FixVault
Home › Lincoln › 2003 › LS 3.9 A › Repair and Diagnosis › External Pages › Different car › Section 1848 (Engine - 3.0L (4V)) › Disassembly › Engine

Section 1848 (Engine - 3.0L (4V)): Disassembly: Engine

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0024234Courtesy of FORD MOTOR CO.
 Plate, Water Pump Pulley 303-456 (T94P-6312-AH1), part of 303-S455
GF0024235Courtesy of FORD MOTOR CO.
 Protector, Water Pump Shaft 303-457 (T94P-6312-AH2), part of 303-S455
GF0000317Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
GF0000385Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
GF0000249Courtesy of FORD MOTOR CO.
 Remover, Oil Seal 303-409 (T92C-6700CH)
GF0003558Courtesy of FORD MOTOR CO.
 Slide Hammer 307-005 (T59L-100-B)
GF0000708Courtesy of FORD MOTOR CO.
 Socket, Exhaust Gas Oxygen Sensor 303-476 (T94P-9472-A)
GF0000246Courtesy of FORD MOTOR CO.
 Strap Wrench 303-D055 (D85L-6000-A)
Material

Item Specification
Penetrating and Lock Lubricant
XL-1 (US); CXC-51-A (Canada)		 -
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 may cause engine failure.
NOTE: For additional information, refer to the exploded view under the assembly procedure in this article.

All vehicles 

  1. Remove the bolts and the flexplate.
    2. Fig 1: Locating Flexplate & Bolts
    GF0024303Courtesy of FORD MOTOR CO.
  2. Remove the engine-to-transaxle separator plate.
    3. Fig 2: Locating Engine-To-Transaxle Separator Plate
    GF0029006Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove and discard the crankshaft rear oil seal.
    4. Fig 3: Identifying Special Tools (307-005 And 303-519)
    G03898286Courtesy of FORD MOTOR CO.
  4. Mount the engine on a suitable stand.
  5. Detach the wiring harness connectors from the upper intake manifold.
    6. Fig 4: Locating Engine Control Sensor Wiring Connectors
    GF0024304Courtesy of FORD MOTOR CO.
  6. Detach the wiring harness retainer, remove the nut and the catalyst monitor sensor electrical connector bracket.
    7. Fig 5: Locating Heated Oxygen Sensor (HO2S) Electrical Connector Bracket
    GF0024305Courtesy of FORD MOTOR CO.
  7. Disconnect the crankshaft position (CKP) sensor electrical connector and detach the wiring harness retainers.
    8. Fig 6: Locating Crankshaft Position (CKP) Sensor Electrical Connector
    GF0024319Courtesy of FORD MOTOR CO.
  8. Disconnect the exhaust gas recirculation (EGR) vacuum regulator electrical connector.
    9. Fig 7: Identifying (EGR) Connector
    GF0042119Courtesy of FORD MOTOR CO.
  9. Remove the 2 wiring harness retaining nuts.
    10. Fig 8: Locating Engine Control Wiring Harness & Nuts
    GF0024308Courtesy of FORD MOTOR CO.
  10. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.
    • Detach the wiring harness retainer.
    11. Fig 9: Identifying (IAC) Valve, (TP) Connector And Retainer
    GF0042120Courtesy of FORD MOTOR CO.
  11. Remove the PCV tube.
    12. Fig 10: Identifying PCV Tube
