Section 1613 (Engine Mechanical - 3.0L (4V)): Disassembly: Engine

	3 Jaw Puller 303-D121
	Installer, Connecting Rod 303-462 (T94P-6136-AH)
	Plate, Water Pump Pulley 303-456 (T94P-6312-AH1), part of 303-S455
	Protector, Water Pump Shaft 303-457 (T94P-6312-AH2), part of 303-S455
	Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
	Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
	Remover, Oil Seal 303-409 (T92C-6700CH)
	Remover, Stretchy Belt 303-1419
	Slide Hammer 307-005 (T59L-100-B)

All engines 

1. Remove the 8 bolts and the flexplate.
   Fig 1: Locating Flexplate Bolts

   Courtesy of FORD MOTOR CO.
2. Remove the engine-to-transaxle separator plate.
   Fig 2: Locating Engine-To-Transaxle Separator Plate

   Courtesy of FORD MOTOR CO.
3. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear oil seal.
   Fig 3: Removing Crankshaft Rear Oil Seal

   Courtesy of FORD MOTOR CO.
4. Mount the engine on a suitable stand.
5. Detach the 2 B+ wiring harness retainers from the valve cover stud bolts.
   Fig 4: Locating B+ Wiring Harness Retainers Of Valve Cover Stud Bolts

   Courtesy of FORD MOTOR CO.
6. Disconnect the A/C compressor clutch electrical connector.
   Fig 5: Locating A/C Compressor Clutch Electrical Connector

   Courtesy of FORD MOTOR CO.
7. Disconnect the generator electrical connector.
   Fig 6: Locating Generator Electrical Connector

   Courtesy of FORD MOTOR CO.
8. Remove the nut and the B+ wire from the generator.
   • Remove the B+ harness from the engine.
     Fig 7: Locating B+ Wire And Nut On Generator

     Courtesy of FORD MOTOR CO.
9. Disconnect the 3 engine wiring connectors.
   • Disconnect the engine block Knock Sensor (KS) electrical connector.
   • Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
   • Disconnect the cylinder head KS electrical connector.
     Fig 8: Locating Engine Block Knock Sensor Electrical Connector And Cylinder Head KS Electrical Connector

     Courtesy of FORD MOTOR CO.
10. Disconnect the electronic throttle control electrical connector.
    Fig 9: Locating Electronic Throttle Control Electrical Connector

    Courtesy of FORD MOTOR CO.
11. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
    Fig 10: Locating Evaporative Emission Canister Purge Valve Electrical Connector

    Courtesy of FORD MOTOR CO.
12. Disconnect the EGR regulator electrical connector and detach the wiring retainer.
    Fig 11: Locating EGR Regulator Electrical Connector And Wiring Retainer

    Courtesy of FORD MOTOR CO.
13. Disconnect the PCV valve electrical connector.
    Fig 12: Locating PCV Valve Electrical Connector

    Courtesy of FORD MOTOR CO.
14. Detach the wiring harness retainer from the upper intake manifold.
    Fig 13: Locating Wiring Harness Retainer Of Upper Intake Manifold

    Courtesy of FORD MOTOR CO.
15. Disconnect the Manifold Absolute Pressure (MAP) electrical connector and detach the wiring retainer.
    Fig 14: Locating Manifold Absolute Pressure Electrical Connector And Wiring Retainer

    Courtesy of FORD MOTOR CO.
16. Disconnect the RH coil-on-plug electrical connectors.
    • Detach the 2 wiring harness retainers.
      Fig 15: Locating RH Coil-On-Plug Electrical Connectors

      Courtesy of FORD MOTOR CO.
17. Disconnect the RH Variable Camshaft Timing (VCT) electrical connector and detach the wiring harness retainer from the valve cover stud bolt.
    Fig 16: Locating RH Variable Camshaft Timing Electrical Connector And Wiring Harness Retainer

    Courtesy of FORD MOTOR CO.
18. Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the 2 wiring harness retainers.
    Fig 17: Locating Crankshaft Position Sensor Electrical Connector And Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
19. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors and detach the wiring harness retainer from the engine front cover stud bolt.
    Fig 18: Locating Camshaft Position Sensor Electrical Connectors, Wiring Harness Retainer And Engine Front Cover Stud Bolt

