Section 113 (Engine Mechanical - 3.7L - F150): Disassembly: Engine

	2, 200# Floor Crane, Fold Away 300-OTC1819E
	3 Jaw Puller 303-D121
	Bar, Engine Spreader 303-1454
	Handle 205-153 (T80T-4000-W)
	Hold Down, Secondary Chain 303-1530
	Installer, Differential Bearing Cone 205-142 (T80T-4000-J)
	Installer, Spindle Bearing 205-150 (T80T-4000-S)
	Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
	Remover, Oil Seal 303-409 (T92C-6700CH)
	Remover, VCT Spark Plug Tube Seal 303-1247/1
	Slide Hammer 307-005 (T59L-100-B)
	Strap Wrench 303-D055 (D85L-6000-A)
	Tool, Camshaft Holding 303-1248

All engines 

1. Remove the 8 bolts and the flexplate.
   Fig 1: Locating Flexplate And Bolts

   Courtesy of FORD MOTOR CO.
2. Remove the spacer plate.
   Fig 2: Locating Spacer Plate

   Courtesy of FORD MOTOR CO.
3. Remove the crankshaft sensor ring.
   Fig 3: Locating Crankshaft Sensor Ring

   Courtesy of FORD MOTOR CO.
4. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.
   Fig 4: Removing Crankshaft Rear Seal

   Courtesy of FORD MOTOR CO.
NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.
Fig 5: Mounting Engine On Suitable Engine Stand Using Heavy Duty Floor Crane And Spreader Bar
Courtesy of FORD MOTOR CO.
5. Using the Heavy Duty Floor Crane and Spreader Bar, mount the engine on a suitable engine stand.
6. Remove the LH and RH engine lift eyes.
7. Remove the 3 bolts and the A/C compressor.
   Fig 6: Locating A/C Compressor Bolts

   Courtesy of FORD MOTOR CO.
8. Remove the 4 bolts and the RH engine support insulator.
   Fig 7: Locating RH Engine Support Insulator Bolts

   Courtesy of FORD MOTOR CO.
9. Remove the 4 bolts and the LH engine support insulator-to-cylinder block bracket.
   Fig 8: Locating LH Engine Support Insulator-To-Cylinder Block Bracket Bolts

   Courtesy of FORD MOTOR CO.
10. Remove the engine oil level indicator.
    Fig 9: Locating Engine Oil Level Indicator

    Courtesy of FORD MOTOR CO.
11. Remove the LH fuel rail insulator.
    Fig 10: Locating LH Fuel Rail Insulator

    Courtesy of FORD MOTOR CO.
12. Remove the RH fuel rail insulator.
    Fig 11: Locating RH Fuel Rail Insulator

    Courtesy of FORD MOTOR CO.
13. Disconnect the 3 RH ignition coil-on-plug electrical connectors.
    Fig 12: Locating RH Ignition Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
14. Disconnect the Cylinder Head Temperature (CHT) sensor wiring harness jumper electrical connector.
    Fig 13: Locating Cylinder Head Temperature Sensor Wiring Harness Jumper Electrical Connector

    Courtesy of FORD MOTOR CO.
15. Disconnect the 3 RH fuel rail electrical connectors.
    Fig 14: Locating RH Fuel Rail Electrical Connectors

    Courtesy of FORD MOTOR CO.
16. Disconnect the 2 RH Variable Camshaft Timing (VCT) solenoid electrical connectors.
    Fig 15: Locating RH Variable Camshaft Timing Solenoid Electrical Connectors

    Courtesy of FORD MOTOR CO.
17. Disconnect the 2 RH Camshaft Position (CMP) sensors electrical connectors.
    Fig 16: Locating RH Camshaft Position Sensors Electrical Connectors

    Courtesy of FORD MOTOR CO.
18. Detach all of the wiring harness retainers from the RH cylinder head, valve cover and stud bolts.
19. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
    • Detach the EOP switch wiring harness retainer from the cylinder head.
      Fig 17: Locating Engine Oil Pressure Switch Electrical Connector And Wiring Harness Retainer

