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Disassembly And Assembly: Engine: Disassembly

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: If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.
  1. Remove the 8 bolts and the flexplate.
    Fig 1: Locating Flywheel And Bolts
    G07998108Courtesy of FORD MOTOR CO.
  2. Remove the crankshaft sensor ring.
    Fig 2: Locating Crankshaft Sensor Ring
    G08029871Courtesy of FORD MOTOR CO.
  3. Using The 303-519  (T95P-6701-EH) and 307-005  (T59L-100-B), remove and discard the rear crankshaft seal.
    Fig 3: Removing Crankshaft Rear Seal
    G07958896Courtesy 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.

    Mount the engine on a suitable engine stand.

  5. If equipped, remove the heat shield and disconnect the block heater electrical connector.
    1. Detach all of the engine block heater harness retainers and remove the harness.
    Fig 4: Locating Block Heater Electrical Connector And Heat Shield
    G08029873Courtesy of FORD MOTOR CO.
  6. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 5: Locating Accessory Drive Belt Tensioner And Bolts
    G08029874Courtesy of FORD MOTOR CO.
  7. Using The 303-D055  (D85L-6000-A), remove the crankshaft pulley bolt and washer.
    1. Discard the bolt.
    Fig 6: Locating Crankshaft Bolt And Washer
    G08029875Courtesy of FORD MOTOR CO.
  8. Using The 303-D021  (D80L-100-S), remove the crankshaft pulley.
    Fig 7: Removing Crankshaft Pulley Using Jaw Puller
    G07997624Courtesy of FORD MOTOR CO.
  9. Using The 303-409  (T92C-6700-CH), remove and discard the crankshaft front seal.
    Fig 8: Removing Crankshaft Front Seal
    G07997630Courtesy of FORD MOTOR CO.
  10. Remove the crankcase vent tube. REFER to QUICK CONNECT COUPLING .
    Fig 9: Locating Crankcase Vent Tube
    G08029878Courtesy of FORD MOTOR CO.
  11. Disconnect the 3 LH coil-on-plug electrical connectors.
    Fig 10: Locating LH Coil-On-Plug Electrical Connectors
    G07960009Courtesy of FORD MOTOR CO.
  12. Remove the oil level indicator.
    Fig 11: Locating Oil Level Indicator
    G07417523Courtesy of FORD MOTOR CO.
  13. Detach the 2 wiring harness retainers from the LH valve cover stud bolts and position the harness aside.
    Fig 12: Locating Wiring Harness Retainers Of LH Valve Cover Stud Bolts
    G07397884Courtesy of FORD MOTOR CO.
  14. Disconnect the 2 VCT oil control solenoid electrical connectors.
    1. Detach the wiring harness pin-type retainer.
    Fig 13: View Of VCT Oil Control Solenoid Electrical Connectors And Harness Retainer
    G07397885Courtesy of FORD MOTOR CO.
  15. Detach the 2 wiring harness pin-type retainers.
    Fig 14: Locating Wiring Harness Pin-Type Retainers
    G07397886Courtesy of FORD MOTOR CO.
  16. Disconnect the LH HO2S  electrical connector.
    1. Detach the wiring harness connector pin-type retainer from the LH valve cover.
    Fig 15: Locating HO2S Electrical Connector
    G07397887Courtesy of FORD MOTOR CO.
  17. Disconnect the 3 fuel injector electrical connectors.
    1. Detach the 2 wiring harness retainers from the LH valve cover stud bolts.
    Fig 16: Locating Fuel Injector Electrical Connectors
    G07397888Courtesy of FORD MOTOR CO.
  18. Detach the wiring harness retainer and position the harness aside.
    Fig 17: Locating Wiring Harness Retainer
    G07417530Courtesy of FORD MOTOR CO.
  19. Disconnect the 2 LH CMP sensor electrical connectors.
    Fig 18: Identifying LH CMP Sensor Electrical Connectors
    G07986846Courtesy of FORD MOTOR CO.
  20. Disconnect the LH CMS electrical connector.
    1. Remove the wiring harness retainer from the rear of the LH cylinder head.
    Fig 19: Locating LH CMS Electrical Connector And Wiring Harness Retainer
    G08029888Courtesy of FORD MOTOR CO.
  21. Detach the wiring harness retainer from the intake manifold.
    Fig 20: Locating Wiring Harness Retainer Of Intake Manifold
    G08029889Courtesy of FORD MOTOR CO.
  22. Disconnect the EVAP canister vent solenoid and throttle body electrical connectors.
    1. Detach the wiring harness pin-type retainer.
    Fig 21: Locating EVAP Canister Vent Solenoid And Throttle Body Electrical Connectors
    G07417506Courtesy of FORD MOTOR CO.
  23. Detach the 2 wiring harness/coolant tube retainers from the upper intake manifold.
    Fig 22: Locating Wiring Harness/Coolant Tube Retainers
    G07417496Courtesy of FORD MOTOR CO.
  24. Disconnect the crankcase ventilation hose from the PCV valve.
    Fig 23: Locating Crankcase Ventilation Hose
    G07417497Courtesy of FORD MOTOR CO.
  25. Remove the upper intake manifold support bracket bolt.
    Fig 24: Locating Upper Intake Manifold Support Bracket Bolt
    G07417498Courtesy of FORD MOTOR CO.
  26. Remove the 7 bolts and the upper intake manifold.
    1. Remove and discard the gasket.
    2. Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
    Fig 25: Locating Upper Intake Manifold Bolts
    G07417499Courtesy of FORD MOTOR CO.
  27. Disconnect the 3 RH coil-on-plug electrical connectors.
    Fig 26: Locating RH Coil-On-Plug Electrical Connectors
    G07960003Courtesy of FORD MOTOR CO.
  28. NOTE: On AWD vehicles the CMS electrical connector was disconnected during the engine removal procedure.

