Section 152 (Engine - 3.5L DURATEC (202KW/275PS)): Disassembly: Engine

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For information on Ford Color Coded Illustrations refer to OEM COLOR CODING

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	303-1245Engine Lift Eye
Courtesy of FORD MOTOR COMPANY	303-1247VCT Spark Plug Tube Seal Remover and Installer
Courtesy of FORD MOTOR COMPANY	303-1248Camshaft holding tools
Courtesy of FORD MOTOR COMPANY	303-1530Tool, Chain Tensioner Hold Down
Courtesy of FORD MOTOR COMPANY	303-409 (T92C-6700-CH)Remover, Crankshaft Seal
Floor Crane
Mounting Stand
Plastic Scraper
Long Nose Pliers

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: If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.

NOTE: Refer to the exploded view under the Engine Component View in the Description and Operation.

Remove the bolts and the flexplate.

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

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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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Remove the floor crane.Use the General Equipment: Floor Crane

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Remove the LH engine lift eye.Remove Special Service Tool: 303-1245 Engine Lift Eye.

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If equipped with block heater, remove the block heater cover.

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If equipped with block heater, disconnect the block heater electrical connector, retainer and remove the block heater wiring harness.

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Remove the bolts and the LH engine mount bracket.

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Remove the bolts and the RH engine mount bracket.

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Disconnect the quick release connector, retainer and remove the coolant hose.

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Remove the crankshaft pulley bolt and washer.

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NOTE: Use a universal puller (such as an OTC 6667, or equivalent).

Using a universal puller, remove the crankshaft pulley.

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Install the original crankshaft pulley bolt and washer.

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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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Remove the original crankshaft pulley bolt and washer.

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

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Follow directions to release the quick release coupling type 3. Remove the crankcase vent tube. Refer to: QUICK RELEASE COUPLING

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1. Remove the bolt.
2. Loosen the nut.
3. Remove the bolts and the EGR inlet tube.
- Discard the EGR inlet tube gasket.
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Loosen the EGR valve bracket nut and bolts.

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- Disconnect the wiring harness electrical connector.
- Disconnect the differential pressure sensor hoses.
- Remove the bolt and the differential pressure sensor.
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1. Remove the bolts.
2. Remove the bolts and the EGR outlet tube.
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Discard the gasket and the O-ring seal.

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- Disconnect the wiring harness electrical connector and retainer.
- Remove the bolts, nut and the EGR valve and bracket.
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Remove the EGR valve mounting bracket bolts and remove the EGR valve.

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- NOTE: When disconnecting the throttle body electrical connector disengage the red locking tab on the throttle body electrical connector by sliding it to the rear of the throttle body electrical connector, away from the throttle body. Squeeze the throttle body electrical connector while removing.
  
  Disconnect the throttle body electrical connector and detach the wire harness retainer.
- Remove the bolts and the upper intake manifold support bracket.
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Follow directions to release the quick release coupling type 3. Remove the PCV tube. Refer to: QUICK RELEASE COUPLING

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Disconnect the MAPT sensor electrical connector and wiring harness retainers.

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Remove the bolts and the upper intake manifold.

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- Visually inspect the upper intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.
- Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
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Remove the bolts and the thermostat housing.

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Inspect and replace if necessary.

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Remove and discard the thermostat housing O-ring seal.

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Remove the nut, bolt and the heat shield.

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Remove the wiring harness retainer stud bolt.

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Remove the wiring harness grommet.

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- Disconnect the CKP sensor electrical connector.
- Remove the bolt and the CKP sensor.
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NOTE: Make note of the high-pressure fuel pump supply Oetiker® clamp end location for correct installation.

Follow directions to release the quick release coupling type 2. Disconnect the quick release couplings and remove the high-pressure fuel pump to port injection fuel rail tube. Refer to: QUICK RELEASE COUPLING

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Remove the bolts and the high-pressure fuel pump bracket.

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- Disconnect the KS and CHT sensor electrical connectors.
- Disconnect the CMP sensor electrical connectors.
- Disconnect the direct injection fuel rail electrical connectors.
- Detach the wiring harness retainers.
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- Disconnect the high-pressure fuel pump electrical connector.
- Disconnect the VCT oil control solenoids electrical connectors.
- Disconnect the ignition coil-on-plug electrical connectors.
- Disconnect the oil pressure sensor electrical connector.
- Detach the wiring harness retainers.
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- Disconnect the FRP temperature sensor electrical connector.
- Detach the wiring harness retainer.
- Disconnect the port injector fuel rail electrical connectors.
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Disconnect the oil pressure control solenoid, EGR valve electrical connectors and detach the wiring harness retainers.

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- Disconnect the VCT oil control solenoids electrical connectors.
- Disconnect the ignition coil-on-plug electrical connectors.
- Detach the wiring harness retainers and remove the engine wiring harness.
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- Remove and discard the high-pressure fuel pump to direct injection fuel rail tube nut.
- Loosen the high-pressure fuel pump to direct injection fuel rail tube flare nuts.
- Remove and discard the high-pressure fuel pump to direct injection fuel rail tube.
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NOTE: Alternately loosen the high-pressure fuel pump bolts one complete revolution at a time.

