Section 178 (Engine Mechanical - 3.5L-GTDI - F150): Disassembly: Engine

	Bar, Engine Spreader 303-1454
	3 Jaw Puller 303-D121
	Brush, Fuel Injector 310-205
	Handle 205-153 (T80T-4000-W)
	2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
	Hold Down, Secondary Chain 303-1530
	Installer, Differential Bearing Cone 205-142 (T80T-4000-J)
	Installer, Spindle Bearing 205-150 (T80T-4000-S)
	Lift Eye, Right Front 303-1566
	Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
	Remover, Fuel Injector 310-206
	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 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: Lifting Engine On Suitable Engine Stand
Courtesy of FORD MOTOR CO.
5. Using the Floor Crane and Engine Spreader Bar, mount the engine on a suitable engine stand.
6. Remove the 2 bolts and the Right Front Lift Eye.
   Fig 6: Locating Right Front Lift Eye Bolts

   Courtesy of FORD MOTOR CO.
7. Remove the A/C compressor and the 3 bolts.
   Fig 7: Locating A/C Compressor And Bolts

   Courtesy of FORD MOTOR CO.
8. Remove the LH crankcase vent tube. For additional information, REFER to FUEL SYSTEM - GENERAL INFORMATION .
   Fig 8: Locating LH Crankcase Vent Tube

   Courtesy of FORD MOTOR CO.
9. Remove the RH PCV tube. For additional information, REFER to FUEL SYSTEM - GENERAL INFORMATION .
   Fig 9: Locating RH PCV Tube

   Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
NOTE: Heat insulating wrap removed for clarity.
Fig 10: Locating Turbocharger Pressure Regulator Solenoid Electrical Connectors
Courtesy of FORD MOTOR CO.
10. Disconnect the turbocharger pressure regulator solenoid electrical connectors.
NOTE: LH shown in illustration, RH similar.
NOTE: The heat insulating wrap is removed with the turbocharger bypass valve.
Fig 11: Locating Wastegate Hose And Vacuum Hoses
Courtesy of FORD MOTOR CO.
11. Disconnect the wastegate hose and the 2 vacuum hoses. Remove the turbocharger bypass valve from the bracket.
NOTE: LH shown in illustration, RH similar.
Fig 12: Locating Tie Strap For Vacuum Hose Assembly
Courtesy of FORD MOTOR CO.
12. Remove the tie straps for the vacuum hose assembly. Remove the vacuum hose assembly.
NOTE: Use a 3/8 inch Jiffy-tite quick disconnect tool, such as a Snap-on® LDTSP4 or equivalent, to disconnect the turbocharger coolant tubes.
Fig 13: Locating Turbocharger Coolant Supply Tube
Courtesy of FORD MOTOR CO.
13. Using a commercially available quick disconnect tool, remove the LH turbocharger coolant supply tube.
14. Remove the 2 bolts at the LH turbocharger oil return tube.
    • Remove and discard the turbocharger return tube gasket.
      Fig 14: Locating LH Turbocharger Oil Return Tube Bolts

      Courtesy of FORD MOTOR CO.
15. Remove the LH turbocharger bracket bolt.
    Fig 15: Locating LH Turbocharger Bracket Bolt

    Courtesy of FORD MOTOR CO.
NOTE: Use a 3/8 inch Jiffy-tite quick disconnect tool, such as a Snap-on® LDTSP4 or equivalent, to disconnect the turbocharger coolant tubes.
NOTE: Cylinder block side shown in illustration, turbocharger side similar.
Fig 16: Locating LH Turbocharger Coolant Return Tube From Cylinder Block
Courtesy of FORD MOTOR CO.
16. Using a commercially available quick disconnect tool, remove the LH turbocharger coolant return tube from the cylinder block.
17. Remove the 3 bolts and the LH turbocharger.
    • Discard the turbocharger exhaust manifold gasket.
      Fig 17: Locating LH Turbocharger Bolts

      Courtesy of FORD MOTOR CO.
18. Remove the bolt for the oil supply tube.
    Fig 18: Locating Oil Supply Tube Bolt

    Courtesy of FORD MOTOR CO.
19. Remove the bolt and the oil turbocharger oil return tube.
    • Remove and discard the O-ring seal.
      Fig 19: Locating Oil Turbocharger Oil Return Tube Bolt