    Disconnect the HO2S  and CMS electrical connectors.

    1. Detach the 2 wiring harness retainers from the RH valve cover.
    Fig 27: Locating HO2S, CMS Electrical Connectors And Wiring Harness Retainers
    G07397910Courtesy of FORD MOTOR CO.
  29. Disconnect the 2 VCT oil control solenoid electrical connectors.
    1. Detach the 2 wiring harness retainers.
    Fig 28: Locating VCT Oil Control Solenoid Electrical Connectors
    G07417554Courtesy of FORD MOTOR CO.
  30. Disconnect the 3 fuel injector electrical connectors.
    1. Detach the 2 wiring harness retainers.
    Fig 29: Locating Fuel Injector Electrical Connectors And Wiring Harness Retainers
    G07397912Courtesy of FORD MOTOR CO.
  31. Detach the wiring harness retainer.
    Fig 30: View Of Wiring Harness Retainers
    G07397913Courtesy of FORD MOTOR CO.
  32. Disconnect the 2 RH CMP sensor electrical connectors.
    Fig 31: Locating RH CMP Sensor Electrical Connectors
    G07986858Courtesy of FORD MOTOR CO.
  33. Disconnect the KS electrical connector.
    Fig 32: Locating Knock Sensor (KS) Electrical Connector
    G08029901Courtesy of FORD MOTOR CO.
  34. Disconnect the CHT sensor electrical connector.
    Fig 33: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G08029902Courtesy of FORD MOTOR CO.
  35. Remove the bolt and the ground cable from the RH cylinder.
    Fig 34: Locating RH Cylinder Head Ground Cable And Bolt
    G08029392Courtesy of FORD MOTOR CO.
  36. Remove the nut, the bolt and the heat shield.
    Fig 35: Locating Heat Shield With Bolt And Nut
    G07958906Courtesy of FORD MOTOR CO.
  37. Remove the wiring harness retainer stud bolt.
    Fig 36: View Of Wiring Harness Retainer Stud Bolt
    G06501781Courtesy of FORD MOTOR CO.
  38. Remove the wiring harness grommet.
    Fig 37: Location of Wiring Harness Grommet
    G07958907Courtesy of FORD MOTOR CO.
  39. Disconnect the CKP sensor electrical connector.
    Fig 38: Locating Crankshaft Position (CKP) Sensor Electrical Connector
    G07958920Courtesy of FORD MOTOR CO.
  40. Disconnect the A/C  compressor electrical connector.
    Fig 39: Locating A/C Compressor Sensor Electrical Connector
    G08029908Courtesy of FORD MOTOR CO.
  41. Remove the nut and disconnect the generator B+ cable.
    Fig 40: Locating Generator B+ Cable Nut
    G07998080Courtesy of FORD MOTOR CO.
  42. Disconnect the generator electrical connector.
    Fig 41: Locating Generator B+ Cable Nut
    G07998081Courtesy of FORD MOTOR CO.
  43. Detach the wiring harness retainer from the generator.
    Fig 42: Location of Wiring Harness Retainer At Generator
    G08020997Courtesy of FORD MOTOR CO.
  44. Disconnect the EOP switch electrical connector and the wiring harness pin-type retainer.
    1. Remove the wiring harness from the engine.
    Fig 43: Locating Engine Oil Pressure (EOP) Switch Electrical Connector And Retainer
    G07998083Courtesy of FORD MOTOR CO.
  45. Remove the nut, 2 bolts and the A/C  compressor.
    Fig 44: Locating A/C Compressor And Mounting Fasteners
    G07998141Courtesy of FORD MOTOR CO.
  46. Remove the A/C  compressor mounting stud from the oil pan.
    Fig 45: Locating A/C Compressor And Mounting Stud
    G07998142Courtesy of FORD MOTOR CO.
  47. Remove the nut, bolt and the generator.
    Fig 46: Locating Generator And Mounting Fasteners
    G07998082Courtesy of FORD MOTOR CO.
  48. NOTE: If necessary, lubricate the LH HO2S  with penetrating and lock lubricant to assist in removal.

