig 15: Locating Nut, Bolt And Heat Shield
    G07958906Courtesy of FORD MOTOR CO.
  32. Remove the wiring harness retainer stud bolt.
    Fig 16: Locating Wiring Harness Retainer Stud Bolt
    G06062405Courtesy of FORD MOTOR CO.
  33. Remove the wiring harness grommet.
    Fig 17: Locating Oil Pump And Bolts
    G06270296Courtesy of FORD MOTOR CO.
  34. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 18: Locating Crankshaft Position (CKP) Sensor Electrical Connector
    G07958920Courtesy of FORD MOTOR CO.
  35. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
  36. Remove the nut, bolt and the generator.
    • Remove the generator stud.
      G07987297
  37. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
    • Inspect the crankshaft pulley sealing surface for nicks or scratches that may effect the crankshaft front seal lip, replace the crankshaft pulley if necessary.
    • Discard the bolt.
      Fig 19: Removing Crankshaft Pulley Bolt And Washer Using Strap Wrench
      G07410333Courtesy of FORD MOTOR CO.
  38. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 20: Removing Crankshaft Pulley Using Jaw Puller
    G07410334Courtesy of FORD MOTOR CO.
  39. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 21: Removing Crankshaft Front Seal Using Oil Seal Remover
    G07410340Courtesy of FORD MOTOR CO.
  40. Remove the 2 bolts and the accessory drive belt tensioner.
    Fig 22: Locating Bolts And Accessory Drive Belt Tensioner
    G07959076Courtesy of FORD MOTOR CO.
  41. Remove the LH cylinder block drain plug or, if equipped, the block heater.
    • Allow coolant to drain from the cylinder block.
      Fig 23: Locating RH Cylinder Block Drain Plug And Block Heater
      G06281684Courtesy of FORD MOTOR CO.
  42. Remove the RH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
      Fig 24: Locating LH Cylinder Block Drain Plug
      G06281685Courtesy of FORD MOTOR CO.
  43. Remove the heater tube bolt.
    G07987304
  44. Detach the heater tube retainer from the RH valve cover stud bolt.
    G07987305
  45. Remove the 4 bolts and the thermostat housing.
    • Discard the thermostat housing and coolant inlet tube O-ring seals.
      G07959079
  46. Remove the 4 bolts and the coolant pump pulley.
    G07959080
  47. Remove the 7 bolts and the coolant pump.
    • Discard the coolant pump gasket and coolant pump O-ring seal.
      G07959081
  48. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

    Remove the 3 bolts and the 3 LH ignition coil-on-plugs.

    Fig 25: Locating LH Ignition Coil-On-Plugs And Bolts
    G07960028Courtesy of FORD MOTOR CO.
  49. NOTE: Only use hand tools when removing the spark plugs, or damage may occur to the cylinder head or spark plug.
    NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.

    Remove the 3 LH spark plugs.

  50. NOTE: While removing the valve cover do not apply excessive force to the Variable Camshaft Timing (VCT) oil control solenoid or damage may occur.
    NOTE: If the Variable Camshaft Timing (VCT) oil control solenoid sticks to the VCT seal, carefully wiggle the valve cover until the bond breaks free or damage to the VCT seal and VCT oil control solenoid may occur.
    NOTE: The plastic electrical connector on the VCT oil control solenoid will rotate approximately 12 degrees inside the steel housing, which is normal.

    Loosen the 7 stud bolts, 4 bolts and remove the LH valve cover.

    • Discard the gasket.
      Fig 26: Locating LH Valve Cover Stud Bolts And Bolts
      G07960029Courtesy of FORD MOTOR CO.
  51. Inspect the 2 VCT solenoid seals. Remove any damaged seals.
    • Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
      G07397890
  52. Inspect the spark plug tube seals. Remove any damaged seals.
    • Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
      G07397891
  53. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
  54. Remove the 2 bolts and the LH exhaust manifold heat shield.
    Fig 27: Locating LH Exhaust Manifold Heat Shield And Bolts
    G07960032Courtesy of FORD MOTOR CO.
  55. Remove the 6 nuts and the LH exhaust manifold.
    • Discard the nuts and exhaust manifold gaskets.
      Fig 28: Locating LH Exhaust Manifold Nuts
      G07960033Courtesy of FORD MOTOR CO.
  56. Clean and inspect the LH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  57. Remove and discard the 6 LH exhaust manifold studs.
    Fig 29: Locating LH Exhaust Manifold Studs
    G07960034Courtesy of FORD MOTOR CO.
  58. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

    Remove the 3 bolts and the 3 RH ignition coil-on-plugs.

