Removal And Installation: Disassembly: Engine: Material

WARNING: This page is about a different car, the 2013 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

Item	Specification
Motorcraft® Metal Surface Prep ZC-31-A	-
Motorcraft® Silicone Gasket Remover ZC-30	-

NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

NOTE: If the components are to be reinstalled, they must be installed in their original location. Mark the components for installation into their original location.

NOTE: For additional information, refer to the exploded view under the Assembly procedure.

Remove the engine. For additional information, refer to ENGINE .
NOTE: The flexplate bolts are torque-to-yield design and are not reusable.

Remove the 8 bolts and the flexplate.
- Discard the bolts.
  
  Fig 1: Locating Flexplate Bolts
  Courtesy of FORD MOTOR CO.
Remove the engine separator plate.

Fig 2: Identifying Engine Separator Plate
Courtesy of FORD MOTOR CO.
NOTE: Inspect the crankshaft sensor ring for damage. If the crankshaft sensor ring has been dropped or has any visual damage, it must be discarded.

Remove the crankshaft sensor ring.

Fig 3: Locating Crankshaft Sensor Ring
Courtesy of FORD MOTOR CO.
Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.

Fig 4: Removing Crankshaft Rear Seal Using Slide Hammer And Crankshaft Rear Oil Seal Remover
Courtesy of FORD MOTOR CO.
Mount the engine on a work stand.
Remove the 3 bolts and the LH engine support insulator bracket.

Fig 5: Locating LH Engine Support Insulator Bracket Bolts
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the RH engine support insulator.

Fig 6: Locating RH Engine Support Insulator Bolts
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the RH exhaust manifold heat shield.

Fig 7: Locating RH Exhaust Manifold Heat Shield Bolts
Courtesy of FORD MOTOR CO.
Remove the 8 nuts and the RH exhaust manifold.
- Discard the gasket.
  
  Fig 8: Locating RH Exhaust Manifold Nuts
  Courtesy of FORD MOTOR CO.
Remove and discard the 8 RH exhaust manifold studs.

Fig 9: Locating RH Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the LH exhaust manifold heat shield.

Fig 10: Locating LH Exhaust Manifold Heat Shield Bolts
Courtesy of FORD MOTOR CO.
Remove the 8 nuts and the LH exhaust manifold.
- Discard the gasket.
  
  Fig 11: Locating LH Exhaust Manifold Nuts
  Courtesy of FORD MOTOR CO.
Remove and discard the 8 LH exhaust manifold studs.

Fig 12: Locating LH Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
Clean and inspect the RH and LH exhaust manifolds. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
NOTE: RH shown in illustration, LH similar.

Disconnect the 8 ignition coil electrical connectors.

Fig 13: Locating Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.

NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease removal. RH shown in illustration, LH similar.

Remove the 8 bolts and the 8 ignition coils.

Fig 14: Locating Bolts And Ignition Coils
Courtesy of FORD MOTOR CO.
Disconnect the 2 Variable Camshaft Timing (VCT) variable force solenoid electrical connectors.
- Detach the 10 wiring harness retainers from the RH valve cover.
  
  Fig 15: Locating VCT Variable Force Solenoid Electrical Connectors And Wiring Harness Retainers
  Courtesy of FORD MOTOR CO.
Disconnect the 2 VCT variable force solenoid electrical connectors.
- Detach the 10 wiring harness retainers from the LH valve cover.
  
  Fig 16: Locating VCT Variable Force Solenoid Electrical Connectors And Wiring Harness Retainers
  Courtesy of FORD MOTOR CO.
Remove the bolt, stud bolt and heat shield from the RH cylinder head.

Fig 17: Locating Bolt And Stud Bolt On RH Cylinder Head
Courtesy of FORD MOTOR CO.
Disconnect the RH intake and exhaust Camshaft Position (CMP) sensor electrical connectors.
- Remove the 2 bolts and the RH intake and exhaust CMP sensors.
  
