Section 676 (Engine - 3.5L DURATEC (209KW/284PS)): Disassembly: Engine

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-142 (T80T-4000-J) Installer, Differential Bearing Cone
Courtesy of FORD MOTOR COMPANY	205-150 (T80T-4000-S) Installer, Spindle Bearing
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	303-1245 Engine Lift Eye TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1248 Camshaft holding tools TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1530 Tool, Chain Tensioner Hold Down TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW
Courtesy of FORD MOTOR COMPANY	303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH
Floor Crane
Three Leg Puller
Mounting Stand
Plastic Scraper
Hose Clamp Remover/Installer

Materials 

Name	Specification
Motorcraft ® Silicone Gasket Remover ZC-30-A	-
Motorcraft ® Metal Surface Prep ZC-31-B	-
Metal Brake Parts Cleaner PM-4-A, PM-4-B	-

1. 1.
   
   Remove the bolts and the flexplate.

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1. 2.
   
   Remove the crankshaft sensor ring and the engine-to-transmission spacer plate.

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1. 3.
   
   
   NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.

   Mount the engine to the mounting stand. Use the General Equipment: Mounting Stand

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1. 4.
   
   Remove the floor crane and chain. Use the General Equipment: Floor Crane

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1. 5.
   
   Remove the bolts and the A/C compressor.

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1. 6.
   
   Remove the bolts and the RH lift eye.

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1. 7.
   
   Remove Special Service Tool: 303-1245 Engine Lift Eye.

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1. 8.
   
   Remove the bolt and the RH engine mount.

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1. 9.
   
   Remove the bolts and the RH engine mount bracket.

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1. 10.
   
   Remove the bolts and the LH engine mount bracket.

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1. 11.
   
   Remove the degas bottle hose. Use the General Equipment: Hose Clamp Remover/Installer

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1. 12.
   
   
   • Remove the crankshaft pulley bolt and washer.
   • Discard the bolt.

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1. 13.
   
   Using a three leg puller, remove the crankshaft pulley. Use the General Equipment: Three Leg Puller

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1. 14.
   
   Using the special tool, remove and discard the crankshaft front seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.

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1. 15.
   
   Remove the bolts, coolant pump pulley and the accessory drive belt tensioner.

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1. 16.
   
   Remove the bolt and the upper intake manifold support bracket.

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1. 17.
   
   Remove the nut, bolt and the heat shield.

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1. 18.
   
   Remove the wiring harness retainer stud bolt.

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1. 19.
   
   Remove the wiring harness grommet.

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1. 20.
   
   
   • Disconnect the CKP sensor electrical connector.
   • Remove the bolt and the CKP sensor.

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1. 21.
   
   Remove the bolt and the ground strap.

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1. 22.
   
   
   • Disconnect the KS sensor electrical connector.
   • Disconnect the CMP sensor electrical connectors.
   • Detach the wiring harness retainers.

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1. 23.
   
   
   • Disconnect the VCT oil control solenoids electrical connectors.
   • Disconnect the ignition coil-on-plug electrical connectors.
   • Disconnect the oil pressure switch electrical connector.
   • Detach the wiring harness retainers.

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1. 24.
   
   Remove the fuel rail insulators.

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1. 25.
   
   
   • Disconnect the VCT oil control solenoids electrical connectors.
   • Disconnect the ignition coil-on-plug electrical connectors.
   • Disconnect the CHT sensor electrical connector.
   • Detach the wiring harness retainers.

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1. 26.
   
   Disconnect the fuel injector electrical connectors and remove the engine wiring harness.

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1. 27.
   
   
   NOTE: Use compressed air to remove any foreign material from the ignition coil-on-plugs and surrounding area before removing the ignition coil-on-plugs.
   NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
   • Remove the bolts and the ignition coil-on-plugs.
   • Remove the oil level indicator.

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1. 28.
   
   Inspect the coil seals for rips, nicks or tears and replace if necessary.

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1. 29.
   
   
   NOTE: While removing the valve cover do not apply excessive force to the VCT oil control solenoid or damage may occur.
   NOTE: If the 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.

   Loosen the bolts and the LH valve cover.

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1. 30.
   
   Discard the gasket.

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1. 31.
   
   
   NOTE: Inspect the VCT solenoid seals. Remove any damaged seals.