    Courtesy of FORD MOTOR CO.
20. Disconnect the fuel injector wiring harness electrical connector and detach the wiring harness retainer.
    Fig 19: Locating Fuel Injector Wiring Harness Electrical Connector And Wiring Harness Retainer

    Courtesy of FORD MOTOR CO.
21. Disconnect the LH VCT electrical connector.
    Fig 20: Locating LH VCT Electrical Connector

    Courtesy of FORD MOTOR CO.
22. Remove the nut and the radio frequency interference capacitor.
    Fig 21: Locating Radio Frequency Interference Capacitor Nut

    Courtesy of FORD MOTOR CO.
23. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wiring retainer from the oil indicator tube.
    Fig 22: Locating Engine Oil Pressure Switch Electrical Connector And Wiring Retainer Of Oil Indicator Tube

    Courtesy of FORD MOTOR CO.
24. Disconnect the 3 LH coil-on-plug electrical connectors.
    • Detach the 2 wiring harness retainers.
      Fig 23: Locating LH Coil-On-Plug Electrical Connectors

      Courtesy of FORD MOTOR CO.
25. Remove the 2 upper intake manifold bracket bolts (1 shown in illustration).
    Fig 24: Locating Upper Intake Manifold Bracket Bolts

    Courtesy of FORD MOTOR CO.
26. Remove the 7 bolts and the upper intake manifold.
    • Remove and discard the gaskets.
      Fig 25: Locating Upper Intake Manifold Bolts

      Courtesy of FORD MOTOR CO.
27. Remove the 4 bolts and the fuel rail and injectors as an assembly.
    Fig 26: Locating Fuel Rail And Injectors Assembly Bolts

    Courtesy of FORD MOTOR CO.
28. Remove the 8 lower intake manifold bolts and the lower intake manifold.
    • Remove and discard the gaskets.
      Fig 27: Locating Lower Intake Manifold Bolts

      Courtesy of FORD MOTOR CO.

    FWD vehicles 

29. Remove the 3 bolts and the RH heat shield.
    Fig 28: Locating RH Heat Shield Bolts

    Courtesy of FORD MOTOR CO.
30. Remove the 3 nuts and the RH catalytic converter.
    • Discard the nuts and gasket.
      Fig 29: Locating RH Catalytic Converter Nuts

      Courtesy of FORD MOTOR CO.

    All engines 

31. Remove the 6 RH exhaust manifold nuts and the manifold.
    • Discard the nuts and gasket.
      Fig 30: Locating RH Exhaust Manifold Nuts

      Courtesy of FORD MOTOR CO.
32. Clean and inspect the RH catalytic converter manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
33. Remove and discard the 6 RH catalytic converter manifold studs.
    Fig 31: Locating RH Catalytic Converter Manifold Studs

    Courtesy of FORD MOTOR CO.
34. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
    Fig 32: Rotating Accessory Drive Belt Tensioner Counterclockwise

    Courtesy of FORD MOTOR CO.
35. Remove the 3 bolts and the A/C compressor.
    Fig 33: Locating A/C Compressor Bolts

    Courtesy of FORD MOTOR CO.
36. Remove the bolt, 2 nuts and the generator.
    Fig 34: Locating Bolt, Nuts And Generator

    Courtesy of FORD MOTOR CO.
37. Remove the 3 bolts and the A/C compressor bracket.
    Fig 35: Locating A/C Compressor Bracket Bolts

    Courtesy of FORD MOTOR CO.
38. Position the Stretchy Belt Remover under the coolant pump belt as shown in illustration.
    Fig 36: Positioning Stretchy Belt Remover Under Coolant Pump Belt

    Courtesy of FORD MOTOR CO.
NOTE: Feed the Stretchy Belt Remover on to the camshaft coolant pump pulley 90 degrees.
Fig 37: Identifying Stretchy Belt Remover
Courtesy of FORD MOTOR CO.
39. Turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant pump pulley as shown in illustration.
40. Remove the coolant pump belt.
    • Fold the Stretchy Belt Remover over the top of the coolant pump belt.
    • In one quick motion, pull the Stretchy Belt Remover up and toward the front of the engine removing the coolant pump belt.
      Fig 38: Removing Coolant Pump Belt

