Removal

NOTE: Ford does not provide a TDC (Top Dead Center) mark or determination procedure for this engine in this vehicle.
ALLDATA users have reported success using aftermarket tools to determine TDC on this engine.

NOTE: Before replacing a valve tappet for noisy operation, make sure the noise is not caused by improper valve-to-rocker arm clearance or by worn rocker arms or push rods.

1. Rotate crankshaft to zero degrees Top Dead Center (TDC) on the compression stroke.
2. Disconnect battery ground cable.
3. Drain engine cooling system.
4. Remove crankcase ventilation hose from valve cover and air cleaner outlet tube.
5. Remove aspirator hose from air cleaner outlet tube. Remove air cleaner outlet tube from throttle body and engine Air Cleaner (ACL).
6. Carefully relieve fuel pressure at fuel pressure relief valve.

WARNING: COVER THE FUEL PRESSURE RELIEF VALVE WITH A SHOP CLOTH TO PREVENT ACCIDENTAL FUEL SPRAY INTO THE EYES.

7. Disconnect fuel tubes.
8. Mark location and remove vacuum lines.
9. Disconnect engine control sensor wiring from Camshaft Position Sensor (CMP sensor), Throttle Position Sensor (TP sensor), Idle Air Control Valve (IAC valve), Engine Coolant Temperature Sensor (ECT sensor), ignition coil water temperature indicator sender unit EGR backpressure transducer and EGR vacuum regulator solenoid electrical connectors.
10. Disconnect upper radiator hose from water hose connection. After loosening retaining clamp, use a twisting motion on upper radiator hose to loosen from water hose connection.
11. Remove brace from generator mounting bracket to throttle body stud bolt.
12. Remove EGR valve to exhaust manifold tube.
13. Remove upper intake manifold.
14. Disconnect engine control sensor wiring retainers from valve cover stud bolts. Carefully disconnect engine control sensor wiring from each fuel injector and remove engine control sensor wiring from engine.
15. Disconnect heater water hoses.
16. Remove ignition wires from spark plugs. Remove wire harness retainers from valve cover bolts.
17. Remove ignition coil from rear of LH cylinder head.
18. Remove valve covers.
19. Loosen cylinder No.3 intake valve rocker arm seat retaining bolt and rotate rocker arm off of push rod and away from top of valve stem. Remove push rod.
20. Remove lower intake manifold retaining bolts using a Torch head socket. Before attempting to remove intake manifold, break seal between intake manifold and cylinder block.
- Wedge a large pry bar or similar tool between intake manifold and cylinder block.
- Pry upward on tool using area between water hose connection and transaxle as a leverage point.

NOTE: Lower intake manifold may be removed with fuel injection supply manifold and fuel injectors in place as an assembly.

21. Loosen rocker arm seat retaining bolt of valve tappet to be replaced enough to allow rocker arm to be lifted off the push rod and rotated to one side.
22. Remove push rods. If more than one is removed, identify the location of each push rod.

NOTE: Push rods should be installed in their original location and position during reassembly.

23. Loosen two valve tappet guide plate and retainer bolts. Remove tappet guide plate and retainer from valve tappet valley.
24. Remove valve tappet guide plate from valve tappets by lifting straight up.





25. To remove, grasp valve tappet and pull in line with bore.

NOTE: If the valve tappets are stuck in the bore(s) due to excessive varnish or gum deposits, it may be necessary to use a claw-type tool to aid removal. Rotate the valve tappet back and forth to loosen it from the deposits.