Ford Workshop Service and Repair Manuals

Connecting Rod Guide Set

303–462 (T94P-6136–AH)

Crankshaft Damper Remover

303–009 (T58P-6316-D)

Cylinder Ridge Reamer

303–016 (T64L-6011–EA)

Flywheel Holding Tool

303–544 (T96P-6375–A)

1. Separate the engine control sensor wiring connectors from the upper intake manifold.

2. Disconnect the idle air control valve and the throttle position sensor.

3. Disconnect the exhaust gas reculation (EGR) vacuum regulator and the differential pressure feedback EGR electrical connectors.

4. Remove the positive crankcase ventilation (PCV) tube.

5. Disconnect the vacuum line from the fuel pressure regulator.

6. Remove the bolts and upper intake manifold.

7. Disconnect the crankshaft and camshaft position sensors.

8. Disconnect the radio ignition interference capacitor.

9. Disconnect the remaining electrical connectors and harness retainers and remove the harness.
   • coils-on-plugs
   • fuel injectors
   • idle air control
   • crankshaft positon sensor

10. Remove the bolts and the six coil-on-plugs.

11. Remove the lower intake manifold.

12. Remove the RH valve cover.
    • Remove and discard the gasket if damaged.

13. Remove the engine lift bracket.

14. Remove the LH exhaust manifold.

15. Remove the RH exhaust manifold.

16. Remove the knock sensor.

17. Remove the LH valve cover.

18. Remove the water pump assembly.

19. Disconnect the coolant hoses at the oil cooler.

20. Remove the bolt.

21. Using the special tool, remove the crankshaft damper.

22. Remove the power steering pump pulley.

23. Remove the oil filter.

24. Remove the power steering pump.

25. Remove the generator support bracket.

26. Remove the oil cooler.

27. Remove the oil pressure sender and the block heater.

28. Remove the bolts and studs and the oil pan.
    • Discard the gasket.

29. Remove the bolts, nut and the oil pick up tube and screen.

30. Remove the nuts and the oil pan baffle.

31. Remove the stud and the oil level indicator and tube.

32. 

    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.
    

    CAUTION:Clean all sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A.
    Remove the bolts, studs, and the front cover.
    • Discard the gasket.

33. Remove the crankshaft front seal from the front cover.

34. 

    CAUTION:This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped 20-25-34Y-30M (Color Blue).
    Remove the ignition pulse wheel.

35. Install the damper bolt.

36. 

    NOTE:RH shown, LH similar.
    Remove the LH and RH spark plugs.

37. 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 number one cylinder at top dead center (TDC).
    • Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and re-check.

38. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.

39. Verify that the RH camshafts are correctly positioned.

40. Remove the RH timing chain tensioner arm.
    1. Remove the bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.

41. Remove the bolts, RH timing chain guide and the timing chain.

42. Rotate the crankshaft clockwise two times to position the crankshaft keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.

43. Remove the LH timing chain and tensioner arm.
    1. Remove the bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.

44. Remove the LH timing chain and timing chain guide.

45. Remove the damper bolt and the crankshaft sprockets.

46. 

    NOTE:RH shown, LH similar.
    

    NOTE:The camshaft caps have alignment dowels.
    Loosen the LH and RH camshaft cap bolts in the indicated sequence and remove the camshaft caps.
    • Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.

47. Remove the LH and RH camshafts.

48. 

    CAUTION:The camshaft followers must be installed in the original position.
    

    NOTE:RH shown, LH similar.
    Remove the LH and RH camshaft followers.
    • Mark the location of the followers using a permanent-type marker.

49. 

    NOTE:RH shown, LH similar.
    Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
    • Discard the gaskets.

50. Remove the bolts in the indicated sequence and remove the oil pump.

51. Using the special tool, remove the cylinder ridge.

52. Remove the connecting rod cap bolts. Hold the piston/rod assembly to keep it from falling from the engine block.

53. Using the special tool, remove the piston/rod assembly from the engine block.

54. Remove the engine block from the stand and place it on a workbench.

55. Remove the bolts and the flexplate.

56. Remove the bolts and studs in the indicated sequence and remove the lower cylinder block.

57. Remove the crankshaft rear main seal and remove the crankshaft.

58. Remove the crankshaft key.

59. Remove the crankshaft thrust bearing from the cylinder block.

60. Remove the bearings from the lower cylinder block.

61. Remove the crankshaft main bearings from the cylinder block.

62. Inspect the cylinder block, lower cylinder block, cylinder heads, pistons and connecting rods. For additional information, refer to Section 303-00 Engine System - General Information.