      Courtesy of FORD MOTOR CO.
NOTE: Failure to use the correct special tools, assembled as shown in the illustration, will result in damage to the coolant pump pulley and/or special tools.
Fig 39: Removing Coolant Pump Pulley
Courtesy of FORD MOTOR CO.
41. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.
42. Remove the 5 coolant pump housing bolts.
    Fig 40: Locating Coolant Pump Housing Bolts

    Courtesy of FORD MOTOR CO.
43. Loosen the clamp and detach the coolant hose.
    • Remove the coolant pump housing.
      Fig 41: Identifying Coolant Hose Clamp

      Courtesy of FORD MOTOR CO.
44. Remove the stud bolt and the oil level indicator and tube.
    • Remove and discard the O-ring seal.
      Fig 42: Locating Oil Level Indicator And Tube Stud Bolt

      Courtesy of FORD MOTOR CO.
45. Remove the EOP switch and, if equipped, the block heater.
    Fig 43: Locating EOP Switch And Block Heater

    Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
Fig 44: Locating Coil-On-Plugs And Bolts
Courtesy of FORD MOTOR CO.
46. Remove the bolts and the 6 coil-on-plugs.
47. Remove the bolts and the RH valve cover.
    • Discard the gasket.
      Fig 45: Locating RH Valve Cover Bolts

      Courtesy of FORD MOTOR CO.
48. Remove the bolts and the LH valve cover.
    • Discard the gasket.
      Fig 46: Locating LH Valve Cover Bolts

      Courtesy of FORD MOTOR CO.
49. Remove the 15 bolts and the oil pan.
    • Discard the gasket.
      Fig 47: Locating Oil Pan Bolts

      Courtesy of FORD MOTOR CO.
50. Remove the 2 bolts and the oil pump screen and pickup tube.
    Fig 48: Locating Oil Pump Screen And Pickup Tube Bolts

    Courtesy of FORD MOTOR CO.
51. Remove and discard the O-ring seal.
    Fig 49: Locating O-Ring Seal On Oil Pickup Tube Flange

    Courtesy of FORD MOTOR CO.
52. Remove the oil pan baffle.
    1. Remove the 4 M6 oil pan baffle nuts.
    2. Remove the 4 M8 oil pan baffle nuts.
       Fig 50: Identifying Oil Pan Baffle Nuts

       Courtesy of FORD MOTOR CO.
53. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 51: Remove/Install Accessory Drive Belt Tensioner

    Courtesy of FORD MOTOR CO.
54. Remove the crankshaft pulley bolt and washer.
    • Discard the crankshaft pulley bolt.
      Fig 52: View Of Crankshaft Pulley Bolt

      Courtesy of FORD MOTOR CO.
55. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 53: Identifying 3-Jaw Puller (303-D121) On Crankshaft Pulley

    Courtesy of FORD MOTOR CO.
56. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 54: Removing Crankshaft Front Seal

    Courtesy of FORD MOTOR CO.
NOTE: Note the position of the alignment dowel on the engine front cover.
Fig 55: Locating LH VCT Connector And Bolts
Courtesy of FORD MOTOR CO.
57. Remove the 2 bolts and the LH VCT.
NOTE: Note the position of the alignment dowel on the engine front cover.
Fig 56: Locating RH VCT Connector And Bolts
Courtesy of FORD MOTOR CO.
58. Remove the 2 bolts and the RH VCT.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
NOTE: Note the location of all bolts and stud bolts for installation.
59. Remove the 14 bolts, 2 stud bolts and the engine front cover.
    • Discard the gaskets.
      Fig 57: Locating Engine Front Cover, Bolts And Stud Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
NOTE: LH shown in illustration, RH similar.
Fig 58: Locating Spark Plugs
Courtesy of FORD MOTOR CO.
60. Remove the LH and RH spark plugs.
NOTE: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30RFF" (orange in color).
Fig 59: Locating Ignition Pulse Wheel
Courtesy of FORD MOTOR CO.
61. Remove the ignition pulse wheel.
62. Install the crankshaft pulley bolt and washer.
    Fig 60: Locating Crankshaft Pulley Bolt And Washer

