Section 537 (Engine Mechanical - 3.5L GTDI): 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)
	Lifting Bracket, Engine 303-F047  (014-00073) or equivalent
	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.
4. 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 3: Lifting Engine Using Engine Stand

   Courtesy of FORD MOTOR CO.
5. Remove the A/C compressor and the 3 bolts.
6. Remove the LH crankcase vent tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
7. Remove the RH PCV tube. Refer to FUEL SYSTEM - GENERAL INFORMATION .
8. NOTE: LH shown in illustration, RH similar.

   Disconnect the 2 wastegate hoses at the turbochargers.

9. NOTE: LH shown in illustration, RH similar.

   Remove the 2 tie straps for the wastegate hose assembly.

10. Disconnect the turbocharger pressure regulator electrical connector. Remove the 2 tie straps and the wastegate hose assembly.
11. Using a commercially available quick disconnect tool, remove the LH turbocharger coolant supply tube.
12. Remove the 2 bolts at the LH turbocharger oil return tube.
    • Remove and discard the turbocharger return tube gasket.
13. Remove the bolt for the LH turbocharger coolant and oil tubes.
14. Remove the 3 bolts and the LH turbocharger.
    • Discard the turbocharger exhaust manifold gasket.
15. Remove the bolt and the LH oil turbocharger oil return tube.
    • Remove and discard the O-ring seal.
16. Using a commercially available quick disconnect tool, remove the RH turbocharger coolant supply tube.
17. Remove the 2 bolts at the RH turbocharger oil return tube.
    • Remove and discard the turbocharger oil return tube gasket.
18. Remove the bolt for the RH turbocharger coolant and oil tubes.
19. Remove the 3 bolts and the RH turbocharger.
    • Discard the turbocharger exhaust manifold gasket.
20. Remove the bolt and the RH turbocharger oil return tube.
    • Remove and discard the O-ring seal.
21. Remove the 4 bolts and the RH engine support insulator.
    • Discard the bolts.
22. Remove the 4 bolts and the LH engine support insulator-to-cylinder block bracket.
    • Discard the bolts.
23. 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.

24. Remove the engine oil level indicator.
25. Disconnect the 2 LH Variable Camshaft Timing (VCT) solenoid electrical connectors. Remove the tie strap.
26. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
    • Detach the EOP  switch wiring harness retainer from the cylinder head.
27. Disconnect the 3 LH ignition coil-on-plug electrical connectors.
28. Remove the nut, the bolt and the CKP  heat shield.
    Fig 4: Identifying CKP Heat Shield Nut And Bolt

    Courtesy of FORD MOTOR CO.
29. Remove the wiring harness retainer stud bolt.
    Fig 5: Locating Wiring Harness Retainer Stud Bolt

    Courtesy of FORD MOTOR CO.
30. Remove the wiring harness grommet.
    Fig 6: Locating Wiring Harness Grommet

    Courtesy of FORD MOTOR CO.
31. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 7: Locating CKP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
32. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
33. Disconnect the 2 LH Camshaft Position (CMP) sensor electrical connectors. Disconnect the CKP  wire retainer. Remove the ground stud bolt.
34. Disconnect the Knock Sensor (KS) sensor electrical connector. Disconnect the 2 fuel charge harness and the Fuel Rail Pressure (FRP) electrical connectors.
35. Disconnect the wire retainer. Remove the bolt, nut and the CMP  heat shield.
36. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. Remove the ground stud bolt and the tie strap.
37. Disconnect the 2 RH VCT  solenoid electrical connectors. Remove the tie strap.
38. Disconnect the 3 RH ignition coil-on-plug electrical connectors.
39. Disconnect the 2 RH CMP  electrical connectors.
40. Disconnect the wire harness retainer and remove the tie strap.
41. Detach all of the wiring harness retainers from the RH valve cover and stud bolts. Remove the engine wire harness.
42. 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 8: Removing Crankshaft Pulley Bolt And Washer

      Courtesy of FORD MOTOR CO.
43. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 9: Removing Crankshaft Pulley

    Courtesy of FORD MOTOR CO.
44. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 10: Removing Crankshaft Front Seal

