Engine Mechanical - 3.5L: Disassembly: Engine

	3 Jaw Puller 303-D121
	Handle 205-153 (T80T-4000-W)
	Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
	Remover, Oil Seal 303-409 (T92C-6700CH)
	Remover, VCT Spark Plug Tube Seal 303-1247/1
	Slide Hammer 307-005 (T59L-100-B)
	Strap Wrench 303-D055 (D85L-6000-A)
	Tool, Camshaft Holding 303-1248

All engines 

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

   Courtesy of FORD MOTOR CO.
2. Remove the crankshaft sensor ring.
   Fig 2: Locating Crankshaft Sensor Ring

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

   Courtesy of FORD MOTOR CO.
NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.
4. Mount the engine on a suitable engine stand.
5. If equipped, remove the heat shield and disconnect the block heater electrical connector.
   • Detach all of the engine block heater harness retainers and remove the harness.
     Fig 4: Locating Block Heater Electrical Connector And Heat Shield

     Courtesy of FORD MOTOR CO.
6. Disconnect the PCV hose from the PCV valve.
   Fig 5: Locating PCV Hose

   Courtesy of FORD MOTOR CO.
7. Disconnect the Throttle Body (TB) electrical connector.
   Fig 6: Locating Throttle Body (TB) Electrical Connector

   Courtesy of FORD MOTOR CO.
8. Detach the wiring harness retainers from the upper intake manifold.
   Fig 7: Locating Upper Intake Manifold Wiring Harness Retainer

   Courtesy of FORD MOTOR CO.
9. Remove the upper intake manifold support bracket bolt.
   Fig 8: Locating Upper Intake Manifold Support Bracket Bolt

   Courtesy of FORD MOTOR CO.
10. Remove the wire harness pin-type retainer and the fuel tube bracket bolt from the upper intake manifold.
    Fig 9: Locating Fuel Tube Bracket Bolt And Wire Harness Pin-Type Retainer

    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.
11. Remove the 6 bolts and the upper intake manifold.
    • Discard the gaskets.
      Fig 10: Locating Upper Intake Manifold Bolts

      Courtesy of FORD MOTOR CO.
12. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
    Fig 11: Locating PSP Switch Electrical Connector

    Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

13. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 12: Locating RH Catalyst Monitor Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.

    All engines 

14. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 13: Locating RH Heated Oxygen Sensor (HO2S) Electrical Connector

    Courtesy of FORD MOTOR CO.
15. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
    Fig 14: Locating RH Variable Camshaft Timing (VCT) Solenoid Electrical Connector

    Courtesy of FORD MOTOR CO.
16. Disconnect the 3 RH coil-on-plug electrical connectors.
    Fig 15: Locating RH Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
17. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
18. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.
    Fig 16: Locating RH Camshaft Position (CMP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
19. Disconnect the Knock Sensor (KS) electrical connector.
    Fig 17: Locating Knock Sensor (KS) Electrical Connector

    Courtesy of FORD MOTOR CO.
20. Remove the bolt and the ground cable from the RH cylinder.
    Fig 18: Locating Ground Cable And Mounting Bolt

    Courtesy of FORD MOTOR CO.
21. Disconnect the 6 fuel injector electrical connectors (3 shown in illustration).
    Fig 19: Locating Fuel Injector Electrical Connectors

    Courtesy of FORD MOTOR CO.
22. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
    Fig 20: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
23. Disconnect the LH CMP sensor electrical connector.
    Fig 21: Locating LH Camshaft Position Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
24. Disconnect the LH CMS electrical connector.
    Fig 22: Locating LH Catalyst Monitor Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
25. Disconnect the LH HO2S electrical connector.
    Fig 23: Locating LH Heated Oxygen Sensor (HO2S) Electrical Connector

    Courtesy of FORD MOTOR CO.
26. Disconnect the 3 LH coil-on-plug electrical connectors.
    Fig 24: Locating LH Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
27. Disconnect the LH VCT solenoid electrical connector.
    Fig 25: Locating LH Camshaft VCT Solenoid Electrical Connector

    Courtesy of FORD MOTOR CO.
28. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
29. Remove the nut, the bolt and the heat shield.
    Fig 26: Locating Heat Shield With Bolt And Nut

    Courtesy of FORD MOTOR CO.
30. Remove the wiring harness retainer stud bolt.
    Fig 27: Locating Wiring Harness Retainer Stud Bolt

    Courtesy of FORD MOTOR CO.
31. Remove the wiring harness grommet.
    Fig 28: Locating Wiring Harness Grommet

