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Removal And Installation: Disassembly: Engine: Material

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Item Specification
Motorcraft® Metal Surface Prep ZC-31-A -
Motorcraft® Silicone Gasket Remover ZC-30 -
NOTE: Remove the cylinder heads before removing the crankshaft. Failure to do so may result in engine damage.
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, may cause engine failure.
NOTE: The flexplate and crankshaft rear seal must be removed before mounting the engine on the engine stand.
NOTE: For additional information, refer to the exploded view under the ASSEMBLY  procedure.
  1. Remove the 8 bolts and the flexplate.
    • Discard the 8 flexplate bolts.
      Fig 1: Locating Flexplate And Mounting Bolts
      G08339650Courtesy of FORD MOTOR CO.
  2. Remove the spacer plate.
    Fig 2: Locating Spacer Plate
    G08339651Courtesy of FORD MOTOR CO.
  3. NOTE: Inspect the ignition pulse ring for damage. If the ignition pulse ring has been dropped or has any visual damage, it must be discarded.

    Remove the crankshaft ignition pulse ring.

    Fig 3: Locating Crankshaft Ignition Pulse Ring
    G08339652Courtesy of FORD MOTOR CO.
  4. Disconnect the electrical connector and remove the bolt and the Crankshaft Position (CKP) sensor.
    Fig 4: Locating Crankshaft Position (CKP) Sensor, Electrical Connector And Bolt
    G08339653Courtesy of FORD MOTOR CO.
  5. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.
    Fig 5: Removing Crankshaft Rear Seal Using Tool
    G08339654Courtesy of FORD MOTOR CO.
  6. Mount the engine on a work stand.
  7. Remove the Engine Lifting Bracket and Engine Support Brackets.
    Fig 6: Installing/Removing Engine Lifting Bracket And Engine Support Brackets
    G08339655Courtesy of FORD MOTOR CO.
  8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and wiring harness retainers.
    Fig 7: Locating Engine Oil Pressure (EOP) Switch Electrical Connector And Wiring Harness Retainers
    G08339656Courtesy of FORD MOTOR CO.
  9. Disconnect the LH Variable Camshaft Timing (VCT) variable force solenoid electrical connector and the 2 wiring harness retainers.
    Fig 8: Locating LH VCT Variable Force Solenoid Electrical Connector And Wiring Harness Retainers
    G08339657Courtesy of FORD MOTOR CO.
  10. Disconnect the 3 engine wiring harness position retainers from the LH valve cover.
    Fig 9: Locating LH Valve Cover Engine Wiring Harness Position Retainers
    G08339658Courtesy of FORD MOTOR CO.
  11. Disconnect the wiring harness retainer, the Knock Sensor (KS) and Cylinder Head Temperature (CHT) sensor electrical connectors.
    Fig 10: Locating Wiring Harness Retainer, Knock Sensor And Cylinder Head Temperature Sensor Electrical Connector
    G08339659Courtesy of FORD MOTOR CO.
  12. Disconnect the LH and RH Camshaft Position (CMP) electrical connectors.
    Fig 11: Locating LH And RH Camshaft Position Sensor Electrical Connectors
    G08339660Courtesy of FORD MOTOR CO.
  13. Remove the nut and the wiring harness ground cable.
    Fig 12: Locating Wiring Harness Ground Cable Mounting Nut
    G08339661Courtesy of FORD MOTOR CO.
  14. Remove the nut and the radio interference capacitor.
    Fig 13: Locating Radio Ignition Interference Capacitor And Nut
    G08339662Courtesy of FORD MOTOR CO.
  15. Disconnect the RH VCT variable force solenoid electrical connector and the 2 wiring harness retainers.
    Fig 14: Locating RH VCT Variable Force Solenoid Electrical Connector And Wiring Harness Retainers
    G08339663Courtesy of FORD MOTOR CO.
  16. Disconnect the 3 engine wiring harness position retainers from the RH valve cover and remove the engine wiring harness.
    Fig 15: Locating Engine Wiring Harness Position Retainers
    G08339664Courtesy of FORD MOTOR CO.
  17. NOTE: RH shown in illustration, LH similar.