      Courtesy of FORD MOTOR CO.
20. Disconnect the 3 LH ignition coil-on-plug electrical connectors.
    Fig 18: Locating LH Ignition Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
21. Disconnect the 3 LH fuel rail electrical connectors.
    Fig 19: Locating LH Fuel Rail Electrical Connectors

    Courtesy of FORD MOTOR CO.
22. Disconnect the 2 LH VCT solenoid electrical connectors.
    Fig 20: Locating LH VCT Solenoid Electrical Connectors

    Courtesy of FORD MOTOR CO.
23. Disconnect the Knock Sensor (KS) sensor electrical connector.
    Fig 21: Locating Knock Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
24. Disconnect the 2 LH CMP sensors electrical connectors.
    • Detach the wiring harness retainer from the rear of the cylinder head.
      Fig 22: Locating LH CMP Sensors Electrical Connectors And Wiring Harness Retainer

      Courtesy of FORD MOTOR CO.
25. Remove the nut, the bolt and the heat shield.
    Fig 23: Locating Heat Shield With Bolt And Nut

    Courtesy of FORD MOTOR CO.
26. Remove the wiring harness retainer stud bolt.
    Fig 24: Locating Wiring Harness Retainer Stud Bolt

    Courtesy of FORD MOTOR CO.
27. Remove the wiring harness grommet.
    Fig 25: Locating Wiring Harness Grommet

    Courtesy of FORD MOTOR CO.
28. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 26: Locating Crankshaft Position (CKP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
29. Detach all of the wiring harness retainers from the LH cylinder head, valve cover and stud bolts.
30. 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 27: Removing Crankshaft Pulley Bolt And Washer Using Strap Wrench

      Courtesy of FORD MOTOR CO.
31. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 28: Removing Crankshaft Pulley Using Jaw Puller

    Courtesy of FORD MOTOR CO.
32. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 29: Removing Crankshaft Front Seal

    Courtesy of FORD MOTOR CO.
33. Remove the 2 bolts and the accessory drive belt tensioner.
    Fig 30: Locating Accessory Drive Belt Tensioner And Bolts

    Courtesy of FORD MOTOR CO.
34. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
      Fig 31: Locating LH Cylinder Block Drain Plug

      Courtesy of FORD MOTOR CO.
35. Remove the RH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
      Fig 32: Locating RH Cylinder Block Drain Plug

      Courtesy of FORD MOTOR CO.
36. Remove the nut and the heater hose bracket from the valve cover stud bolt.
    Fig 33: Locating Heater Hose Bracket Nut

    Courtesy of FORD MOTOR CO.
37. Remove the 4 bolts and the thermostat housing.
    • Discard the thermostat housing and coolant inlet tube O-ring seals.
      Fig 34: Locating Thermostat Housing And Bolts

      Courtesy of FORD MOTOR CO.
38. Remove the 4 bolts and the coolant pump pulley.
    Fig 35: Locating Coolant Pump Pulley And Bolts

    Courtesy of FORD MOTOR CO.
39. Remove the 7 bolts and the coolant pump.
    • Discard the coolant pump gasket and coolant pump O-ring seal.
      Fig 36: Locating Coolant Pump And Bolts

      Courtesy of FORD MOTOR CO.
NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
Fig 37: Locating LH Ignition Coil-On-Plugs And Bolts
Courtesy of FORD MOTOR CO.
40. Remove the 3 bolts and the 3 LH ignition coil-on-plugs.
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.
41. Remove the 3 LH spark plugs.
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.
42. Loosen the 7 stud bolts, 4 bolts and remove the LH valve cover.
    • Discard the gasket.
      Fig 38: Locating Stud Bolts And Bolts Of LH Valve Cover

      Courtesy of FORD MOTOR CO.
43. Inspect the 2 VCT solenoid seals. Remove any damaged seals.
    • Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
      Fig 39: Removing Seals Using Differential Bearing Cone Installer And Handle

      Courtesy of FORD MOTOR CO.
44. Inspect the spark plug tube seals. Remove any damaged seals.
    • Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
      Fig 40: Removing Seal Using VCT Spark Plug Tube Seal Remover And Handle

      Courtesy of FORD MOTOR CO.
45. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
46. Remove the 2 bolts and the LH exhaust manifold heat shield.
    Fig 41: Locating LH Exhaust Manifold Heat Shield And Bolts

    Courtesy of FORD MOTOR CO.
47. Remove the 6 nuts and the LH exhaust manifold.
    • Discard the nuts and exhaust manifold gaskets.
      Fig 42: Locating LH Exhaust Manifold And Nuts

      Courtesy of FORD MOTOR CO.
48. Clean and inspect the LH exhaust manifold. For additional information, REFER to ENGINE SYSTEM - GENERAL INFORMATION .
49. Remove and discard the 6 LH exhaust manifold studs.
    Fig 43: Locating LH Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.
NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
Fig 44: Locating RH Ignition Coil-On-Plugs And Bolts
Courtesy of FORD MOTOR CO.
50. Remove the 3 bolts and the 3 RH ignition coil-on-plugs.
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.
51. Remove the 3 RH spark plugs.
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.
52. Loosen the 8 stud bolts, 3 bolts and remove the RH valve cover.
    • Discard the gasket.
      Fig 45: Locating Stud Bolts And Bolts Of RH Valve Cover

      Courtesy of FORD MOTOR CO.
53. Inspect the 2 VCT solenoid seals. Remove any damaged seals.
    • Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
      Fig 46: Removing Seal Using Differential Bearing Cone Installer And Handle

      Courtesy of FORD MOTOR CO.
54. Inspect the spark plug tube seals. Remove any damaged seals.
    • Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
      Fig 47: Removing Seal Using VCT Spark Plug Tube Seal Remover And Handle

      Courtesy of FORD MOTOR CO.
55. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
56. Remove the 2 bolts and the RH exhaust manifold heat shield.
    Fig 48: Locating RH Exhaust Manifold Heat Shield And Bolts

    Courtesy of FORD MOTOR CO.
57. Remove the 6 nuts and the RH exhaust manifold.
    • Discard the nuts and exhaust manifold gaskets.
      Fig 49: Locating RH Exhaust Manifold And Nuts

      Courtesy of FORD MOTOR CO.
58. Clean and inspect the RH exhaust manifold. For additional information, REFER to ENGINE SYSTEM - GENERAL INFORMATION .
59. Remove and discard the 6 RH exhaust manifold studs.
    Fig 50: Locating RH Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.
60. Remove the 2 bolts and the LH CMP sensors.
    Fig 51: Locating LH CMP Sensors And Bolts

    Courtesy of FORD MOTOR CO.
61. Remove the 2 bolts and the RH CMP sensors.
    Fig 52: Locating RH CMP Sensors And Bolts

    Courtesy of FORD MOTOR CO.
62. Remove the bolt and the CKP sensor.
    Fig 53: Locating CKP Sensor And Bolt

    Courtesy of FORD MOTOR CO.
NOTE: A new oil cooler must be installed or severe damage to the engine can occur.
Fig 54: Locating Oil Cooler Mounting Bolt
Courtesy of FORD MOTOR CO.
63. If equipped, remove the oil cooler mounting bolt and the oil cooler.
64. Remove the 5 bolts and the oil filter adapter.
    • Discard the gasket.
      Fig 55: Locating Oil Filter Adapter And Bolts

      Courtesy of FORD MOTOR CO.
65. Remove the 22 engine front cover bolts.
    Fig 56: Locating Engine Front Cover Bolts

    Courtesy of FORD MOTOR CO.
66. Using a pry tool, locate the 7 pry pads shown in illustration and pry the engine front cover loose and remove.
    Fig 57: Locating Engine Front Cover Pads