   Using the special tools, remove and discard the seal(s). Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone., 205-153 (T80T-4000-W) Handle.

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1. 32.
   
   
   NOTE: Inspect the spark plug tube seals. Remove any damaged seals.

   Using the special tools, remove and discard the seal(s). Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

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1. 33.
   
   Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation . Use the General Equipment: Plastic Scraper

   Material

   : Motorcraft ® Silicone Gasket Remover / ZC-30-A

   Material

   : Metal Brake Parts Cleaner / PM-4-A, PM-4-B

   Material

   : Motorcraft ® Metal Surface Prep / ZC-31-B

Courtesy of FORD MOTOR COMPANY

1. 34.
   
   
   NOTE: Use compressed air to remove any foreign material from the ignition coil-on-plugs and surrounding area before removing the ignition coil-on-plugs.
   NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

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

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1. 35.
   
   Inspect the coil seals for rips, nicks or tears and replace if necessary.

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1. 36.
   
   
   NOTE: While removing the valve cover do not apply excessive force to the VCT oil control solenoid or damage may occur.
   NOTE: If the 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.

   Loosen the bolts and remove the RH valve cover.

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1. 37.
   
   Discard the gasket.

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1. 38.
   
   
   NOTE: Inspect the VCT solenoid seals. Remove any damaged seals.

   Using the special tools, remove and discard the seal(s). Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone., 205-153 (T80T-4000-W) Handle.

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1. 39.
   
   
   NOTE: Inspect the spark plug tube seals. Remove any damaged seals.

   Using the special tools, remove and discard the seal(s). Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

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1. 40.
   
   Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation . Use the General Equipment: Plastic Scraper

   Material

   : Motorcraft ® Silicone Gasket Remover / ZC-30-A

   Material

   : Metal Brake Parts Cleaner / PM-4-A, PM-4-B

   Material

   : Motorcraft ® Metal Surface Prep / ZC-31-B

Courtesy of FORD MOTOR COMPANY

1. 41.
   
   
   • Remove the nuts and the LH exhaust manifold.
   • Discard the nuts.

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1. 42.
   
   Clean and inspect the catalytic converter flange. Refer to: Exhaust Manifold Cleaning and Inspection .

1. 43.
   
   Remove and discard the LH exhaust manifold gasket and studs.

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1. 44.
   
   Remove the bolt and discard the oil cooler.

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1. 45.
   
   Remove the bolts and the oil filter adapter.

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1. 46.
   
   Inspect and replace if necessary.

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1. 47.
   
   
   • Remove the nuts and the RH exhaust manifold.
   • Discard the nuts.

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1. 48.
   
   Remove and discard the RH exhaust manifold gasket and studs.

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1. 49.
   
   Clean and inspect the catalytic converter flange. Refer to: Exhaust Manifold Cleaning and Inspection .

1. 50.
   
   Remove the LH block coolant drain plug and allow coolant to drain from the cylinder block.

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1. 51.
   
   Remove the RH block coolant drain plug and allow coolant to drain from the cylinder block.

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1. 52.
   
   Remove the bolts and the CMP sensors.

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1. 53.
   
   Remove the bolts and the thermostat housing.

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1. 54.
   
   Inspect and replace if necessary.

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1. 55.
   
   Remove and discard the thermostat housing O-ring seal.

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1. 56.
   
   Remove the bolts and the lower intake manifold.

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1. 57.
   
   Remove and discard the lower intake manifold gaskets.

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1. 58.
   
   Remove the foam insulator.

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1. 59.
   
   Disconnect the CHT sensor electrical connector.

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1. 60.
   
   Remove the bolts and the coolant pump.

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1. 61.
   
   Remove and discard the coolant pump gasket and O-ring seal.

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1. 62.
   
   Remove the engine front cover bolts.

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1. 63.
   
   Using a pry tool, locate the pry pads shown and pry the engine front cover loose and remove.

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1. 64.
   
   Using the special tools, remove the engine front cover to coolant pipe seal. Use Special Service Tool: 205-150 (T80T-4000-S) Installer, Spindle Bearing., 205-153 (T80T-4000-W) Handle.

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1. 65.
   
   
   NOTE: Only use a 3M™ Roloc ® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 RPM, to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean front cover.
   • Make sure that the mating faces of the front cover are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .

     Material

     : Motorcraft ® Silicone Gasket Remover / ZC-30-A

     Material

     : Metal Brake Parts Cleaner / PM-4-A, PM-4-B

     Material

     : Motorcraft ® Metal Surface Prep / ZC-31-B

   • Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.

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1. 66.
   
   
   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: 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 will cause premature engine failure. Remove all traces of the gasket.

   Make sure that the mating faces of the engine block and oil pan are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation . Use the General Equipment: Plastic Scraper

   Material

   : Motorcraft ® Silicone Gasket Remover / ZC-30-A

   Material

   : Metal Brake Parts Cleaner / PM-4-A, PM-4-B

   Material

   : Motorcraft ® Metal Surface Prep / ZC-31-B

Courtesy of FORD MOTOR COMPANY

1. 67.
   
   
   NOTE: Rotate the crankshaft in a clockwise direction only.

   Rotate the crankshaft clockwise and align the timing marks on the intake VCT units as shown.

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1. 68.
   
   Remove the bolts and the LH oil tube.

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1. 69.
   
   
   NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

   Install Special Service Tool: 303-1248 Camshaft holding tools.

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1. 70.
   
   Remove the bolts and the RH oil tube.

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1. 71.
   
   
   NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

   Install Special Service Tool: 303-1248 Camshaft holding tools.

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1. 72.
   
   Mark the timing chain link that aligns with the timing mark on the LH intake VCT unit as shown.

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1. 73.
   
   Mark the timing chain link that aligns with the timing mark on the RH intake VCT unit as shown.

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1. 74.
   
   
   NOTE: The crankshaft sprocket timing mark should be between the colored links.

   Mark the timing chain links that aligns with the timing mark on the crankshaft sprocket as shown.

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1. 75.
   
   Remove the bolts and the timing chain tensioner.

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1. 76.
   
   Remove the timing chain tensioner arm.

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1. 77.
   
   Remove the bolts and the lower LH timing chain guide.

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1. 78.
   
   
   NOTE: Removal of the VCT oil control solenoid will aid in the removal of the timing chain.
   NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoids.
   NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

   Remove the bolts and the VCT oil control solenoids.

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1. 79.
   
   Remove the timing chain.

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1. 80.
   
   Remove the crankshaft sprocket.

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1. 81.
   
   
   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 timing chain guide.

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1. 82.
   
   
   NOTE: The VCT oil control solenoids are removed for clarity.

   Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

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1. 83.
   
   Remove and discard the LH VCT unit bolts.

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1. 84.
   
   Remove the LH VCT units and secondary timing chain.

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1. 85.
   
   Remove Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

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1. 86.
   
   Remove Special Service Tool: 303-1248 Camshaft holding tools.

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1. 87.
   
   
   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 bolts, camshaft caps and the camshafts.

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1. 88.
   
   
   NOTE: The VCT oil control solenoids are removed for clarity.

   Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

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1. 89.
   
   Remove and discard the RH VCT unit bolts.

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1. 90.
   
   Remove the RH VCT units and secondary timing chain.

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1. 91.
   
   Remove Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

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1. 92.
   
   Remove Special Service Tool: 303-1248 Camshaft holding tools.

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1. 93.
   
   
   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 bolts, camshaft caps and the camshafts.

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1. 94.
   
   
   NOTE: Do not use power tools to remove the bolt or damage to the RH primary timing chain guide may occur.

   Remove the bolt and the RH timing chain guide.

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1. 95.
   
   
   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: RH shown, LH similar.

   Remove the valve tappets from the cylinder heads.

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1. 96.
   
   Inspect and install new components as necessary.

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1. 97.
   
   Remove and discard the M6 bolt.

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1. 98.
   
   
   NOTE: Place clean 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 can 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 tighten-to-yield designed and cannot be reused.
   • Remove and discard the bolts from the cylinder head.
   • Remove the cylinder head.

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1. 99.
   
   
   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.

   Make sure that the mating faces of the cylinder head are clean and free of foreign material.

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1. 100.
   
   Remove and discard the cylinder head gasket.

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1. 101.
   
   
   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: 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.

   Make sure that the mating faces of the engine block are clean and free of foreign material.

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1. 102.
   
   Remove and discard the M6 bolt.

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1. 103.
   