    GF0042121Courtesy of FORD MOTOR CO.
  12. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
    13. Fig 11: Locating Fuel Rail Pressure & Temperature Sensor Electrical Connector
    GF0024320Courtesy of FORD MOTOR CO.
  13. Disconnect the throttle body coolant hose.
    14. Fig 12: Locating Throttle Body Coolant Hose
    GF0024312Courtesy of FORD MOTOR CO.
  14. Remove the bolts and upper intake manifold.
    • Discard the gaskets.
    15. Fig 13: Locating Upper Intake Manifold Bolts
    GF0024313Courtesy of FORD MOTOR CO.
  15. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    16. Fig 14: Locating Engine Coolant Temperature (ECT) Sensor Electrical Connector
    GF0024314Courtesy of FORD MOTOR CO.
  16. Disconnect the RH coil-on-plug electrical connectors.
    • Detach the 2 wiring harness retainers.
    17. Fig 15: Identifying Connectors
    GF0042122Courtesy of FORD MOTOR CO.
  17. Disconnect the radio interference capacitor electrical connector.
    • Detach the wiring harness retainers.
    18. Fig 16: Locating Radio Interference Capacitor Electrical Connector
    GF0024316Courtesy of FORD MOTOR CO.
  18. Disconnect the LH coil-on-plug electrical connectors.
    • Detach the 2 wiring harness retainers.
    19. Fig 17: Coil-On-Plug Electrical Connectors & Wiring Retainers
    GF0024317Courtesy of FORD MOTOR CO.
  19. Disconnect the camshaft position sensor (CMP) and engine oil pressure (EOP) switch electrical connectors.
    • Detach the wiring harness retainers.
    20. Fig 18: Locating Camshaft Position Sensor (CMP) & Oil Pressure Sensor Electrical Connectors & Wiring Retainers
    GF0024318Courtesy of FORD MOTOR CO.
  20. Disconnect the generator electrical connector.
    21. Fig 19: Identifying Connector
    GF0042123Courtesy of FORD MOTOR CO.
  21. Remove the nut and the B+ wire from the generator.
    22. Fig 20: Identifying Nut
    GF0042124Courtesy of FORD MOTOR CO.
  22. Disconnect the 6 fuel injector electrical connectors.
    23. Fig 21: Locating Fuel Injector Electrical Connectors
    GF0024321Courtesy of FORD MOTOR CO.
  23. Detach the 2 wiring harness retainers (1 shown).
    • Remove the fuel charging wiring harness from the engine.
    24. Fig 22: Identifying Harness Retainer
    GF0042125Courtesy of FORD MOTOR CO.
  24. Remove the nut and detach the 4 wiring harness retainers.
    • Remove the B+ harness from the engine.
    25. Fig 23: Identifying Harness Retianers
    GF0042126Courtesy of FORD MOTOR CO.
  25. Remove the bolts and the lower intake manifold.
    • Discard the gaskets.
    26. Fig 24: Locating Lower Intake Manifold Bolts
    GF0024322Courtesy of FORD MOTOR CO.
    NOTE: When removing the coil-on-plugs, a slight twisting motion will break the seal and ease removal.
    NOTE: LH shown, RH similar.
  26. Remove the bolts and the 6 coil-on-plugs.
    27. Fig 25: Coil-On-Plug Bolts
    GF0024323Courtesy of FORD MOTOR CO.

    Front wheel drive (FWD) vehicles 

  27. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
    28. Fig 26: Identifying Connector
    GF0042114Courtesy of FORD MOTOR CO.
  28. Remove the 6 nuts, the RH exhaust manifold and the gasket.
    • Discard the gasket and nuts.
    29. Fig 27: Locating Gasket & Nuts
    GF0024328Courtesy of FORD MOTOR CO.
  29. Remove and discard the 6 RH exhaust manifold studs.
    30. Fig 28: Locating Exhaust Manifold Studs
    G03898429Courtesy of FORD MOTOR CO.
  30. Remove the bolts and the halfshaft support bracket.
    31. Fig 29: Locating Halfshaft Support Bracket & Bolts
    GF0024329Courtesy of FORD MOTOR CO.

    All vehicles 

  31. Remove the bolt, 2 nuts and the generator.
    32. Fig 30: Identifying Bolt And Nuts
    GF0042127Courtesy of FORD MOTOR CO.
  32. Remove the 3 bolts and the A/C compressor bracket.
    33. Fig 31: Identifying Bolts
    GF0042128Courtesy of FORD MOTOR CO.
  33. Remove the EOP switch and, if equipped, the block heater.
    34. Fig 32: Locating Oil Pressure Sender
    GF0024341Courtesy of FORD MOTOR CO.
  34. Remove the stud bolt and the oil level indicator and tube.
    • Remove and discard the O-ring seal.
    35. Fig 33: Oil Level Indicator Tube & Nut
    GF0024337Courtesy of FORD MOTOR CO.
    NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal.
  35. Using the special tool, remove the HO2S.
    36. Fig 34: Identifying Special Oxygen Sensor Tool
    G03901976Courtesy of FORD MOTOR CO.
  36. Remove the nuts, the LH exhaust manifold and the gasket.
    • Discard the gasket and nuts.
    37. Fig 35: Identifying Nuts
    GF0042129Courtesy of FORD MOTOR CO.
  37. Remove and discard the 6 LH exhaust manifold studs.
    38. Fig 36: Locating Exhaust Manifold Studs
    G03898429Courtesy of FORD MOTOR CO.
  38. Remove and discard the oil filter.
    39. Fig 37: Identifying Oil Filter
    GF0042130Courtesy of FORD MOTOR CO.
  39. Cut and discard the coolant pump belt.
    40. Fig 38: Locating Coolant Pump Belt
    GF0024332Courtesy of FORD MOTOR CO.
    CAUTION: 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.
  40. Using the special tools, remove the coolant pump pulley.
    41. Fig 39: Removing Coolant Pump Pulley Using Special Tools (303-009, 303-456, 303-457)
    GF0024237Courtesy of FORD MOTOR CO.
  41. Disconnect the 2 hoses and remove the thermostat housing.
    42. Fig 40: Locating Coolant Tube
    GF0024335Courtesy of FORD MOTOR CO.
  42. Remove the nut, stud bolt and the coolant bypass tube.
    43. Fig 41: Locating Coolant Bypass Tube Bolt & Nut
    GF0024336Courtesy of FORD MOTOR CO.
  43. Disconnect the coolant pump hose from the cylinder block outlet.
    44. Fig 42: Locating Coolant Pump Hose From Cylinder Block Outlet
    GF0029057Courtesy of FORD MOTOR CO.
  44. Remove the 3 bolts and the coolant pump.
    45. Fig 43: Identifying Coolant Pump Assembly Bolts
    GF0029058Courtesy of FORD MOTOR CO.
  45. Remove the nut and the radio interference capacitor.
    46. Fig 44: Locating Radio Interference Capacitor Nut
    GF0024324Courtesy of FORD MOTOR CO.
  46. Remove the bolts and the RH valve cover.
    • Discard the gasket.
    47. Fig 45: Locating RH Valve Cover Bolts
    GF0024325Courtesy of FORD MOTOR CO.
  47. Remove the bolts and the LH valve cover.
    • Discard the gasket.
    48. Fig 46: Locating LH Valve Cover Bolts
    GF0024327Courtesy of FORD MOTOR CO.
  48. Remove the bolts, studs and the oil pan.
    • Discard the gasket.
    49. Fig 47: Locating Oil Pan Gasket Bolts & Stud Bolts
    GF0024338Courtesy of FORD MOTOR CO.
  49. Remove the bolts, nut and the oil pump screen and pickup tube.
    50. Fig 48: Locating Oil Pump Screen & Pickup Tube Bolts
    GF0024256Courtesy of FORD MOTOR CO.
  50. Remove and discard the O-ring seal.
    51. Fig 49: Locating O-Ring Seal
    GF0024339Courtesy of FORD MOTOR CO.
  51. Remove the nuts and the oil pan baffle.
    52. Fig 50: Locating Oil Pan Baffle Nuts
    GF0024340Courtesy of FORD MOTOR CO.
  52. Remove the 3 bolts and the accessory drive belt tensioner, LH and center idler pulley.
    53. Fig 51: Locating Accessory Drive Belt Tensioner And Idler Pulleys
    GF0029067Courtesy of FORD MOTOR CO.
  53. Use the special tool to hold the crankshaft pulley and remove the bolt.
    54. Fig 52: Identifying Special Tool (303-D055) And Crankshaft Pulley Bolts
    GF0024221Courtesy of FORD MOTOR CO.
  54. Using the special tool, remove the crankshaft pulley.
    55. Fig 53: Removing Crankshaft Pulley Using Special Tool (303-009)
    GF0024222Courtesy of FORD MOTOR CO.
  55. Remove and discard the crankshaft front seal.
    56. Fig 54: Removing Crankshaft Front Seal Using Special Tool (303-409)
    GF0024224Courtesy of FORD MOTOR CO.
    CAUTION: 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.
  56. Remove the 14 bolts, 2 stud bolts and the front cover.
    • Discard the gaskets.
    57. Fig 55: Locating Engine Front Cover Bolts
    GF0024345Courtesy 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).
  57. Remove the ignition pulse wheel.
    58. Fig 56: Identifying Ignition Pulse Wheel
    G03898322Courtesy of FORD MOTOR CO.
    CAUTION: 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, RH similar.
  58. Remove the LH and RH spark plugs.
    59. Fig 57: Spark Plugs
    GF0024346Courtesy of FORD MOTOR CO.
  59. Install the crankshaft pulley bolt.
    60. Fig 58: Identifying Damper Bolt
    G03898296Courtesy of FORD MOTOR CO.
  60. 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.
    61. Fig 59: Identifying Crankshaft Keyway In 11 O'Clock Position
    G03898298Courtesy of FORD MOTOR CO.
  61. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
    62. Fig 60: Identifying Crankshaft Keyway
    G03898299Courtesy of FORD MOTOR CO.
  62. Verify that the RH camshafts are in the neutral position.
    63. Fig 61: Locating Camshafts Align Marks
    G03898496Courtesy of FORD MOTOR CO.
  63. Remove the RH timing chain tensioner arm.
    1. Remove the 2 bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
    64. Fig 62: Identifying RH Timing Chain Tensioner Arm & Bolts
    GF0017028Courtesy of FORD MOTOR CO.
  64. Remove the bolts, RH timing chain guide and the timing chain.
    65. Fig 63: Locating Timing Chain Guide & Bolts
    G03898302Courtesy of FORD MOTOR CO.
  65. 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.
    66. Fig 64: Positioning Crankcase Key Way In 11 O'Clock Position
    G03898303Courtesy of FORD MOTOR CO.
  66. Verify the LH camshafts are in the neutral position.
    67. Fig 65: Locating Camshafts Aligning Marks
    G03955709Courtesy of FORD MOTOR CO.
  67. Remove the LH timing chain and tensioner arm.
    1. Remove the 2 bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
    68. Fig 66: Locating LH Timing Chain & Tensioner Arm
    GF0017029Courtesy of FORD MOTOR CO.
  68. Remove the LH timing chain and timing chain guide.
    69. Fig 67: Locating Timing Chain & Timing Chain Guide
    G03898306Courtesy of FORD MOTOR CO.
  69. Remove the crankshaft pulley bolt and the crankshaft sprocket.
    70. Fig 68: Locating Damper Bolt & Crankshaft Sprockets
    G03898307Courtesy of FORD MOTOR CO.
  70. Remove the 4 bolts in the sequence shown.
    • Remove the oil pump.
    71. Fig 69: Identifying Removal Sequence Of Oil Pump Bolts
    GF0029069Courtesy of FORD MOTOR CO.
    CAUTION: Do not scratch the camshaft sealing surface while removing the camshaft oil seal. If scratched, camshaft oil seal leakage may occur.
  71. Using the special tools, remove the camshaft oil seal and discard.
    72. Fig 70: Identifying Special Tools (303-409)
    GF0024238Courtesy of FORD MOTOR CO.
  72. Remove the 2 bolts and the camshaft oil seal retainer.
    • Discard the press-in-place gasket.
    73. Fig 71: Locating Camshaft Oil Seal Retainer And Bolts
    GF0024347Courtesy of FORD MOTOR CO.
    CAUTION: 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 position may result in severe engine damage.
  73. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
    74. Fig 72: Identifying Bearing Cap Position And Orientation Marks
    GF0042131Courtesy of FORD MOTOR CO.
    CAUTION: 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.
  74. 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.
    75. Fig 73: Camshaft Bearing Cap Bolts Loosening Sequence
    GF0024348Courtesy of FORD MOTOR CO.
    CAUTION: 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 position may result in severe engine damage.
  75. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
    76. Fig 74: Identifying Bearing Cap Position And Orientation Marks
    GF0042132Courtesy of FORD MOTOR CO.
    CAUTION: 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.
  76. 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.
    77. Fig 75: Camshaft Bearing Cap Bolts Loosening Sequence
    GF0024349Courtesy of FORD MOTOR CO.
    CAUTION: 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, LH similar.
  77. Remove the LH and RH camshaft roller followers.
    • Mark the location of the roller followers, using a permanent-type marker.
    78. Fig 76: Locating Camshaft Roller Followers
    G03898508Courtesy of FORD MOTOR CO.
    CAUTION: The hydraulic lash adjusters must be installed in their original positions. If not reassembled in their original positions, severe engine damage may occur.
  78. Remove the hydraulic lash adjusters.
    79. NOTE: RH shown, LH similar.
  79. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
    • Discard the bolts and the gaskets.
    80. Fig 77: Identifying Loosening Sequence Of Cylinder Heads Bolts
    GF0017189Courtesy of FORD MOTOR CO.
  80. Support the cylinder head on a bench with the head gasket side up.
    81. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
  81. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
  82. Remove the bolts and the oil separator cover.
    • Discard the gasket.
    83. Fig 78: Locating Oil Separator Cover Bolts
    G03898510Courtesy of FORD MOTOR CO.
  83. Remove the crankshaft key.
    84. Fig 79: Locating Crankshaft Key
    G03898511Courtesy of FORD MOTOR CO.
About FixVault