    Courtesy of FORD MOTOR CO.
NOTE: Inspect front cover radial seal and replace if necessary.
NOTE: Use Spindle Bearing Installer 205-150 to remove the seal.
Fig 58: Removing Front Cover Radial Seal
Courtesy of FORD MOTOR CO.
67. If necessary, using the Spindle Bearing Installer and Handle, remove the front cover radial seal from the rear side of the front cover.
68. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration.
    Fig 59: Locating Timing Marks On Intake Variable Camshaft Timing Assemblies

    Courtesy of FORD MOTOR CO.
69. Remove the 3 bolts and the LH valve train oil tube.
    Fig 60: Locating LH Valve Train Oil Tube Bolts

    Courtesy of FORD MOTOR CO.
NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.
Fig 61: Installing Camshaft Holding Tool Onto Flats Of LH Camshafts
Courtesy of FORD MOTOR CO.
70. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
71. Remove the 3 bolts and the RH valve train oil tube.
    Fig 62: Locating RH Valve Train Oil Tube Bolts

    Courtesy of FORD MOTOR CO.
NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Fig 63: Installing Camshaft Holding Tool Onto Flats Of RH Camshafts
Courtesy of FORD MOTOR CO.
NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.
72. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
73. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown in illustration.
    Fig 64: Locating Timing Chain Link And Timing Mark On LH Intake VCT Assembly

    Courtesy of FORD MOTOR CO.
74. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown in illustration.
    Fig 65: Locating Timing Chain Link And Timing Mark On RH Intake VCT Assembly

    Courtesy of FORD MOTOR CO.
NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Fig 66: Locating Timing Chain Links And Timing Mark On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
75. Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown in illustration.
76. Remove the 2 bolts and the primary timing chain tensioner.
    Fig 67: Locating Primary Timing Chain Tensioner And Bolts

    Courtesy of FORD MOTOR CO.
77. Remove the primary timing chain tensioner arm.
    Fig 68: Locating Primary Timing Chain Tensioner Arm

    Courtesy of FORD MOTOR CO.
78. Remove the 2 bolts and the lower LH primary timing chain guide.
    Fig 69: Locating Lower LH Primary Timing Chain Guide And Bolts

    Courtesy of FORD MOTOR CO.
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.
Fig 70: Locating LH Intake VCT Oil Control Solenoid And Bolt
Courtesy of FORD MOTOR CO.
79. Remove the bolt and the LH intake VCT oil control solenoid.
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.
Fig 71: Locating RH Intake VCT Oil Control Solenoid And Bolt
Courtesy of FORD MOTOR CO.
80. Remove the bolt and the RH intake VCT oil control solenoid.
81. Remove the primary timing chain.
    Fig 72: Locating Primary Timing Chain

    Courtesy of FORD MOTOR CO.
82. Remove the crankshaft timing chain sprocket.
    Fig 73: Locating Crankshaft Timing Chain Sprocket

    Courtesy of FORD MOTOR CO.
NOTE: Do not use power tools to remove the bolt or damage to the LH primary timing chain guide may occur.
Fig 74: Locating Upper LH Primary Timing Chain Guide And Bolt
Courtesy of FORD MOTOR CO.
83. Remove the bolt and the upper LH primary timing chain guide.
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.
Fig 75: Compressing LH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
84. 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.
85. Remove and discard the 2 LH VCT assembly bolts.
    Fig 76: Locating LH VCT Assembly Bolts

    Courtesy of FORD MOTOR CO.
86. Remove the 2 LH VCT assemblies and secondary timing chain.
    Fig 77: Locating LH VCT Assemblies And Secondary Timing Chain

    Courtesy of FORD MOTOR CO.
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.
Fig 78: Compressing RH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
87. 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.
88. Remove and discard the 2 RH VCT assembly bolts.
    Fig 79: Locating RH VCT Assembly Bolts