    Courtesy of FORD MOTOR CO.
32. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 29: Locating Crankshaft Position (CKP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
33. Disconnect the A/C compressor electrical connector.
    • Detach the A/C compressor wiring harness retainer.
      Fig 30: Locating A/C Compressor Electrical Connector And Wiring Harness Retainer

      Courtesy of FORD MOTOR CO.
34. Remove the nut and disconnect the generator B+ cable.
    Fig 31: Locating Generator B+ Cable Nut

    Courtesy of FORD MOTOR CO.
35. Disconnect the generator electrical connector.
    Fig 32: Locating Generator Electrical Connector

    Courtesy of FORD MOTOR CO.
36. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness pin-type retainer.
    • Remove the wiring harness from the engine.
      Fig 33: Locating Engine Oil Pressure Switch Electrical Connector And Wiring Harness Pin-Type Retainer

      Courtesy of FORD MOTOR CO.
37. Remove the nut, 2 bolts and the A/C compressor.
    Fig 34: Locating A/C Compressor With Bolts And Nut

    Courtesy of FORD MOTOR CO.
38. Remove the A/C compressor mounting stud from the oil pan.
    Fig 35: Locating A/C Compressor Mounting Stud Of Oil Pan

    Courtesy of FORD MOTOR CO.
39. Remove the nut, bolt and the generator.
    • Remove the generator stud.
      Fig 36: Locating Generator Nut And Bolt

      Courtesy of FORD MOTOR CO.
40. Remove the PSP tube bracket-to-power steering pump bolt.
    Fig 37: Locating PSP Tube Bracket-To-Power Steering Pump Bolt

    Courtesy of FORD MOTOR CO.
41. Remove the nut and the PSP tube bracket from the RH valve cover stud bolt.
    Fig 38: Locating Nut And PSP Tube Bracket

    Courtesy of FORD MOTOR CO.
42. Remove the bolt and the PSP tube bracket from the RH cylinder head.
    Fig 39: Locating Power Steering Pressure (PSP) Tube Bracket And Bolt

    Courtesy of FORD MOTOR CO.
43. Remove the 3 bolts and position aside the power steering pump.
    Fig 40: Locating Power Steering Pump Bolts

    Courtesy of FORD MOTOR CO.
44. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 41: Locating Accessory Drive Belt Tensioner Bolts

    Courtesy of FORD MOTOR CO.
45. Remove the 4 bolts and the LH exhaust heat shield.
    Fig 42: Locating LH Exhaust Heat Shield Mounting Bolts

    Courtesy of FORD MOTOR CO.
46. Remove the 6 nuts and the LH catalytic converter.
    • Discard the nuts and gaskets.
      Fig 43: Locating LH Catalytic Converter Mounting Nuts

      Courtesy of FORD MOTOR CO.
47. Clean and inspect the catalytic converter flange. For additional information, refer to EXHAUST MANIFOLD CLEANING AND INSPECTION exhaust manifold cleaning and inspection .
48. Remove and discard the 6 LH exhaust studs.
    Fig 44: Locating LH Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.

    FWD vehicles 

49. Remove the 4 nuts and the RH catalytic converter.
    • Discard the nuts and the gasket.
      Fig 45: Locating RH Catalytic Converter Nuts

      Courtesy of FORD MOTOR CO.

    All engines 

50. Remove the 3 bolts and the RH exhaust manifold heat shield.
    Fig 46: Locating RH Exhaust Manifold Heat Shield And Bolts

    Courtesy of FORD MOTOR CO.
51. Remove the 6 nuts and the RH exhaust manifold.
    • Discard the nuts and exhaust manifold gaskets.
      Fig 47: Locating RH Exhaust Manifold And Nuts

      Courtesy of FORD MOTOR CO.
52. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
53. Remove and discard the 6 RH exhaust studs.
    Fig 48: Locating RH Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.
54. Remove the RH cylinder block drain plug or, if equipped, the block heater.
    • Allow coolant to drain from the cylinder block.
      Fig 49: Locating RH Cylinder Block Drain Plug

      Courtesy of FORD MOTOR CO.
55. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
      Fig 50: Locating LH Cylinder Block Drain Plug

      Courtesy of FORD MOTOR CO.
56. Remove the pin-type retainer and the cover.
    Fig 51: Locating Pin-Type Retainer And Cover

    Courtesy of FORD MOTOR CO.
57. Remove the 2 bolts and the engine lifting eye.
    Fig 52: Locating Engine Lifting Eye And Bolts

