Engine Mechanical: Mechanical: Engine: Disassembly: Engine

SPECIAL TOOL(S)

Courtesy of FORD MOTOR CO.	Remover/Installer, Crankshaft Rear Oil Seal 303-647
Courtesy of FORD MOTOR CO.	Adapter for 204-185 204-208 (T95T-5310-AR2)
Courtesy of FORD MOTOR CO.	Strap Wrench 303-D055
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-6700-CH)
Courtesy of FORD MOTOR CO.	Aligner, Camshaft 303-530

MATERIAL SPECIFICATION

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

NOTE: For additional information, refer to the exploded views under the ENGINE ASSEMBLY  procedure.

1. Remove the bolts in the sequence shown.
   • Remove the flexplate.
     Fig 1: Identifying Flexplate Bolts Removing Sequence

     Courtesy of FORD MOTOR CO.
2. Using the special tools, remove the rear main seal.
   • Discard the seal.
     Fig 2: Identifying Special Tools

     Courtesy of FORD MOTOR CO.
3. Install the engine on a suitable engine stand.
4. Remove the engine block plug to drain the engine coolant.
5. Remove the 3 bolts, the stud bolt and the RH engine mount bracket.
   Fig 3: Locating LH Engine Mount Bracket, Stud Bolt And Bolts

   Courtesy of FORD MOTOR CO.
6. Remove the 3 bolts, the stud bolt and the LH engine mount bracket.
   Fig 4: Locating RH Engine Mount Bracket, Stud Bolt And Bolts

   Courtesy of FORD MOTOR CO.
7. Disconnect the oil pressure and oil temperature sensor electrical connectors.
   Fig 5: Locating Oil Pressure And Oil Temperature Sensor Electrical Connectors

   Courtesy of FORD MOTOR CO.
8. Remove and discard the oil filter.
CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
9. Remove the bolt and oil cooler.
   • Discard the oil cooler and gasket.
     Fig 6: Locating Oil Cooler And Bolt

     Courtesy of FORD MOTOR CO.
10. Remove the 3 bolts and the oil filter adapter.
    • Discard the O-ring seals.
      Fig 7: Locating Oil Filter Adapter Mounting Bolts

      Courtesy of FORD MOTOR CO.
11. Remove the bolt and the accessory drive belt tensioner.
    Fig 8: Locating Accessory Drive Belt Tensioner And Bolt

    Courtesy of FORD MOTOR CO.
12. Remove the 3 bolts and the coolant pump pulley.
    Fig 9: Locating Coolant Pump Pulley And Bolts

    Courtesy of FORD MOTOR CO.
13. Disconnect the throttle position (TP) sensor electrical connector.
    Fig 10: Locating Throttle Position (TP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
14. Disconnect the fuel pressure sensor electrical connector.
    Fig 11: Locating Fuel Pressure Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
15. Disconnect the electronic throttle body electrical connector.
    Fig 12: Locating Electronic Throttle Body Electrical Connector

    Courtesy of FORD MOTOR CO.
16. Disconnect the evaporative emissions (EVAP) tube.
    Fig 13: Locating Evaporative Emissions Tube

    Courtesy of FORD MOTOR CO.
17. Disconnect the fuel rail temperature sensor electrical connector.
    Fig 14: Locating Fuel Rail Temperature Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
18. Disconnect the exhaust gas recirculation (EGR) system module electrical connector.
    Fig 15: Locating EGR System Module Electrical Connector

    Courtesy of FORD MOTOR CO.
19. Disconnect the coolant vent hose from the coolant outlet.
    • Remove the coolant vent hose.
      Fig 16: Locating Coolant Vent Hose

      Courtesy of FORD MOTOR CO.
20. Remove the vacuum harness.
    Fig 17: Locating Vacuum Harness

    Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
21. Remove the LH and RH ignition coil covers.
22. Remove all silicone sealer and residue from the ignition coil covers.
    Fig 18: Identifying Ignition Coil Covers Silicone Sealer

