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Section 552 (Engine - 4.6L): Disassembly: Engine

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Service Tool
G03181360Courtesy of FORD MOTOR CO.
MATERIAL SPECIFICATION CHART

Item Specification
Motorcraft Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
NOTE: For additional information, refer to the exploded views under DESCRIPTION AND OPERATION .
  1. Remove the bolts and the flexplate.
    Fig 2: Removing Flexplate
    G03181361Courtesy of FORD MOTOR CO.
  2. Remove the spacer plate.
    Fig 3: Removing Spacer Plate
    G03181362Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove the crankshaft rear oil slinger.
    Fig 4: Removing Crankshaft Rear Oil Slinger
    G03181363Courtesy of FORD MOTOR CO.
  4. Using the special tools, remove the crankshaft rear seal.
    Fig 5: Removing Crankshaft Rear Seal
    G03181364Courtesy of FORD MOTOR CO.
  5. Remove the bolts and the rear seal retainer plate.
    Fig 6: Removing Rear Seal Retainer Plate
    G03181365Courtesy of FORD MOTOR CO.
  6. Install the engine on a suitable engine stand.
  7. Rotate the belt tensioner and remove the accessory drive belt.
    Fig 7: Removing Accessory Drive Belt
    G03181366Courtesy of FORD MOTOR CO.
  8. Remove the nuts and position the wiring harness bracket aside.
    Fig 8: Removing Wiring Harness Bracket Aside
    G03181367Courtesy of FORD MOTOR CO.
  9. Remove the oil filter.
    10. NOTE: Lower radiator hose removed for clarity.
    Fig 9: Removing Bolts And Oil Filter Adapter
    G03181368Courtesy of FORD MOTOR CO.
  10. Disconnect the oil pressure switch electrical connector, and remove the bolts and the oil filter adapter.
  11. Remove the power steering hose support bracket.
    Fig 10: Removing Power Steering Hose Support Bracket
    G03181369Courtesy of FORD MOTOR CO.
  12. Disconnect the return and pressure hoses from the power steering pump.
    Fig 11: Disconnecting Pressure Hoses From Power Steering Pump
    G03181370Courtesy of FORD MOTOR CO.
  13. Remove the bolts and the power steering pump.
    Fig 12: Removing Power Steering Pump
    G03181371Courtesy of FORD MOTOR CO.
  14. Remove the nut and position the radio interference capacitor and ground cable aside. Remove the power steering reservoir and bracket from the stud bolt.
    Fig 13: Removing Bracket From Stud Bolt
    G03181372Courtesy of FORD MOTOR CO.
  15. Disconnect the A/C compressor and crankshaft position (CKP) sensor electrical connectors.
    Fig 14: Disconnecting A/C Compressor And Crankshaft Position (CKP) Sensor Electrical Connectors
    G03181373Courtesy of FORD MOTOR CO.
  16. Disconnect the wiring harness retainers.
    Fig 15: Disconnecting Wiring Harness Retainers
    G03181374Courtesy of FORD MOTOR CO.
  17. Detach the wiring harness retainer from the A/C tube.
    Fig 16: Disconnecting Wiring Harness Retainer From A/C Tube
    G03181375Courtesy of FORD MOTOR CO.
  18. Remove the bolt and position the wiring harness aside.
    Fig 17: Removing Wiring Harness
    G03181376Courtesy of FORD MOTOR CO.
  19. Remove the crankcase air inlet tube.
    Fig 18: Removing Crankcase Air Inlet Tube
    G03181377Courtesy of FORD MOTOR CO.
  20. Remove the studs and the A/C compressor.
    Fig 19: Removing Studs And A/C Compressor
    G03181378Courtesy of FORD MOTOR CO.
  21. Remove the nut and the upper radiator hose bracket and position the radio interference capacitor aside.
    Fig 20: Removing Upper Radiator Hose Bracket And Positioning Radio Interference Capacitor Aside
    G03181379Courtesy of FORD MOTOR CO.
  22. Remove the bolts and the idler pulleys.
    Fig 21: Removing Idler Pulleys
    G03181380Courtesy of FORD MOTOR CO.
  23. Disconnect the generator electrical connectors and pin-type retainer.
    Fig 22: Disconnecting Generator Electrical Connectors And Pin-Type Retainer
    G03181381Courtesy of FORD MOTOR CO.
  24. Remove the bolts and the bracket.
    Fig 23: Removing Bracket
    G03181382Courtesy of FORD MOTOR CO.
  25. Remove the bolts and the generator.
    Fig 24: Removing Generator
    G03181383Courtesy of FORD MOTOR CO.
