303-01B-1

Engine 3.0L (4V)

303-01B-1

DISASSEMBLY
Special Tool(s)

Engine

Slide Hammer
307-005 (T59L-100-B)

Special Tool(s)
Plate, Water Pump Pulley
303-456 (T94P-6312-AH1), part
of 303-S455

Strap Wrench
303-D055 (D85L-6000-A)
Protector, Water Pump Shaft
303-457 (T94P-6312-AH2), part
of 303-S455

Remover, Crankshaft Rear Oil

Seal
303-519 (T95P-6701-EH)

Remover, Crankshaft Vibration

Damper
303-009 (T58P-6316-D)

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,
can cause engine failure.
NOTE: For additional information, refer to the
exploded view under the assembly procedure in this
section.
All vehicles
1.

Remove the bolts and the flexplate.

Remover, Oil Seal

303-409 (T92C-6700CH)

(Continued)

Copyright 2004, Ford Motor Company

Last updated: 7/9/2007

2005 Escape, Mariner, Escape Hybrid 10/2004

303-01B-2

Engine 3.0L (4V)

303-01B-2

DISASSEMBLY (Continued)
2.

Using the special tools, remove and discard the

crankshaft rear oil seal.

6.

Disconnect the exhaust gas recirculation (EGR)

vacuum regulator electrical connector and
remove the nut. Detach the wiring harness
retainer.

3.

Mount the engine on a suitable stand.

4.

Detach the engine control sensor wiring

connectors from the upper intake manifold.

7.

Disconnect the knock sensor (KS) electrical

connector.

5.

Detach the wiring retainer, remove the nut and

the heated oxygen sensor (HO2S) electrical
connector bracket.

8.

Remove the nuts and the engine control wire

harness.

2005 Escape, Mariner, Escape Hybrid 10/2004

303-01B-3

Engine 3.0L (4V)

303-01B-3

DISASSEMBLY (Continued)
9.

Disconnect the idle air control (IAC) valve and

the throttle position (TP) sensor electrical
connectors, and detach the wiring retainer.

12. Disconnect the throttle body coolant hose.

13. Remove the bolts and upper intake manifold.

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

11. Disconnect the vacuum tube fittings from the

EGR valve, EGR vacuum regulator and the
intake manifold.

Discard the gaskets.

14. Disconnect the engine coolant temperature

(ECT) sensor electrical connector.

2005 Escape, Mariner, Escape Hybrid 10/2004

303-01B-4

Engine 3.0L (4V)

303-01B-4

DISASSEMBLY (Continued)
15. Disconnect the RH coil-on-plug electrical
connectors and detach the wiring retainer.

16. Disconnect the radio interference capacitor

electrical connector and detach the wiring
retainers.

17. Disconnect the LH coil-on-plug electrical

connectors and detach the wiring retainers.

19. Disconnect the crankshaft position (CKP) sensor

electrical connector and detach the wiring
retainers.

20. Disconnect the fuel rail pressure and

temperature sensor electrical connector and
vacuum tube.

Remove the engine vacuum harness.

18. Disconnect the camshaft position sensor (CMP)

and oil pressure sensor electrical connectors and
detach the wiring retainers.
2005 Escape, Mariner, Escape Hybrid 10/2004

303-01B-5

Engine 3.0L (4V)

303-01B-5

DISASSEMBLY (Continued)
21. Disconnect the fuel injector electrical
connectors and remove the fuel charging wiring
harness.

24. Remove the nut and the radio interference

capacitor.

25. Remove the bolts and the RH valve cover.

22. Remove the bolts and the lower intake
manifold.

Discard the gasket.

Discard the gaskets.

26. Remove the bolt and the engine lift bracket.

23.

CAUTION: When removing the

coil-on-plugs, a slight twisting motion will
break the seal and ease removal.
NOTE: LH shown, RH similar.
Remove the bolts and the 6 coil-on-plugs.

2005 Escape, Mariner, Escape Hybrid 10/2004

303-01B-6

Engine 3.0L (4V)

303-01B-6

DISASSEMBLY (Continued)
27. Remove the nuts and the coolant pump belt
cover.

4x2 vehicles
30. Remove the nuts, the RH exhaust manifold and
the gasket.

Discard the gasket.

28. Remove the bolts and the LH valve cover.

Discard the gasket.

31. Remove the bolts and the halfshaft support
bracket.

29. Remove the nuts, the LH exhaust manifold and

the gasket.

Discard the gasket.

2005 Escape, Mariner, Escape Hybrid 10/2004

303-01B-7

Engine 3.0L (4V)

303-01B-7

DISASSEMBLY (Continued)
All vehicles

35. Cut and remove the coolant pump belt.

32. If equipped, disconnect the coolant hoses and

detach the hoses from the retainer.

Remove the coolant hoses.

36. Disconnect the hoses.

33. Remove and discard the oil filter.

37. Remove the 3 bolts and the coolant pump.

34.

CAUTION: A new oil cooler must be

installed or severe damage to the engine can
occur.
If equipped, remove and discard the oil cooler.

2005 Escape, Mariner, Escape Hybrid 10/2004

303-01B-8

Engine 3.0L (4V)

303-01B-8

DISASSEMBLY (Continued)
38. Disconnect the hoses and remove the coolant
tube.

41. Remove the bolts, studs and the oil pan.

39. Remove the nut, bolt and the coolant bypass

tube.

42. Remove the bolts, nut and the oil pump screen
and pickup tube.

40. Remove the stud bolt and the oil level indicator
and tube.

43. Remove and discard the O-ring seal.

Discard the gasket.

Remove and discard the O-ring seal.

2005 Escape, Mariner, Escape Hybrid 10/2004

303-01B-9

Engine 3.0L (4V)

303-01B-9

DISASSEMBLY (Continued)
44. Remove the nuts and the oil pan baffle.

45. Remove the oil pressure sender and, if

equipped, the block heater.

46. Remove the bolt and the KS.

48. Using the special tool, remove the crankshaft

damper.

49. Remove and discard the crankshaft front seal

from the front cover.

47. Use the special tool to hold the crankshaft

damper and remove the bolt.

2005 Escape, Mariner, Escape Hybrid 10/2004

303-01B-10

Engine 3.0L (4V)

303-01B-10

DISASSEMBLY (Continued)
50. Remove the bolt and the idler pulley.

51. Remove the bolt and the belt tensioner.

53.

52.

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: 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).
Remove the ignition pulse wheel.

Remove the bolts, studs and the front cover.

Discard the gaskets.

2005 Escape, Mariner, Escape Hybrid 10/2004

303-01B-11

Engine 3.0L (4V)

303-01B-11

DISASSEMBLY (Continued)
54. Install the damper bolt.

55.

CAUTION: Only use hand tools when

removing or installing the spark plugs,
damage can occur to the cylinder head or
spark plug.

57. Rotate the crankshaft clockwise 120 degrees to

the 3 oclock position to position the RH
camshafts in the neutral position.

NOTE: LH shown, RH similar.

Remove the LH and RH spark plugs.

58. Verify that the RH camshafts are in the neutral

position.

56. Rotate the crankshaft clockwise to position the

crankshaft keyway in the 11 oclock 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 recheck.

2005 Escape, Mariner, Escape Hybrid 10/2004

303-01B-12

Engine 3.0L (4V)

303-01B-12

DISASSEMBLY (Continued)
59. Remove the RH timing chain tensioner arm.
1

Remove the bolts.

Remove the tensioner.

Remove the tensioner arm.

62. Verify the LH camshafts are in the neutral

position.

63. Remove the LH timing chain and tensioner

arm.
60. Remove the bolts, RH timing chain guide and
the timing chain.

61. Rotate the crankcase clockwise 600 degrees

(1-2/3 turns) to position the crankcase keyway
in the 11 oclock position. This will position
the LH camshafts in the neutral position.

Remove the bolts.

Remove the tensioner.

Remove the tensioner arm.

64. Remove the LH timing chain and timing chain

guide.

2005 Escape, Mariner, Escape Hybrid 10/2004

303-01B-13

Engine 3.0L (4V)

303-01B-13

DISASSEMBLY (Continued)
65. Remove the damper bolt and the crankshaft
sprockets.

66.

CAUTION: The OEM pulley is pressed

on 4.74 mm (0.18 in) past flush of the end of
the camshaft. The service pulley is pressed
on flush to the end of the camshaft.
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.
Using the special tools, remove and discard the
coolant pump pulley.

67.

CAUTION: To make sure of correct

sealing, do not scratch the camshaft.
Using the special tools, remove the camshaft oil
seal and discard.

2005 Escape, Mariner, Escape Hybrid 10/2004

303-01B-14

Engine 3.0L (4V)

303-01B-14

DISASSEMBLY (Continued)
68. Remove the intake camshaft oil seal retainer
and discard the press-in-place gasket.

69.

CAUTION: Cylinder head camshaft

journal caps and cylinder heads are
numbered to verify that they are assembled
in their original positions.
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.

70. Remove the LH and RH camshafts.

71.

CAUTION: The camshaft roller

followers must be installed in their original
positions.
NOTE: RH shown, LH similar.
Remove the LH and RH camshaft roller
followers.

Mark the location of the roller followers,

using a permanent-type marker.

2005 Escape, Mariner, Escape Hybrid 10/2004

303-01B-15

Engine 3.0L (4V)

303-01B-15

DISASSEMBLY (Continued)
72. NOTE: RH shown, LH similar.
Loosen the bolts in the indicated sequence and
remove the LH and RH cylinder heads.

75. Remove the bolts and the oil separator cover.

Discard the gasket.

Discard the bolts and the gaskets.

76. Remove the crankshaft key.

73. Support the cylinder head on a bench with the
head gasket side up.
74. NOTE: The straightedge used must be flat
within 0.0051 mm (0.0002 in) per foot of tool
length.
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).

2005 Escape, Mariner, Escape Hybrid 10/2004