    Remove the LH HO2S  .

    Fig 47: Locating LH HO2S
    G08029916Courtesy of FORD MOTOR CO.
  49. Remove the 3 bolts and the LH exhaust heat shield.
    Fig 48: Locating LH Exhaust Heat Shield Bolts
    G08029917Courtesy of FORD MOTOR CO.
  50. Remove the 6 nuts and the LH catalytic converter.
    1. Discard the nuts and the gasket.
    Fig 49: Locating LH Catalytic Converter And Nuts
    G08029918Courtesy of FORD MOTOR CO.
  51. Clean and inspect the catalytic converter flange. REFER to EXHAUST MANIFOLD CLEANING AND INSPECTION .
  52. Remove and discard the 6 LH exhaust manifold studs.
    Fig 50: Locating LH Exhaust Manifold Studs
    G07998086Courtesy of FORD MOTOR CO.
  53. If equipped with FWD, remove the 4 nuts and the RH catalytic converter. Discard the nuts and the gasket.
    Fig 51: Locating RH Catalytic Converter And Fasteners
    G08020804Courtesy of FORD MOTOR CO.
  54. NOTE: Heat shield removed from graphic for clarity.

    Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and exhaust manifold gaskets.

    Fig 52: Locating RH Exhaust Manifold And Nuts
    G07998059Courtesy of FORD MOTOR CO.
  55. Clean and inspect the RH exhaust manifold. REFER to EXHAUST MANIFOLD CLEANING AND INSPECTION .
  56. Remove and discard the 6 RH exhaust manifold studs.
    Fig 53: Locating RH Exhaust Manifold Studs
    G07997750Courtesy of FORD MOTOR CO.
  57. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
    Fig 54: Locating RH Cylinder Block Drain Plug Or Block Heater
    G06281684Courtesy of FORD MOTOR CO.
  58. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
    Fig 55: Locating LH Cylinder Block Drain Plug
    G07463896Courtesy of FORD MOTOR CO.
  59. Remove the pin-type retainer and the cover.
    Fig 56: View Of Cover And Pin-Type Retainer
    G06281687Courtesy of FORD MOTOR CO.
  60. Remove the 2 bolts and the 2 LH CMP sensors.
    Fig 57: Locating LH CMP Sensors And Bolts
    G07986847Courtesy of FORD MOTOR CO.
  61. Remove the 2 bolts and the 2 LH CMP sensors.
    Fig 58: Locating CMP Sensors And Bolts
    G07986859Courtesy of FORD MOTOR CO.
  62. Remove the 2 thermostat housing-to-lower intake manifold bolts.
    Fig 59: Locating Thermostat Housing-To-Lower Intake Manifold Bolts
    G07417511Courtesy of FORD MOTOR CO.
  63. 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.

    1. Remove and discard the intake manifold and thermostat housing gaskets.
    2. Clean and inspect all sealing surfaces.
    Fig 60: Locating Lower Intake Manifold Mounting Bolts
    G07417512Courtesy of FORD MOTOR CO.
  64. NOTE: Early built coolant tube shown in illustration, late build coolant tube similar.

    Remove the coolant inlet tube and thermostat assembly.

