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Section 9 (Engine Mechanical - 3.5L): Disassembly: Engine

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOLS DESCRIPTION

G08976614
 3 Jaw Puller
303-D121 or equivalent
G08976615
 Handle
205-153 (T80T-4000-W)
G08976616
 Installer, Differential Bearing Cone
205-142 (T80T-4000-J)
G08976617
 Remover, Crankshaft Rear Oil Seal
303-519 (T95P-6701-EH)
G08976618
 Remover, Oil Seal
303-409 (T92C-6700CH)
G08976619
 Remover, VCT Spark Plug Tube Seal
303-1247/1
G08976620
 Slide Hammer
307-005 (T59L-100-B)
G08976621
 Strap Wrench
303-D055 (D85L-6000-A) or equivalent
G08976622
 Tool, Camshaft Holding
303-1248
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® Metal Surface Prep
ZC-31-A		 -
Motorcraft® Silicone Gasket Remover
ZC-30		 -
Penetrating and Lock Lubricant (US); Penetrating Fluid (Canada)
XL-1 (US); CXC-51-A (Canada)		 -
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: The engine is equipped with a cast aluminum (early build) or stamped steel (late build) crankshaft rear seal retainer plate. If the engine is equipped with a stamped steel plate, the seal and plate must be removed as an assembly and discarded.
NOTE: If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.
NOTE: For additional information, refer to the exploded view under the Assembly procedure in this article.

All vehicles 

  1. Remove the 8 bolts and the flexplate.
    G08976623
  2. Remove the crankshaft sensor ring.
    G08976624
  3. If equipped with a cast aluminum crankshaft rear seal retainer plate, use the Crankshaft Rear Oil Seal Remover and Slide Hammer to remove and discard the rear crankshaft seal.
    G08976625
  4. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.

    Mount the engine on a suitable engine stand.

  5. If equipped, remove the block heater heat shield.
    G08976626
  6. If equipped, disconnect the block heater electrical connector.
    • Remove the block heater wiring harness from the engine.
      G08976627
  7. Remove the 3 bolts and the accessory drive belt tensioner.
    G08976628
  8. Remove the crankshaft pulley bolt and washer.
    • Discard the bolt.
      G08976629
  9. Using the 3 Jaw Puller, remove the crankshaft pulley.
    G08976630
  10. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    G08976631
  11. Remove the crankcase vent tube. For additional information, refer to the QUICK CONNECT COUPLING procedure.
    G08976632
  12. Disconnect the 3 LH coil-on-plug electrical connectors.
    G08976633
  13. Detach the wiring harness connector pin-type retainer from the LH valve cover.
    G08976634
  14. Detach the 2 wiring harness retainers from the LH valve cover stud bolts and position the harness aside.
    G08976635
  15. Disconnect the 2 VCT oil control solenoid electrical connectors.
    • Detach the wiring harness pin-type retainer.
      G08976636
  16. Detach the 2 wiring harness pin-type retainers.
    G08976637
  17. Disconnect the LH HO2S electrical connector.
    • Detach the wiring harness connector pin-type retainer from the LH valve cover.
      G08976638
  18. Disconnect the 3 fuel injector electrical connectors.
    • Detach the 2 wiring harness retainers from the LH valve cover stud bolts.
      G08976639
  19. Detach the 2 wiring harness retainers and position the harness aside.
    G08976640
  20. Disconnect the 2 LH CMP sensor electrical connectors.
    G08976641
  21. Disconnect the LH CMS electrical connector.
    • Remove the wiring harness retainer from the rear of the LH cylinder head.
      G08976642
  22. Detach the wiring harness retainer from the intake manifold.
    G08976643
  23. Disconnect the EVAP canister vent solenoid and throttle body electrical connectors.
    • Detach the wiring harness pin-type retainer.
      G08976644
  24. Detach the 2 wiring harness/coolant tube retainers from the upper intake manifold.
    G08976645
  25. Disconnect the crankcase ventilation hose from the upper intake manifold.
    G08976646
  26. Remove the upper intake manifold support bracket bolt.
    G08976647
  27. Remove the 7 bolts and the upper intake manifold.
    • Remove and discard the gasket.
    • Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
      G08976648
  28. Disconnect the 3 RH coil-on-plug electrical connectors.
    G08976649
  29. Remove the PCV crankcase vent tube.
    G08976650
  30. NOTE: On AWD vehicles the CMS electrical connector was disconnected during the engine removal procedure.

    Disconnect the HO2S and CMS electrical connectors.