    Disconnect the 8 ignition wires from the valve cover retainers and the lower spark plugs.

    Fig 16: Locating Lower Spark Plugs
    G08339665Courtesy of FORD MOTOR CO.
  18. Remove the 2 bolts and the LH and RH CMP sensors.
    Fig 17: Locating LH And RH CMP Sensors Mounting Bolts
    G08339666Courtesy of FORD MOTOR CO.
  19. Remove the 2 bolts and the RH and LH KS.
    Fig 18: Locating RH And LH Knock Sensor Mounting Bolts
    G08339667Courtesy of FORD MOTOR CO.
  20. Remove the 2 bolts and the LH exhaust manifold heat shield.
    Fig 19: Locating Exhaust Shield Mounting Bolts
    G08339668Courtesy of FORD MOTOR CO.
  21. Remove the 8 nuts, the 8 studs, the LH exhaust manifold and the 2 gaskets.
    • Discard the gaskets, nuts and studs.
    • Inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
      Fig 20: Locating LH Exhaust Manifold Mounting Bolts
      G08339669Courtesy of FORD MOTOR CO.
  22. Remove the 2 bolts and the RH exhaust manifold heat shield.
    Fig 21: Locating RH Exhaust Manifold Heat Shield And Bolts
    G08339670Courtesy of FORD MOTOR CO.
  23. Remove the 8 nuts, the 8 bolts, the RH exhaust manifold and the 2 gaskets.
    • Discard the gaskets, nuts and studs.
    • Inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
      Fig 22: Locating RH Exhaust Manifold Gaskets Mounting Nuts And Studs
      G08339671Courtesy of FORD MOTOR CO.
  24. Remove the 3 bolts and the LH engine support insulator-to-cylinder block bracket.
    Fig 23: Locating Engine Support Insulator-To-Cylinder Block Bracket Mounting Bolts
    G08339672Courtesy of FORD MOTOR CO.
  25. Remove the 3 bolts and the RH engine support insulator.
    Fig 24: Identifying RH Engine Support Insulator Mounting Bolts
    G08339673Courtesy of FORD MOTOR CO.
  26. Remove the bolt and the oil level indicator tube.
    • Discard the O-ring seal.
      Fig 25: Locating Oil Level Indicator Tube And Bolt
      G08339674Courtesy of FORD MOTOR CO.
  27. 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.
    NOTE: Remove the valve cover carefully, or the Variable Camshaft Timing (VCT) variable force solenoid may be damaged.
    NOTE: The bolts are part of the valve cover and should not be removed.

    Loosen the 10 bolts and remove the LH valve cover.

    • 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 LH Valve Cover Mounting Bolts
      G08339675Courtesy of FORD MOTOR CO.
  28. 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.
    NOTE: Remove the valve cover carefully, or the Variable Camshaft Timing (VCT) variable force solenoid may be damaged.
    NOTE: The bolts are part of the valve cover and should not be removed.

    Loosen the 10 bolts and remove the RH valve cover.