    1. Remove and discard the O-ring seal.
    Fig 61: Locating Coolant Inlet Tube And Thermostat Assembly
    G08029930Courtesy of FORD MOTOR CO.
  65. Disconnect and remove the CHT sensor jumper harness.
    Fig 62: Locating CHT Sensor Jumper Harness Connector
    G07960088Courtesy of FORD MOTOR CO.
  66. Remove the bolt and the CKP sensor.
    Fig 63: Locating CHT Sensor Jumper Harness Connector
    G07958909Courtesy of FORD MOTOR CO.
  67. Remove the EOP switch.
    Fig 64: Locating EOP Switch
    G07998170Courtesy of FORD MOTOR CO.
  68. NOTE: A new oil cooler must be installed or severe damage to the engine can occur.

    If equipped, remove the 6 bolts and the oil cooler.

    • Discard the oil cooler and gasket.
    Fig 65: Locating Oil Cooler And Bolts
    G08029934Courtesy of FORD MOTOR CO.
  69. NOTE: Without oil cooler shown in illustration, with oil cooler similar.

    Remove the 3 bolts and the oil filter adapter. Discard the gasket.

    Fig 66: Locating Oil Filter Adapter And Bolts
    G07998169Courtesy of FORD MOTOR CO.
  70. Remove the 3 bolts and the 3 LH -coil-on-plugs.
    Fig 67: Locating LH Ignition Coil-On-Plugs And Bolts
    G07960028Courtesy of FORD MOTOR CO.
  71. NOTE: While removing the valve cover do not apply excessive force to the VCT oil control solenoid or damage may occur.
    NOTE: If the VCT solenoid seal sticks to the VCT oil control solenoid, then carefully wiggle the valve cover until the bond breaks free.
    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 4 bolts and 7 stud bolts. Remove the LH valve cover. Discard the gasket.

    Fig 68: Locating LH Valve Cover Bolts And Stud Bolts
    G07417531Courtesy of FORD MOTOR CO.
  72. Inspect the 2 VCT solenoid seals. Remove any damaged seals.
    1. Using 205-142  (T80T-4000-J) and 205-153  (T80T-4000-W) remove and discard the damaged seal(s).
    Fig 69: Removing Damaged VCT Solenoid Seals
    G07397890Courtesy of FORD MOTOR CO.
  73. Inspect the spark plug tube seals. Remove any damaged seals.
    1. Using 303-1247/1  and 205-153  (T80T-4000-W) remove and discard the damaged seal(s).
    Fig 70: Removing Damaged Spark Plug Tube Seals
    G07397891Courtesy of FORD MOTOR CO.
  74. Remove the 3 bolts and the 3 RH -coil-on-plugs.
    Fig 71: Locating RH Ignition Coil-On-Plugs And Bolts
    G07960035Courtesy of FORD MOTOR CO.
  75. NOTE: While removing the valve cover do not apply excessive force to the VCT oil control solenoid or damage may occur.
    NOTE: If the VCT solenoid seal sticks to the VCT oil control solenoid, then carefully wiggle the valve cover until the bond breaks free.
    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 3 bolts and 8 stud bolts. Remove the RH valve cover. Discard the gasket.

