Section 6 (Engine - 3.0L (4V)): Disassembly: Engine

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	3-Jaw Puller	303-D121
Courtesy of FORD MOTOR CO.	Rod Installer, Connecting	303-462 (T94P-6136-AH)
Courtesy of FORD MOTOR CO.	Plate, Water Pump Pulley	303-456 (T94P-6312-AH1), part of 303-S455
Courtesy of FORD MOTOR CO.	Protector, Water Pump Shaft	303-457 (T94P-6312-AH2), part of 303-S455
Courtesy of FORD MOTOR CO.	Remover, Crankshaft Rear Oil Seal	303-519 (T95P-6701-EH)
Courtesy of FORD MOTOR CO.	Remover, Crankshaft Vibration Damper	303-009 (T58P-6316-D)
Courtesy of FORD MOTOR CO.	Remover, Oil Seal	303-409 (T92C-6700CH)
Courtesy of FORD MOTOR CO.	Remover, Stretchy Belt	303-1419
Courtesy of FORD MOTOR CO.	Slide Hammer	307-005 (T59L-100-B)
Courtesy of FORD MOTOR CO.	Strap Wrench	303-D055 (D85L-6000-A)

All engines 

1. Remove the 8 bolts and the flexplate.
Fig 1: Locating Flexplate And 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: Identifying Special Tools (307-005 And 303-519)
Courtesy of FORD MOTOR CO.
4. Mount the engine on a suitable stand.
5. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector and the pin-type retainer.
Fig 4: Locating Manifold Actual Pressure Sensor Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.
6. Detach the wiring harness pin-type retainer from the upper intake manifold.
Fig 5: Locating Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
7. Disconnect the crankcase vent hose from the upper intake manifold.
Fig 6: Locating Crankcase Vent Hose From Upper Intake Manifold
Courtesy of FORD MOTOR CO.
8. Disconnect the electronic Throttle Body (TB) electrical connector.
Fig 7: Locating Electronic Throttle Body Electrical Connector
Courtesy of FORD MOTOR CO.
9. Disconnect the TB coolant hose.
Fig 8: Locating Throttle Body Coolant Hose
Courtesy of FORD MOTOR CO.
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.
10. Remove the 8 bolts and the upper intake manifold.
    • Discard the gaskets.
Fig 9: Locating Upper Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
11. Disconnect the A/C compressor electrical connector and the wiring harness retainer.
Fig 10: Identifying A/C Compressor Electrical Connector & Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
12. If equipped, disconnect the block heater electrical connector.
Fig 11: Locating Block Heater Electrical Connector
Courtesy of FORD MOTOR CO.
13. If equipped, detach the block heater wiring harness retainers from the oil level indicator tube and remove the harness.
Fig 12: Locating Block Heater Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
14. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness retainer.
Fig 13: Identifying Engine Oil Pressure (EOP) Switch Electrical Connector & Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
15. Remove the nut and disconnect the generator B+ cable and electrical connector.
Fig 14: Locating Generator B+ Cable, Electrical Connector And Nut
Courtesy of FORD MOTOR CO.
16. Disconnect the LH Variable Camshaft Timing (VCT) solenoid and LH Camshaft Position (CMP) sensor electrical connectors.
    • Detach the 2 wiring harness retainers from the valve cover stud bolts.
Fig 15: Locating LH Variable Camshaft Timing Solenoid And LH Camshaft Position Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
17. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector and pin-type retainer.
Fig 16: Locating LH Heated Oxygen Sensor Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.
18. Detach the 3 wiring harness retainers from the valve cover stud bolts.
Fig 17: Locating Wiring Harness Retainers From Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.
19. Disconnect the 3 LH coil-on-plug electrical connectors.
    • Detach the 2 wiring harness pin-type retainers from the valve cover.
Fig 18: Locating LH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
20. If equipped, detach the wiring harness retainer from the LH valve cover stud bolt.
Fig 19: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
21. Disconnect the 6 fuel injector electrical connectors (3 shown).
Fig 20: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
NOTE: One wiring harness retainer shown, other wiring harness retainers similar.
22. Detach the 3 wiring harness retainers from the fuel rail.
Fig 21: Locating Fuel Rail Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
23. Disconnect the 3 RH coil-on-plug electrical connectors.
    • Detach the 2 wiring harness pin-type retainers from the valve cover.
Fig 22: Locating RH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
24. Disconnect the RH VCT solenoid and LH CMP sensor electrical connectors.
    • If equipped, detach the 2 wiring harness retainers from the valve cover stud bolts.
Fig 23: Locating RH VCT Solenoid And LH Camshaft Position Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
25. Remove the nut and the radio frequency interference capacitor.
Fig 24: Locating Radio Frequency Interference Capacitor And Nut
Courtesy of FORD MOTOR CO.
26. Detach the 2 wiring harness retainers.
Fig 25: Identifying Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
27. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
Fig 26: Identifying Crankshaft Position (CKP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
28. Disconnect the PSP switch electrical connector.
Fig 27: Identifying Power Steering Pressure (PSP) Switch Electrical Connector
Courtesy of FORD MOTOR CO.