    Courtesy of FORD MOTOR CO.
23. Remove all silicone sealer and residue from the valve cover surface and ignition coil wiring harness.
    Fig 19: Locating Ignition Coil Wiring Harness

    Courtesy of FORD MOTOR CO.
24. Disconnect the 8 ignition coil electrical connectors.
    Fig 20: Locating Ignition Coil Electrical Connectors

    Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
Fig 21: Locating Engine Wiring Harness
Courtesy of FORD MOTOR CO.
25. Disconnect the engine wiring harness retainers from the engine appearance cover support brackets.
26. Detach the vacuum hose retainers from the LH engine appearance cover support bracket.
    Fig 22: Locating Vacuum Hose Retainers

    Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
Fig 23: Locating Engine Appearance Cover Brackets And Nuts
Courtesy of FORD MOTOR CO.
27. Remove the 4 nuts and the 2 engine appearance cover brackets.
NOTE: LH shown, RH similar.
Fig 24: Locating Fuel Injector And Radio Interference Capacitor Electrical Connectors
Courtesy of FORD MOTOR CO.
28. Disconnect the 8 fuel injector and the 2 radio interference capacitor electrical connectors.
29. Disconnect the knock sensor (KS) and camshaft position (CMP) senor electrical connectors.
    • Detach the pin-type retainers.
      Fig 25: Locating KS And CMP Sensor Electrical Connectors

      Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
Fig 26: Locating VCT Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
30. Disconnect the 2 variable cam timing (VCT) sensor electrical connectors.
31. Remove the 5 bolts and the power steering bracket.
    Fig 27: Locating Power Steering Bracket And Bolts

    Courtesy of FORD MOTOR CO.
32. Disconnect the wiring harness retainers from the LH valve cover.
    Fig 28: Locating Wiring Harness Retainers At LH Valve Cover

    Courtesy of FORD MOTOR CO.
33. Detach the wiring harness from the front cover.
    Fig 29: Locating Wiring Harness At Front Cover

    Courtesy of FORD MOTOR CO.
34. Disconnect the crankshaft position (CKP) sensor electrical connector and wiring harness retainers.
    Fig 30: Locating CKP Sensor Electrical Connector And Wiring Harness

    Courtesy of FORD MOTOR CO.
35. Disconnect the wiring harness retainers from the RH valve cover.
    Fig 31: Locating Wiring Harness Retainers At RH Valve Cover

    Courtesy of FORD MOTOR CO.
36. Disconnect the generator electrical connector and wiring harness retainers.
    Fig 32: Locating Generator Electrical Connector, Wiring Harness And Retainers

    Courtesy of FORD MOTOR CO.
37. Remove the heated oxygen sensor (HO2S) electrical connectors from the brackets.
    Fig 33: Locating Heated Oxygen Sensor (HO2S) Electrical Connector Brackets

    Courtesy of FORD MOTOR CO.
38. Remove the engine wiring harness from the engine.
39. Remove the bolt and the CKP sensor.
    Fig 34: Locating CKP Sensor And Bolt

    Courtesy of FORD MOTOR CO.
40. Remove the nut and the oil level indicator tube.
    • Discard the O-ring seal.
      Fig 35: Locating Oil Level Indicator Tube And Nut

      Courtesy of FORD MOTOR CO.
41. Remove the 8 bolts and ignition coils.
    Fig 36: Locating Ignition Coils And Bolts

    Courtesy of FORD MOTOR CO.
42. Remove the crankcase vent tube.
    Fig 37: Locating Crankcase Vent Tube

    Courtesy of FORD MOTOR CO.
43. Remove the bolt, the 2 nuts and the generator.
    Fig 38: Locating Generator, Bolt And Nuts

    Courtesy of FORD MOTOR CO.
44. Remove the 4 bolts and the generator bracket.
    Fig 39: Locating Generator Bracket And Bolts

    Courtesy of FORD MOTOR CO.
45. Remove the 2 bolts and the starter motor.
    Fig 40: Locating Starter Motor And Bolts

    Courtesy of FORD MOTOR CO.
46. Remove the 2 EGR system module bolts and loosen the EGR tube nut.
    • Remove the EGR system module.
    • Discard the gasket.
      Fig 41: Locating EGR System Module Bolts And EGR Tube Nut

      Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
Fig 42: Locating Radio Interference Ignition Capacitors Mounting Bracket And Nuts
Courtesy of FORD MOTOR CO.
47. Remove the 2 nuts and the 2 radio interference capacitors.
48. Remove the 4 bolts and the fuel rail with fuel injector assembly.
    Fig 43: Locating Fuel Rail With Fuel Injector Assembly And Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Remove and discard the 16 O-ring seals from the fuel injectors.
Fig 44: Locating Fuel Injectors And Clips Onto Fuel Rail
Courtesy of FORD MOTOR CO.
49. Remove the clips and the 8 fuel injectors from the fuel rail.
50. Disconnect the 2 throttle body coolant hoses.
    Fig 45: Locating Throttle Body Coolant Hoses

    Courtesy of FORD MOTOR CO.
NOTE: The throttle body and adapter are shown removed for clarity. It is not necessary to remove the throttle body and adapter to remove the intake manifold.
51. Remove the 7 bolts and 3 studs in the sequence shown.
    • Remove the intake manifold.
    • Discard the gaskets.
      Fig 46: Identifying Intake Manifold Bolts Removing Sequence

      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, which make leak paths. Use a plastic scraping tool to clean the surfaces.
Fig 47: Locating Sealing Surfaces
Courtesy of FORD MOTOR CO.
52. Clean the sealing surfaces.
53. Remove the 4 bolts and the coolant bypass housing.
    • Discard the O-ring seals.
      Fig 48: Locating Coolant Bypass Housing And Bolts

      Courtesy of FORD MOTOR CO.
54. Remove the 4 bolts and the coolant inlet housing.
    • Discard the O-ring seal.
      Fig 49: Locating Coolant Inlet Housing And Bolts

      Courtesy of FORD MOTOR CO.
55. Remove the throttle body coolant hose.
    Fig 50: Locating Throttle Body Coolant Hose

    Courtesy of FORD MOTOR CO.
56. Remove the 5 bolts and the coolant pump.
    • Discard the gasket.
      Fig 51: Locating Coolant Pump And Bolts

      Courtesy of FORD MOTOR CO.
57. Remove the bolts in the sequence shown and remove the RH valve cover.
    • Discard the gasket.
      Fig 52: Identifying RH Valve Cover Bolt Removing Sequence

      Courtesy of FORD MOTOR CO.
58. Remove the bolts in the sequence shown and remove the LH valve cover.
    • Discard the gasket.
      Fig 53: Identifying LH Valve Cover Bolt Removing Sequence

      Courtesy of FORD MOTOR CO.
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, which make leak paths. Use a plastic scraping tool to clean the surfaces.
Fig 54: Identifying Gaskets And Silicone Sealer Applying Points
Courtesy of FORD MOTOR CO.
59. Remove the gaskets and all silicone sealer. Clean the mating surfaces with silicone gasket remover.
60. Remove the 2 nuts and the EGR tube.
    • Discard the gasket.
      Fig 55: Locating EGR Tube And Nuts

      Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
Fig 56: Locating Exhaust Manifold Heat Shield And Bolts
Courtesy of FORD MOTOR CO.
61. Remove the 8 bolts and the 2 exhaust manifold heat shields.
NOTE: LH shown, RH similar.
62. Remove the nuts and exhaust manifolds.
    • Discard the nuts.
      Fig 57: Locating LH Exhaust Manifold And Nuts

      Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
63. Remove the 2 exhaust manifold heat shield stud bolts.
    • Discard the 2 exhaust manifold gaskets.
      Fig 58: Locating LH Exhaust Manifold Heat Shield Stud Bolt

      Courtesy of FORD MOTOR CO.
64. Remove the 16 exhaust manifold studs and discard.
65. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
NOTE: Hold the crankshaft pulley with the special tool while removing the bolt and washer.
Fig 59: Identifying Special Tool And Bolt
Courtesy of FORD MOTOR CO.
66. Remove and discard the bolt and washer.
67. Using the special tool, remove the crankshaft damper.
    Fig 60: Identifying Special Tool

    Courtesy of FORD MOTOR CO.
68. Using the special tool, remove and discard the front crankshaft seal.
    Fig 61: Identifying Special Tool

    Courtesy of FORD MOTOR CO.
69. Remove the engine front cover bolts in the sequence shown.
    • Remove the engine front cover.
    • Discard the gaskets.
      Fig 62: Identifying Engine Front Cover Bolts Removing Sequence

      Courtesy of FORD MOTOR CO.
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, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
Fig 63: Locating Sealing Surfaces
Courtesy of FORD MOTOR CO.
70. Clean the sealing surfaces.
71. Remove the 17 bolts and the oil pan.
    • Discard the gasket.
      Fig 64: Locating Oil Pan Bolts And Gasket

      Courtesy of FORD MOTOR CO.
CAUTION: Use only hand tools to remove the oil pump screen and tube.
Fig 65: Locating Oil Pump Screen Bolts
Courtesy of FORD MOTOR CO.
72. Remove the oil pump screen and tube, and the seal.
73. Remove the 4 bolts and the oil pump.
    Fig 66: Locating Oil Pump Bolts

    Courtesy of FORD MOTOR CO.
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, which make leak paths. Use a plastic scraping tool to remove all traces of the sealant.
Fig 67: Identifying Sump Body Bolts Removing Sequence
Courtesy of FORD MOTOR CO.
74. Remove the bolts in the sequence shown and remove the sump body.
75. Remove the RH and LH VCT bush carriers.
    Fig 68: Locating Variable Cam Timing Bush Carriers, Bolts & Nuts

    Courtesy of FORD MOTOR CO.
76. Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position.
77. Make sure the flats of the camshaft are facing upward. If not, repeat the previous step.
    Fig 69: Locating Camshaft Flats

    Courtesy of FORD MOTOR CO.
CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
Fig 70: Identifying Special Tool On RH Cylinder Head
Courtesy of FORD MOTOR CO.
78. Install the special tool on the RH cylinder head.
CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.
Fig 71: Locating Exhaust Camshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
79. Remove and discard the exhaust camshaft sprocket bolt.
CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.
Fig 72: Locating VCT Unit Bolt
Courtesy of FORD MOTOR CO.
80. Remove and discard the VCT unit bolt.
81. Remove the RH timing chain tensioner.
    1. Push the lever down and install a drill rod to lock the piston.
    2. Remove the bolts and the tensioner.
       Fig 73: Identifying Timing Chain Tensioner Bolts And Drill Rod

       Courtesy of FORD MOTOR CO.
82. Remove the bolt and the RH tensioner arm.
    Fig 74: Locating RH Timing Chain Tensioner Arm And Bolt

    Courtesy of FORD MOTOR CO.
83. Remove the bolt and the RH timing chain guide.
    Fig 75: Locating RH Timing Chain Guide And Bolt

    Courtesy of FORD MOTOR CO.
84. Remove the RH primary timing chain.
    Fig 76: Locating RH Primary Timing Chain

    Courtesy of FORD MOTOR CO.
85. Remove the special tool from the RH cylinder head.
    Fig 77: Identifying Special Tool On RH Cylinder Head

    Courtesy of FORD MOTOR CO.
CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
Fig 78: Identifying Special Tool
Courtesy of FORD MOTOR CO.
86. Install the special tool on the LH cylinder head.
CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the cylinder head will occur.
Fig 79: Locating LH VCT Unit Bolt And Exhaust Camshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
87. Remove and discard the LH VCT unit bolt and the exhaust camshaft sprocket bolt.
88. Remove the LH timing chain tensioner.
    1. Push the lever down and install a drill rod to lock the piston.
    2. Remove the 2 bolts and the tensioner.
       Fig 80: Identifying Timing Chain Tensioner Bolts And Drill Rod

       Courtesy of FORD MOTOR CO.
89. Remove the nut and the LH tensioner arm.
    Fig 81: Locating LH Timing Chain Tensioner Arm And Nut

    Courtesy of FORD MOTOR CO.
90. Remove the bolt and the LH timing chain guide.
    Fig 82: Locating LH Timing Chain Guide And Bolt

    Courtesy of FORD MOTOR CO.
91. Remove the LH primary timing chain.
    Fig 83: Locating LH Primary Timing Chain

    Courtesy of FORD MOTOR CO.
92. Remove the crankshaft sprocket.
93. Collapse the LH secondary timing chain tensioner and install a pin to lock the piston.
    Fig 84: Locating Locking Pin And Collapsing LH Secondary Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
94. Remove the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
    Fig 85: Locating LH VCT Unit, Exhaust Camshaft Sprocket And Timing Chain

    Courtesy of FORD MOTOR CO.
95. Remove the 2 bolts and the LH secondary timing chain tensioner.
96. Collapse the RH secondary timing chain tensioner and install a pin to lock the piston.
    Fig 86: Locating Locking Pin For RH Secondary Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
97. Remove the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
    Fig 87: Locating RH VCT Unit, Exhaust Camshaft Sprocket And Timing Chain

    Courtesy of FORD MOTOR CO.
98. Remove the 2 bolts and the RH secondary timing chain tensioner.
99. Remove the special tool.
    Fig 88: Identifying Special Tool

    Courtesy of FORD MOTOR CO.
CAUTION: Record the camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
100. Remove the LH camshaft bearing caps.
     • Remove the bolts.
     • Remove the LH camshaft bearing caps.
       Fig 89: Locating LH Camshaft Bearing Caps

       Courtesy of FORD MOTOR CO.
101. Remove the LH camshafts.
     Fig 90: Locating LH Camshafts

     Courtesy of FORD MOTOR CO.
CAUTION: Record the camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
102. Remove the RH camshaft bearing caps.
     • Remove the bolts.
     • Remove the RH camshaft bearing caps.
       Fig 91: Locating RH Camshaft

       Courtesy of FORD MOTOR CO.
103. Remove the RH camshafts.
     Fig 92: Locating RH Camshaft Bearing Caps

     Courtesy of FORD MOTOR CO.
CAUTION: Do not use any means of marking the shims other than a permanent-type marker. Any scratches or paint on the shims can result in incorrect lash adjustments and severe engine damage.
CAUTION: Record the shim and bucket tappet location. The shim and bucket tappet are positional and if installed in the incorrect location, engine damage can occur.
104. Record the location of the valve tappets.
     • Remove the valve tappets.
CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
NOTE: RH shown, LH similar.
105. Remove the RH and LH cylinder head end bolts.
     • Discard the bolts.
       Fig 93: Locating RH And LH Cylinder Head End Bolts

       Courtesy of FORD MOTOR CO.
106. Remove and discard the bolts from both cylinder heads in the sequence shown.
     • Remove the cylinder heads.
     • Discard the gaskets.
       Fig 94: Identifying Cylinder Heads Bolts Removing Sequence

       Courtesy of FORD MOTOR CO.
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, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
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.
107. Clean the cylinder head-to-cylinder block mating surfaces 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 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: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
108. Support the cylinder head 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 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).
109. Remove the bolts and the knock sensor.
     Fig 95: Locating Knock Sensors

     Courtesy of FORD MOTOR CO.