    Courtesy of FORD MOTOR CO.
89. Remove the 2 RH VCT assemblies and secondary timing chain.
    Fig 80: Locating RH VCT Assemblies And Secondary Timing Chain

    Courtesy of FORD MOTOR CO.
NOTE: Do not use power tools to remove the bolt or damage to the RH primary timing chain guide may occur.
Fig 81: Locating RH Primary Timing Chain Guide And Bolt
Courtesy of FORD MOTOR CO.
90. Remove the bolt and the RH primary timing chain guide.
91. Remove the 9 bolts and the channel cover plate.
    • Discard the gaskets.
      Fig 82: Locating Channel Cover Plate And Bolts

      Courtesy of FORD MOTOR CO.

      Engines with secondary timing chain tensioner removed 

      NOTE: The following steps are only for the replacement of the secondary timing chain tensioners. Do not reuse the secondary timing chain tensioners if removed, or damage to the engine may occur.
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.
Fig 83: Locating LH Exhaust Vct Oil Control Solenoid And Bolt
Courtesy of FORD MOTOR CO.
92. Remove the LH exhaust VCT oil control solenoid.
93. Remove the LH secondary timing chain tensioner shoe.
    Fig 84: Locating LH Secondary Timing Chain Tensioner Shoe

    Courtesy of FORD MOTOR CO.
94. Remove the LH secondary timing chain tensioner by pushing up from the bottom and remove.
    Fig 85: Removing LH Secondary Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
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.
Fig 86: Locating RH Exhaust VCT Oil Control Solenoid And Bolt
Courtesy of FORD MOTOR CO.
95. Remove the RH exhaust VCT oil control solenoid.
96. Remove the RH secondary timing chain tensioner shoe.
    Fig 87: Locating RH Secondary Timing Chain Tensioner Shoe

    Courtesy of FORD MOTOR CO.
97. Remove the RH secondary timing chain tensioner by pushing up from the bottom and remove.
    Fig 88: Removing RH Secondary Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.

    All engines 

NOTE: When the Camshaft Holding Tool is removed, valve spring pressure may rotate the LH camshafts approximately 3 degrees to a neutral position.
Fig 89: Removing Camshaft Holding Tool From LH Camshafts
Courtesy of FORD MOTOR CO.
98. Remove the Camshaft Holding Tool from the LH camshafts.
NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.
Fig 90: Locating Camshafts Onto LH Cylinder Head In Neutral Position
Courtesy of FORD MOTOR CO.
99. Verify the LH camshafts are in the neutral position.
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.
Fig 91: Locating Bolts, Camshaft Caps, Mega Cap Of LH Camshafts
Courtesy of FORD MOTOR CO.
100. Remove the 12 bolts, 6 camshaft caps, mega cap and the LH camshafts.
NOTE: When the Camshaft Holding Tool is removed, valve spring pressure may rotate the RH camshafts approximately 3 degrees to a neutral position.
Fig 92: Removing Camshaft Holding Tool From RH Camshafts
Courtesy of FORD MOTOR CO.
101. Remove the Camshaft Holding Tool from the RH camshafts.
NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.
Fig 93: Locating Camshafts Onto RH Cylinder Head In Neutral Position
Courtesy of FORD MOTOR CO.
102. Rotate the RH camshafts counterclockwise to the neutral position.
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.
Fig 94: Locating Bolts, Camshaft Caps, Mega Cap Of RH Camshafts
Courtesy of FORD MOTOR CO.
103. Remove the 12 bolts, 6 camshaft caps, mega cap and the RH camshafts.
NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
NOTE: LH shown in illustration, RH similar.
Fig 95: Locating Valve Tappets
Courtesy of FORD MOTOR CO.
104. Remove the valve tappets from the cylinder heads.
105. Inspect the valve tappets. For additional information, REFER to ENGINE SYSTEM - GENERAL INFORMATION .
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.
106. Remove the 10 bolts and the lower intake manifold.
     • Discard the gaskets.
       Fig 96: Locating Lower Intake Manifold And Bolts