    Fig 30: Locating RH Ignition Coil-On-Plugs And Bolts
    G07960035Courtesy of FORD MOTOR CO.
  59. NOTE: Only use hand tools when removing the spark plugs, or damage may occur to the cylinder head or spark plug.
    NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.

    Remove the 3 RH spark plugs.

  60. NOTE: While removing the valve cover do not apply excessive force to the Variable Camshaft Timing (VCT) oil control solenoid or damage may occur.
    NOTE: If the Variable Camshaft Timing (VCT) oil control solenoid sticks to the VCT seal, carefully wiggle the valve cover until the bond breaks free or damage to the VCT seal and VCT oil control solenoid may occur.
    NOTE: The plastic electrical connector on the VCT oil control solenoid will rotate approximately 12 degrees inside the steel housing, which is normal.

    Loosen the 8 stud bolts, 3 bolts and remove the RH valve cover.

    • Discard the gasket.
      Fig 31: Locating RH Valve Cover Stud Bolts And Bolts
      G07959102Courtesy of FORD MOTOR CO.
  61. Inspect the 2 VCT solenoid seals. Remove any damaged seals.
    • Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
      G07397915
  62. Inspect the spark plug tube seals. Remove any damaged seals.
    • Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
      G07397916
  63. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
  64. Remove the 2 bolts and the RH exhaust manifold heat shield.
    Fig 32: Locating RH Exhaust Manifold Heat Shield And Bolts
    G07960039Courtesy of FORD MOTOR CO.
  65. Remove the 6 nuts and the RH exhaust manifold.
    • Discard the nuts and exhaust manifold gaskets.
      Fig 33: Locating RH Exhaust Manifold Nuts
      G07960040Courtesy of FORD MOTOR CO.
  66. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  67. Remove and discard the 6 RH exhaust manifold studs.
    Fig 34: Locating RH Exhaust Manifold Studs
    G07960041Courtesy of FORD MOTOR CO.
  68. Remove the 2 bolts and the LH CMP sensors.
    G07960042
  69. Remove the 2 bolts and the RH CMP sensors.
    G07960043
  70. Remove the bolt and the CKP sensor.
    Fig 35: Locating CKP Sensor And Bolt
    G07958909Courtesy of FORD MOTOR CO.
  71. Remove the 5 bolts and the oil filter adapter.
    • Discard the gasket.
      Fig 36: Locating Oil Filter Adapter Bolts
      G07959111Courtesy of FORD MOTOR CO.
  72. Remove the 22 engine front cover bolts.
    Fig 37: Locating Engine Front Cover Bolts
    G07410349Courtesy of FORD MOTOR CO.
  73. Using a suitable pry tool, locate the 7 pry pads shown in illustration and pry the engine front cover loose and remove.
    Fig 38: Locating Engine Front Cover Pry Pads
    G07959113Courtesy of FORD MOTOR CO.
  74. NOTE: The front cover radial seal must be replaced.
    NOTE: Use Spindle Bearing Installer 205-150 to remove the seal.

    Using the Spindle Bearing Installer and Handle, remove the front cover radial seal from the rear side of the front cover.

    G07410351
  75. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration.
    G07410365
  76. Remove the 3 bolts and the LH valve train oil tube.
    G07399049
  77. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.

    Install the Camshaft Holding Tool onto the flats of the LH camshafts.

    G07399050
  78. Remove the 3 bolts and the RH valve train oil tube.
    G07399051
  79. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install the Camshaft Holding Tool onto the flats of the RH camshafts.

    G07399052
    NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.
  80. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown in illustration.
    G07399053
  81. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown in illustration.
    G07410371
  82. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.

    Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown in illustration.