    Courtesy of FORD MOTOR CO.
58. Remove the bolt and the upper intake manifold support bracket.
    Fig 53: Locating Upper Intake Manifold Support Bracket And Bolt

    Courtesy of FORD MOTOR CO.
59. Remove the bolt and the RH CMP sensor.
    Fig 54: Locating RH CMP Sensor And Bolt

    Courtesy of FORD MOTOR CO.
60. Remove the coolant bypass hose from the thermostat housing.
    Fig 55: Locating Coolant Bypass Hose Clamp

    Courtesy of FORD MOTOR CO.
61. Remove the 4 bolts and the fuel rail and injectors as an assembly.
    Fig 56: Locating Fuel Rail And Injectors Assembly Bolts

    Courtesy of FORD MOTOR CO.
62. Remove the 3 thermostat housing-to-lower intake manifold bolts.
    • Remove the thermostat housing and discard the gasket.
      Fig 57: Locating Thermostat Housing And Bolts

      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.
63. Remove the 10 bolts and the lower intake manifold.
    • Discard the gaskets.
      Fig 58: Locating Lower Intake Manifold Bolts

      Courtesy of FORD MOTOR CO.
64. Disconnect and remove the CHT sensor jumper harness.
    Fig 59: Locating CHT Sensor Jumper Harness Connector

    Courtesy of FORD MOTOR CO.
65. Remove the bolt and the LH CMP sensor.
    Fig 60: Locating LH Camshaft Position Sensor And Bolt

    Courtesy of FORD MOTOR CO.
66. Remove the bolt and the CKP sensor.
    Fig 61: Locating CKP Sensor And Bolt

    Courtesy of FORD MOTOR CO.
67. Remove the 3 bolts and the oil filter adapter.
    • Discard the gasket.
      Fig 62: Locating Oil Filter Adapter And Bolts

      Courtesy of FORD MOTOR CO.
68. Remove the EOP switch.
    Fig 63: Locating EOP Switch

    Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
Fig 64: Locating Coil-On-Plug Assemblies And Bolts
Courtesy of FORD MOTOR CO.
69. Remove the 6 bolts and the 6 coil-on-plugs.
70. Loosen the 9 stud bolts and remove the LH valve cover.
    • Discard the gasket.
      Fig 65: Locating LH Valve Cover Stud Bolts

      Courtesy of FORD MOTOR CO.
71. Loosen the bolt, the 8 stud bolts and remove the RH valve cover.
    • Discard the gasket.
      Fig 66: Locating RH Valve Cover Bolt And Stud Bolts

      Courtesy of FORD MOTOR CO.
NOTE: VCT solenoid seal removal shown in illustration, spark plug tube seal similar.
72. Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals.
    • Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
      Fig 67: Removing Seal Using VCT Spark Plug Tube Seal Remover And Handle

      Courtesy of FORD MOTOR CO.
73. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
    • Discard the bolt.
      Fig 68: Removing Crankshaft Pulley Bolt And Washer

      Courtesy of FORD MOTOR CO.
74. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 69: Removing Crankshaft Pulley Using Jaw Puller

    Courtesy of FORD MOTOR CO.
75. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 70: Removing Crankshaft Front Seal Using Oil Seal Remover

    Courtesy of FORD MOTOR CO.
76. Remove the 2 bolts and the engine mount bracket.
    Fig 71: Locating Engine Mount Bracket And Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Only use hand tools to remove the studs.
Fig 72: Locating Engine Mount Studs
Courtesy of FORD MOTOR CO.
77. Remove the 2 engine mount studs.
78. Remove the 3 bolts and the engine mount bracket.
    Fig 73: Locating Engine Mount Bracket And Bolts

    Courtesy of FORD MOTOR CO.
79. Remove the 22 engine front cover bolts.
    Fig 74: Locating Engine Front Cover Bolts

    Courtesy of FORD MOTOR CO.
80. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover.
    • Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.
      • Remove the engine front cover.
        Fig 75: Locating Engine Front Cover Bolts

        Courtesy of FORD MOTOR CO.
81. Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown in illustration.
    Fig 76: Locating Timing Marks On Variable Camshaft Timing Assemblies

    Courtesy of FORD MOTOR CO.
NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.
Fig 77: Installing Camshaft Holding Tool On Flats Of LH Camshafts
Courtesy of FORD MOTOR CO.
82. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Fig 78: Installing Camshaft Holding Tool On Flats Of RH Camshafts
Courtesy of FORD MOTOR CO.
83. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
84. Remove the 3 bolts and the RH VCT housing.
    Fig 79: Locating RH VCT Housing Bolts

    Courtesy of FORD MOTOR CO.
85. Remove the 3 bolts and the LH VCT housing.
    Fig 80: Locating LH VCT Housing Bolts

    Courtesy of FORD MOTOR CO.
    NOTE: The following 3 steps are for primary timing chains when the colored links are not visible.
86. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown in illustration.
    Fig 81: Locating Timing Mark On RH Intake VCT Assembly

    Courtesy of FORD MOTOR CO.
87. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown in illustration.
    Fig 82: Locating Timing Mark On LH Intake VCT Assembly

    Courtesy of FORD MOTOR CO.
NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Fig 83: Locating Timing Mark On Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
88. Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown in illustration.
89. Remove the 2 bolts and the primary timing chain tensioner.
    Fig 84: Locating Bolts And Primary Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
90. Remove the primary timing chain tensioner arm.
    Fig 85: Locating Primary Timing Chain Tensioner Arm

    Courtesy of FORD MOTOR CO.
91. Remove the 2 bolts and the lower LH primary timing chain guide.
    Fig 86: Locating Bolts And Lower LH Primary Timing Chain Guide

    Courtesy of FORD MOTOR CO.
92. Remove the primary timing chain.
    Fig 87: Locating Primary Timing Chain

    Courtesy of FORD MOTOR CO.
93. Remove the crankshaft timing chain sprocket.
    Fig 88: Locating Crankshaft Timing Chain Sprocket

    Courtesy of FORD MOTOR CO.
94. Remove the bolt and the upper LH primary timing chain guide.
    Fig 89: Locating Bolt And Upper LH Primary Timing Chain Guide

    Courtesy of FORD MOTOR CO.
95. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
    Fig 90: Compressing LH Secondary Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
96. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt.
    • Remove the VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
      Fig 91: Locating LH VCT Assembly Bolt And LH Exhaust Camshaft Sprocket Bolt

      Courtesy of FORD MOTOR CO.
NOTE: When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.
Fig 92: Removing Camshaft Holding Tool From LH Camshafts
Courtesy of FORD MOTOR CO.
97. Remove the Camshaft Holding Tool from the LH camshafts.
NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.
Fig 93: Locating Camshafts
Courtesy of FORD MOTOR CO.
98. Verify the LH camshafts are in the neutral position.
99. Remove the 2 bolts and the LH secondary timing chain tensioner.
    Fig 94: Locating LH Secondary Timing Chain Tensioner And Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
100. Remove the bolts and the LH camshaft bearing caps.
     • Remove the LH camshafts.
       Fig 95: Locating LH Camshaft Bearing Caps And Bolts

       Courtesy of FORD MOTOR CO.
101. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
     Fig 96: Compressing RH Secondary Timing Chain Tensioner

     Courtesy of FORD MOTOR CO.
NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
102. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt.
     • Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
       Fig 97: Locating RH VCT Assembly Bolt And RH Exhaust Camshaft Sprocket Bolt

       Courtesy of FORD MOTOR CO.
103. Remove the Camshaft Holding Tool from the RH camshafts.
     Fig 98: Removing Camshaft Holding Tool From RH Camshafts

     Courtesy of FORD MOTOR CO.
NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.
Fig 99: Locating Camshafts In Neutral Position
Courtesy of FORD MOTOR CO.
104. Rotate the RH camshafts counterclockwise to the neutral position.
105. Remove the 2 bolts and the RH secondary timing chain tensioner.
     Fig 100: Locating RH Secondary Timing Chain Tensioner And Bolts

     Courtesy of FORD MOTOR CO.
106. Remove the bolt and the RH timing chain guide.
     Fig 101: Locating RH Timing Chain Guide And Bolt

     Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
107. Remove the bolts and the RH camshaft bearing caps.
     • Remove the RH camshafts.
       Fig 102: Locating RH Camshaft Bearing Caps Bolts

       Courtesy of FORD MOTOR CO.
NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
NOTE: LH shown in illustration, RH similar.
Fig 103: Locating Valve Tappets Of Cylinder Head
Courtesy of FORD MOTOR CO.
108. Remove the valve tappets from the cylinder heads.
NOTE: LH shown in illustration, RH similar.
Fig 104: Locating Cylinder Head M6 Bolt
Courtesy of FORD MOTOR CO.
109. Remove and discard the M6 bolt from each cylinder head.
NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
NOTE: Aluminum surfaces are soft and may 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 a tighten-to-yield design and cannot be reused.
NOTE: LH shown in illustration, RH similar.
110. Remove and discard the 8 bolts from each cylinder head.
     • Remove the cylinder heads.
     • Discard the cylinder head gaskets.
       Fig 105: Locating Cylinder Head 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.
111. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence.
     1. Remove any large deposits of silicone or gasket material with a plastic scraper.
     2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
     3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
     4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
112. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
113. Remove the coolant inlet tube.
     • Remove and discard the O-ring seals.
       Fig 106: Locating Coolant Inlet Tube

       Courtesy of FORD MOTOR CO.
114. Remove the 2 bolts and the KS.
     Fig 107: Locating Knock Sensor And Bolts

     Courtesy of FORD MOTOR CO.
115. Remove the 8 bolts and the coolant pump.
     Fig 108: Locating Coolant Pump Bolts

     Courtesy of FORD MOTOR CO.
116. Remove the 16 oil pan bolts.
     Fig 109: Locating Oil Pan Bolts

     Courtesy of FORD MOTOR CO.
117. Install 2 of the oil pan bolts (finger-tight) into the 2 threaded holes in the oil pan.
     • Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released.
       • Remove the oil pan.
         Fig 110: Locating Oil Pan Bolts

         Courtesy of FORD MOTOR CO.
118. Remove the 2 bolts and the oil pump screen and the pickup tube.
     • Discard the O-ring seal.
       Fig 111: Locating Oil Pump Screen And Pickup Tube With Bolts

       Courtesy of FORD MOTOR CO.
119. Remove the 3 bolts and the oil pump.
     Fig 112: Locating Bolts And Oil Pump

     Courtesy of FORD MOTOR CO.
120. Remove the 8 crankshaft rear seal retainer bolts.
     Fig 113: Locating Crankshaft Rear Seal Retainer Bolts

     Courtesy of FORD MOTOR CO.
121. Install the 2 M6 oil pan bolts (finger-tight) into the 2 threaded holes in the crankshaft rear seal retainer.
     • Alternately tighten the 2 bolts one turn at a time until the crankshaft rear seal retainer-to-cylinder block seal is released.
       • Remove the crankshaft rear seal retainer.
         Fig 114: Locating M6 Oil Pan Bolts

         Courtesy of FORD MOTOR CO.
NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover, oil pan and crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.
122. Clean the engine front cover, oil pan and crankshaft rear seal retainer plate using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 RPM.
     • Thoroughly wash the engine front cover, oil pan and crankshaft rear seal retainer plate to remove any foreign material, including any abrasive particles created during the cleaning process.
123. 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: The main bearing cap support brace bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
124. Remove the bolts in the sequence shown in illustration.
     • Remove the main bearing cap support brace.
     • Discard the bolts.
       Fig 115: Identifying Bearing Cap Support Brace Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
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.
Fig 116: Locating Connecting Rod Cap Bolts And Cap
Courtesy of FORD MOTOR CO.
125. Remove the connecting rod cap bolts and cap.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Fig 117: Removing Piston/Rod Assembly From Engine Block
Courtesy of FORD MOTOR CO.
126. Remove the piston/rod assembly from the engine block.
127. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
NOTE: The 8 main bearing cap side bolts and the 8 main bearing cap bolts must be discarded and new bolts must be installed. They are a torque-to-yield design and cannot be reused.
NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.
128. Remove the 8 main bearing cap side bolts and the 8 main bearing cap bolts in the sequence shown in illustration.
     • Discard the bolts.
       Fig 118: Identifying Bearing Cap Side Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
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.
Fig 119: Locating Main Bearing Caps
Courtesy of FORD MOTOR CO.
129. Remove the 4 main bearing caps.
NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
Fig 120: Locating Crankshaft Onto Upper Main Bearings
Courtesy of FORD MOTOR CO.
130. Remove the crankshaft.
NOTE: Inside shown in illustration, outside similar.
Fig 121: Locating Crankshaft Thrust Bearing
Courtesy of FORD MOTOR CO.
131. Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.
NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
Fig 122: Locating Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
132. Remove the 4 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 123: Locating Crankshaft Bearing
Courtesy of FORD MOTOR CO.
133. Remove the 4 crankshaft main bearings from the main bearing caps.
134. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of sealant.
135. Clean the sealing surfaces of the cylinder block in the following sequence.
     1. Remove any large deposits of silicone or gasket material.
     2. Apply silicone gasket remover and allow to set for several minutes.
     3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
     4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
     5. Make sure the 2 engine front cover locating dowel pins are seated correctly in the cylinder block.