       Courtesy of FORD MOTOR CO.
107. Disconnect and remove the CHT sensor jumper harness.
     Fig 97: Locating CHT Sensor Jumper Harness

     Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
Fig 98: Locating LH Cylinder Head M6 Bolt
Courtesy of FORD MOTOR CO.
108. Remove and discard the M6 bolt from each cylinder head.
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.
109. Remove and discard the 8 bolts from each cylinder head.
     • Remove the cylinder heads.
     • Discard the cylinder head gaskets.
       Fig 99: Locating Cylinder Head Bolts

       Courtesy of FORD MOTOR CO.
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.
110. 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.
111. 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 .
112. Remove the 2 bolts and the KS.
     Fig 100: Locating Knock Sensor And Bolts

     Courtesy of FORD MOTOR CO.
113. Remove the 16 oil pan bolts.
     Fig 101: Locating Oil Pan Bolts

     Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
Fig 102: Locating Pads At LH And RH Side Of Oil Pan
Courtesy of FORD MOTOR CO.
114. Using a 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.
115. Remove the 3 bolts and the oil pump screen and the pickup tube.
     • Discard the O-ring seal.
       Fig 103: Locating Oil Pump Screen And Pickup Tube With Bolts

       Courtesy of FORD MOTOR CO.
116. Remove the 3 bolts and the oil pump.
     Fig 104: Locating Oil Pump With Bolts

     Courtesy of FORD MOTOR CO.
117. Remove the 8 crankshaft rear seal retainer bolts.
     Fig 105: Locating Crankshaft Rear Seal Retainer Bolts

     Courtesy of FORD MOTOR CO.
118. Install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal retainer.
     • Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released.
       • Remove the crankshaft rear seal retainer.
         Fig 106: Locating M6 Oil Pan Bolts

         Courtesy of FORD MOTOR CO.
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.
119. 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.
120. 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.
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.
121. Remove the bolts in the sequence shown in illustration.
     • Remove the main bearing cap support brace.
     • Discard the bolts.
       Fig 107: Identifying Main Bearing Cap Support Brace Bolts Loosening Sequence

       Courtesy of FORD MOTOR CO.
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.
Fig 108: Locating Connecting Rod Cap Bolts And Cap
Courtesy of FORD MOTOR CO.
122. Remove the connecting rod cap bolts and cap.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Fig 109: Locating Piston/Rod Assembly
Courtesy of FORD MOTOR CO.
123. Remove the piston/rod assembly from the engine block.
124. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
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.
125. Remove the 8 main bearing cap side bolts in the sequence shown in illustration.
     • Discard the bolts.
       Fig 110: Identifying Main Bearing Cap Side Bolts Loosening Sequence

       Courtesy of FORD MOTOR CO.
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.
126. Remove the 8 main bearing cap bolts in the sequence shown in illustration.
     • Discard the bolts.
       Fig 111: Identifying Main Bearing Cap Bolts Loosening Sequence

       Courtesy of FORD MOTOR CO.
NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.
Fig 112: Locating Bearing Caps
Courtesy of FORD MOTOR CO.
127. Remove the 4 main bearing caps.
NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
Fig 113: Locating Crankshaft Onto Upper Main Bearings
Courtesy of FORD MOTOR CO.
128. Remove the crankshaft.
NOTE: Inside shown in illustration, outside similar.
Fig 114: Locating Crankshaft Thrust Bearing
Courtesy of FORD MOTOR CO.
129. Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.
NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Fig 115: Locating Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
130. Remove the 4 crankshaft main bearings from the cylinder block.
NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Fig 116: Locating Crankshaft Bearings Cap
Courtesy of FORD MOTOR CO.
131. Remove the 4 crankshaft main bearings from the main bearing caps.
132. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional information, REFER to ENGINE SYSTEM - GENERAL INFORMATION .
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.
133. 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.
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.
134. 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.