  Fig 18: Locating Bolts, RH Intake And Exhaust CMP Sensors Connectors
  Courtesy of FORD MOTOR CO.
Disconnect the Cylinder Head Temperature (CHT) sensor and the Crankshaft Position (CKP) sensor electrical connectors.

Fig 19: Locating Cylinder Head Temperature Sensor And Crankshaft Position Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the heat shield from the LH cylinder head.

Fig 20: Locating LH Cylinder Heat Shield Head Bolts
Courtesy of FORD MOTOR CO.
Disconnect the LH intake and exhaust Camshaft Position (CMP) sensor electrical connectors.
- Remove the 2 bolts and the LH intake and exhaust CMP sensors.
  
  Fig 21: Locating Bolts, LH Intake And Exhaust CMP Sensors Electrical Connectors
  Courtesy of FORD MOTOR CO.
Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the 3 wiring harness retainers.

Fig 22: Locating Engine Oil Pressure Switch Electrical Connector And Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Detach the wiring harness retainer from the engine front cover stud bolt.

Fig 23: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Remove the nut and the ground wire from the engine front cover stud bolt.

Fig 24: Locating Engine Front Cover Stud Bolt Nut
Courtesy of FORD MOTOR CO.
Disconnect the 2 Knock Sensor (KS) electrical connectors.
- Remove the wiring harness from the engine.
  
  Fig 25: Locating Knock Sensor Electrical Connectors
  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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Loosen the 14 fasteners and remove the RH valve cover and gasket.
- Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
  
  Fig 26: Locating RH Valve Cover Fasteners
  Courtesy of FORD MOTOR CO.
Remove the oil level indicator.
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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Loosen the 14 fasteners and remove the LH valve cover and gasket.
- Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
  
  Fig 27: Locating LH Valve Cover Fasteners
  Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.

Inspect the 2 VCT variable force solenoid seals. Remove any damaged seals.
- Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
  
  Fig 28: Removing VCT Variable Force Solenoid Seal Using Differential Bearing Cone Installer And Handle
  Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.

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 29: Removing Spark Plug Tube Seal Using VCT Spark Plug Tube Seal Remover And Handle
  Courtesy of FORD MOTOR CO.
Remove the 2 bolts and position the thermostat housing and lower radiator hose aside.
- Remove and discard the thermostat housing O-ring seal.
  
  Fig 30: Locating Thermostat Housing Bolts
  Courtesy of FORD MOTOR CO.
Release the 2 clamps and disconnect the coolant hoses from the oil cooler.

Fig 31: Locating Coolant Hoses Clamps
Courtesy of FORD MOTOR CO.
Loosen the 4 coolant pump pulley bolts.

Fig 32: Locating Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.

Fig 33: Rotating Accessory Drive Belt Tensioner Counterclockwise
Courtesy of FORD MOTOR CO.
Rotate the A/C compressor belt tensioner clockwise and remove the A/C compressor belt.

Fig 34: Rotating A/C Compressor Belt Tensioner Clockwise
Courtesy of FORD MOTOR CO.
Remove the 4 bolts and the coolant pump pulley.

Fig 35: Locating Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
Remove the 4 bolts and the coolant pump.
- Remove and discard the O-ring seal.
  
  Fig 36: Locating Coolant Pump Bolts
  Courtesy of FORD MOTOR CO.
Remove the bolt and the accessory drive belt tensioner.

Fig 37: Locating Bolts And Accessory Drive Belt Tensioner
Courtesy of FORD MOTOR CO.
Disconnect the A/C compressor electrical connector and the 2 wiring harness retainers.

Fig 38: Locating A/C Compressor Electrical Connector And Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Detach the 3 wiring harness retainers.

Fig 39: Locating Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the generator.

Fig 40: Locating Generator Bolts
Courtesy of FORD MOTOR CO.
Remove the crankshaft pulley bolt and washer.

Fig 41: Locating Crankshaft Pulley Bolt And Washer
Courtesy of FORD MOTOR CO.
Using the 3 Jaw Puller and the crankshaft pulley bolt, remove the crankshaft pulley.
- Discard the crankshaft pulley bolt.
  