    Fig 72: Locating RH Valve Cover Bolts And Stud Bolts
    G07417557Courtesy of FORD MOTOR CO.
  76. Inspect the 2 VCT solenoid seals. Remove any damaged seals.
    1. Using 205-142  (T80T-4000-J) and 205-153  (T80T-4000-W) remove and discard the damaged seal(s).
    Fig 73: Removing Damaged VCT Solenoid Seals
    G07397915Courtesy of FORD MOTOR CO.
  77. Inspect the spark plug tube seals. Remove any damaged seals.
    1. Using 303-1247/1  and 205-153  (T80T-4000-W) remove and discard the damaged seal(s).
    Fig 74: Removing Damaged Spark Plug Tube Seals
    G07397916Courtesy of FORD MOTOR CO.
  78. Clean the valve covers, cylinder heads and engine front cover sealing surfaces with metal surface prep.
  79. Remove the 26 front cover bolts.
    Fig 75: Identifying Tightening Sequence Of Engine Front Cover Bolts
    G08028979Courtesy of FORD MOTOR CO.
  80. Using a suitable pry tool, locate the 7 pry pads shown in illustration and pry the engine front cover loose and remove.
    Fig 76: Locating Engine Front Cover Pry Pads
    G08028971Courtesy of FORD MOTOR CO.
  81. Rotate the crankshaft clockwise and align the timing marks on the intake VCT assemblies as shown in illustration.
    Fig 77: Locating Timing Marks On Intake VCT Assemblies
    G07399048Courtesy of FORD MOTOR CO.
  82. Remove the 3 bolts and the LH valve train oil tube.
    Fig 78: Locating LH Valve Train Oil Tube And Mounting Bolts
    G07399049Courtesy of FORD MOTOR CO.
  83. NOTE: The 303-1248  will hold the camshafts in the TDC position. Install The 303-1248  onto the flats of the LH camshafts.
    Fig 79: Installing Camshaft Holding Tool Onto Flats Of LH Camshafts
    G07399050Courtesy of FORD MOTOR CO.
  84. Remove the 3 bolts and the RH valve train oil tube.
    Fig 80: Locating RH Valve Train Oil Tube Bolts
    G07399051Courtesy of FORD MOTOR CO.
  85. NOTE: The 303-1248  will hold the camshafts in the TDC position.

    Install 303-1248  onto the flats of the RH camshafts.

    Fig 81: Installing Camshaft Holding Tool Onto Flats Of RH Camshafts
    G07399052Courtesy of FORD MOTOR CO.
  86. NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.

    Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown in illustration.

    Fig 82: Locating Timing Mark On LH Intake VCT Assembly
    G07399053Courtesy of FORD MOTOR CO.
  87. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown in illustration.
    Fig 83: Locating Timing Mark On RH Intake VCT Assembly
    G07410371Courtesy of FORD MOTOR CO.
  88. 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.

    Fig 84: Locating Timing Mark On Crankshaft Sprocket
    G07399055Courtesy of FORD MOTOR CO.
  89. Remove the 2 bolts and the primary timing chain tensioner.
    Fig 85: Locating Primary Timing Chain Tensioner Mounting Bolts
    G07399056Courtesy of FORD MOTOR CO.
  90. Remove the primary timing chain tensioner arm.
    Fig 86: Locating Primary Timing Chain Tensioner Arm
    G07420450Courtesy of FORD MOTOR CO.
  91. Remove the 2 bolts and the lower LH primary timing chain guide.
    Fig 87: Locating Lower LH Primary Timing Chain Guide And Mounting Bolts
    G07420449Courtesy of FORD MOTOR CO.
  92. 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.

