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Home >> Ford >> 2012 >> Explorer Limited, 3.5 8, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 222 (Engine Mechanical -3.5L Ti-VCT) >> Removal And Installation >> Engine >> Disassembly

Removal And Installation: Engine: Disassembly

WARNING: This page is about a different car, the 2013 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Before beginning any service procedure, refer to SAFETY WARNINGS . Failure to follow this instruction 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, can 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: 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.
    G08621636
  2. Remove the crankshaft sensor ring.
    G08029522
  3. If equipped with a cast aluminum crankshaft rear seal retainer plate, use the 303-519 T95P-6701-EH and 307-005 T59L-100-B to remove the rear crankshaft seal.
    • Discard the seal.
      G08029523
  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 block heater heat shield.
    G08029343
  6. If equipped, disconnect the block heater electrical connector.
    • Detach all of the engine block heater harness retainers and remove the harness.
      G08029344
  7. Remove the 3 bolts and the accessory drive belt tensioner.
    G08029874
  8. Using the 303-D055 D85L-6000-A, remove the crankshaft pulley bolt and washer.
    • Discard the bolt.
      G08621625
  9. Using the 303-D021 D80L-100-S, remove the crankshaft pulley.
    G08621626
  10. Using the 303-409 T92C-6700-CH, remove and discard the crankshaft front seal.
    G08028948
  11. Remove the crankcase vent tube. REFER to QUICK CONNECT COUPLING .
    G09086899
  12. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

    Disconnect the 3 LH coil-on-plug electrical connectors and remove the 3 bolts and the 3 LH coil-on-plugs.

    • Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
      G08621585
  13. Remove the oil level indicator.
    G08028905
  14. Remove the bolt and position the wire harness aside.
    G08622023
  15. Remove the engine wiring harness from the LH valve cover.
    • Disconnect the 2 VCT  oil control solenoid electrical connectors.
    • Detach and disconnect the LH HO2S  electrical connector.
    • Disconnect the 3 fuel injector electrical connectors.
    • Detach the 11 wiring harness retainers from the LH valve cover and stud bolts and position the harness aside.
      G09086903
  16. Disconnect the 2 LH CMP  sensor electrical connectors.
    G08029345
  17. Disconnect the wiring harness retainer from the rear of the LH cylinder head.
    G08029347
  18. Disconnect the EVAP  canister purge valve and throttle body electrical connectors.
    • Detach the wiring harness pin-type retainer.
      G08028879
  19. Disconnect the EVAP  vapor tube from the EVAP  canister purge valve. REFER to QUICK CONNECT COUPLING .
    • Detach the EVAP  vapor tube from the 2 retainers.
      G08028880
  20. Disconnect the crankcase ventilation hose from the upper intake manifold.
    G09086120
  21. Detach the 2 coolant tube retainers from the upper intake manifold.
    G08028882
  22. Remove the upper intake manifold support bracket bolt.
    G08028883
  23. Remove the 7 bolts and the upper intake manifold.
    • Remove and discard the gasket.
    • Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
      G08028884
  24. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

    Disconnect the 3 RH coil-on-plug electrical connectors and remove the 3 bolts and the 3 RH coil-on-plugs.

    • Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
      G08621606
  25. Remove the PCV  crankcase vent tube.
    G08028924
  26. Remove the engine wiring harness from the RH valve cover.
    • Disconnect the 2 VCT  oil control solenoid electrical connectors.
    • Detach and disconnect the RH CMS  electrical connector.
    • Disconnect the 3 fuel injector electrical connectors.
    • Disconnect the CHT  sensor wiring harness jumper electrical connector.
    • Detach the 9 wiring harness retainers from the RH valve cover and stud bolts and position the harness aside.
      G08028925
  27. 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 and remove the LH valve cover.

    • Discard the gasket.
      G08028908
  28. Inspect the 2 VCT  solenoid seals. Remove any damaged seals.
    • Using 205-142 T80T-4000-J and 205-153 T80T-4000-W, remove and discard the damaged seal(s).
      G08028909
  29. Inspect the spark plug tube seals. Remove any damaged seals.
    • Using 303-1247/1 and 205-153 T80T-4000-W, remove and discard the damaged seal(s).
      G08028910
  30. 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.

    G08028926
  31. Inspect the 2 VCT  solenoid seals. Remove any damaged seals.
    • Using 205-142 T80T-4000-J and 205-153 T80T-4000-W, remove and discard the damaged seal(s).
      G08028927
  32. Inspect the spark plug tube seals. Remove any damaged seals.
    • Using 303-1247/1 and 205-153 T80T-4000-W, remove and discard the damaged seal(s).
      G09086920
  33. Clean the valve covers, cylinder heads and engine front cover sealing surfaces with metal surface prep.
  34. Disconnect the 2 RH CMP  sensor electrical connectors.
    G08622076
  35. Disconnect the KS electrical connector.
    G08622154
  36. Remove the nut, the bolt and the heat shield.
    G08622157
  37. Remove the wiring harness retainer stud bolt.
    G08622158
  38. Remove the wiring harness grommet.
    G08622159
  39. Disconnect the CKP  sensor electrical connector.
    G08622160
  40. Remove the bolt and the CKP  sensor.
    G08622161
  41. Remove the nut, bolt and the generator.
    • Remove the generator stud.
      G08029352
  42. Disconnect the EOP switch electrical connector and the wiring harness pin-type retainer.
    • Remove the wiring harness from the engine.
      G08029353
  43. Remove the nut, 2 stud bolts and the A/C compressor.
    G08029349
  44. Remove the A/C compressor mounting stud from the oil pan.
    G08622166
  45. NOTE: If necessary, lubricate the Left Hand (LH) HO2S  with penetrating and lock lubricant to assist in removal.