    Courtesy of FORD MOTOR CO.
63. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the No. 1 cylinder at Top Dead Center (TDC).
    • Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
      Fig 61: Identifying Timing Mark Location

      Courtesy of FORD MOTOR CO.
64. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
    Fig 62: Locating Crankshaft 3 O'Clock Position

    Courtesy of FORD MOTOR CO.
65. Verify that the RH camshafts are in the neutral position.
    Fig 63: Locating RH Camshafts Are In Neutral Position

    Courtesy of FORD MOTOR CO.
66. Remove the RH timing chain tensioner arm.
    1. Remove the 2 bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
       Fig 64: Identifying RH Timing Chain Tensioner Arm With Bolts

       Courtesy of FORD MOTOR CO.
67. Remove the 2 bolts and the RH timing chain guide.
    • Remove the RH timing chain from the engine.
      Fig 65: Locating RH Timing Chain Guide And Bolts

      Courtesy of FORD MOTOR CO.
68. Rotate the crankcase clockwise 600 degrees (one and two-thirds turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
    Fig 66: Locating Crankcase Keyway In 11 O'Clock Position

    Courtesy of FORD MOTOR CO.
69. Verify the LH camshafts are in the neutral position.
    Fig 67: Locating LH Camshafts Are In Neutral Position

    Courtesy of FORD MOTOR CO.
70. Remove the LH timing chain and tensioner arm.
    1. Remove the 2 bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
       Fig 68: Identifying LH Timing Chain, Tensioner Arm And Bolts

       Courtesy of FORD MOTOR CO.
71. Remove the 2 bolts and the LH timing chain guide.
    • Remove the LH timing chain from the engine.
      Fig 69: Locating Bolts And LH Timing Chain Guide

      Courtesy of FORD MOTOR CO.
72. Remove the crankshaft pulley bolt and the crankshaft sprocket.
    Fig 70: Locating Crankshaft Pulley Bolt And Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
73. Remove the 4 bolts in the sequence shown in illustration.
    • Remove the oil pump.
      Fig 71: Identifying Oil Pump Bolts Removing Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Do not scratch the camshaft sealing surface while removing the camshaft oil seal. If scratched, camshaft oil seal leakage may occur.
Fig 72: Removing Camshaft Oil Seal
Courtesy of FORD MOTOR CO.
74. Using the Oil Seal Remover, remove the camshaft oil seal and discard.
75. Remove the 2 bolts and the camshaft oil seal retainer.
    • Discard the press-in-place gasket.
      Fig 73: Locating Camshaft Oil Seal Retainer And Bolts

      Courtesy of FORD MOTOR CO.
NOTE: The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
Fig 74: View Of LH Camshafts Timing Marks In Neutral Position
Courtesy of FORD MOTOR CO.
76. Verify the LH camshafts are in the neutral position.
NOTE: Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket or damage to the engine may occur.
NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the camshaft phaser and sprocket bolts.
Fig 75: Locating LH Camshaft Phaser, Sprocket And Bolts
Courtesy of FORD MOTOR CO.
77. Remove the 3 bolts and the LH camshaft phaser and sprocket.
78. Remove and discard the VCT system oil filter screen from the LH camshaft.
    Fig 76: Locating VCT System Oil Filter Screen

    Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in illustration). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original positions may result in severe engine damage.
Fig 77: Locating Cylinder Head Camshaft Bearing Caps
Courtesy of FORD MOTOR CO.
79. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
NOTE: After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (1L and 5L) first, or damage to the thrust caps may occur.
NOTE: Make sure the camshaft bearing caps are marked as instructed in the previous step.
80. Loosen the bolts evenly in the sequence shown in illustration.
    1. Remove the camshaft bearing thrust caps (1L and 5L).
    2. Remove the remaining camshaft bearing caps.
    3. Remove the camshafts from the cylinder head.
       Fig 78: Identifying Camshaft Bearing Cap Bolts Loosening Sequence