    • Detach the 2 wiring harness retainers from the RH valve cover.
      G08976651
  31. Disconnect the 2 VCT oil control solenoid electrical connectors.
    • Detach the 2 wiring harness retainers.
      G08976652
  32. Disconnect the 3 fuel injector electrical connectors.
    • Detach the 2 wiring harness retainers.
      G08976653
  33. Detach the wiring harness retainer.
    G08976654
  34. Disconnect the 2 RH Camshaft Position CMP sensor electrical connectors.
    G08976655
  35. Disconnect the KS electrical connector.
    G08976656
  36. Disconnect the CHT sensor electrical connector.
    G08976657
  37. Remove the bolt and the ground cable from the RH cylinder.
    G08976658
  38. Remove the nut, the bolt and the heat shield.
    G08976659
  39. Remove the wiring harness retainer stud bolt.
    G08976660
  40. Remove the wiring harness grommet.
    G08976661
  41. Disconnect the CKP sensor electrical connector.
    G08976662
  42. Disconnect the A/C compressor electrical connector.
    G08976663
  43. Lift the cover and remove the nut.
    • Disconnect the generator B+ cable.
      G08976664
  44. Disconnect the generator electrical connector.
    G08976665
  45. Detach the wiring harness retainer from the generator.
    G08976666
  46. Disconnect the EOP switch electrical connector and the wiring harness pin-type retainer.
    • Remove the wiring harness from the engine.
      G08976667
  47. Remove the nut, 2 bolts and the A/C compressor.
    G08976668
  48. Remove the A/C compressor mounting stud from the oil pan.
    G08976669
  49. Remove the nut, bolt and the generator.
    G08976670
  50. Remove the 2 nuts and position aside the power steering hose.
    G08976671
  51. NOTE: Power steering hoses removed from graphic for clarity.

    Remove the 3 bolts and the power steering pump.

    G08976672
  52. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to assist in removal.

    Remove the LH HO2S.

    G08976673
  53. Remove the 3 bolts and the LH exhaust heat shield.
    G08976674
  54. Remove the 6 nuts and the LH catalytic converter.
    • Discard the nuts and the gasket.
      G08976675
  55. Clean and inspect the catalytic converter flange. For additional information, refer to EXHAUST MANIFOLD CLEANING AND INSPECTION .
  56. Remove and discard the 6 LH exhaust manifold studs.
    G08976676

    FWD vehicles 

  57. Remove the 4 nuts and the RH catalytic converter.
    • Discard the nuts.
      G08976677
  58. Discard the gasket.
    G08976678

    All vehicles 

  59. NOTE: Heat shield removed from graphic for clarity.

    Remove the 6 nuts and the RH exhaust manifold.

    • Discard the nuts and exhaust manifold gasket.
      G08976679
  60. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  61. Remove and discard the 6 RH exhaust manifold studs.
    G08976680
  62. Remove the RH cylinder block drain plug or, if equipped, the block heater.
    • Allow coolant to drain from the cylinder block.
      G08976681
  63. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
      G08976682
  64. Remove the pin-type retainer and the cover.
    G08976683
  65. Remove the 2 bolts and the 2 LH CMP sensors.
    G08976684
  66. Remove the 2 bolts and the 2 RH CMP sensors.
    G08976685
  67. Remove the 2 thermostat housing-to-lower intake manifold bolts.
    G08976686
  68. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

    Remove the 10 bolts and the lower intake manifold.

    • Remove and discard the intake manifold and thermostat housing gaskets.
    • Clean and inspect all sealing surfaces.
      G08976687
  69. Remove the coolant inlet tube and thermostat assembly.
    • Remove and discard the O-ring seal.
      G08976688
  70. Disconnect and remove the CHT sensor jumper harness.
    G08976689
  71. Remove the bolt and the CKP sensor.
    G08976690
  72. Remove the 3 bolts and the oil filter adapter.
    G08976691
  73. Discard the gasket.
    G08976692
  74. Remove the EOP switch.
    G08976693
  75. Remove the 3 bolts and the 3 LH-coil-on-plugs.
    G08976694
  76. 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 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 4 bolts and 7 stud bolts.

    • Remove the LH valve cover.
    • Discard the gasket.
      G08976695
  77. Remove the 3 bolts and the 3 RH-coil-on-plugs.
    G08976696
  78. 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 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 3 bolts and 8 stud bolts.

    • Remove the RH valve cover.
    • Discard the gasket.
      G08976697
  79. NOTE: LH shown, RH similar.

    Inspect the VCT solenoid seals. Remove any damaged seals.

    • Using the Differential Bearing Cone Installer and Handle, remove and discard the seal(s).
      G08976698
  80. NOTE: LH shown, RH similar.

    Inspect the spark plug tube seals. Remove any damaged seals.