    G07399055
  83. Remove the 2 bolts and the primary timing chain tensioner.
    G07986667
  84. Remove the primary timing chain tensioner arm.
    G07986668
  85. Remove the 2 bolts and the lower LH primary timing chain guide.
    G07986669
  86. NOTE: Removal of the VCT oil control solenoid will aid in the removal of the primary timing chain.
    NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.
    NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

    Remove the bolt and the LH intake VCT oil control solenoid.

    G07399059
  87. NOTE: Removal of the VCT oil control solenoid will aid in the removal of the primary timing chain.
    NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.
    NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

    Remove the bolt and the RH intake VCT oil control solenoid.

    G07399060
  88. Remove the primary timing chain.
    G07986672
  89. Remove the crankshaft timing chain sprocket.
    G07986673
  90. NOTE: Do not use power tools to remove the bolt or damage to the LH primary timing chain guide may occur.

    Remove the bolt and the upper LH primary timing chain guide.

    G07410380
  91. NOTE: The 2 VCT oil control solenoids are removed for clarity.
    NOTE: The Secondary Chain Hold Down is inserted through a hole in the top of the mega cap.

    Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.

    G07410381
  92. Remove and discard the 2 LH VCT assembly bolts.
    G07410382
  93. Remove the 2 LH VCT assemblies and secondary timing chain.
    G07410383
  94. NOTE: The 2 VCT oil control solenoids are removed for clarity.
    NOTE: The Secondary Chain Hold Down is inserted through a hole in the top of the mega cap.

    Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.

    G07399063
  95. Remove and discard the 2 RH VCT assembly bolts.
    G07399064
  96. Remove the 2 RH VCT assemblies and secondary timing chain.
    G07399065
  97. NOTE: Do not use power tools to remove the bolt or damage to the RH primary timing chain guide may occur.

    Remove the bolt and the RH primary timing chain guide.

    G07410387
  98. Remove the 9 bolts and the channel cover plate.
    • Discard the gasket.
      G07410388
  99. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure may rotate the LH camshafts approximately 3 degrees to a neutral position.

    Remove the Camshaft Holding Tool from the LH camshafts.

    G07410457
  100. NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.

    Verify the LH camshafts are in the neutral position.

    Fig 39: Locating LH Camshafts Neutral Position
    G07410459Courtesy of FORD MOTOR CO.
  101. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
    NOTE: Mark the exhaust and intake camshafts for installation into their original locations.

    Remove the 12 bolts, 6 camshaft caps, mega cap and the LH camshafts.

    Fig 40: Locating Camshaft Caps Bolts
    G07410458Courtesy of FORD MOTOR CO.
  102. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure may rotate the RH camshafts approximately 3 degrees to a neutral position.

    Remove the Camshaft Holding Tool from the RH camshafts.

    G07958713
  103. NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.

    Rotate the RH camshafts counterclockwise to the neutral position.

    Fig 41: Locating Camshafts Neutral Position
    G07958714Courtesy of FORD MOTOR CO.
  104. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
    NOTE: Mark the exhaust and intake camshafts for installation into their original locations.

    Remove the 12 bolts, 6 camshaft caps, mega cap and the RH camshafts.

    Fig 42: Locating Camshaft Caps, Mega Cap And RH Camshafts Bolts
    G07959686Courtesy of FORD MOTOR CO.
  105. 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.

    Remove the valve tappets from the cylinder heads.

    Fig 43: Locating Valve Tappets
    G06062580Courtesy of FORD MOTOR CO.
  106. Inspect the valve tappets. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  107. 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.

    Remove the 10 bolts and the lower intake manifold.

    • Discard the gaskets.
      Fig 44: Locating Lower Intake Manifold Bolts
      G07960087Courtesy of FORD MOTOR CO.
  108. Disconnect and remove the CHT sensor jumper harness.
    Fig 45: Locating CHT Sensor Jumper Harness
    G06270123Courtesy of FORD MOTOR CO.
  109. NOTE: LH shown in illustration, RH similar.

    Remove and discard the M6 bolt from each cylinder head.

    Fig 46: Locating M6 Bolt
    G07959152Courtesy of FORD MOTOR CO.
  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 may 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 a tighten-to-yield design and cannot be reused.
    NOTE: LH shown in illustration, RH similar.

