Removal And Installation: Disassembly: Engine: Material

ll 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: Identifying Crankshaft Sensor Ring

   Courtesy of FORD MOTOR CO.

   Cast aluminum (early build) crankshaft rear seal retainer plate 

4. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove and discard the rear crankshaft seal.
   Fig 4: Removing Rear Crankshaft Seal Using Crankshaft Rear Oil Seal Remover And Slide Hammer

   Courtesy of FORD MOTOR CO.

   All engines 

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

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

   Fig 5: Mounting Engine On Suitable Engine Stand Using Floor Crane And Engine Spreader Bar

   Courtesy of FORD MOTOR CO.
6. Remove the 2 bolts and the Right Front Lift Eye.
   Fig 6: Locating Right Front Lift Eye And 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. Refer to FUEL SYSTEM - GENERAL INFORMATION .
   Fig 9: Locating RH PCV Tube

   Courtesy of FORD MOTOR CO.
10. NOTE: LH shown in illustration, RH similar.

    Disconnect the 2 wastegate hoses at the turbochargers.

    Fig 10: Locating Turbocharger Wastegate Hose

    Courtesy of FORD MOTOR CO.
11. NOTE: LH shown in illustration, RH similar.

    Remove the 2 tie straps for the wastegate hose assembly.

    Fig 11: Locating Tie Strap For Turbocharger Wastegate Hose

    Courtesy of FORD MOTOR CO.
12. Disconnect the turbocharger pressure regulator electrical connector. Remove the 2 tie straps and the wastegate hose assembly.
    Fig 12: Locating Turbocharger Pressure Regulator Electrical Connector, Tie Straps And Wastegate Hose Assembly

    Courtesy of FORD MOTOR CO.
13. 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.

    Using a commercially available quick disconnect tool, remove the LH turbocharger coolant supply tube.

    Fig 13: Locating Turbocharger Coolant Supply Tube

    Courtesy of FORD MOTOR CO.
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 And 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.
16. Remove the bolt for the LH turbocharger coolant and oil tubes.
    Fig 16: Locating Bolt For LH Turbocharger Coolant And Oil Tubes

    Courtesy of FORD MOTOR CO.
17. Remove the 3 bolts and the LH turbocharger.
    • Discard the turbocharger exhaust manifold gasket.
      Fig 17: Locating Bolts And LH Turbocharger

      Courtesy of FORD MOTOR CO.
18. Remove the bolt and the LH oil turbocharger oil return tube.
    • Remove and discard the O-ring seal.
      Fig 18: Locating Oil Turbocharger Oil Return Tube And Bolt

      Courtesy of FORD MOTOR CO.
19. Remove the 2 bolts and the LH turbocharger mounting bracket.
    Fig 19: Locating LH Turbocharger Mounting Bracket Bolts

    Courtesy of FORD MOTOR CO.
20. 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.

    Using a commercially available quick disconnect tool, remove the RH turbocharger coolant supply tube.

    Fig 20: Locating RH Turbocharger Coolant Supply Tube

    Courtesy of FORD MOTOR CO.
21. Remove the 2 bolts at the RH turbocharger oil return tube.
    • Remove and discard the turbocharger oil return tube gasket.
      Fig 21: Locating RH Turbocharger Oil Return Tube And Bolts

      Courtesy of FORD MOTOR CO.
22. Remove the RH turbocharger bracket bolt.
    Fig 22: Locating RH Turbocharger Bracket Bolt

    Courtesy of FORD MOTOR CO.
23. Remove the bolt for the RH turbocharger coolant and oil tubes.
    Fig 23: Locating Bolt For RH Turbocharger Coolant And Oil Tubes

    Courtesy of FORD MOTOR CO.
24. Remove the 3 bolts and the RH turbocharger.
    • Discard the turbocharger exhaust manifold gasket.
      Fig 24: Locating Bolts And RH Turbocharger

      Courtesy of FORD MOTOR CO.
25. Remove the bolt and the RH turbocharger oil return tube.
    • Remove and discard the O-ring seal.
      Fig 25: Locating Turbocharger Oil Return Tube Bolt

      Courtesy of FORD MOTOR CO.
26. Remove the 2 bolts and the RH turbocharger mounting bracket.
    Fig 26: Locating RH Turbocharger Mounting Bracket Bolts

    Courtesy of FORD MOTOR CO.
27. Remove the 4 bolts and the RH engine support insulator.
    • Discard the bolts.
      Fig 27: Locating RH Engine Support Insulator Bolts

      Courtesy of FORD MOTOR CO.
28. Remove the 4 bolts and the LH engine support insulator-to-cylinder block bracket.
    • Discard the bolts.
      Fig 28: Locating LH Engine Support Insulator-To-Cylinder Block Bracket And Bolts

      Courtesy of FORD MOTOR CO.
29. NOTE: Do not use excessive force when removing the vacuum pump or the vacuum pump oil tube may be dislodged from the vacuum pump causing internal oil seal damage to the pump. If the oil tube becomes dislodged from the pump, a new vacuum pump must be installed.

    Remove the 3 bolts and the vacuum pump.

    Fig 29: Locating Bolts And Vacuum Pump

    Courtesy of FORD MOTOR CO.
30. Remove the engine oil level indicator.
    Fig 30: Locating Oil Level Indicator

    Courtesy of FORD MOTOR CO.
31. Disconnect the 2 LH Variable Camshaft Timing (VCT) solenoid electrical connectors. Remove the tie strap.
    Fig 31: Locating LH Variable Camshaft Timing (VCT) Solenoid Electrical Connectors And Tie Strap

    Courtesy of FORD MOTOR CO.
32. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
    • Detach the EOP switch wiring harness retainer from the cylinder head.
      Fig 32: Locating EOP Switch Wiring Harness Retainer And Engine Oil Pressure (EOP) Switch Electrical Connector

      Courtesy of FORD MOTOR CO.
33. Disconnect the 3 LH ignition coil-on-plug electrical connectors.
    Fig 33: Locating LH Ignition Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
34. Remove the nut, the bolt and the CKP heat shield.
    Fig 34: Locating Crankshaft Position Heat Shield, Bolt And Nut

    Courtesy of FORD MOTOR CO.
35. Remove the wiring harness retainer stud bolt.
    Fig 35: Locating Wiring Harness Retainer Stud Bolt

    Courtesy of FORD MOTOR CO.
36. Remove the wiring harness grommet.
    Fig 36: Locating Wiring Harness Grommet

    Courtesy of FORD MOTOR CO.
37. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 37: Locating Crankshaft Position (CKP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
38. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
39. Disconnect the 2 LH Camshaft Position (CMP) sensor electrical connectors. Disconnect the CKP wire retainer. Remove the ground stud bolt.
    Fig 38: Locating LH Camshaft Position (CMP) Sensor Electrical Connectors, Crankshaft Position (CKP) Wire Retainer And Ground Stud Bolt

    Courtesy of FORD MOTOR CO.
40. Disconnect the Knock Sensor (KS) sensor electrical connector. Disconnect the 2 fuel charge harness and the Fuel Rail Pressure (FRP) electrical connectors.
    Fig 39: Locating Knock Sensor Electrical Connector, Fuel Charge Harness And Fuel Rail Pressure Electrical Connectors

    Courtesy of FORD MOTOR CO.
41. Disconnect the wire retainer. Remove the bolt, nut and the CMP heat shield.
    Fig 40: Locating Wire Retainer, Nut, Bolt And CMP Heat Shield

    Courtesy of FORD MOTOR CO.
42. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. Remove the ground stud bolt and the tie strap.
    Fig 41: Locating Cylinder Head Temperature Sensor Electrical Connector, Ground Stud Bolt And Tie Strap

    Courtesy of FORD MOTOR CO.
43. Disconnect the 2 RH VCT solenoid electrical connectors. Remove the tie strap.
    Fig 42: Locating RH VCT Solenoid Electrical Connectors And Tie Strap

    Courtesy of FORD MOTOR CO.
44. Disconnect the 3 RH ignition coil-on-plug electrical connectors.
    Fig 43: Locating RH Ignition Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
45. Disconnect the 2 RH CMP electrical connectors.
    Fig 44: Locating Camshaft Position Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
46. Disconnect the wire harness retainer and remove the tie strap.
    Fig 45: Locating Tie Strap And Wire Retainer On Valve Cover

    Courtesy of FORD MOTOR CO.
47. Detach all of the wiring harness retainers from the RH valve cover and stud bolts. Remove the engine wire harness.
48. 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 46: Removing Crankshaft Pulley Bolt And Washer Using Strap Wrench

      Courtesy of FORD MOTOR CO.
49. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 47: Removing Crankshaft Pulley

    Courtesy of FORD MOTOR CO.
50. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 48: Removing Crankshaft Front Seal

    Courtesy of FORD MOTOR CO.
51. Remove the 2 bolts and the accessory drive belt tensioner.
    Fig 49: Locating Accessory Drive Belt Tensioner And Bolts

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

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

      Courtesy of FORD MOTOR CO.
54. Remove the 4 bolts and the thermostat housing.
    • Discard the thermostat housing and coolant inlet tube O-ring seals.
      Fig 52: Locating Thermostat Housing And Bolts

      Courtesy of FORD MOTOR CO.
55. Remove the 4 bolts and the coolant pump pulley.
    Fig 53: Locating Coolant Pump Pulley And Bolts

    Courtesy of FORD MOTOR CO.
56. Remove the 7 bolts and the coolant pump.
    • Discard the coolant pump gasket and coolant pump O-ring seal.
      Fig 54: Locating Coolant Pump And Bolts

      Courtesy of FORD MOTOR CO.
57. Remove the coolant inlet pipe.
    • Remove and discard the coolant inlet pipe O-ring seals.
      Fig 55: Locating Coolant Inlet Pipe O-Ring Seals

      Courtesy of FORD MOTOR CO.
58. Remove the 3 bolts and the coolant crossover manifold assembly.
    • Remove and discard the 2 gaskets.
      Fig 56: Locating Coolant Crossover Manifold Assembly And Bolts

      Courtesy of FORD MOTOR CO.
59. Remove the bolt for the high-pressure fuel tube.
    Fig 57: Locating High-Pressure Fuel Tube Bolt

    Courtesy of FORD MOTOR CO.
60. Loosen the 2 flare nuts, remove and discard the high-pressure fuel tube assembly.
    Fig 58: Locating High-Pressure Fuel Tube Assembly And Flare Nuts

    Courtesy of FORD MOTOR CO.
61. 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.

    Remove the 6 bolts and the LH fuel rail.

    • Discard the bolts.
      Fig 59: Locating LH Fuel Rail Bolts

      Courtesy of FORD MOTOR CO.
62. 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.

    Remove the 6 bolts and the RH fuel rail.

    • Discard the bolts.
      Fig 60: Locating RH Fuel Rail Bolts

      Courtesy of FORD MOTOR CO.
63. NOTE: RH shown in illustration, LH similar.

    Disconnect the 6 fuel injector electrical connectors and remove the 2 fuel injector wire harness.

    Fig 61: Locating Fuel Injector Electrical Connectors And Fuel Injector Wire Harness

    Courtesy of FORD MOTOR CO.
64. Using the Slide Hammer and the Fuel Injector Remover, remove any fuel injectors remaining in the cylinder head.
    Fig 62: Removing Fuel Injectors Remaining In Cylinder Head Using Slide Hammer And Fuel Injector Remover

    Courtesy of FORD MOTOR CO.
65. Remove and discard the 6 upper fuel injector O-rings.
    Fig 63: Locating Upper Fuel Injector O-Rings

    Courtesy of FORD MOTOR CO.
66. Remove and discard the 6 fuel injector clips.
    Fig 64: Locating Fuel Injector Clip

    Courtesy of FORD MOTOR CO.
67. 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.

    Using the Fuel Injector Brush, clean the 6 fuel injector bores in the cylinder heads.

    Fig 65: Cleaning Fuel Injector Bores In Cylinder Heads Using Fuel Injector Brush

    Courtesy of FORD MOTOR CO.
68. Remove the bolt and the fuel injection pump mounting plate.
    • Remove and discard the gaskets.
      Fig 66: Locating Fuel Injection Pump Mounting Plate And Bolt

      Courtesy of FORD MOTOR CO.
69. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

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

    Fig 67: Locating LH Ignition Coil-On-Plugs And Bolts

    Courtesy of FORD MOTOR CO.
70. NOTE: Only use hand tools when removing the spark plugs, or damage may occur to the cylinder head or spark plug.
    NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.

    Remove the 3 LH spark plugs.

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

    Loosen the 11 stud bolts and remove the LH valve cover.

    • Discard the gasket.
      Fig 68: Locating LH Valve Cover And Stud Bolts

      Courtesy of FORD MOTOR CO.
72. Inspect the 2 VCT solenoid seals. Remove any damaged seals.
    • Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
      Fig 69: Removing VCT Solenoid Seals

      Courtesy of FORD MOTOR CO.
73. 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 70: Removing Spark Plug Tube Seals

      Courtesy of FORD MOTOR CO.
74. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
75. Remove the 8 nuts and the LH exhaust manifold.
    • Discard the nuts and exhaust manifold gasket.
      Fig 71: Locating LH Exhaust Manifold And Nuts

      Courtesy of FORD MOTOR CO.
76. Clean and inspect the LH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
77. Remove and discard the 8 LH exhaust manifold studs.
    Fig 72: Locating LH Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.
78. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

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

    Fig 73: Locating RH Ignition Coil-On-Plugs And Bolts

    Courtesy of FORD MOTOR CO.
79. NOTE: Only use hand tools when removing the spark plugs, or damage may occur to the cylinder head or spark plug.
    NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.

    Remove the 3 RH spark plugs.

80. Remove the 2 bolts and the CMP sensors.
    Fig 74: Locating Bolts And CMP Sensors

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

    Loosen the 12 stud bolts and remove the RH valve cover.

    • Discard the gasket.
      Fig 75: Locating Valve Cover Stud Bolts

      Courtesy of FORD MOTOR CO.
82. Inspect the 2 VCT solenoid seals. Remove any damaged seals.
    • Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
      Fig 76: Removing VCT Solenoid Seals Using Differential Bearing Cone Installer And Handle

      Courtesy of FORD MOTOR CO.
83. 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 77: Removing Spark Plug Tube Seals

      Courtesy of FORD MOTOR CO.
84. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
85. Remove the 8 nuts and the RH exhaust manifold.
    • Discard the nuts and exhaust manifold gasket.
      Fig 78: Locating RH Exhaust Manifold And Nuts

      Courtesy of FORD MOTOR CO.
86. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
87. Remove and discard the 8 RH exhaust manifold studs.
    Fig 79: Locating RH Exhaust Manifold Studs

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

    Courtesy of FORD MOTOR CO.
89. Remove and discard the CHT sensor
    Fig 81: Locating CHT Sensor

    Courtesy of FORD MOTOR CO.
90. Remove the bolt and the CKP sensor.
    Fig 82: Locating CKP Sensor And Bolt

    Courtesy of FORD MOTOR CO.
91. NOTE: A new oil cooler must be installed or severe damage to the engine can occur.

    Remove the threaded shaft and the oil cooler.

    • Discard the oil cooler.
      Fig 83: Locating Threaded Shaft

      Courtesy of FORD MOTOR CO.
92. Remove the 5 bolts and the oil filter adapter.
    • Discard the gasket.
      Fig 84: Locating Oil Filter Adapter And Bolts

      Courtesy of FORD MOTOR CO.
93. Remove the 22 engine front cover bolts.
    Fig 85: Locating Engine Front Cover Bolts

    Courtesy of FORD MOTOR CO.
94. Using a suitable pry tool, locate the 7 pry pads shown and pry the engine front cover loose and remove.
    Fig 86: Locating Engine Front Cover Pry Pads

    Courtesy of FORD MOTOR CO.
95. NOTE: Inspect and replace the front cover radial seal as necessary.
    NOTE: Use Spindle Bearing Installer 205-150 to remove the seal.

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

    Fig 87: Removing Front Cover Radial Seal From Rear Side Of Front Cover

    Courtesy of FORD MOTOR CO.
96. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration.
    Fig 88: Locating Timing Marks On Intake Variable Camshaft Timing (VCT) Assemblies

    Courtesy of FORD MOTOR CO.
97. Remove the 3 bolts and the LH valve train oil tube.
    Fig 89: Locating Bolts And LH Valve Train Oil Tube

    Courtesy of FORD MOTOR CO.
98. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.

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

    Fig 90: Identifying LH Camshaft Holding Tool

    Courtesy of FORD MOTOR CO.
99. Remove the 3 bolts and the RH valve train oil tube.
    Fig 91: Locating Bolts And RH Valve Train Oil Tube

    Courtesy of FORD MOTOR CO.
100. 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.

     Fig 92: Identifying RH Camshaft Holding Tool

     Courtesy of FORD MOTOR CO.
     NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.
101. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown in illustration.
     Fig 93: Locating Timing Mark On LH Intake VCT Assembly And Timing Chain Link

     Courtesy of FORD MOTOR CO.
102. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown in illustration.
     Fig 94: Locating Timing Mark On RH Intake VCT Assembly And Timing Chain Link

     Courtesy of FORD MOTOR CO.
103. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.

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

     Fig 95: Locating Timing Chain Links That Align With Timing Mark On Crankshaft Sprocket

     Courtesy of FORD MOTOR CO.
104. Remove the 2 bolts and the primary timing chain tensioner.
     Fig 96: Locating Bolts And Primary Timing Chain Tensioner

     Courtesy of FORD MOTOR CO.
105. Remove the primary timing chain tensioner arm.
     Fig 97: Identifying Primary Timing Chain Tensioner Arm

     Courtesy of FORD MOTOR CO.
106. Remove the 2 bolts and the lower LH primary timing chain guide.
     Fig 98: Locating Bolts And Lower LH Primary Timing Chain Guide

     Courtesy of FORD MOTOR CO.
107. NOTE: Removal of the VCT oil control solenoid will aid in the removal of the primary timing chain.
     NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.
     NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

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

     Fig 99: Locating Bolt And LH Intake VCT Oil Control Solenoid

     Courtesy of FORD MOTOR CO.
108. NOTE: Removal of the VCT oil control solenoid will aid in the removal of the primary timing chain.
     NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.
     NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

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

     Fig 100: Locating Bolt And RH Intake VCT Oil Control Solenoid

     Courtesy of FORD MOTOR CO.
109. Remove the primary timing chain.
     Fig 101: Identifying Primary Timing Chain

     Courtesy of FORD MOTOR CO.
110. Remove the crankshaft timing chain sprocket.
     Fig 102: Locating Crankshaft Timing Chain Sprocket

     Courtesy of FORD MOTOR CO.
111. NOTE: Do not use power tools to remove the bolt or damage to the LH primary timing chain guide may occur.

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

     Fig 103: Locating Upper LH Primary Timing Chain Guide And Bolt

     Courtesy of FORD MOTOR CO.
112. 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.

     Fig 104: Locating LH Secondary Timing Chain Tensioner And Secondary Chain Hold Down

     Courtesy of FORD MOTOR CO.
113. Remove and discard the 2 LH VCT assembly bolts.
     Fig 105: Locating LH VCT Assembly Bolts

     Courtesy of FORD MOTOR CO.
114. Remove the 2 LH VCT assemblies and secondary timing chain.
     Fig 106: Locating LH VCT Assemblies And Secondary Timing Chain

     Courtesy of FORD MOTOR CO.
115. 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.

     Fig 107: Locating RH Secondary Timing Chain Tensioner And Secondary Chain Hold Down

     Courtesy of FORD MOTOR CO.
116. Remove and discard the 2 RH VCT assembly bolts.
     Fig 108: Locating RH VCT Assembly Bolts

     Courtesy of FORD MOTOR CO.
117. Remove the 2 RH VCT assemblies and secondary timing chain.
     Fig 109: Locating RH VCT Assemblies And Secondary Timing Chain

     Courtesy of FORD MOTOR CO.
118. NOTE: Do not use power tools to remove the bolt or damage to the RH primary timing chain guide may occur.

     Remove the 2 bolts and the RH primary timing chain guide.

     Fig 110: Locating RH Primary Timing Chain Guide And Bolts

     Courtesy of FORD MOTOR CO.
119. Remove the 9 bolts and the timing chain gear.
     • Discard the gasket.
       Fig 111: 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.
120. 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 LH exhaust VCT oil control solenoid.

     Fig 112: Locating LH Exhaust VCT Oil Control Solenoid And Bolt

     Courtesy of FORD MOTOR CO.
121. Remove the LH secondary timing chain tensioner shoe.
     Fig 113: Locating LH Secondary Timing Chain Tensioner Shoe

     Courtesy of FORD MOTOR CO.
122. Remove the LH secondary timing chain tensioner by pushing up from the bottom and remove.
     Fig 114: Removing LH Secondary Timing Chain Tensioner By Pushing Up From Bottom

     Courtesy of FORD MOTOR CO.
123. 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 RH exhaust VCT oil control solenoid.

     Fig 115: Locating RH Exhaust VCT Oil Control Solenoid And Bolt

     Courtesy of FORD MOTOR CO.
124. Remove the RH secondary timing chain tensioner shoe.
     Fig 116: Locating RH Secondary Timing Chain Tensioner Shoe

     Courtesy of FORD MOTOR CO.
125. Remove the RH secondary timing chain tensioner by pushing up from the bottom and remove.
     Fig 117: Removing RH Secondary Timing Chain Tensioner By Pushing Up From Bottom

     Courtesy of FORD MOTOR CO.

     All engines 

126. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure may rotate the LH camshafts approximately 3 degrees to a neutral position.

     Remove the Camshaft Holding Tool from the LH camshafts.

     Fig 118: Identifying Camshaft Holding Tool

     Courtesy of FORD MOTOR CO.
127. NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.

     Verify the LH camshafts are in the neutral position.

     Fig 119: Positioning Camshafts Onto LH Cylinder Head In Neutral Position

     Courtesy of FORD MOTOR CO.
128. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
     NOTE: Mark the exhaust and intake camshafts for installation into their original locations.

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

     Fig 120: Locating Bolts, Camshaft Caps, Mega Cap And LH Camshafts

     Courtesy of FORD MOTOR CO.
129. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure may rotate the RH camshafts approximately 3 degrees to a neutral position.

     Remove the Camshaft Holding Tool from the RH camshafts.

     Fig 121: Identifying Camshaft Holding Tool

     Courtesy of FORD MOTOR CO.
130. NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.

     Rotate the RH camshafts counterclockwise to the neutral position.

     Fig 122: Positioning Camshafts Onto RH Cylinder Head In Neutral Position

     Courtesy of FORD MOTOR CO.
131. Remove the 2 bolts and the camshaft bearing cap assembly.
     Fig 123: Locating Bolts And Camshaft Bearing Cap Assembly

     Courtesy of FORD MOTOR CO.
132. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
     NOTE: Mark the exhaust and intake camshafts for installation into their original locations.

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

     Fig 124: Locating Bolts, Camshaft Caps, Mega Cap And RH Camshafts

     Courtesy of FORD MOTOR CO.
133. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
     NOTE: LH shown in illustration, RH similar.

     Remove the valve tappets from the cylinder heads.

     Fig 125: Locating Valve Tappet

     Courtesy of FORD MOTOR CO.
134. Inspect the valve tappets. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
135. NOTE: LH shown in illustration, RH similar.

     Remove and discard the M6 bolt from each cylinder head.

     Fig 126: Locating Cylinder Head M6 Bolt

     Courtesy of FORD MOTOR CO.
136. NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
     NOTE: Aluminum surfaces are soft and may be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
     NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
     NOTE: LH shown in illustration, RH similar.

     Remove and discard the 8 bolts from each cylinder head.

     • Remove the cylinder heads.
     • Discard the cylinder head gaskets.
       Fig 127: Locating Cylinder Head Bolts

       Courtesy of FORD MOTOR CO.
137. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
     NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
     NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

     Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence.

     1. Remove any large deposits of silicone or gasket material with a plastic scraper.
     2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
     3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
     4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
138. 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 .
139. Remove the 2 bolts and the KS.
     Fig 128: Locating Knock Sensors And Bolts

     Courtesy of FORD MOTOR CO.
140. Remove the 16 oil pan bolts.
     Fig 129: Locating Oil Pan Bolts

     Courtesy of FORD MOTOR CO.
141. NOTE: RH shown in illustration, LH similar.

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

     Fig 130: Locating Pry Pads

     Courtesy of FORD MOTOR CO.
142. Remove the 3 bolts and the oil pump screen and the pickup tube.
     • Discard the O-ring seal.
       Fig 131: Locating Bolts, Oil Pump Screen And Pickup Tube

       Courtesy of FORD MOTOR CO.
143. Remove the 3 bolts and the oil pump.
     Fig 132: Locating Bolts And Oil Pump

     Courtesy of FORD MOTOR CO.

     Cast aluminum (early build) crankshaft rear seal retainer plate 

144. Remove the 8 crankshaft rear seal retainer bolts.
     Fig 133: Locating Crankshaft Rear Seal Retainer Bolts

     Courtesy of FORD MOTOR CO.
145. 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 134: Locating Crankshaft Rear Seal Retainer Bolts

         Courtesy of FORD MOTOR CO.

     Stamped steel (late build) crankshaft rear seal retainer plate 

146. Remove the 8 bolts and the crankshaft rear seal retainer.
     • Discard the crankshaft rear seal retainer and seal assembly.
       Fig 135: Locating Crankshaft Rear Seal Retainer Bolts

       Courtesy of FORD MOTOR CO.

     All vehicles 

147. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.

     Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 rpm.

     • Thoroughly wash the engine front cover, oil pan and crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.
148. 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.
149. NOTE: The main bearing cap support brace bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.

     Remove the bolts in the sequence shown in illustration.

     • Remove the main bearing cap support brace.
     • Discard the bolts.
       Fig 136: Identifying Main Bearing Cap Support Brace Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
150. NOTE: The connecting rod cap bolts are a tighten-to-yield design. The original connecting rod cap bolts will be used when measuring the connecting rod large end bore during assembly. The connecting rod cap bolts will be discarded after measurement.
     NOTE: Clearly mark the position and orientation of the connecting rods, connecting rod caps and connecting rod bearings for reassembly.

     Remove the connecting rod cap bolts and cap.

     Fig 137: Locating Connecting Rod Cap Bolts And Cap

     Courtesy of FORD MOTOR CO.
151. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

     Remove the piston/rod assembly from the engine block.

     Fig 138: Removing Piston/Rod Assembly From Engine Block

     Courtesy of FORD MOTOR CO.
152. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
153. NOTE: The 8 main bearing cap side bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
     NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.

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

     • Discard the bolts.
       Fig 139: Identifying Main Bearing Cap Side Bolts Loosening Sequence

       Courtesy of FORD MOTOR CO.
154. NOTE: The 8 main bearing cap bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
     NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.

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

     • Discard the bolts.
       Fig 140: Identifying Main Bearing Cap Bolts Loosening Sequence

       Courtesy of FORD MOTOR CO.
155. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
     NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.

     Remove the 4 main bearing caps.

     Fig 141: Locating Bearing Caps

     Courtesy of FORD MOTOR CO.
156. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.

     Remove the crankshaft.

     Fig 142: Locating Crankshaft Onto Upper Main Bearings

     Courtesy of FORD MOTOR CO.
157. NOTE: Inside shown in illustration, outside similar.

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

     Fig 143: Locating Crankshaft Thrust Bearing

     Courtesy of FORD MOTOR CO.
158. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

     Remove the 4 crankshaft main bearings from the cylinder block.

     Fig 144: Locating Crankshaft Main Bearings

     Courtesy of FORD MOTOR CO.
159. Using a hexagonal screwdriver, remove the 6 piston oil cool valves.
     Fig 145: Locating Piston Oil Cool Valves

     Courtesy of FORD MOTOR CO.
160. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

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

     Fig 146: Locating Crankshaft Main Bearing In Main Bearing Cap

     Courtesy of FORD MOTOR CO.
161. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
162. NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that causes premature engine failure. Remove all traces of the gasket.

     Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.

     1. Remove any large deposits of silicone or gasket material.
     2. Apply silicone gasket remover and allow to set for several minutes.
     3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
     4. Apply metal surface prep to remove any remaining traces of oil and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
     5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
163. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.

     Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 rpm.

     • Thoroughly wash the engine front cover, oil pan and crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.