  Fig 42: Removing Crankshaft Pulley Using 3 Jaw Puller And Crankshaft Pulley Bolt
  Courtesy of FORD MOTOR CO.
NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

Using the Oil Seal Remover, remove the crankshaft front oil seal.

Fig 43: Removing Crankshaft Front Oil Seal Using Oil Seal Remover
Courtesy of FORD MOTOR CO.
Remove the 2 front oil pan stud bolts and 2 front oil pan bolts.

Fig 44: Locating Front Oil Pan Stud Bolts And Bolts
Courtesy of FORD MOTOR CO.
Remove the engine front cover-to-oil filter adapter bolt.

Fig 45: Locating Engine Front Cover-To-Oil Filter Adapter Bolt
Courtesy of FORD MOTOR CO.
Using a 10 mm (0.393 in) Hex Bit loosen the engine front cover-to-oil filter adapter jack screw.

Fig 46: Locating Engine Front Cover-To-Oil Filter Adapter Jack Screw
Courtesy of FORD MOTOR CO.
Remove the 13 engine front cover bolts and the 2 stud bolts.

Fig 47: Locating Engine Front Cover Bolts And Stud 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Remove the engine front cover.
- Remove and discard the engine front cover gaskets.
- Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Inspect the mating surfaces.
  
  Fig 48: Removing Engine Front Cover
  Courtesy of FORD MOTOR CO.
Using the crankshaft holding tool, rotate the crankshaft clockwise until the keyway is at the 12 o'clock position.

Fig 49: Rotating Crankshaft Clockwise Using Crankshaft Holding Tool (Till Keyway At 12 O'Clock Position)
Courtesy of FORD MOTOR CO.
Verify the data matrix on the camshafts is facing up, if not, rotate the crankshaft clockwise one revolution.

Fig 50: Locating Data Matrix On Camshafts
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the RH primary timing chain tensioner.

Fig 51: Locating Bolts And RH Primary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the RH timing chain tensioner arm. Return the crankshaft keyway to the 12 o'clock position after removing the RH timing chain tensioner arm.

Remove the RH timing chain tensioner arm.

Fig 52: Locating RH Timing Chain Tensioner Arm
Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the RH timing chain guide. Return the crankshaft keyway to the 12 o'clock position after removing the RH timing chain guide.

Remove the bolt and the RH timing chain guide.

Fig 53: Locating Bolt And RH Timing Chain Guide
Courtesy of FORD MOTOR CO.
Remove the RH primary timing chain.

Fig 54: Locating RH Primary Timing Chain
Courtesy of FORD MOTOR CO.
Remove the 3 RH intake Variable Camshaft Timing (VCT) assembly bolts and the 3 RH exhaust VCT assembly bolts.

Fig 55: Locating RH Intake And Exhaust Variable Camshaft Timing Assembly Bolts
Courtesy of FORD MOTOR CO.
Slide the RH VCT assemblies and secondary timing chain forward 2 mm (0.078 in).

Fig 56: Sliding RH VCT Assemblies And Secondary Timing Chain Forward
Courtesy of FORD MOTOR CO.
Depress the RH secondary timing chain tensioner and turn the tensioner 90 degrees.

Fig 57: Turning RH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Remove the RH VCT assemblies and the RH secondary timing chain.

Fig 58: Locating RH VCT Assemblies And RH Secondary Timing Chain
Courtesy of FORD MOTOR CO.
NOTE: The front camshaft bearing mega cap must be removed first and then the remaining camshaft bearing caps. Failure to follow this direction may result in damage to the engine.

Remove the 4 bolts and the RH front camshaft bearing mega cap.

Fig 59: Locating Bolts And RH Front Camshaft Bearing Mega Cap
Courtesy of FORD MOTOR CO.
Remove the 16 bolts and the 8 camshaft bearing caps.

Fig 60: Locating Bolts And Camshaft Bearing Caps
Courtesy of FORD MOTOR CO.
NOTE: Intake camshaft shown in illustration, exhaust camshaft similar.

Remove the VCT system oil filter from the intake and exhaust camshafts.