    Remove and discard the 8 bolts from each cylinder head.

    • Remove the cylinder heads.
    • Discard the cylinder head gaskets.
      Fig 47: Locating Cylinder Head Bolts
      G07959153Courtesy 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.

    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.
  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 2 bolts and the KS.
    Fig 48: Locating Bolts
    G07959154Courtesy of FORD MOTOR CO.
  114. Remove the 16 oil pan bolts.
    Fig 49: Locating Oil Pan Bolts
    G07958806Courtesy of FORD MOTOR CO.
  115. NOTE: RH shown in illustration, LH similar.

    Using a suitable pry tool, locate the 2 pry pads at the LH and RH side of the oil pan and pry the oil pan loose and remove.

    G07959156
  116. Remove the 3 bolts and the oil pump screen and the pickup tube.
    • Discard the O-ring seal.
      G07958859
  117. Remove the 3 bolts and the oil pump.
    Fig 50: Locating Bolts And Oil Pump
    G06062564Courtesy of FORD MOTOR CO.

    Cast aluminum (early build) crankshaft rear seal retainer plate 

  118. Remove the 8 crankshaft rear seal retainer bolts.
    G08337857
  119. 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.
        G08337858

    Stamped steel (late build) crankshaft rear seal retainer plate 

    NOTE: Cast aluminum crankshaft rear seal retainer plate shown in illustration, stamped steel crankshaft rear seal retainer plate similar.
  120. Remove the 8 bolts and the crankshaft rear seal retainer plate.
    • Discard the plate and seal assembly.
      G08337857

    All engines 

  121. 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.

    Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M™ Roloc® Bristle Disk (2-in 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.
  122. 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.
  123. 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.

    Remove the bolts in the sequence shown in illustration.

    • Remove the main bearing cap support brace.
    • Discard the bolts.
      Fig 51: Identifying Main Bearing Cap Support Brace Bolts Removing Sequence
      G07959161Courtesy of FORD MOTOR CO.
  124. NOTE: The connecting rod cap bolts are a tighten-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.

    Remove the connecting rod cap bolts and cap.

    Fig 52: Locating Connecting Rod Cap Bolts
    G07959162Courtesy of FORD MOTOR CO.
  125. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

    Remove the piston/rod assembly from the engine block.

    Fig 53: Removing Piston/Rod Assembly From Engine Block
    G07959163Courtesy of FORD MOTOR CO.
  126. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
  127. NOTE: The 8 main bearing cap side 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.

    Remove the 8 main bearing cap side bolts in the sequence shown in illustration.

    • Discard the bolts.
      Fig 54: Identifying Main Bearing Cap Side Bolts Removing Sequence
      G07960101Courtesy of FORD MOTOR CO.
  128. NOTE: 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.

    Remove the 8 main bearing cap bolts in the sequence shown in illustration.

    • Discard the bolts.
      Fig 55: Identifying Main Bearing Cap Bolts Removing Sequence
      G07959165Courtesy 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.

    Remove the 4 main bearing caps.

    Fig 56: Locating Main Bearing Caps
    G07959166Courtesy of FORD MOTOR CO.
  130. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.

    Remove the crankshaft.

    Fig 57: Locating Thrust Surfaces Of Crankshaft
    G07959167Courtesy of FORD MOTOR CO.
  131. NOTE: Inside shown in illustration, outside similar.

    Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.

    Fig 58: Locating Crankshaft Thrust Bearings
    G06270307Courtesy of FORD MOTOR CO.
  132. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

    Remove the 4 crankshaft main bearings from the cylinder block.

    Fig 59: Locating Crankshaft Main Bearings
    G07959169Courtesy of FORD MOTOR CO.
  133. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

    Remove the 4 crankshaft main bearings from the main bearing caps.

    Fig 60: Locating Crankshaft Main Bearings On Main Bearing Caps
    G07959170Courtesy of FORD MOTOR CO.
  134. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  135. 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 causes premature engine failure. Remove all traces of the gasket.

    Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan 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 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.
  136. 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.

    Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M™ Roloc® Bristle Disk (2-in 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.
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