Remove the bolts and the high-pressure fuel pump.

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Remove and discard the high-pressure fuel pump O-ring seal.

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Remove the high-pressure fuel pump roller tappet.

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Inspect the high-pressure fuel pump roller tappet. If any flat spots or scoring are found, especially in the indicated areas, then inspect the high-pressure fuel pump and the high-pressure fuel pump roller tappet drive lobe. Install new components as needed.

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Loosen the high-pressure fuel pump mounting plate bolt and remove the mounting plate.

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Remove the nuts and the brake vacuum tube bracket.

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

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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 stud bolts and remove the LH valve cover.

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Discard the valve cover gasket.

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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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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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Make sure that the mating faces are clean and free of foreign material.Use the General Equipment: Plastic Scraper

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

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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 bolt, stud bolts and remove the RH valve cover.

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Discard the valve cover gasket.

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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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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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Make sure that the mating faces are clean and free of foreign material.Use the General Equipment: Plastic Scraper

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Remove the nut, bolt and the generator.

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Remove the generator stud bolt.

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Remove the bolts and the LH exhaust manifold heat shield.

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- Remove the nuts and the LH exhaust manifold.
- Discard the nuts.
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Clean and inspect the exhaust manifold. Refer to: Exhaust Manifold Cleaning and Inspection .
Remove and discard the LH exhaust manifold gasket and studs.

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NOTE: If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may cause engine failure.
- Remove the bolt and the oil cooler.
- Discard the oil cooler.
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Remove the bolts and the oil filter adapter.

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Remove and discard the oil filter adapter gasket.

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Remove the bolts and the RH lift eye.

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Remove the bolts and the RH exhaust manifold heat shield.

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- Remove the nuts and the RH exhaust manifold.
- Discard the nuts.
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Remove and discard the RH exhaust manifold gasket and studs.

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Clean and inspect the exhaust manifold. Refer to: Exhaust Manifold Cleaning and Inspection .
Remove the RH block coolant drain plug and allow coolant to drain from the cylinder block.

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1. Remove the LH block coolant drain plug and allow coolant to drain from the cylinder block.
2. If equipped, remove the block heater and allow coolant to drain from the cylinder block.
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Remove the stud bolts and the heat shield.

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Remove the bolts and the CMP sensors.

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Remove and bolts and the port injection fuel rail.

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1. Remove the fuel injector retaining clips.
2. Remove the fuel injectors from the fuel rail.
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Remove and discard all of the fuel injector O-ring seals.

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Remove the bolts and the lower intake manifold.

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- Visually inspect the lower intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.
- Clean and inspect all sealing surfaces.
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- Loosen the fuel rail to fuel rail high-pressure fuel tube flare nuts and remove.
- Discard the fuel rail to fuel rail high-pressure fuel tube.
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Remove the bolts and the coolant pump.

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

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Remove the engine front cover bolts.

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

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

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Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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Install the original crankshaft pulley bolt and washer.

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NOTE: Rotate the crankshaft in a clockwise direction only.

Using the crankshaft bolt, rotate the crankshaft clockwise and align the timing marks on the intake VCT units as shown.

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Remove the bolts and the LH oil tube.

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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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Remove the bolts and the RH oil tube.

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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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NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.
Mark the timing chain link that aligns with the timing mark on the LH intake VCT unit as shown.

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

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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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Remove the bolts and the timing chain tensioner.

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Remove the timing chain tensioner arm.

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Remove the bolts and the lower LH timing chain guide.

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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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Remove the timing chain.

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Remove the crankshaft pulley bolt and washer.

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Remove the crankshaft sprocket.

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

Compress the LH secondary timing chain tensioner and install the special tool 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.Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

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Remove and discard the LH VCT unit bolts.

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Remove the LH VCT units and secondary timing chain.

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

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

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

Compress the RH secondary timing chain tensioner and install the special tool 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.Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

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Remove and discard the RH VCT unit bolts.

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Remove the RH VCT units and secondary timing chain.

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

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

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

Remove the bolts and the RH timing chain guide.

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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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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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Inspect and install new components as necessary.

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Remove and discard the M6 bolt.

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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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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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Remove and discard the cylinder head gasket.

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Remove the RH water jacket spacer.Use the General Equipment: Long Nose Pliers

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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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Remove and discard the M6 bolt.

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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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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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Remove and discard the cylinder head gasket.

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Remove the LH water jacket spacer.Use the General Equipment: Long Nose Pliers

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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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Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
Remove the bolts and the KS.

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Remove the bolts and the channel cover plate.

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Inspect and replace if necessary.

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Remove the oil pan bolts.

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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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Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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

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

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Remove the bolts and the oil pump.

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- Remove the bolts and the crankshaft rear seal.
- Discard the crankshaft rear seal.
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Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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Inspect and clean the specified component with a abrasive pad.

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- Remove and discard the bolts in the sequence shown.
- Remove the main bearing cap support brace.
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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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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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Inspect the pistons. Refer to: Piston Inspection .
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.

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

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

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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.

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

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