    • Using the Spark Plug Tube Seal Remover and Handle, remove and discard the seal(s).
      G08976699
  81. Clean the valve covers, cylinder heads and engine front cover sealing surfaces with metal surface prep.
  82. Remove the 26 front cover bolts.
    G08976700
  83. Using a suitable pry tool, locate the 7 pry pads shown below and pry the engine front cover loose and remove.
    G08976701
  84. Rotate the crankshaft clockwise and align the timing marks on the intake VCT assemblies as shown below.
    G08976702
  85. Remove the 3 bolts and the LH valve train oil tube.
    G08976703
  86. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

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

    G08976704
  87. Remove the 3 bolts and the RH valve train oil tube.
    G08976705
  88. 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.

    G08976706
    NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.
  89. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown below.
    G08976707
  90. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown below.
    G08976708
  91. 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 below.

    G08976709
  92. Remove the 2 bolts and the primary timing chain tensioner.
    G08976710
  93. Remove the primary timing chain tensioner arm.
    G08976711
  94. Remove the 2 bolts and the lower LH primary timing chain guide.
    G08976712
  95. 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.

    G08976713
  96. 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.

    G08976714
  97. Remove the primary timing chain.
    G08976715
  98. 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.

    G08976716
  99. Remove the crankshaft timing chain sprocket.
    G08976717
  100. 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.

    G08976718
  101. Remove and discard the 2 LH VCT assembly bolts.
    G08976719
  102. Remove the 2 LH VCT assemblies and secondary timing chain.
    • Remove the Secondary Chain Hold Down.
      G08976720
  103. 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.

    G08976721
  104. 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.

    G08976722
  105. 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.

    G08976723
  106. Remove and discard the 2 RH VCT assembly bolts.
    G08976724
  107. Remove the 2 RH VCT assemblies and secondary timing chain.
    • Remove the Secondary Chain Hold Down.
      G08976725
  108. 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 primary timing chain guide.

    G08976726
  109. 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.

    G08976727
  110. 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.

    G08976728
  111. Remove the 2 bolts and the engine lifting eye.
    G08976729
  112. NOTE: Index-mark the location of the bracket on the cylinder head for installation.

    Remove the bolt and the upper intake manifold bracket.

    G08976730
  113. 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, RH similar.

    Remove the 24 valve tappets from the cylinder heads.

    G08976731
  114. NOTE: LH shown, RH similar.

    Remove and discard the M6 bolt from each cylinder head.

    G08976732
  115. 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 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.
    NOTE: LH shown, RH similar.

    Remove and discard the 8 bolts from each cylinder head.

    • Remove the cylinder heads.
    • Discard the cylinder head gaskets.
      G08976733
  116. 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.
    5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
  117. 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 .
  118. Remove the 2 bolts and the KS.
    G08976734
  119. Remove the 8 bolts and the coolant pump.
    G08976735
  120. Remove the 16 oil pan bolts.
    G08976736
  121. Using a suitable pry tool, locate the pry pads and pry the oil pan loose and remove.
    G08976737
  122. Remove the 2 bolts and the oil pump screen and pickup tube.
    • Discard the O-ring seal.
      G08976738
  123. Remove the 3 bolts and the oil pump.
    G08976739
  124. Remove the 8 crankshaft rear seal retainer bolts.
    • If equipped with a stamped steel rear seal retainer plate, remove and discard the plate and seal.
      G08976740
  125. If equipped with a cast aluminum rear seal retainer plate, install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal retainer.
    • Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released.
      • Remove the crankshaft rear seal retainer.
        G08976741
  126. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.

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

    • Thoroughly wash the engine front cover, oil pan and crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.
  127. 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.
  128. 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 below.

    • Remove the main bearing cap support brace.
    • Discard the bolts.
      G08976742
  129. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    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 2 connecting rod cap bolts and cap.

    • Remove the piston/rod assembly from the engine block.
    • Repeat until all the piston/rod assemblies are removed from the engine block.
      G08976743
  130. NOTE: The 8 main bearing cap side bolts and 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 side bolts and the 8 main bearing cap bolts in the sequence shown below.

    • Discard the bolts.
      G08976744
  131. 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.

    G08976745
  132. Remove the lower crankshaft thrust washer from the back side of the No. 4 rear main bearing cap.
    G08976746
  133. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.

    Remove the crankshaft.

    G08976747
  134. NOTE: Inside shown, outside similar.

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

    G08976748
  135. 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.

    G08976749
  136. Using a hexagonal screwdriver, remove the 6 piston oil cool valves.
    G08976750
  137. 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.

    G08976751
  138. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  139. 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.

    Clean the sealing surfaces of the cylinder block 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 or coolant 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.
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