Front Wheel Drive (FWD) engines 

29. Disconnect the RH catalyst monitor sensor electrical connector.
Fig 28: Identifying RH Catalyst Monitor Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
30. Detach the wiring harness retainer from the power steering stud bolt.
Fig 29: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
31. Disconnect the RH HO2S electrical connector.
Fig 30: Identifying RH HO2S Electrical Connector
Courtesy of FORD MOTOR CO.

All engines 

32. Disconnect the PCV valve electrical connector.
Fig 31: Locating Positive Crankcase Ventilation Valve Electrical Connector
Courtesy of FORD MOTOR CO.
33. Disconnect the Knock Sensor (KS) electrical connector.
Fig 32: Locating Knock Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
34. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
Fig 33: Locating Electronic Coolant Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
35. Detach the wiring harness retainer from the coolant bypass stud bolt.
Fig 34: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
36. Disconnect the LH catalyst monitor sensor electrical connector.
Fig 35: Locating LH Catalyst Monitor Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
37. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
Fig 36: Rotating Accessory Drive Belt Tensioner Counterclockwise
Courtesy of FORD MOTOR CO.
38. Remove the 3 power steering reservoir nuts.
Fig 37: Locating Power Steering Reservoir Nuts
Courtesy of FORD MOTOR CO.
39. Remove the 3 bolts and the power steering pump and reservoir assembly.
Fig 38: Locating Power Steering Pump Bolts
Courtesy of FORD MOTOR CO.
40. Remove the wiring harness retainer bolt.
Fig 39: Identifying Wiring Harness Retainer Bolt
Courtesy of FORD MOTOR CO.
41. Detach the wiring harness from the cylinder block.
Fig 40: Locating Wiring Harness From Cylinder Block
Courtesy of FORD MOTOR CO.
42. Remove the wiring harness from the engine.
43. Remove the 3 bolts and the generator.
Fig 41: Locating Generator Bolts
Courtesy of FORD MOTOR CO.
44. Remove the 3 bolts and the A/C compressor.
Fig 42: Locating A/C Compressor Bolts
Courtesy of FORD MOTOR CO.
45. Remove the 3 bolts and the A/C compressor bracket.
Fig 43: Locating A/C Compressor Bracket Bolts
Courtesy of FORD MOTOR CO.

FWD engines 

46. Remove the 6 nuts and the RH catalytic converter manifold.
    • Discard the gasket and nuts.
Fig 44: Locating RH Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.
47. Clean and inspect the RH catalytic converter manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.

All-Wheel Drive (AWD) engines 

48. Remove the 6 nuts and the RH exhaust manifold.
    • Discard the gasket and nuts.
Fig 45: Identifying RH Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
49. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.