   
   NOTE: Place clean 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 can 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 tighten-to-yield designed and cannot be reused.
   • Remove and discard the bolts from the cylinder head.
   • Remove the cylinder head.

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1. 104.
   
   
   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.

   Make sure that the mating faces of the cylinder head are clean and free of foreign material.

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1. 105.
   
   Remove and discard the cylinder head gasket.

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1. 106.
   
   
   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: 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.

   Make sure that the mating faces of the engine block are clean and free of foreign material.

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1. 107.
   
   Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion. Refer to: Cylinder Head Distortion .

1. 108.
   
   Remove the bolts and the KS.

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1. 109.
   
   Remove the bolts and the channel cover plate.

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1. 110.
   
   Inspect and replace if necessary.

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1. 111.
   
   Remove the oil pan bolts.

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1. 112.
   
   Using a pry tool, locate the pry pads at the LH and RH side of the oil pan and pry the oil pan loose and remove.

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1. 113.
   
   
   NOTE: Only use a 3M™ Roloc ® Bristle Disk (2-in white, part number 07528) to clean the oil pan and engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean. These tools cause scratches and gouges that make leak paths.
   • Make sure that the mating faces of the oil pan are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .

     Material

     : Motorcraft ® Silicone Gasket Remover / ZC-30-A

     Material

     : Metal Brake Parts Cleaner / PM-4-A, PM-4-B

     Material

     : Motorcraft ® Metal Surface Prep / ZC-31-B

   • Thoroughly wash the oil pan to remove any foreign material, including any abrasive particles created during the cleaning process.

Courtesy of FORD MOTOR COMPANY

1. 114.
   
   
   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 of the engine block. 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.

   Make sure that the mating faces of the engine block are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation . Use the General Equipment: Plastic Scraper

   Material

   : Motorcraft ® Silicone Gasket Remover / ZC-30-A

   Material

   : Metal Brake Parts Cleaner / PM-4-A, PM-4-B

   Material

   : Motorcraft ® Metal Surface Prep / ZC-31-B

Courtesy of FORD MOTOR COMPANY

1. 115.
   
   Remove the bolts and the oil pump screen and pickup tube.

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1. 116.
   
   Remove and discard the oil pump screen and pickup tube O-ring seal.

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1. 117.
   
   Remove the bolts and the oil pump.

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1. 118.
   
   
   • Remove the bolts and the crankshaft rear seal.
   • Discard the crankshaft rear seal.

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1. 119.
   
   
   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 of the engine block. 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.

   Make sure that the mating faces is clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation . Use the General Equipment: Plastic Scraper

   Material

   : Motorcraft ® Silicone Gasket Remover / ZC-30-A

   Material

   : Metal Brake Parts Cleaner / PM-4-A, PM-4-B

   Material

   : Motorcraft ® Metal Surface Prep / ZC-31-B

Courtesy of FORD MOTOR COMPANY

1. 120.
   
   Inspect and clean the specified component with a abrasive pad.

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1. 121.
   
   
   • Remove and discard the bolts in the sequence shown.
   • Remove the main bearing cap support brace.

1. 122.
   
   
   NOTE: The connecting rod cap bolts are a torque-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 caps.

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1. 123.
   
   
   NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod while removing the pistons.

   Remove the piston/rod assembly from the engine block.

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1. 124.
   
   Inspect the pistons. Refer to: Piston Inspection .

1. 125.
   
   
   NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.

   Remove and discard the main bearing caps bolts in the sequence shown.

1. 126.
   
   
   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 main bearing caps.

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1. 127.
   
   Remove the lower crankshaft thrust washer from the back side of the No. 4 rear main bearing cap.

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1. 128.
   
   
   NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

   Remove the crankshaft main bearings from the main bearing caps.

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1. 129.
   
   
   NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.

   Remove the crankshaft.

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1. 130.
   
   Remove the crankshaft thrust bearings from the rear main bearing bulkhead.

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1. 131.
   
   
   NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

   Remove the crankshaft main bearings from the cylinder block.

Courtesy of FORD MOTOR COMPANY

1. 132.
   
   Using a hex bit, remove the piston oil cool valves.

Courtesy of FORD MOTOR COMPANY

1. 133.
   
   Inspect the cylinder block distortion. Refer to: Cylinder Block Distortion .