      Courtesy of FORD MOTOR CO.
20. Remove the 2 bolts and the LH turbocharger mounting bracket.
    Fig 20: Locating LH Turbocharger Mounting Bracket Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Use a 3/8 inch Jiffy-tite quick disconnect tool, such as a Snap-on® LDTSP4 or equivalent, to disconnect the turbocharger coolant tubes.
Fig 21: Locating RH Turbocharger Coolant Supply Tube
Courtesy of FORD MOTOR CO.
21. Using a commercially available quick disconnect tool, remove the RH turbocharger coolant supply tube.
22. Remove the 2 bolts at the RH turbocharger oil return tube.
    • Remove and discard the turbocharger oil return tube gasket.
      Fig 22: Locating RH Turbocharger Oil Return Tube Bolts

      Courtesy of FORD MOTOR CO.
23. Remove the RH turbocharger bracket bolt.
    Fig 23: Locating RH Turbocharger Bracket Bolt

    Courtesy of FORD MOTOR CO.
NOTE: Use a 3/8 inch Jiffy-tite quick disconnect tool, such as a Snap-on® LDTSP4 or equivalent, to disconnect the turbocharger coolant tubes.
NOTE: Cylinder block side shown in illustration, turbocharger side similar.
Fig 24: Locating Turbocharger Coolant Tubes
Courtesy of FORD MOTOR CO.
24. Using a commercially available quick disconnect tool, disconnect the RH turbocharger coolant return tube from the cylinder block.
25. Remove the 3 bolts and the RH turbocharger.
    • Discard the turbocharger exhaust manifold gasket.
      Fig 25: Locating RH Turbocharger And Bolts

      Courtesy of FORD MOTOR CO.
26. Remove the bolt for the oil supply tube.
    Fig 26: Locating Oil Supply Tube Bolt

    Courtesy of FORD MOTOR CO.
27. Remove the bolt and the turbocharger oil return tube.
    • Remove and discard the O-ring seal.
      Fig 27: Locating Turbocharger Oil Return Tube Bolt

      Courtesy of FORD MOTOR CO.
28. Remove the 2 bolts and the RH turbocharger mounting bracket.
    Fig 28: Locating RH Turbocharger Mounting Bracket Bolts

    Courtesy of FORD MOTOR CO.
29. Remove the 4 bolts and the RH engine support insulator.
    Fig 29: Locating RH Engine Support Insulator Bolts

    Courtesy of FORD MOTOR CO.
30. Remove the 4 bolts and the LH engine support insulator-to-cylinder block bracket.
    Fig 30: Locating LH Engine Support Insulator-To-Cylinder Block Bracket And Bolts

    Courtesy of FORD MOTOR CO.
31. Remove the engine oil level indicator.
    Fig 31: Locating Oil Level Indicator

    Courtesy of FORD MOTOR CO.
32. Disconnect the 2 LH Variable Camshaft Timing (VCT) solenoid electrical connectors.
    Fig 32: Locating LH Variable Camshaft Timing (VCT) Solenoid Electrical Connectors

    Courtesy of FORD MOTOR CO.
33. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
    • Detach the EOP switch wiring harness retainer from the cylinder head.
      Fig 33: Locating EOP Switch Wiring Harness Retainer From Cylinder Head

      Courtesy of FORD MOTOR CO.
34. Disconnect the 3 LH ignition coil-on-plug electrical connectors.
    Fig 34: Locating LH Ignition Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
35. Remove the nut, the bolt and the CKP heat shield.
    Fig 35: Locating Heat Shield With Bolt And Nut

    Courtesy of FORD MOTOR CO.
36. Remove the wiring harness retainer stud bolt.
    Fig 36: Locating Wiring Harness Retainer Stud Bolt

    Courtesy of FORD MOTOR CO.
37. Remove the wiring harness grommet.
    Fig 37: Locating Wiring Harness Grommet

    Courtesy of FORD MOTOR CO.
38. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 38: Locating Crankshaft Position (CKP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
39. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
40. Disconnect the 2 LH Camshaft Position (CMP) sensor electrical connectors. Disconnect the CKP wire retainer. Remove the ground stud bolt.
    Fig 39: Locating LH Camshaft Position (CMP) Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
41. Disconnect the Knock Sensor (KS) sensor electrical connector. Disconnect the 2 fuel charge harness and the Fuel Rail Pressure (FRP) electrical connectors.
    Fig 40: Locating Fuel Charge Harness And Fuel Rail Pressure Electrical Connectors

    Courtesy of FORD MOTOR CO.
42. Remove the bolt, nut and the CMP heat shield. Remove the bolt and the ground strap.
    Fig 41: Locating CMP Heat Shield Bolt And Nut

    Courtesy of FORD MOTOR CO.
43. Disconnect the 2 RH CMP sensor and the Cylinder Head Temperature (CHT) sensor electrical connectors. Remove the ground stud bolt.
    Fig 42: Locating RH CMP Sensor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
44. Disconnect the 2 RH VCT solenoid electrical connectors.
    Fig 43: Locating RH VCT Solenoid Electrical Connectors

    Courtesy of FORD MOTOR CO.
45. Disconnect the 3 RH ignition coil-on-plug electrical connectors.
    Fig 44: Locating RH Ignition Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
46. Detach all of the wiring harness retainers from the RH valve cover and stud bolts. Remove the engine wire harness.
47. 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 45: Removing Crankshaft Pulley Bolt And Washer

      Courtesy of FORD MOTOR CO.
48. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 46: Removing Crankshaft Pulley

    Courtesy of FORD MOTOR CO.
49. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 47: Removing Crankshaft Front Seal

    Courtesy of FORD MOTOR CO.
50. Remove the 2 bolts and the accessory drive belt tensioner.
    Fig 48: Locating Accessory Drive Belt Tensioner And Bolts

    Courtesy of FORD MOTOR CO.
51. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
      Fig 49: Locating LH Cylinder Block Drain Plug

      Courtesy of FORD MOTOR CO.
52. Remove the RH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
      Fig 50: Locating RH Cylinder Block Drain Plug

      Courtesy of FORD MOTOR CO.
53. Remove the 4 bolts and the thermostat housing.
    • Discard the thermostat housing and coolant inlet tube O-ring seals.
      Fig 51: Locating Thermostat Housing And Bolts

      Courtesy of FORD MOTOR CO.
54. Remove the 4 bolts and the coolant pump pulley.
    Fig 52: Locating Coolant Pump Pulley And Bolts

    Courtesy of FORD MOTOR CO.
55. Remove the 7 bolts and the coolant pump.
    • Discard the coolant pump gasket and coolant pump O-ring seal.
      Fig 53: Locating Coolant Pump And Bolts

      Courtesy of FORD MOTOR CO.
56. Remove the coolant inlet pipe.
    • Remove and discard the coolant inlet pipe O-ring seals.
      Fig 54: Locating Coolant Inlet Pipe O-Ring Seals

      Courtesy of FORD MOTOR CO.
57. Remove the 3 bolts and the coolant crossover manifold assembly.
    • Remove and discard the 2 gaskets.
      Fig 55: Locating Coolant Crossover Manifold Assembly And Bolts

      Courtesy of FORD MOTOR CO.
58. Remove the bolt for the high-pressure fuel tube.
    Fig 56: Locating High-Pressure Fuel Tube And Bolt

    Courtesy of FORD MOTOR CO.
59. Loosen the 2 flare nuts, remove and discard the high-pressure fuel tube assembly.
    Fig 57: Locating High-Pressure Fuel Tube Assembly And Flare Nuts

    Courtesy of FORD MOTOR CO.
NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors
NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain lodged in the cylinder heads and require the use of a Fuel Injector Remover to extract.
60. Remove the 6 bolts and the LH fuel rail.
    • Discard the bolts.
      Fig 58: Locating LH Fuel Rail Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors
NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain lodged in the cylinder heads and require the use of a Fuel Injector Remover to extract.
61. Remove the 6 bolts and the RH fuel rail.
    • Discard the bolts.
      Fig 59: Locating RH Fuel Rail Bolts

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
Fig 60: Locating Fuel Injector Electrical Connectors And Fuel Injector Wire Harness
Courtesy of FORD MOTOR CO.
62. Disconnect the 6 fuel injector electrical connectors and remove the 2 fuel injector wire harness.
63. Using the Slide Hammer and the Fuel Injector Remover, remove any fuel injectors remaining in the cylinder head.
    Fig 61: Removing Fuel Injectors In Cylinder Head

    Courtesy of FORD MOTOR CO.
64. Remove and discard the 6 upper fuel injector O-rings.
    Fig 62: Locating Upper Fuel Injector O-Ring Seal

    Courtesy of FORD MOTOR CO.
65. Remove and discard the 6 fuel injector clips.
    Fig 63: Locating Fuel Injector Clip

    Courtesy of FORD MOTOR CO.
NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and general surrounding area of the fuel rails and fuel injectors.
NOTE: Do not use compressed air to clean the tip of the fuel injector.
NOTE: Do not use the brush to clean the tip of the fuel injector.
Fig 64: Cleaning Fuel Injector Bores In Cylinder Heads Using Fuel Injector Brush
Courtesy of FORD MOTOR CO.
66. Using the Fuel Injector Brush, clean the 6 fuel injector bores in the cylinder heads.
67. Remove the bolt and the fuel injection pump mounting plate.
    • Remove and discard the gaskets.
      Fig 65: Locating Fuel Injection Pump Mounting Plate And Bolt

      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 66: Locating LH Ignition Coil-On-Plugs And Bolts
Courtesy of FORD MOTOR CO.
68. 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.
69. 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.
70. Loosen the 11 stud bolts and remove the LH valve cover.
    • Discard the gasket.
      Fig 67: Locating LH Valve Cover And Stud Bolts

      Courtesy of FORD MOTOR CO.
71. Inspect the 2 VCT solenoid seals. Remove any damaged seals.
    • Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
      Fig 68: Removing VCT Solenoid Seals

      Courtesy of FORD MOTOR CO.
72. 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 69: Removing Spark Plug Tube Seals

      Courtesy of FORD MOTOR CO.
73. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
74. Remove the 8 nuts and the LH exhaust manifold.
    • Discard the nuts and exhaust manifold gasket.
      Fig 70: Locating LH Exhaust Manifold And Nuts

      Courtesy of FORD MOTOR CO.
75. Clean and inspect the LH exhaust manifold. For additional information, REFER to ENGINE SYSTEM - GENERAL INFORMATION .
76. Remove and discard the 8 LH exhaust manifold studs.
    Fig 71: 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 72: Locating RH Ignition Coil-On-Plugs Bolts
Courtesy of FORD MOTOR CO.
77. 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.
78. Remove the 3 RH spark plugs.
79. Remove the 2 nuts and the engine appearance cover bracket.
    Fig 73: Locating Engine Appearance Cover Bracket And Nuts

    Courtesy of FORD MOTOR CO.
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.
80. Loosen the 8 stud bolts, 3 bolts and remove the RH valve cover.
    • Discard the gasket.
      Fig 74: Locating RH Valve Cover Stud Bolts And Bolts

      Courtesy of FORD MOTOR CO.
81. Inspect the 2 VCT solenoid seals. Remove any damaged seals.
    • Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
      Fig 75: Removing VCT Solenoid Seals

      Courtesy of FORD MOTOR CO.
82. 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 76: Removing Spark Plug Tube Seals

      Courtesy of FORD MOTOR CO.
83. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
84. Remove the 8 nuts and the RH exhaust manifold.
    • Discard the nuts and exhaust manifold gasket.
      Fig 77: Locating RH Exhaust Manifold And Nuts

      Courtesy of FORD MOTOR CO.
85. Clean and inspect the RH exhaust manifold. For additional information, REFER to ENGINE SYSTEM - GENERAL INFORMATION .
86. Remove and discard the 8 RH exhaust manifold studs.
    Fig 78: Locating RH Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.
87. Remove the 2 bolts and the LH CMP sensors.
    Fig 79: Locating LH CMP Sensors And Bolts

    Courtesy of FORD MOTOR CO.
88. Remove the 2 bolts and the RH CMP sensors. Remove and discard the CHT sensor
    Fig 80: Locating RH CMP Sensors And Bolts

    Courtesy of FORD MOTOR CO.
89. Remove the bolt and the CKP sensor.
    Fig 81: 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.
90. Remove the threaded shaft and the oil cooler.
    • Discard the oil cooler.
      Fig 82: Locating Oil Cooler

      Courtesy of FORD MOTOR CO.
91. Remove the 5 bolts and the oil filter adapter.
    • Discard the gasket.
      Fig 83: Locating Oil Filter Adapter And Bolts

      Courtesy of FORD MOTOR CO.
92. Remove the 22 engine front cover bolts.
    Fig 84: Locating Engine Front Cover Bolts

    Courtesy of FORD MOTOR CO.
93. Using a suitable pry tool, locate the 7 pry pads shown in illustration and pry the engine front cover loose and remove.
    Fig 85: Locating Engine Front Cover And Pry Pads

    Courtesy of FORD MOTOR CO.
NOTE: Inspect and replace the front cover radial seal as necessary.
NOTE: Use Spindle Bearing Installer 205-150 to remove the seal.
Fig 86: Removing Front Cover Radial Seal From Rear Side Of Front Cover
Courtesy of FORD MOTOR CO.
94. Using the Spindle Bearing Installer and Handle, remove the front cover radial seal from the rear side of the front cover.
95. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration.
    Fig 87: Locating Timing Marks On Intake Variable Camshaft Timing (VCT) Assemblies

    Courtesy of FORD MOTOR CO.
96. Remove the 3 bolts and the LH valve train oil tube.
    Fig 88: Locating LH Valve Train Oil Tube And Bolts

    Courtesy of FORD MOTOR CO.
NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.
Fig 89: Installing Camshaft Holding Tool Onto Flats Of LH Camshafts
Courtesy of FORD MOTOR CO.
97. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
98. Remove the 3 bolts and the RH valve train oil tube.
    Fig 90: Locating RH Valve Train Oil Tube And Bolts

    Courtesy of FORD MOTOR CO.
NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Fig 91: 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.
99. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
100. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown in illustration.
     Fig 92: Locating Timing Mark On LH Intake VCT Assembly

     Courtesy of FORD MOTOR CO.
101. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown in illustration.
     Fig 93: Locating 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 94: Locating Timing Mark On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
102. Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown in illustration.
103. Remove the 2 bolts and the primary timing chain tensioner.
     Fig 95: Locating Primary Timing Chain Tensioner And Bolts

     Courtesy of FORD MOTOR CO.
104. Remove the primary timing chain tensioner arm.
     Fig 96: Locating Primary Timing Chain Tensioner Arm

     Courtesy of FORD MOTOR CO.
105. Remove the 2 bolts and the lower LH primary timing chain guide.
     Fig 97: 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 98: Locating LH Intake VCT Oil Control Solenoid And Bolt
Courtesy of FORD MOTOR CO.
106. 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 99: Locating RH Intake VCT Oil Control Solenoid And Bolt
Courtesy of FORD MOTOR CO.
107. Remove the bolt and the RH intake VCT oil control solenoid.
108. Remove the primary timing chain.
     Fig 100: Identifying Primary Timing Chain

     Courtesy of FORD MOTOR CO.
109. Remove the crankshaft timing chain sprocket.
     Fig 101: 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 102: Locating Upper LH Primary Timing Chain Guide And Bolt
Courtesy of FORD MOTOR CO.
110. 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 103: Locating VCT Oil Control Solenoids
Courtesy of FORD MOTOR CO.
111. 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.
112. Remove and discard the 2 LH VCT assembly bolts.
     Fig 104: Locating LH VCT Assembly Bolts

     Courtesy of FORD MOTOR CO.
113. Remove the 2 LH VCT assemblies and secondary timing chain.
     Fig 105: 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 106: Locating VCT Oil Control Solenoids
Courtesy of FORD MOTOR CO.
114. 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.
115. Remove and discard the 2 RH VCT assembly bolts.
     Fig 107: Locating RH VCT Assembly Bolts

     Courtesy of FORD MOTOR CO.
116. Remove the 2 RH VCT assemblies and secondary timing chain.
     Fig 108: 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 109: Locating RH Primary Timing Chain Guide And Bolts
Courtesy of FORD MOTOR CO.
117. Remove the 2 bolts and the RH primary timing chain guide.
118. Remove the 9 bolts and the timing chain gear.
     • Discard the gasket.
       Fig 110: Locating Timing Chain Gear 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 111: Locating LH Exhaust VCT Oil Control Solenoid
Courtesy of FORD MOTOR CO.
119. Remove the LH exhaust VCT oil control solenoid.
120. Remove the LH secondary timing chain tensioner shoe.
     Fig 112: Locating LH Secondary Timing Chain Tensioner Shoe

     Courtesy of FORD MOTOR CO.
121. Remove the LH secondary timing chain tensioner by pushing up from the bottom and remove.
     Fig 113: Locating 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 114: Locating RH Exhaust VCT Oil Control Solenoid
Courtesy of FORD MOTOR CO.
122. Remove the RH exhaust VCT oil control solenoid.
123. Remove the RH secondary timing chain tensioner shoe.
     Fig 115: Locating RH Secondary Timing Chain Tensioner Shoe

     Courtesy of FORD MOTOR CO.
124. Remove the RH secondary timing chain tensioner by pushing up from the bottom and remove.
     Fig 116: Locating 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 117: Removing Camshaft Holding Tool From LH Camshafts
Courtesy of FORD MOTOR CO.
125. 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 118: Locating Camshafts Onto LH Cylinder Head In Neutral Position
Courtesy of FORD MOTOR CO.
126. 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 119: Locating Bolts, Camshaft Caps, Mega Cap And LH Camshafts
Courtesy of FORD MOTOR CO.
127. 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 120: Removing Camshaft Holding Tool From RH Camshafts
Courtesy of FORD MOTOR CO.
128. 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 121: Locating Camshafts Onto RH Cylinder Head In Neutral Position
Courtesy of FORD MOTOR CO.
129. 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 122: Locating Bolts, Camshaft Caps, Mega Cap And RH Camshafts
Courtesy of FORD MOTOR CO.
130. 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 123: Locating Valve Tappets From Cylinder Heads
Courtesy of FORD MOTOR CO.
131. Remove the valve tappets from the cylinder heads.
132. Inspect the valve tappets. For additional information, REFER to ENGINE SYSTEM - GENERAL INFORMATION .
NOTE: LH shown in illustration, RH similar.
Fig 124: Locating Cylinder Head M6 Bolt
Courtesy of FORD MOTOR CO.
133. 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.
134. Remove and discard the 8 bolts from each cylinder head.
     • Remove the cylinder heads.
     • Discard the cylinder head gaskets.
       Fig 125: 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.
135. 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.
136. 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 .
137. Remove the 2 bolts and the KS.
     Fig 126: Locating Knock Sensor And Bolts

     Courtesy of FORD MOTOR CO.
138. Remove the 16 oil pan bolts.
     Fig 127: Locating Oil Pan Bolts

     Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
Fig 128: Locating Pry Pads
Courtesy of FORD MOTOR CO.
139. 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.
140. Remove the 3 bolts and the oil pump screen and the pickup tube.
     • Discard the O-ring seal.
       Fig 129: Locating Oil Pump Screen And Pickup Tube And Bolts

       Courtesy of FORD MOTOR CO.
141. Remove the 3 bolts and the oil pump.
     Fig 130: Locating Bolts And Oil Pump

     Courtesy of FORD MOTOR CO.
142. Remove the 8 crankshaft rear seal retainer bolts.
     Fig 131: Locating Crankshaft Rear Seal Retainer Bolts

     Courtesy of FORD MOTOR CO.
143. 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 132: 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.
144. 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.
145. 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.
146. Remove the bolts in the sequence shown in illustration.
     • Remove the main bearing cap support brace.
     • Discard the bolts.
       Fig 133: Identifying Main Bearing Cap Support Brace Bolts Tightening 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 134: Locating Connecting Rod Cap Bolts
Courtesy of FORD MOTOR CO.
147. Remove the connecting rod cap bolts and cap.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Fig 135: Locating Piston/Rod Assembly
Courtesy of FORD MOTOR CO.
148. Remove the piston/rod assembly from the engine block.
149. 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.
150. Remove the 8 main bearing cap side bolts in the sequence shown in illustration.
     • Discard the bolts.
       Fig 136: Identifying Main Bearing Cap Side Bolts Tightening 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.
151. Remove the 8 main bearing cap bolts in the sequence shown in illustration.
     • Discard the bolts.
       Fig 137: Identifying Main Bearing Cap Bolts Tightening 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 138: Locating Main Bearing Caps
Courtesy of FORD MOTOR CO.
152. 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 139: Locating Thrust Washers Of Rear Main Bearing Bulkhead
Courtesy of FORD MOTOR CO.
153. Remove the crankshaft.
NOTE: Inside shown in illustration, outside similar.
Fig 140: Locating Crankshaft Thrust Bearing
Courtesy of FORD MOTOR CO.
154. 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 141: Locating Crankshaft Main Bearings Caps
Courtesy of FORD MOTOR CO.
155. 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 142: Locating Crankshaft Bearings Cap
Courtesy of FORD MOTOR CO.
156. Remove the 4 crankshaft main bearings from the main bearing caps.
157. 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.
158. 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.
159. 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.