    Fig 88: Locating LH Intake VCT Oil Control Solenoid And Mounting Bolt
    G07399059Courtesy of FORD MOTOR CO.
  93. 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.

    Fig 89: Locating RH Intake VCT Oil Control Solenoid And Mounting Bolt
    G07399060Courtesy of FORD MOTOR CO.
  94. Remove the primary timing chain.
    Fig 90: Identifying Primary Timing Chain
    G07399061Courtesy of FORD MOTOR CO.
  95. 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.

    Fig 91: Locating Upper LH Primary Timing Chain Guide And Mounting Bolts
    G07420447Courtesy of FORD MOTOR CO.
  96. Remove the crankshaft timing chain sprocket.
    Fig 92: Locating Crankshaft Timing Chain Sprocket
    G08021038Courtesy of FORD MOTOR CO.
  97. NOTE: The 2 VCT oil control solenoids are removed for clarity.
    NOTE: The 303-1530  is inserted through a hole in the top of the mega cap.

    Compress the LH secondary timing chain tensioner and install The 303-1530  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.

    Fig 93: Compressing LH Secondary Timing Chain Tensioner
    G07410381Courtesy of FORD MOTOR CO.
  98. Remove and discard the 2 LH VCT assembly bolts.
    Fig 94: Locating LH VCT Assembly Bolts
    G07410382Courtesy of FORD MOTOR CO.
  99. Remove the 2 LH VCT assemblies and secondary timing chain. Remove The 303-1530  .
    Fig 95: Locating LH VCT Assemblies And Secondary Timing Chain
    G07410383Courtesy of FORD MOTOR CO.
  100. NOTE: When The 303-1248  is removed, valve spring pressure may rotate the LH camshafts approximately 3 degrees to a neutral position.

    Remove 303-1248  from the LH camshafts.

    Fig 96: Identifying Camshaft Holding Tool On LH Camshafts
    G07410457Courtesy 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 97: Locating LH Camshafts Caps Mounting Bolts
    G08029185Courtesy of FORD MOTOR CO.
  102. NOTE: The 2 VCT oil control solenoids are removed for clarity.
    NOTE: The 303-1530  is inserted through a hole in the top of the mega cap.

    Compress the RH secondary timing chain tensioner and install The 303-1530  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.

    Fig 98: Compressing RH Secondary Timing Chain Tensioner
    G07399063Courtesy of FORD MOTOR CO.
  103. Remove and discard the 2 RH VCT assembly bolts.
    Fig 99: Compressing RH Secondary Timing Chain Tensioner
    G07399064Courtesy of FORD MOTOR CO.
  104. Remove the 2 RH VCT assemblies and secondary timing chain. Remove The 303-1530  .
    Fig 100: Locating RH VCT Assemblies And Secondary Timing Chain
    G07399065Courtesy of FORD MOTOR CO.
  105. 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.

    Fig 101: Locating RH Primary Timing Chain Guide And Bolt
    G07399066Courtesy of FORD MOTOR CO.
  106. NOTE: When The 303-1248  is removed, valve spring pressure may rotate the RH camshafts approximately 3 degrees to a neutral position.
    NOTE: Remove 303-1248  from the RH camshafts.
    Fig 102: Identifying Camshaft Holding Tool On RH Camshafts
    G07958713Courtesy of FORD MOTOR CO.
  107. 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 103: Locating RH Camshaft Caps Mounting Bolts
    G08029190Courtesy of FORD MOTOR CO.
  108. Remove the 2 bolts and the engine lifting eye.
    Fig 104: Locating Engine Lifting Eye And Mounting Bolts
    G08029398Courtesy of FORD MOTOR CO.
  109. NOTE: Index-mark the location of the bracket on the cylinder head for installation. Remove the bolt and the upper intake manifold bracket.
    Fig 105: Locating Upper Intake Manifold Bracket And Bolt
    G08029399Courtesy of FORD MOTOR CO.
  110. 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 106: Locating Valve Tappets
    G07958742Courtesy of FORD MOTOR CO.
  111. NOTE: LH shown in illustration, RH similar.

    Remove and discard the M6 bolt from each cylinder head.

    Fig 107: Locating LH Cylinder Head M6 Bolt
    G07958755Courtesy of FORD MOTOR CO.
  112. 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.

    Remove and discard the 8 bolts from each cylinder head. Remove the cylinder heads. Discard the cylinder head gaskets.

    Fig 108: Locating Cylinder Head M6 Bolt
    G07958756Courtesy of FORD MOTOR CO.
  113. 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. Remove any large deposits of silicone or gasket material with a plastic scraper.

    Apply silicone gasket remover, following package directions, and allow to set for several minutes. 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.

    1. 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.
    2. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
  114. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. REFER to CYLINDER HEAD DISTORTION , and CYLINDER BLOCK DISTORTION .
  115. Remove the 2 bolts and the KS.
    Fig 109: Locating Knock Sensor And Bolts
    G07959154Courtesy of FORD MOTOR CO.
  116. Remove the 8 bolts and the coolant pump.
    Fig 110: Locating Knock Sensor And Bolts
    G07998215Courtesy of FORD MOTOR CO.
  117. Remove the 16 oil pan bolts.
    Fig 111: Locating Coolant Pump Bolts
    G07998216Courtesy of FORD MOTOR CO.
  118. NOTE: Oil pan shown in illustration removed from engine for clarity.

    Using a suitable pry tool, locate the 5 pry pads shown in illustration and pry the oil pan loose and remove.

    Fig 112: Locating Oil Pan Bolts
    G07998856Courtesy of FORD MOTOR CO.
  119. Remove the 2 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.
    Fig 113: Locating Oil Pump Screen And Pickup Tube With Bolts
    G07998218Courtesy of FORD MOTOR CO.
  120. Remove the 3 bolts and the oil pump.
    Fig 114: Locating Oil Pump With Bolts
    G07958860Courtesy of FORD MOTOR CO.
  121. Remove the 8 crankshaft rear seal retainer bolts.
    Fig 115: Locating Oil Pump And Bolts
    G07958911Courtesy of FORD MOTOR CO.
  122. Install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal retainer.
    1. Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released.
    2. Remove the crankshaft rear seal retainer.
    Fig 116: Locating Crankshaft Rear Seal Retainer Bolts
    G07958912Courtesy of FORD MOTOR CO.
  123. 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 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.

  124. 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.
  125. 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 117: Locating M6 Oil Pan Bolts
    G07998222Courtesy of FORD MOTOR CO.
  126. 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.

    Remove the connecting rod cap bolts and cap.

    Fig 118: Identifying Tightening Sequence Of Bearing Cap Support Brace Bolts
    G07959162Courtesy of FORD MOTOR CO.
  127. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

    Remove the piston/rod assembly from the engine block.

    Fig 119: Locating Connecting Rod Cap Bolts
    G07959163Courtesy of FORD MOTOR CO.
  128. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
  129. 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.

    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 120: Locating Piston/Rod Assembly From Engine Block
    G07998225Courtesy of FORD MOTOR CO.
  130. 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 121: Identifying Tightening Sequence Of Bearing Cap Side Bolts
    G07959166Courtesy of FORD MOTOR CO.
  131. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.

    Remove the crankshaft.

    Fig 122: Locating Bearing Caps
    G07959167Courtesy of FORD MOTOR CO.
  132. NOTE: Inside shown in illustration, outside similar.

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

    Fig 123: Locating Crankshaft Upper Main Bearings
    G07959168Courtesy 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 cylinder block.

    Fig 124: Locating Crankshaft Thrust Bearing
    G07959169Courtesy of FORD MOTOR CO.
  134. 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 125: Locating Crankshaft Main Bearings
    G07959170Courtesy of FORD MOTOR CO.
  135. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods.
  136. 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.

    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.
    4. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    5. 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.
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