All engines 

50. Remove and discard the 6 RH catalytic converter manifold studs.
Fig 46: Locating Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.
51. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
52. Remove the 4 bolts and the LH heat shield.
Fig 47: Locating Heat Shield Bolts
Courtesy of FORD MOTOR CO.
53. Remove the 2 bolts from the LH catalytic converter bracket.
Fig 48: Locating LH Catalytic Converter Bracket Bolts
Courtesy of FORD MOTOR CO.
54. Remove the 6 nuts and the LH catalytic converter manifold.
    • Discard the gasket and nuts.
Fig 49: Locating LH Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.
55. Clean and inspect the LH catalytic converter manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
56. Remove and discard the 6 LH catalytic converter manifold studs.
Fig 50: Locating LH Catalytic Converter Studs
Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.
57. Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.
58. Remove the 2 bolts and the LH catalytic converter bracket.
Fig 51: Locating LH Catalytic Converter Bracket Bolts
Courtesy of FORD MOTOR CO.
59. Remove the bolt and the oil level indicator tube.
    • Remove and discard the O-ring seal.
Fig 52: Locating Oil Level Indicator Tube And Bolt
Courtesy of FORD MOTOR CO.
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.
60. Remove the 8 bolts and the lower intake manifold.
    • Discard the gaskets.
Fig 53: Locating Lower Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
61. Position the Stretchy Belt Remover under the coolant pump belt as shown.
    Fig 54: Positioning Stretchy Belt Remover

    Courtesy of FORD MOTOR CO.
62. Turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly on the camshaft coolant pump pulley as shown.
    NOTE: Feed the Stretchy Belt Remover on to the camshaft coolant pump pulley 90 degrees.
    Fig 55: Identifying Stretchy Belt Remover

    Courtesy of FORD MOTOR CO.
63. 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 56: Removing Coolant Pump Belt

    Courtesy of FORD MOTOR CO.
64. Release the 2 clamps and remove the thermostat housing.
    Fig 57: Locating Clamps And Thermostat Housing

    Courtesy of FORD MOTOR CO.
65. Remove the bolt, stud bolt and the coolant bypass.
    • Remove and discard the O-ring seals.
Fig 58: Locating Bolt, Stud Bolt And Coolant Bypass
Courtesy of FORD MOTOR CO.
66. Disconnect the coolant pump hose from the cylinder block outlet.
Fig 59: Locating Coolant Pump Hose From Cylinder Block Outlet
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.
67. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.
Fig 60: Removing Coolant Pump Pulley Using Special Tools (303-009, 303-456, 303-457)
Courtesy of FORD MOTOR CO.
68. Remove the 3 bolts and the coolant pump.
Fig 61: Identifying Coolant Pump Assembly Bolts
Courtesy of FORD MOTOR CO.
69. Remove the bolt and the KS.
Fig 62: Locating Knock Sensor (KS) And Bolt
Courtesy of FORD MOTOR CO.
70. Remove the EOP switch.
Fig 63: Locating EOP Switch
Courtesy of FORD MOTOR CO.
71. If equipped, remove the block heater.
Fig 64: Locating Block Heater
Courtesy of FORD MOTOR CO.
NOTE: When removing the coil-on-plug assemblies, a slight twisting motion will break the seal and ease removal.
72. Remove the 3 bolts and the 3 LH coil-on-plug assemblies.
Fig 65: Locating LH Coil-On-Plug Assemblies And Bolts
Courtesy of FORD MOTOR CO.
73. Remove the bolts, stud bolts and the LH valve cover.
    • Discard the gaskets.
Fig 66: Locating LH Valve Cover And Bolts
Courtesy of FORD MOTOR CO.
NOTE: When removing the coil-on-plug assemblies, a slight twisting motion will break the seal and ease removal.
74. Remove the 3 bolts and the 3 RH coil-on-plug assemblies.
Fig 67: Locating RH Coil-On-Plug Assemblies And Bolts
Courtesy of FORD MOTOR CO.
75. Remove the bolts, stud bolts and the RH valve cover.
    • Discard the gaskets.
Fig 68: Locating RH Valve Cover And Bolts
Courtesy of FORD MOTOR CO.
76. Remove the 10 bolts, 5 stud bolts and the oil pan.
    • Discard the gasket.
Fig 69: Locating Oil Pan And Bolts
Courtesy of FORD MOTOR CO.
77. Remove the 2 bolts and the oil pump screen and pickup tube.
    • Remove and discard the O-ring seal.
Fig 70: Locating Oil Pump Screen & Pickup Tube Bolts
Courtesy of FORD MOTOR CO.
78. Remove the 8 nuts and the oil pan baffle.
Fig 71: Locating Oil Pan Baffle Nuts
Courtesy of FORD MOTOR CO.
79. Remove the accessory drive belt tensioner and the 2 idler pulleys.
Fig 72: Locating Accessory Drive Belt Tensioner And Idler Pulleys
Courtesy of FORD MOTOR CO.
80. Using the Strap Wrench, remove the crankshaft pulley bolt.
Fig 73: Identifying Crankshaft Pulley Bolt & Special Tools
Courtesy of FORD MOTOR CO.
81. Using the 3-Jaw Puller, remove the crankshaft pulley.
Fig 74: Identifying Special Tools (303-D121) And Crankshaft Pulley
Courtesy of FORD MOTOR CO.
82. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
Fig 75: Identifying Special Tools (303-409) And Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
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.
83. Remove the 16 bolts and the engine front cover.
    • Discard the gaskets.
Fig 76: Locating Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
NOTE: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped 30 or 30RFF (orange in color).
84. Remove the ignition pulse wheel.
Fig 77: Identifying Ignition Pulse Wheel
Courtesy of FORD MOTOR CO.
85. Install the crankshaft pulley bolt and washer.
Fig 78: Identifying Damper Bolt
Courtesy of FORD MOTOR CO.
NOTE: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
86. Remove the 6 spark plugs
Fig 79: Locating Spark Plugs
Courtesy of FORD MOTOR CO.
87. 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 80: Locating Keyways Position
Courtesy of FORD MOTOR CO.
88. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
Fig 81: Identifying Crankshaft Keyway
Courtesy of FORD MOTOR CO.
89. Verify that the RH camshafts are in the neutral position.
Fig 82: Locating RH Camshafts In Neutral Position
Courtesy of FORD MOTOR CO.
90. Remove the RH timing chain tensioner arm.
    1. Remove the bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
Fig 83: Identifying RH Timing Chain Tensioner Arm & Bolts
Courtesy of FORD MOTOR CO.
91. Remove the RH timing chain.
Fig 84: Locating RH Timing Chain
Courtesy of FORD MOTOR CO.
92. Remove the 3 bolts and the RH VCT assembly.
Fig 85: Locating RH VCT Assembly Bolts
Courtesy of FORD MOTOR CO.
93. Rotate the crankcase clockwise 600 degrees (1-2/3 turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
Fig 86: Positioning Crankcase Key Way In 11 O'Clock Position
Courtesy of FORD MOTOR CO.
94. Verify the LH camshafts are in the neutral position.
Fig 87: Locating LH Camshafts Position In NEUTRAL Position
Courtesy of FORD MOTOR CO.
95. Remove the LH timing chain tensioner and tensioner arm.
    1. Remove the bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
Fig 88: Locating LH Timing Chain & Tensioner Arm
Courtesy of FORD MOTOR CO.
96. Remove the LH timing chain.
Fig 89: Locating LH Timing Chain
Courtesy of FORD MOTOR CO.
97. Remove the 4 bolts and the LH VCT assembly.
Fig 90: Identifying LH VCT Assembly Bolts
Courtesy of FORD MOTOR CO.
98. Remove the pulley bolt, washer and the crankshaft sprocket.
Fig 91: Locating Damper Bolt & Crankshaft Sprockets
Courtesy of FORD MOTOR CO.
99. Remove the 4 bolts in the sequence shown.
    • Remove the oil pump.