    • 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 RH Valve Cover And Bolts
      G08339676Courtesy of FORD MOTOR CO.
  29. Remove the 4 bolts and the oil filter adapter.
    Fig 28: Locating Oil Filter Adapter Mounting Bolts
    G08339677Courtesy of FORD MOTOR CO.
  30. Remove the bolt and the heater coolant tube.
    Fig 29: Locating Heater Coolant Tube And Bolt
    G08339678Courtesy of FORD MOTOR CO.
  31. Remove the 6 bolts, coolant pump pulley and the 2 accessory drive belt idler pulleys.
    Fig 30: Locating Coolant Pump Pulley, Accessory Drive Belt Idler Pulley And Bolts
    G08339679Courtesy of FORD MOTOR CO.
  32. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 31: Identifying Accessory Drive Belt Tensioner Mounting Bolts
    G08339680Courtesy of FORD MOTOR CO.
  33. Remove the 4 bolts and the coolant pump from the cylinder block.
    • Discard the O-ring seal.
      Fig 32: Locating Coolant Pump Housing Mounting Bolts
      G08339681Courtesy of FORD MOTOR CO.
  34. Remove the crankshaft pulley bolt.
    • Discard the crankshaft pulley bolt.
  35. Using the 3 Jaw Puller and Step Plate, remove the crankshaft pulley.
    Fig 33: Removing Crankshaft Pulley Using 3 Jaw Puller And Step Plate
    G08339682Courtesy of FORD MOTOR CO.
  36. 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 34: Removing Crankshaft Front Oil Seal Using Oil Seal Remover
    G08339683Courtesy of FORD MOTOR CO.
  37. Remove the 20 bolts, oil pan and oil pan gasket.
    • 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 35: Locating Oil Pan Gasket Bolts
      G08339684Courtesy of FORD MOTOR CO.
  38. 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 8 bolts and the crankshaft rear seal retainer plate.

    • Clean and inspect the sealing surfaces.
      Fig 36: Locating Crankshaft Rear Seal Retainer Plate And Bolts
      G08339685Courtesy of FORD MOTOR CO.
  39. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.

    Remove the 17 bolts and the 3 studs.

    Fig 37: Locating Engine Front Cover Studs And Bolts
    G08339686Courtesy of FORD MOTOR CO.
  40. Remove the engine front cover from the front cover-to-cylinder block dowel.
    • Remove and discard the engine front cover gaskets.
      Fig 38: Removing Engine Front Cover Gaskets
      G08339687Courtesy of FORD MOTOR CO.
  41. Rotate the engine clockwise until the No. 1 intake valve is open.
  42. Remove the 10 bolts and the LH intake rocker arm shaft assembly.
    Fig 39: Locating LH Intake Rocker Arm Shaft Assembly Mounting Bolts
    G08339688Courtesy of FORD MOTOR CO.
  43. Rotate the engine clockwise until the No. 1 exhaust valve is open.
  44. Remove the 10 bolts and the LH exhaust rocker arm shaft assembly.
    Fig 40: Locating LH Exhaust Rocker Arm Shaft Assembly Mounting Bolts
    G08339689Courtesy of FORD MOTOR CO.
  45. Rotate the engine clockwise until the No. 1 intake valve is closed.
  46. Remove the 10 bolts and the RH intake rocker arm shaft assembly.
    Fig 41: Locating RH Intake Rocker Arm Shaft Assembly Mounting Bolts
    G08339690Courtesy of FORD MOTOR CO.
  47. Rotate the engine clockwise until the No. 1 exhaust valve is closed.
  48. Remove the 10 bolts and the RH exhaust rocker arm shaft assembly.
    Fig 42: Locating RH Exhaust Rocker Arm Shaft Assembly Mounting Bolts
    G06518387Courtesy of FORD MOTOR CO.
  49. Position the crankshaft keyway at the 11 o'clock position.
    Fig 43: Locating Crankshaft Keyway
    G06518157Courtesy of FORD MOTOR CO.
  50. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
    Fig 44: Locating RH Timing Chain Tensioner And Tensioner Arm Bolts
    G06518158Courtesy of FORD MOTOR CO.
  51. Remove the bolt and the RH timing chain guide.
    Fig 45: Locating RH Timing Chain Guide Mounting Bolt
    G06518159Courtesy of FORD MOTOR CO.
  52. Remove the RH timing chain.
    Fig 46: Locating RH Timing Chain
    G06518160Courtesy of FORD MOTOR CO.
  53. Remove the 2 bolts and the LH timing chain tensioner.
    Fig 47: Locating LH Timing Chain Tensioner Mounting Bolts
    G06518161Courtesy of FORD MOTOR CO.
  54. Remove the LH timing chain tensioner arm.
    Fig 48: Locating LH Timing Chain Tensioner Arm
    G08339697Courtesy of FORD MOTOR CO.
  55. Remove the bolt and the LH timing chain guide.
    Fig 49: Locating LH Timing Chain Guide And Mounting Bolt
    G06518163Courtesy of FORD MOTOR CO.
  56. Remove the LH timing chain.
    Fig 50: Locating LH Timing Chain
    G06518164Courtesy of FORD MOTOR CO.
  57. Remove the crankshaft sprocket.
    Fig 51: Locating Crankshaft Sprocket
    G06518165Courtesy of FORD MOTOR CO.
  58. NOTE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage may 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. Failure to follow this instruction may cause engine damage.
    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, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. Failure to follow this instruction may cause engine damage.

    Remove the 10 bolts and the RH cylinder head.

    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 52: Locating RH Cylinder Head Mounting Bolts
      G06518402Courtesy of FORD MOTOR CO.
  59. NOTE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage may 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. Failure to follow this instruction may cause engine damage.
    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, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. Failure to follow this instruction may cause engine damage.

    Remove the 10 bolts and the LH cylinder head.

    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 53: Locating LH Cylinder Head Mounting Bolts
      G06518398Courtesy of FORD MOTOR CO.
  60. 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.
    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. Failure to follow this procedure may cause engine damage.
    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.

    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.
  61. Support the cylinder heads 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 .
  62. Remove the oil pump screen and pickup tube support bracket nut.
    Fig 54: Locating Oil Pump Pickup Tube Support Bracket Nut
    G06518262Courtesy of FORD MOTOR CO.
  63. Remove the 2 bolts and the oil pump screen and pickup tube.
    Fig 55: Locating Oil Pump Pickup Tube Bolts
    G06518263Courtesy of FORD MOTOR CO.
  64. Remove the 2 upper bolts, the 2 lower stud bolts and the oil pump.
    Fig 56: Locating Oil Pump Upper Bolts And Lower Stud Bolts
    G06518264Courtesy of FORD MOTOR CO.
  65. 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 instructions.
  66. NOTE: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for correct orientation. Failure to follow these instructions may result in engine damage.

    Remove the 16 bolts and the 8 connecting rod caps and bearings. Discard the bolts.

    Fig 57: Locating Connecting Rod Caps And Bearing Mounting Bolts
    G06137989Courtesy of FORD MOTOR CO.
  67. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Failure to follow this instruction may result in engine damage.

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

    Fig 58: Pushing Piston Through Top Of Cylinder Block
    G07479787Courtesy of FORD MOTOR CO.
  68. Disassemble the 8 pistons. For additional information, refer to PISTON  procedure.
  69. Remove and discard the 10 cross-mounted main cap bolts.
    Fig 59: Identifying Cross-Mounted Main Cap And Bolts
    G07479788Courtesy of FORD MOTOR CO.
  70. NOTE: Correct stud bolt location is essential for assembly procedure. Record the stud bolt location.

    Remove and discard the 19 main bearing cap bolts and the stud bolt.

    Fig 60: Locating Main Bearing Cap Bolts And Stud Bolt
    G07479789Courtesy of FORD MOTOR CO.
  71. Remove the main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
    Fig 61: Locating Main Bearing Caps, Lower Crankshaft Main Bearings And Lower Thrust Washer
    G07479790Courtesy of FORD MOTOR CO.
  72. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.
    Fig 62: Removing Crankshaft From Cylinder Block
    G07479791Courtesy of FORD MOTOR CO.
  73. Remove the 4 bolts and the 4 piston oil cooler valves.
    Fig 63: Locating Piston Oil Cooler Valves And Bolts
    G06518470Courtesy of FORD MOTOR CO.
  74. Inspect the cylinder block. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
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