  26. Disconnect the electrical connector, and remove the bolt and the camshaft position (CMP) sensor.
    Fig 25: Removing Camshaft Position (CMP) Sensor
    G03181384Courtesy of FORD MOTOR CO.
  27. Remove the bolts and the drive belt tensioner.
    Fig 26: Removing Drive Belt Tensioner
    G03181385Courtesy of FORD MOTOR CO.
  28. Remove the bolt and the CKP sensor.
    Fig 27: Removing CKP Sensor
    G03181386Courtesy of FORD MOTOR CO.
  29. Remove the coolant pump pulley.
    1. Remove the bolts.
    2. Remove the coolant pump pulley.
    Fig 28: Removing Coolant Pump Pulley
    G03181387Courtesy of FORD MOTOR CO.
  30. Remove the bolts.
    Fig 29: Removing Bolts
    G03181388Courtesy of FORD MOTOR CO.
  31. Remove the coolant pump from the cylinder block.
    • Discard the O-ring seal.
    Fig 30: Disconnecting O-Ring Seal
    G03181389Courtesy of FORD MOTOR CO.
  32. Remove the exhaust gas recirculation (EGR) tube from the exhaust manifold.
    Fig 31: Removing Exhaust Gas Recirculation (EGR) Tube From Exhaust Manifold
    G03181390Courtesy of FORD MOTOR CO.
  33. Remove the bolts and the RH exhaust manifold heat shield.
    Fig 32: Removing RH Exhaust Manifold Heat Shield
    G03181391Courtesy of FORD MOTOR CO.
  34. Remove the RH exhaust manifold.
    1. Remove the eight nuts.
    2. Remove the RH exhaust manifold.
    3. Remove and discard the RH exhaust manifold gasket.
    Fig 33: Removing RH Exhaust Manifold Gasket
    G03181392Courtesy of FORD MOTOR CO.
  35. Remove the LH exhaust manifold heat shield.
    Fig 34: Removing LH Exhaust Manifold Heat Shield
    G03181393Courtesy of FORD MOTOR CO.
  36. Remove the LH exhaust manifold.
    1. Remove the eight nuts.
    2. Remove the LH exhaust manifold.
    3. Remove and discard the LH exhaust manifold gasket.
    Fig 35: Removing LH Exhaust Manifold Gasket
    G03181394Courtesy of FORD MOTOR CO.
  37. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  38. Remove the bolt and the oil level indicator tube.
    Fig 36: Removing Oil Level Indicator Tube
    G03181395Courtesy of FORD MOTOR CO.
  39. Remove the bolt and the brake booster vacuum hose.
    Fig 37: Removing Brake Booster Vacuum Hose
    G03181396Courtesy of FORD MOTOR CO.
  40. Disconnect the throttle position (TP) sensor and the electronic throttle body electrical connectors.
    Fig 38: Disconnecting Throttle Position (TP) Sensor And Electronic Throttle Body Electrical Connectors
    G03181397Courtesy of FORD MOTOR CO.
  41. Remove the positive crankcase ventilation (PCV) tube and disconnect the vacuum tube from the throttle body adapter.
    Fig 39: Removing PCV Tube And Vacuum Tube From Throttle Body Adapter
    G03181398Courtesy of FORD MOTOR CO.
  42. Disconnect the EGR system module and fuel pressure sensor vacuum fittings.
    • Remove the vacuum harness from the engine.
    Fig 40: Removing Vacuum Harness From Engine
    G03181399Courtesy of FORD MOTOR CO.
  43. Disconnect the EGR system module and fuel pressure sensor electrical connectors.
    Fig 41: Disconnecting EGR System Module And Fuel Pressure Sensor Electrical Connectors
    G03181400Courtesy of FORD MOTOR CO.
  44. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 42: Disconnecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03181401Courtesy of FORD MOTOR CO.
  45. Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.
    Fig 43: Disconnecting Knock Sensor (KS) Electrical Connector
    G03181402Courtesy of FORD MOTOR CO.
  46. Disconnect the coolant hoses.
    Fig 44: Disconnecting Coolant Hoses (1 Of 2)
    G03181403Courtesy of FORD MOTOR CO.
  47. Disconnect the coolant hose.
    Fig 45: Disconnecting Coolant Hoses (2 Of 2)
    G03181404Courtesy of FORD MOTOR CO.
  48. Remove the bolts and the throttle body adapter.
    Fig 46: Removing Throttle Body Adapter
    G03181405Courtesy of FORD MOTOR CO.
  49. Disconnect the RH fuel injector, coil and ground electrical connectors, and the wiring harness retainers.
    Fig 47: Disconnecting RH Fuel Injector, Coil And Ground Electrical Connectors
    G03181406Courtesy of FORD MOTOR CO.
  50. Disconnect the LH fuel injector and coil pack electrical connectors and the fuel charging wiring harness retainers.
    Fig 48: Disconnecting LH Fuel Injector And Coil Pack Electrical Connectors
    G03181407Courtesy of FORD MOTOR CO.
  51. Disconnect the wiring harness retainers.
    Fig 49: Disconnecting Wiring Harness Retainers
    G03181408Courtesy of FORD MOTOR CO.
  52. Disconnect the ground wire.
    Fig 50: Disconnecting Ground Wire
    G03181409Courtesy of FORD MOTOR CO.
  53. Disconnect all remaining wiring harness retainers and remove the fuel charging wiring harness.
    54. NOTE: LH is shown, RH is similar.
    Fig 51: Removing Ignition Coils
    G03181410Courtesy of FORD MOTOR CO.
  54. Remove the bolts and all eight ignition coils.
  55. Remove the bolts and the thermostat housing.
    Fig 52: Removing Thermostat Housing
    G03181411Courtesy of FORD MOTOR CO.
  56. Remove the nine bolts and the intake manifold.
    Fig 53: Removing Intake Manifold
    G03181412Courtesy of FORD MOTOR CO.
  57. Remove the intake manifold gaskets.
    Fig 54: Removing Intake Manifold Gaskets
    G03181413Courtesy of FORD MOTOR CO.
    58. 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.
  58. Clean the sealing surfaces.
  59. Remove the bolt and the ground wire.
    Fig 55: Removing Ground Wire
    G03181414Courtesy of FORD MOTOR CO.
  60. Remove the heater hose if necessary.
    Fig 56: Removing Heater Hose
    G03181415Courtesy of FORD MOTOR CO.
  61. Remove the bolts and the KS.
    Fig 57: Removing Bolts And KS
    G03181416Courtesy of FORD MOTOR CO.
  62. Remove the nut and the coolant tube.
    Fig 58: Removing Coolant Tube
    G03181417Courtesy of FORD MOTOR CO.
  63. Remove the bolts and the LH engine mount.
    Fig 59: Removing LH Engine Mount
    G03181418Courtesy of FORD MOTOR CO.
  64. Remove the bolts and the RH engine mount.
    Fig 60: Removing RH Engine Mount
    G03181419Courtesy of FORD MOTOR CO.
  65. Remove the RH cylinder block drain plug.
    • Reinstall the drain plug after draining the coolant.
    Fig 61: Installing Drain Plug After Draining Coolant
    G03181420Courtesy of FORD MOTOR CO.
  66. Remove the LH cylinder block drain plug.
    • Reinstall the drain plug after draining the coolant.
    Fig 62: Removing Drain Plug After Draining Coolant
    G03181421Courtesy of FORD MOTOR CO.
    67. 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.
    NOTE: There are several kinds of bolts used in fastening the valve cover. The bolts must be installed in their original locations.
    Fig 63: Identifying Valve Cover
    G03181422Courtesy of FORD MOTOR CO.
  67. Loosen the bolts and remove the left valve cover.
    • Clean and inspect the mating surfaces and if necessary, install new gaskets.
    68. 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.
    NOTE: There are several kinds of bolts used in fastening the valve cover. The bolts must be installed in their original locations.
    Fig 64: Identifying Valve Cover
    G03181423Courtesy of FORD MOTOR CO.
  68. Loosen the bolts and remove the right valve cover.
    • Clean and inspect the mating surfaces and if necessary, install new gaskets.
    69. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
  69. Remove the spark plugs.
  70. Position the lobe of the camshaft upward.
    Fig 65: Positioning Lobe Of Camshaft Upward
    G03181424Courtesy of FORD MOTOR CO.
  71. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 66: Installing Special Tool Between Valve Spring Coils
    G03181425Courtesy of FORD MOTOR CO.
    72. NOTE: The roller followers are positional. Mark the followers for installation in their original locations.
    Fig 67: Removing Camshaft Roller Followers
    G03181426Courtesy of FORD MOTOR CO.
  72. Using the special tool, compress the valve springs and remove the camshaft roller followers.
  73. Remove the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
    Fig 68: Removing Crankshaft Pulley
    G03181427Courtesy of FORD MOTOR CO.
  74. Using the special tool, remove the crankshaft front oil seal.
    Fig 69: Removing Crankshaft Front Oil Seal
    G03181428Courtesy of FORD MOTOR CO.
  75. Remove the four oil pan bolts.
    Fig 70: Removing Oil Pan Bolts
    G03181429Courtesy of FORD MOTOR CO.
    76. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 71: Removing Fasteners
    G03181430Courtesy of FORD MOTOR CO.
  76. Remove the fasteners.
  77. Remove the engine front cover from the cylinder block.
    Fig 72: Removing Engine Front Cover From Cylinder Block
    G03181431Courtesy of FORD MOTOR CO.
  78. Remove the crankshaft sensor ring from the crankshaft.
    Fig 73: Removing Crankshaft Sensor Ring From Crankshaft
    G03181432Courtesy of FORD MOTOR CO.
  79. Remove the timing chain tensioning system from both timing chains.
    1. Remove the bolts.
    2. Remove the timing chain tensioners.
    3. Remove the timing chain tensioner arms.
    Fig 74: Removing Timing Chain Tensioner Arms
    G03181433Courtesy of FORD MOTOR CO.
    80. CAUTION: Unless otherwise instructed, at not time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
    Fig 75: Removing LH And RH Timing Chains And Crankshaft Sprockets
    G03181434Courtesy of FORD MOTOR CO.
  80. Remove the LH and RH timing chains and the crankshaft sprockets.
    • Remove the RH timing chain from the camshaft sprocket.
    • Remove the RH timing chain and outer crankshaft sprocket from the crankshaft sprocket.
    • Repeat for the LH timing chain and remove the crankshaft sprocket.
  81. Remove both timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
    Fig 76: Removing Timing Chain Guides
    G03181435Courtesy of FORD MOTOR CO.
  82. Install the special tool on both ends of the cylinder head.
    Fig 77: Installing Special Tool On Both Ends Of Cylinder Head
    G03181436Courtesy of FORD MOTOR CO.
    83. 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 torque-to-yield designed and cannot be reused.
    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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    NOTE: RH is shown, LH is similar.
    Fig 78: Removing Cylinder Heads
    G03181437Courtesy of FORD MOTOR CO.
  83. Remove the bolts and discard.
    • Remove the cylinder heads.
  84. Discard the head gasket.
    Fig 79: Removing Head Gasket
    G03181438Courtesy of FORD MOTOR CO.
    85. 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    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.
  85. 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 straining of the metal surfaces is normal.
    86. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.
    NOTE: Use a straightedge that is calibrated by the manufacturer to be flat with 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat with 0.010 mm (0.0004 in) from end to end.
    NOTE: LH is shown, RH is similar.
    Fig 80: Identifying Oil Pressure Feed Area
    G03181439Courtesy of FORD MOTOR CO.
  86. 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).
  87. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent.
    Fig 81: Removing Carbon Deposits
    G03181440Courtesy of FORD MOTOR CO.
  88. Remove the oil pan.
    • Remove the bolts.
    • Remove the oil pan.
    • Remove the oil pan gasket.
    Fig 82: Removing Oil Pan Gasket
    G03181441Courtesy of FORD MOTOR CO.
  89. Remove the bolts and the oil pump screen cover and tube.
    Fig 83: Removing Oil Pump Screen Cover And Tube
    G03181442Courtesy of FORD MOTOR CO.
  90. Remove the oil pump screen cover and tube spacer.
    Fig 84: Removing Oil Pump Screen Cover And Tube Spacer
    G03181443Courtesy of FORD MOTOR CO.
  91. Remove the oil pump.
    1. Remove the bolts.
    2. Remove the oil pump.
    Fig 85: Removing Oil Pump
    G03181444Courtesy of FORD MOTOR CO.
    92. CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for correct orientation.
    Fig 86: Removing Bolts And Connecting Rod Cap
    G03181445Courtesy of FORD MOTOR CO.
  92. Remove the bolts and the connecting rod cap. Discard the bolts.
    93. CAUTION: Do not scratch the cylinder walls or crankshaft journal with the connecting rod.
    Fig 87: Installing Connecting Rod
    G03181446Courtesy of FORD MOTOR CO.
  93. Use the Connecting Rod Installer to push the piston through the top of the cylinder block.
  94. Remove the piston rings.
    Fig 88: Removing Piston Rings
    G03181447Courtesy of FORD MOTOR CO.
  95. Clean and inspect the piston and connecting rods. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
    96. CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
    Fig 89: Removing Side Bolts
    G03181448Courtesy of FORD MOTOR CO.
  96. Remove the side bolts.
  97. Remove and discard the bolts.
    Fig 90: Removing Bolts
    G03181449Courtesy of FORD MOTOR CO.
  98. Remove the five main bearing caps and the lower crankshaft main bearings.
    Fig 91: Removing Lower Crankshaft Main Bearings
    G03181450Courtesy of FORD MOTOR CO.
  99. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.
    Fig 92: Removing Upper Crankshaft Main Bearings From Cylinder Block
    G03181451Courtesy of FORD MOTOR CO.
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