    Remove the LH HO2S  .

    G08029354
  46. Remove the 3 bolts and the LH exhaust heat shield.
    G08029355
  47. Remove the 6 nuts and the LH catalytic converter.
    • Discard the nuts and the gasket.
      G08029356
  48. Clean and inspect the catalytic converter flange. REFER to EXHAUST MANIFOLD CLEANING AND INSPECTION .
  49. Remove and discard the 6 LH exhaust manifold studs.
    G08029357
  50. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
    G08029359
  51. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
    G08029358
  52. Remove the pin-type retainer and the cover.
    G08622179
  53. Remove the 2 bolts and the 2 LH CMP sensors.
    G08029346
  54. Remove the 2 bolts and the 2 LH CMP sensors.
    G08622077
  55. Remove the 2 thermostat housing-to-lower intake manifold bolts.
    G08029360
  56. 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.

    • Remove and discard the intake manifold and thermostat housing gaskets.
    • Clean and inspect all sealing surfaces.
      G08622184
  57. Disconnect and remove the CHT  sensor jumper harness.
    G08622089
  58. 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.
      G08029507
  59. NOTE: Oil filter adapter with oil cooler shown in illustration, oil filter adapter without oil cooler similar.

    Remove the 3 bolts and the oil filter adapter.

    • Discard the gasket.
      G08029501
  60. Remove the EOP  switch.
    G08622186
  61. Remove the 26 front cover bolts.
    G08028979
  62. Using a suitable pry tool, locate the 7 pry pads shown in illustration and pry the engine front cover loose and remove.
    G08028971
  63. Rotate the crankshaft clockwise and align the timing marks on the intake VCT  assemblies as shown in illustration.
    G08028991
  64. Remove the 3 bolts and the LH valve train oil tube.
    G08028992
  65. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC  position.

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

    G08028993
  66. Remove the 3 bolts and the RH valve train oil tube.
    G08028994
  67. 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.

    G08028995
  68. 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.

    G08028996
  69. Mark the timing chain link that aligns with the timing mark on the RH intake VCT  assembly as shown in illustration.
    G08028997
  70. 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.

    G08028998
  71. Remove the 2 bolts and the primary timing chain tensioner.
    G08028999
  72. Remove the primary timing chain tensioner arm.
    G08029000
  73. Remove the 2 bolts and the lower LH primary timing chain guide.
    G08029001
  74. 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.

    G08029002
  75. 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.

    G08029003
  76. Remove the primary timing chain.
    G09086962
  77. Remove the crankshaft timing chain sprocket.
    G08029005
  78. 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

    G08029006
  79. 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.

    G08029007
  80. Remove and discard the 2 LH VCT  assembly bolts.
    G08029008
  81. Remove the 2 LH VCT  assemblies and secondary timing chain.
    G08029009
  82. 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.

    G08028993
  83. 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.

    G08622062
  84. 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.

    G08029010
  85. Remove and discard the 2 RH VCT  assembly bolts.
    G08029011
  86. Remove the 2 RH VCT  assemblies and secondary timing chain.
    G08029012
  87. 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.

    G08029013
  88. 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.
    G08028995
  89. 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.

    G08622214
  90. Remove the 2 bolts and the engine lifting eye.
    G09086275
  91. NOTE: Index-mark the location of the bracket on the cylinder head for installation. Remove the bolt and the upper intake manifold bracket.
    G08622086
  92. 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.

    G08029334
  93. NOTE: LH shown in illustration, RH similar.

    Remove and discard the M6 bolt from each cylinder head.

    G08029364
  94. 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.

    G08029365
  95. 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.

    • 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.
    • 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.
  96. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.
  97. NOTE: Cylinder heads removed for clarity.

    Remove the coolant inlet tube and thermostat assembly.

    • Remove and discard the O-ring seal.
      G08622221
  98. Remove the 2 bolts and the KS.
    G08622222
  99. Remove the 8 bolts and the coolant pump.
    G08622223
  100. Remove the 16 oil pan bolts.
    G08621803
  101. Using a suitable pry tool, locate the pry pads and pry the oil pan loose and remove.
    G08621804
  102. Remove the 2 bolts and the oil pump screen and pickup tube.
    • Discard the O-ring seal.
      G08622226
  103. Remove the 3 bolts and the oil pump.
    G08029483
  104. Remove the 8 crankshaft rear seal retainer bolts.
    • If equipped with a stamped steel rear seal retainer plate (late build), remove and discard the plate and seal.
      G08337857
  105. If equipped with a cast aluminum rear seal retainer plate (early build), 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 plate.
      G08337858
  106. 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.

  107. 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.
  108. 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.

    G08622231
  109. 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.

    G08622232
  110. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

    Remove the piston/rod assembly from the engine block.

    G08622233
  111. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
  112. 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.

    G08622234
  113. 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.

    G08622235
  114. Remove the lower crankshaft thrust washer from the back side of the No. 4 rear main bearing cap.
    G08622236
  115. 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.

    G08622237
  116. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.

    Remove the crankshaft.

    G08622238
  117. NOTE: Inside shown in illustration, outside similar.

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

    G08622239
  118. 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.

    G08622240
  119. Using a hexagonal screwdriver, remove the 6 piston oil cool valves.
    G08337138
  120. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods.
  121. 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.

    • Remove any large deposits of silicone or gasket material.
    • Apply silicone gasket remover and allow to set for several minutes.
    • Remove the silicone gasket remover.
    • A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    • 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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