Fig 61: Removing VCT System Oil Filter From Intake And Exhaust Camshafts
Courtesy of FORD MOTOR CO.
Remove the RH intake and exhaust camshafts.

Fig 62: Locating RH Intake And Exhaust Camshafts
Courtesy of FORD MOTOR CO.
Remove the 16 camshaft roller follower and hydraulic lash adjuster assemblies.

Fig 63: Locating Camshaft Roller Follower
Courtesy of FORD MOTOR CO.
Remove the bolt and the coolant outlet pipe from the RH cylinder head.
- Remove and discard the O-ring seal.
  
  Fig 64: Locating Bolt And Coolant Outlet Pipe
  Courtesy of FORD MOTOR CO.
Remove the CHT sensor.

Fig 65: Locating CHT Sensor
Courtesy of FORD MOTOR CO.
NOTE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.

NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

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: 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: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

Remove the 10 bolts and the RH cylinder head.
- Discard the bolts and the cylinder head gasket.
  
  Fig 66: Locating RH 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 notices 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 head 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.
NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.

NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.

Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

Fig 67: Locating Oil Pressure Feed Area
Courtesy of FORD MOTOR CO.
Using the crankshaft holding tool, rotate the crankshaft counterclockwise until the crankshaft keyway is at the 9 o'clock position.

Fig 68: Rotating Crankshaft Counterclockwise Until Crankshaft Keyway At 9 O'Clock Position
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the LH primary timing chain tensioner.

Fig 69: Locating Bolts And LH Primary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the LH timing chain tensioner arm. Return the crankshaft keyway to the 9 o'clock position after removing the LH timing chain tensioner arm.

Remove the LH timing chain tensioner arm.

Fig 70: Locating LH Timing Chain Tensioner Arm
Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the LH timing chain guide. Return the crankshaft keyway to the 9 o'clock position after removing the LH timing chain guide.

Remove the bolt and the LH timing chain guide.

Fig 71: Locating Bolt And LH Timing Chain Guide
Courtesy of FORD MOTOR CO.
Remove the LH primary timing chain.

Fig 72: Locating LH Primary Timing Chain
Courtesy of FORD MOTOR CO.
Remove the crankshaft sprocket.

Fig 73: Locating Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Remove the 3 LH intake Variable Camshaft Timing (VCT) assembly bolts and the 3 LH exhaust VCT assembly bolts.

Fig 74: Locating LH Intake And Exhaust Variable Camshaft Timing Assembly Bolts
Courtesy of FORD MOTOR CO.
Slide the LH VCT assemblies and secondary timing chain forward 2 mm (0.078 in).

Fig 75: Sliding LH VCT Assemblies And Secondary Timing Chain Forward
Courtesy of FORD MOTOR CO.
Depress the LH secondary timing chain tensioner and turn the tensioner 90 degrees.

Fig 76: Turning LH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Remove the LH VCT assemblies and the LH secondary timing chain.

Fig 77: Locating LH VCT Assemblies And LH Secondary Timing Chain
Courtesy of FORD MOTOR CO.
NOTE: The front camshaft bearing mega cap must be removed first and then the remaining camshaft bearing caps. Failure to follow this direction may result in damage to the engine.

Remove the 4 bolts and the LH front camshaft bearing mega cap.

Fig 78: Locating Bolts And LH Front Camshaft Bearing Mega Cap
Courtesy of FORD MOTOR CO.
Remove the 16 bolts and the 8 camshaft bearing caps.

Fig 79: Locating Bolts And Camshaft Bearing Caps
Courtesy of FORD MOTOR CO.
NOTE: Intake camshaft shown in illustration, exhaust camshaft similar.

Remove the VCT system oil filter from the intake and exhaust camshafts.

Fig 80: Removing VCT System Oil Filter From Intake And Exhaust Camshafts
Courtesy of FORD MOTOR CO.
Remove the LH intake and exhaust camshafts.

Fig 81: Locating LH Intake And Exhaust Camshafts
Courtesy of FORD MOTOR CO.
Remove the 16 camshaft roller follower and hydraulic lash adjuster assemblies.

Fig 82: Locating Camshaft Roller Follower
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the coolant outlet from the LH cylinder head.
- Remove and discard the gasket.
  
  Fig 83: Locating Bolts And Coolant Outlet On LH Cylinder Head
  Courtesy of FORD MOTOR CO.
NOTE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.

NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

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: 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: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

Remove the 10 bolts and the LH cylinder head.
- Discard the bolts and the cylinder head gasket.
  
  Fig 84: Locating LH 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 notices 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 head 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.
NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.

NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.

Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

Fig 85: Locating Oil Pressure Feed Area
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the 2 KS.

Fig 86: Locating Bolts And Knock Sensor
Courtesy of FORD MOTOR CO.
Remove the bolt and the Crankshaft Position (CKP) sensor.

Fig 87: Locating Bolt And Crankshaft Position Sensor
Courtesy of FORD MOTOR CO.
NOTE: A new oil cooler must be installed or severe damage to the engine can occur.

Remove the oil cooler threaded insert and the oil cooler.
- Discard the oil cooler.
  
  Fig 88: Locating Oil Cooler Threaded Insert In Oil Cooler
  Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the oil filter adapter.
- Discard the gasket.
  
  Fig 89: Locating Oil Filter Adapter Bolts
  Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the A/C compressor.

Fig 90: Locating A/C Compressor 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Remove the bolts and the oil pan.
- Discard the gasket.
- Clean and inspect the sealing surface.
  
  Fig 91: Locating Bolts And Oil Pan
  Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the oil pump screen and pickup tube.
- Discard the O-ring seal.
  
  Fig 92: Locating Oil Pump Screen And Pickup Tube Bolts
  Courtesy of FORD MOTOR CO.
Remove the oil pump screen and pickup tube spacer.

Fig 93: Locating Oil Pump Screen And Pickup Tube Spacer
Courtesy of FORD MOTOR CO.
Remove the 6 bolts and the crankshaft rear seal retainer plate.
- 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
  
  Clean and inspect the sealing surfaces.
  
  Fig 94: Locating Crankshaft Rear Seal Retainer Plate Bolts
  Courtesy of FORD MOTOR CO.
Remove the 2 bolts, the 2 stud bolts and the oil pump.

Fig 95: Locating Bolts, Stud Bolts And Oil Pump
Courtesy of FORD MOTOR CO.
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 the manufacturer's instructions.
NOTE: Verify that the connecting rod and rod cap have orientation numbers cast into them. If not, number the connecting rod and rod cap for correct orientation. Failure to do so can result in engine damage.

Remove the bolts and the connecting rod cap. Discard the bolts.

Fig 96: Locating Bolts And Connecting Rod Cap
Courtesy of FORD MOTOR CO.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

Use the Connecting Rod Installer to push the piston through the top of the cylinder block.

Fig 97: Pushing Piston Through Top Of Cylinder Block Using Connecting Rod Installer
Courtesy of FORD MOTOR CO.
Repeat the previous 2 steps for each of the remaining pistons.
Disassemble the 8 pistons. For additional information, refer to PISTON .
Remove the main bearing cap fasteners.
1. Remove and discard the cross-mounted main cap bolts.
2. Remove and discard the main bearing cap bolts and stud bolt.
  
  Fig 98: Identifying Main Bearing Cap Bolts And Stud Bolts
  Courtesy of FORD MOTOR CO.
Remove the main bearing caps (1), the lower crankshaft main bearings (2) and the lower thrust bearing (3).

Fig 99: Identifying Main Bearing Caps, Lower Crankshaft Main Bearings And Lower Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the crankshaft (1), the upper crankshaft main bearings (2) and the upper thrust washer (3) from the cylinder block.

Fig 100: Identifying Crankshaft, Upper Crankshaft Main Bearings And Upper Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the 4 bolts and 4 piston cooling jets from the cylinder block.

Fig 101: Locating Bolts And Piston Cooling Jets
Courtesy of FORD MOTOR CO.