    Courtesy of FORD MOTOR CO.
45. Remove the 2 bolts and the accessory drive belt tensioner.
    Fig 11: Locating Accessory Drive Belt Tensioner And Bolts

    Courtesy of FORD MOTOR CO.
46. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
47. Remove the RH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
48. Remove the 4 bolts and the thermostat housing.
    • Discard the thermostat housing and coolant inlet tube O-ring seals.
49. Remove the 4 bolts and the coolant pump pulley.
50. Remove the 7 bolts and the coolant pump.
    • Discard the coolant pump gasket and coolant pump O-ring seal.
51. Remove the coolant inlet pipe.
    • Remove and discard the coolant inlet pipe O-ring seals.
52. Remove the 3 bolts and the coolant crossover manifold assembly.
    • Remove and discard the 2 gaskets.
53. Remove the bolt for the high-pressure fuel tube.
54. Loosen the 2 flare nuts, remove and discard the high-pressure fuel tube assembly.
55. 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 12: Locating LH Fuel Rail Bolts

      Courtesy of FORD MOTOR CO.
56. 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 13: Locating RH Fuel Rail Bolts

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

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

    Fig 14: Locating Fuel Injector Electrical Connectors And Fuel Injector Wire Harness

    Courtesy of FORD MOTOR CO.
58. Using the Slide Hammer and the Fuel Injector Remover, remove any fuel injectors remaining in the cylinder head.
    Fig 15: Removing Fuel Injectors

    Courtesy of FORD MOTOR CO.
59. Remove and discard the 6 upper fuel injector O-rings.
    Fig 16: Locating Upper Fuel Injector O-Ring Seal

    Courtesy of FORD MOTOR CO.
60. Remove and discard the 6 fuel injector clips.
    Fig 17: Locating Fuel Injector Clip

    Courtesy of FORD MOTOR CO.
61. 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 18: Cleaning Cylinder Heads Fuel Injector Bores

    Courtesy of FORD MOTOR CO.
62. Remove the bolt and the fuel injection pump mounting plate.
    • Remove and discard the gaskets.
63. 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.

64. 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.

65. 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.
66. Inspect the 2 VCT  solenoid seals. Remove any damaged seals.
    • Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
67. Inspect the spark plug tube seals. Remove any damaged seals.
    • Using the VCT  Spark Plug Tube Seal Remover and Handle, remove the seal(s).
68. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
69. Remove the 8 nuts and the LH exhaust manifold.
    • Discard the nuts and exhaust manifold gasket.
70. Clean and inspect the LH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
71. Remove and discard the 8 LH exhaust manifold studs.
72. 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.

73. 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.

74. Remove the 2 bolts and the CMP  sensors.
75. 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.
76. Inspect the 2 VCT  solenoid seals. Remove any damaged seals.
    • Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
77. Inspect the spark plug tube seals. Remove any damaged seals.
    • Using the VCT  Spark Plug Tube Seal Remover and Handle, remove the seal(s).
78. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
79. Remove the 8 nuts and the RH exhaust manifold.
    • Discard the nuts and exhaust manifold gasket.
80. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
81. Remove and discard the 8 RH exhaust manifold studs.
82. Remove the 2 bolts and the LH CMP  sensors.
83. Remove and discard the CHT  sensor
84. Remove the bolt and the CKP  sensor.
    Fig 19: Locating CKP Sensor And Bolt

    Courtesy of FORD MOTOR CO.
85. 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.
86. Remove the 5 bolts and the oil filter adapter.
    • Discard the gasket.
      Fig 20: Locating Oil Filter Adapter And Bolts

      Courtesy of FORD MOTOR CO.
87. Remove the 22 engine front cover bolts.
    Fig 21: Locating Engine Front Cover Bolts

    Courtesy of FORD MOTOR CO.
88. Using a suitable pry tool, locate the 7 pry pads shown in illustration and pry the engine front cover loose and remove.
    Fig 22: Locating Engine Front Cover Pry Pads

    Courtesy of FORD MOTOR CO.
89. 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.

90. Rotate the crankshaft clockwise and align the timing marks on the VCT  assemblies as shown in illustration.
91. Remove the 3 bolts and the LH valve train oil tube.
92. 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.

93. Remove the 3 bolts and the RH valve train oil tube.
94. 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.

    NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.
95. Mark the timing chain link that aligns with the timing mark on the LH intake VCT  assembly as shown in illustration.
96. Mark the timing chain link that aligns with the timing mark on the RH intake VCT  assembly as shown in illustration.
97. 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.

98. Remove the 2 bolts and the primary timing chain tensioner.
99. Remove the primary timing chain tensioner arm.
100. Remove the 2 bolts and the lower LH primary timing chain guide.
101. 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.

102. 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.

103. Remove the primary timing chain.
104. Remove the crankshaft timing chain sprocket.
105. 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.

106. 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.

107. Remove and discard the 2 LH VCT  assembly bolts.
108. Remove the 2 LH VCT  assemblies and secondary timing chain.
109. 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.

110. Remove and discard the 2 RH VCT  assembly bolts.
111. Remove the 2 RH VCT  assemblies and secondary timing chain.
112. 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.

113. Remove the 9 bolts and the timing chain gear.
     • Discard the gasket.

     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.
114. 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.

115. Remove the LH secondary timing chain tensioner shoe.
116. Remove the LH secondary timing chain tensioner by pushing up from the bottom and remove.
117. 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.

118. Remove the RH secondary timing chain tensioner shoe.
119. Remove the RH secondary timing chain tensioner by pushing up from the bottom and remove.

     All engines 

120. 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.

121. 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 23: Locating Camshafts Onto LH Cylinder Head In Neutral Position

     Courtesy of FORD MOTOR CO.
122. 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.

123. 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.

124. 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 24: Locating Camshafts Onto RH Cylinder Head In Neutral Position

     Courtesy of FORD MOTOR CO.
125. Remove the 2 bolts and the camshaft bearing cap assembly.
126. 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.

127. 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 25: Locating Cylinder Head Valve Tappet

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

     Remove and discard the M6 bolt from each cylinder head.

     Fig 26: Locating Cylinder Head M6 Bolt

     Courtesy of FORD MOTOR CO.
130. 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 27: Locating Cylinder Head Bolts

       Courtesy of FORD MOTOR CO.
131. 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.
132. 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 .
133. Remove the 2 bolts and the KS  .
     Fig 28: Locating Knock Sensor And Bolts

     Courtesy of FORD MOTOR CO.
134. Remove the 16 oil pan bolts.
     Fig 29: Locating Oil Pan Bolts

     Courtesy of FORD MOTOR CO.
135. 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.

136. Remove the 3 bolts and the oil pump screen and the pickup tube.
     • Discard the O-ring seal.
137. Remove the 3 bolts and the oil pump.
138. Remove the 8 bolts and the crankshaft rear seal retainer plate.
     • Discard the plate and seal assembly.
139. 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.
140. 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 30: Identifying Main Bearing Cap Support Brace Bolts Loosening Sequence

       Courtesy of FORD MOTOR CO.
141. 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 31: Locating Connecting Rod Cap And Bolts

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

     Remove the piston/rod assembly from the engine block.

     Fig 32: Removing Piston/Rod Assembly

     Courtesy of FORD MOTOR CO.
143. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
144. 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 33: Identifying Main Bearing Cap Side Bolts Loosening Sequence

       Courtesy of FORD MOTOR CO.
145. 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 34: Identifying Main Bearing Cap Bolts Loosening Sequence

       Courtesy of FORD MOTOR CO.
146. 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 35: Locating Main Bearing Caps

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

     Remove the crankshaft.

     Fig 36: Locating Crankshaft Onto Upper Main Bearings

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

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

     Fig 37: Locating Crankshaft Thrust Bearing

     Courtesy of FORD MOTOR CO.
149. 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 38: Locating Crankshaft Main Bearing Caps

     Courtesy of FORD MOTOR CO.
150. Using a hexagonal screwdriver, remove the 6 piston oil cool valves.
151. 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 39: Locating Crankshaft Main Bearing Cap

     Courtesy of FORD MOTOR CO.
152. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
153. 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.
154. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover and oil pan. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover and oil pan. These tools cause scratches and gouges that make leak paths.

     Clean the engine front cover and oil pan 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 and oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.