       Courtesy of FORD MOTOR CO.
NOTE: The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
Fig 79: View Of RH Camshafts Timing Marks In Neutral Position
Courtesy of FORD MOTOR CO.
81. Verify the RH camshafts are in the neutral position.
NOTE: Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket or damage to the engine may occur.
NOTE: Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the camshaft phaser and sprocket bolts.
Fig 80: Locating RH Camshaft Phaser, Sprocket And Bolts
Courtesy of FORD MOTOR CO.
82. Remove the 3 bolts and the RH camshaft phaser and sprocket.
83. Remove and discard the VCT system oil filter screen from the RH camshaft.
    Fig 81: Locating VCT System Oil Filter Screen

    Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in illustration). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original positions may result in severe engine damage.
Fig 82: Locating Camshaft Bearing Cap Position And Orientation Mark
Courtesy of FORD MOTOR CO.
84. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
NOTE: After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (5R and 1R) first, or damage to the thrust caps may occur.
NOTE: Make sure the camshaft bearing caps are marked as instructed in the previous step.
85. Loosen the bolts evenly in the sequence shown in illustration.
    1. Remove the camshaft bearing thrust caps (5R and 1R).
    2. Remove the remaining camshaft bearing caps.
    3. Remove the camshafts from the cylinder head.
       Fig 83: Identifying Camshaft Bearing Caps Bolts Loosening Sequence

       Courtesy of FORD MOTOR CO.
NOTE: The camshaft roller followers must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
NOTE: RH shown in illustration, LH similar.
86. Remove the LH and RH camshaft roller followers.
    • Mark the location of the roller followers, using a permanent-type marker.
      Fig 84: Locating Camshaft Roller Followers

      Courtesy of FORD MOTOR CO.
NOTE: The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
87. Remove the hydraulic lash adjusters.
NOTE: RH shown in illustration, LH similar.
88. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
    • Discard the bolts and the gaskets.
      Fig 85: Identifying Cylinder Head Bolts Loosening Sequence

      Courtesy of FORD MOTOR CO.
89. Support the cylinder heads 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 .
90. Remove the bolts and the oil separator cover.
    • Discard the gasket.
      Fig 86: Locating Oil Separator Cover Bolts

      Courtesy of FORD MOTOR CO.
91. Remove the crankshaft key.
    Fig 87: Locating Crankshaft Key

    Courtesy of FORD MOTOR CO.
92. 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.
NOTE: Clearly mark the position and orientation of the pistons, connecting rods, connecting rod caps and connecting rod bearings for reassembly.
93. Remove the connecting rod cap bolts and cap.
    • Discard the connecting rod cap bolts.
      Fig 88: Locating Connecting Rod Cap Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
94. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
    • Repeat these 2 steps until all the piston/rod assemblies are removed from the engine block.
      Fig 89: Removing Piston/Rod Assembly From Engine Block Using Connecting Rod Installer

      Courtesy of FORD MOTOR CO.
95. Remove the engine block from the stand and place on a workbench.
96. Remove the bolts and studs in the indicated sequence.
    • Discard the lower cylinder block bolts.
    • Remove the lower cylinder block.
      Fig 90: Identifying Lower Cylinder Block Bolts And Studs Removing Sequence

      Courtesy of FORD MOTOR CO.
97. Remove the crankshaft rear main seal.
    • Remove the crankshaft.
      Fig 91: Locating Crankshaft Rear Main Seal And Crankshaft

      Courtesy of FORD MOTOR CO.
98. Remove the crankshaft thrust bearing from the cylinder block.
    Fig 92: Locating Crankshaft Thrust Bearing

    Courtesy of FORD MOTOR CO.
NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Fig 93: Locating Crankshaft Main Bearings In Lower Cylinder Block
Courtesy of FORD MOTOR CO.
99. Remove the bearings from the lower cylinder block.
NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Fig 94: Locating Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
100. Remove the crankshaft main bearings from the cylinder block.
101. Inspect the cylinder block, lower cylinder block, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .