Engine Mechanical: Mechanical: Engine: Disassembly: Engine

SPECIAL TOOL(S)

Courtesy of FORD MOTOR CO.	Crankshaft Damper Remover 303-009 (T58P-6316-D)
Courtesy of FORD MOTOR CO.	Camshaft Bearing Set 303-017 (T65L-6250-A)
Courtesy of FORD MOTOR CO.	Engine Stand 014-00232 or equivalent

MATERIAL

Item	Specification
Motorcraft Metal Surface Prep ZC-31	-
Silicone Gasket Remover ZC-30	-

CAUTION: 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: For additional information, refer to the exploded view under ASSEMBLY  in this article.

1. Remove the 6 bolts and the flexplate.
   Fig 1: Locating Flexplate And Spacer Bolts

   Courtesy of FORD MOTOR CO.
2. Mount the engine on a suitable engine stand.
3. Remove the drive belt.
   Fig 2: Identifying Drive Belt Routing

   Courtesy of FORD MOTOR CO.
4. Remove the nut, bolt and the engine roll restrictor brace.
   Fig 3: Locating Engine Roll Restrictor Brace Nut And Bolt

   Courtesy of FORD MOTOR CO.
5. Remove the nut, bolt, generator support bracket and the generator.
   Fig 4: Locating Generator Support Bracket Nut And Bolt

   Courtesy of FORD MOTOR CO.
6. Remove the bolt and the drive belt idler pulley.
   Fig 5: Identifying Accessory Drive Belt Idler Pulley Retaining Bolt

   Courtesy of FORD MOTOR CO.
7. Remove the bolt and the drive belt tensioner.
   Fig 6: Locating Drive Belt Tensioner Pulley Retaining Bolt

   Courtesy of FORD MOTOR CO.
8. Remove the nut, bolt and the support bracket.
   Fig 7: Locating Support Bracket Nut And Bolt

   Courtesy of FORD MOTOR CO.
9. Remove the 2 nuts, bolt and the power steering pump and bracket assembly.
   Fig 8: Locating Power Steering Pump Bracket Assembly Nut And Bolt

   Courtesy of FORD MOTOR CO.
10. Disconnect the A/C high-pressure cutoff switch electrical connector.
    Fig 9: Identifying A/C High-Pressure Cutoff Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
11. Disconnect the A/C compressor clutch coil electrical connector.
    Fig 10: Locating A/C Compressor Clutch Coil Electrical Connector

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12. Disconnect the LH heated oxygen sensor (HO2S) electrical connector and separate the connector ends from the bracket.
    Fig 11: Locating Heated Oxygen Sensor (HO2S) Electrical Connector

    Courtesy of FORD MOTOR CO.
13. Remove the 4 bolts and the A/C compressor.
    Fig 12: Locating A/C Compressor Bolts

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14. Remove the 4 bolts and the A/C compressor mounting bracket.
    Fig 13: Locating A/C Compressor Mounting Bracket Bolts

    Courtesy of FORD MOTOR CO.
15. Disconnect the knock sensor (KS) electrical connector and the 3 wiring harness pin-type retainers.
    Fig 14: Locating Knock Sensor (KS) Electrical Connector

    Courtesy of FORD MOTOR CO.
16. Remove the bolt and the KS.
    Fig 15: Locating KS Bolt

    Courtesy of FORD MOTOR CO.
17. Remove the 2 pin-type retainers and the heat shield.
    Fig 16: Locating Heat Shield Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
18. Remove the 4 bolts and the RH engine support bracket.
    Fig 17: Locating RH Engine Support Bracket Bolts

    Courtesy of FORD MOTOR CO.
19. Remove the 4 bolts and the coolant pump pulley.
    Fig 18: Locating Coolant Pump Pulley Bolts

    Courtesy of FORD MOTOR CO.
20. Disconnect the crankshaft position sensor (CKP) electrical connector.
    Fig 19: Locating Crankshaft Position Sensor (CKP) Electrical Connector

    Courtesy of FORD MOTOR CO.
21. Disconnect the electrical connector, loosen the 2 nuts and remove the exhaust gas recirculation (EGR) tube.
    Fig 20: Locating Electrical Connector Exhaust Gas Recirculation (EGR) Tube

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22. Disconnect the idle air control (IAC) valve and throttle position (TP) sensor electrical connectors.
    • Detach the harness retainer from the throttle body stud bolt.
    Fig 21: Locating Throttle Body Stud Bolt

    Courtesy of FORD MOTOR CO.
23. Remove the upper intake manifold support bracket bolt and 2 nuts.
    • Detach the pin-type harness retainer and remove the support bracket.
    Fig 22: Locating Upper Intake Manifold Support Bracket Bolt

    Courtesy of FORD MOTOR CO.
24. Disconnect the vacuum tube and electrical connector from the fuel rail pressure (FRP) sensor.
    Fig 23: Locating Vacuum Tube And Electrical Connector From Fuel Rail Pressure (FRP) Sensor

    Courtesy of FORD MOTOR CO.
25. Disconnect the vacuum tube and electrical connector from the EGR vacuum regulator.
    Fig 24: Locating Vacuum Tube And Electrical Connector From EGR Vacuum Regulator

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26. Disconnect the RH HO2S electrical connector.
    Fig 25: Locating RH Heated Oxygen Sensor (HO2S) Electrical Connector

    Courtesy of FORD MOTOR CO.
27. Disconnect the intake manifold runner control (IMRC) and positive crankcase ventilation (PCV) electrical connectors.
    Fig 26: Locating Positive Crankcase Ventilation (PCV) Electrical Connectors

    Courtesy of FORD MOTOR CO.
28. Disconnect the PCV tube from the upper intake manifold.
    Fig 27: Locating PCV Tube On Upper Intake Manifold

    Courtesy of FORD MOTOR CO.
29. Disconnect the PCV tube from the PCV valve and remove the tube.
    Fig 28: Locating PCV Tube On PCV Valve

    Courtesy of FORD MOTOR CO.
30. Detach the spark plug wire retainer from the intake manifold stud bolt.
    Fig 29: Locating Spark Plug Wire Retainer From Intake Manifold Stud Bolt

    Courtesy of FORD MOTOR CO.
31. Remove the 2 nuts and the EGR vacuum regulator.
    Fig 30: Locating EGR Vacuum Regulator Nuts

    Courtesy of FORD MOTOR CO.
32. Remove the bolt, 3 stud bolts, radio interference capacitor and the upper intake manifold.
    Fig 31: Locating Radio Interference Capacitor Bolts And Stud Bolts

    Courtesy of FORD MOTOR CO.
33. Disconnect the camshaft position (CMP) sensor and engine coolant temperature (ECT) sensor electrical connectors.
    Fig 32: Locating Camshaft Position (CMP) Sensor And Engine Coolant Temperature (ECT) Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
34. Disconnect the oil pressure switch electrical connector.
    Fig 33: Locating Oil Pressure Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
35. Disconnect the 6 fuel injector electrical connectors.
    Fig 34: Locating Fuel Injector Electrical Connectors

    Courtesy of FORD MOTOR CO.
36. Detach the wiring harness retainers from the valve cover studs and remove the engine control sensor wiring harness from the engine.
37. Detach the LH spark plug wire retainers from the valve cover stud bolts.
    • Disconnect and remove the LH spark plug wires.
    Fig 35: Locating Spark Plug Wire Retainers

    Courtesy of FORD MOTOR CO.
38. Remove the nut and the oil level indicator and tube assembly.
    Fig 36: Locating Oil Level Indicator And Tube Assembly

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39. Remove the 6 bolts and the LH exhaust manifold.
    • Discard the gasket.
    Fig 37: Locating LH Exhaust Manifold Bolts

    Courtesy of FORD MOTOR CO.
40. Detach the RH spark plug wire retainers from the valve cover stud bolts.
    • Disconnect and remove the RH spark plug wires.
    Fig 38: Locating Spark Plug Wire Retainers

    Courtesy of FORD MOTOR CO.
41. Remove the 3 bolts and the RH exhaust manifold heat shield.
    Fig 39: Locating RH Exhaust Manifold Heat Shield Bolts

    Courtesy of FORD MOTOR CO.
42. Remove the 6 bolts and the RH exhaust manifold.
    • Discard the gasket.
    Fig 40: Locating RH Exhaust Manifold Bolts

    Courtesy of FORD MOTOR CO.
43. Remove the retainers and the RH valve cover.
    Fig 41: Locating Retainers And RH Valve Cover

    Courtesy of FORD MOTOR CO.
44. Remove the retainers and the LH valve cover.
    Fig 42: Locating LH Valve Cover And Retainers

    Courtesy of FORD MOTOR CO.
NOTE: Mark the location of the push rods and rocker arms before removing.
Fig 43: Locating Rocker Arm Bolts
Courtesy of FORD MOTOR CO.
45. Remove the 12 rocker arms and 12 push rods.
46. Remove the 8 bolts and the lower intake manifold.
    Fig 44: Locating Lower Intake Manifold Bolts

    Courtesy of FORD MOTOR CO.
47. Remove and discard the lower intake manifold gaskets.
    Fig 45: Locating Intake Manifold Gaskets

    Courtesy of FORD MOTOR CO.
48. Remove the 4 bolts and the crankshaft pulley.
    Fig 46: Locating Crankshaft Pulley Bolts

    Courtesy of FORD MOTOR CO.
49. Remove the crankshaft damper bolt.
    Fig 47: Locating Crankshaft Damper Bolt

    Courtesy of FORD MOTOR CO.
50. Remove the crankshaft position (CKP) sensor.
    Fig 48: Locating Crankshaft Position Sensor

    Courtesy of FORD MOTOR CO.
51. Using the special tool, remove the crankshaft damper.
    Fig 49: Identifying Special Tool (303-009)

    Courtesy of FORD MOTOR CO.
52. Remove the oil filter.
    Fig 50: Locating Oil Filter

    Courtesy of FORD MOTOR CO.
53. Remove the 2 bolts and the valve tappet guide plate retainer.
    Fig 51: Locating Tappet Guide Plate Retainer Bolts

    Courtesy of FORD MOTOR CO.
54. Remove the 6 valve tappet guide plates.
    Fig 52: Locating Valve Tappet Guide Plates

    Courtesy of FORD MOTOR CO.
NOTE: The valve tappets are positional. Identify each valve tappet for installation in the original position.
Fig 53: Locating Valve Tappets
Courtesy of FORD MOTOR CO.
55. Remove the 12 valve tappets.
56. Remove the 2 screws and the CMP sensor.
    Fig 54: Locating CMP Sensor Screws

    Courtesy of FORD MOTOR CO.
57. Remove the camshaft synchronizer bolt.
    Fig 55: Locating Camshaft Synchronizer Bolt

    Courtesy of FORD MOTOR CO.
NOTE: In some cases, the oil pump intermediate shaft may not come out with the synchronizer assembly. If so, retrieve the intermediate shaft before proceeding.
Fig 56: Removing Camshaft Synchronizer
Courtesy of FORD MOTOR CO.
58. Remove the camshaft synchronizer.
59. Remove the 16 bolts and the oil pan.
    Fig 57: Locating Oil Pan Mounting Bolts

    Courtesy of FORD MOTOR CO.
60. Remove and discard the oil pan gasket.
    Fig 58: Locating Oil Pan Gasket

    Courtesy of FORD MOTOR CO.
61. Remove the 5 bolts and 5 stud bolts the engine front cover.
    Fig 59: Locating Engine Front Cover Bolts And Stud Bolts

    Courtesy of FORD MOTOR CO.
62. Remove the engine front cover gasket.
    Fig 60: Locating Engine Front Cover Gasket

    Courtesy of FORD MOTOR CO.
63. Remove the 8 bolts and the RH cylinder head.
    Fig 61: Locating Cylinder Head Bolts

    Courtesy of FORD MOTOR CO.
64. Remove the 8 bolts and the LH cylinder head.
    Fig 62: Locating LH Cylinder Head Bolts

    Courtesy of FORD MOTOR CO.
65. Remove and discard both cylinder head gaskets.
    Fig 63: Locating Cylinder Head Gaskets

    Courtesy of FORD MOTOR CO.
CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
Fig 64: Locating Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
66. Remove the cylinder head bolts and the cylinder heads.
    • Remove and discard the head gaskets.
CAUTION: 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.
CAUTION: 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.
67. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads 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 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.
NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.
NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61-cm (24-in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.
68. Support the cylinder heads on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder heads must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1-mm (1.5-in) square area, or scratches longer than 0.0254 mm (0.001 in).
69. Remove the camshaft sprocket bolt.
    Fig 65: Locating Camshaft Sprocket Bolt

    Courtesy of FORD MOTOR CO.
70. Remove the timing sprockets and the timing chain as an assembly.
    Fig 66: Locating Timing Chain, Camshaft Sprocket And Crankshaft Sprocket Assembly

    Courtesy of FORD MOTOR CO.
71. Remove the 2 bolts and the camshaft thrust plate.
    Fig 67: Removing Camshaft Thrust Plate Bolts

    Courtesy of FORD MOTOR CO.
72. Remove the camshaft.
    Fig 68: Locating Camshaft

    Courtesy of FORD MOTOR CO.
73. If required, remove the camshaft bearings.
    Fig 69: Locating Camshaft Bearings

    Courtesy of FORD MOTOR CO.
74. Remove the bolt and the oil pump.
    Fig 70: Locating Oil Pump Bolt

    Courtesy of FORD MOTOR CO.
75. 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 the manufacturer instructions.
76. Remove the piston and connecting rod assemblies one at a time.
    • Remove the connecting rod nuts in pairs.
    • Remove the connecting rod cap.
    • Remove the piston and connecting rod assembly.
    Fig 71: Locating Piston And Connecting Rod Assembly

    Courtesy of FORD MOTOR CO.
77. Remove the 8 main bearing cap bolts.
    Fig 72: Locating Main Bearing Cap Bolts

    Courtesy of FORD MOTOR CO.
78. Remove the 4 main bearing caps.
    Fig 73: Locating Main Bearing Caps

    Courtesy of FORD MOTOR CO.
79. Remove the lower crankshaft main bearings.
    Fig 74: Locating Lower Crankshaft Main Bearings

    Courtesy of FORD MOTOR CO.
80. Remove the crankshaft rear seal.
    Fig 75: Locating Crankshaft Rear Oil Seal

    Courtesy of FORD MOTOR CO.
81. Remove the crankshaft.
    Fig 76: Locating Crankshaft

    Courtesy of FORD MOTOR CO.
82. Remove the upper crankshaft main bearings.
    Fig 77: Locating Upper Crankshaft Main Bearings

    Courtesy of FORD MOTOR CO.