Fig 92: Identifying Removal Sequence Of Oil Pump Bolts
Courtesy of FORD MOTOR CO.
100. Remove the crankshaft key.
Fig 93: Locating Crankshaft Key
Courtesy of FORD MOTOR CO.
NOTE: To make sure of correct sealing, do not scratch the camshaft.
101. Using the special tools, remove the camshaft oil seal and discard.
Fig 94: Removing Camshaft Oil Seal Using Special Tool (303-409)
Courtesy of FORD MOTOR CO.
102. Remove the 2 bolts and the camshaft oil seal retainer.
     • Discard the press-in-place gasket.
Fig 95: 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.
103. Verify the camshafts are in the neutral position.
Fig 96: Locating Camshafts In Neutral Position
Courtesy of FORD MOTOR CO.
NOTE: Do not allow the camshaft to rotate from the neutral position while removing the Variable Camshaft Timing (VCT) actuator 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 VCT actuator bolt.
104. Remove the bolt and the VCT actuator.
Fig 97: Locating VCT Actuator And Bolt
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.
105. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
Fig 98: Marking Camshaft Bearing Cap Position & Orientation
Courtesy of FORD MOTOR CO.
NOTE: After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (1L and 6L) first or damage to the thrust caps may occur.
NOTE: Make sure the camshaft bearing caps are marked as instructed in the previous step.
106. Loosen the bolts evenly in the sequence shown.
     1. Remove the camshaft bearing thrust caps (1L and 6L).
     2. Remove the remaining camshaft bearing caps.
     3. Remove the camshafts from the cylinder head.
Fig 99: Loosening Bolts Evenly In 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.
107. Verify the camshafts are in the neutral position.
Fig 100: Locating RH Camshafts Position
Courtesy of FORD MOTOR CO.
NOTE: Do not allow the camshaft to rotate from the neutral position while removing the Variable Camshaft Timing (VCT) actuator 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 VCT actuator bolt.
108. Remove the bolt and the VCT actuator.
Fig 101: Locating VCT Actuator And Bolt
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.
109. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
Fig 102: Marking Camshaft Bearing Cap Position & Orientation
Courtesy of FORD MOTOR CO.
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.
110. Loosen the bolts evenly in the sequence shown.
     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 103: Identifying Loosening Sequence Of Camshaft Bearing Bolts
Courtesy of FORD MOTOR CO.
NOTE: The camshaft roller followers must be installed in their original positions or damage to the engine may occur.
NOTE: RH shown, LH similar.
NOTE: Mark the location of the roller followers, using a permanent-type marker.
111. Remove the LH and RH camshaft roller followers.
Fig 104: Locating Camshaft Roller Followers
Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
112. Loosen the 8 bolts in the indicated sequence and remove the LH and RH cylinder heads.
     • Discard the bolts and the gaskets.
Fig 105: Identifying Loosening Sequence Of Cylinder Heads Bolts
Courtesy of FORD MOTOR CO.
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.
113. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
     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 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.
114. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.
115. Remove the bolts and the oil separator cover.
     • Discard the gasket.
     Fig 106: Locating Oil Separator Cover Bolts
     Courtesy of FORD MOTOR CO.
116. 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.
117. Remove the connecting rod cap bolts and cap.
     • Discard the connecting rod cap bolts.
     NOTE: Clearly mark the position and orientation of the pistons, connecting rods, connecting rod caps and connecting rod bearings for reassembly.
     Fig 107: Locating Connecting Rod Cap Bolts

     Courtesy of FORD MOTOR CO.
118. 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.
     NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
     Fig 108: Removing Piston/Rod Assembly

     Courtesy of FORD MOTOR CO.
119. Remove the engine block from the stand and place on a workbench.
120. Remove the bolts and studs in the indicated sequence.
     • Discard the lower cylinder block bolts.
     • Remove the lower cylinder block.
     Fig 109: Identifying Lower Cylinder Block Bolts & Studs In Sequence

     Courtesy of FORD MOTOR CO.
121. Remove the crankshaft rear main seal.
     • Remove the crankshaft.
     Fig 110: Locating Crankshaft Rear Main Seal

     Courtesy of FORD MOTOR CO.
122. Remove the crankshaft thrust bearing from the cylinder block.
     Fig 111: Locating Crankshaft Thrust Bearing

     Courtesy of FORD MOTOR CO.
123. 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 112: Identifying Main Bearings Installation Position

     Courtesy of FORD MOTOR CO.
124. Remove the crankshaft main bearings from the cylinder block.
     NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
     Fig 113: Locating Crankshaft Main Bearings From Cylinder Block

     Courtesy of FORD MOTOR CO.
125. Inspect the cylinder block, lower cylinder block, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .