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Section 255 (Engine): Disassembly: Engine

WARNING: This page is about a different car, the 2003 Ford Windstar. However, it is still accessible from the selected car via links, so may be relevant.

Special Tool(s) 

Fig 1: Identifying Special Tool
G01307924Courtesy of FORD MOTOR CO.
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.
  1. Remove the water pump pulley. For additional information, refer to ENGINE COOLING .
  2. Remove the power steering pump. For additional information, refer to POWER STEERING .
  3. Remove the generator and bracket. For additional information, refer to GENERATOR .
  4. Remove the air conditioning compressor. For additional information, refer to AIR CONDITIONING .
  5. Remove the water pump extension tube and bracket.
    Fig 2: Identifying Water Pump Extension Tube & Bracket Bolt
    G01307925Courtesy of FORD MOTOR CO.
  6. Remove the bolts and the drive belt tensioner.
    Fig 3: Identifying Drive Belt Tensioner Bolt
    G01307926Courtesy of FORD MOTOR CO.
  7. Remove the heater outlet tube bracket bolt.
    Fig 4: Identifying Heater Outlet Tube Bracket Bolt
    G01307927Courtesy of FORD MOTOR CO.
  8. Remove the bolts and the power steering pump bracket.
    Fig 5: Identifying Power Steering Pump Bracket Bolt
    G01307928Courtesy of FORD MOTOR CO.
  9. Disconnect the differential pressure feedback EGR system electrical and vacuum connections.
    Fig 6: Identifying Differential Pressure Feedback EGR System Electrical & Vacuum Connections
    G01307929Courtesy of FORD MOTOR CO.
  10. Disconnect the idle air control (IAC) and the throttle position (TP) sensor electrical connectors.
    Fig 7: Disconnecting Identifying Idle Air Control (IAC) & Throttle Position (TP) Sensor Electrical Connectors
    G01307930Courtesy of FORD MOTOR CO.
  11. Lift the spark plug wire separators, then position the spark plug wires aside.
    Fig 8: Identifying Spark Plug Wire Separators
    G01307931Courtesy of FORD MOTOR CO.
  12. Separate the wire harness from the upper intake manifold.
    Fig 9: Separating Wire Harness From Upper Intake Manifold
    G01307932Courtesy of FORD MOTOR CO.
  13. Remove the bolts and the upper intake manifold.
    Fig 10: Identifying Upper Intake Manifold Bolt
    G01307933Courtesy of FORD MOTOR CO.
  14. Disconnect the following vacuum tubes.
    • Disconnect the vacuum tube.
    • Disconnect the positive crankcase ventilation (PCV) tube.
      Fig 11: Identifying Vacuum Tube & Positive Crankcase Ventilation (PCV) Tube
      G01307934Courtesy of FORD MOTOR CO.
  15. Disconnect the EGR vacuum regulator solenoid electrical and vacuum connections.
    Fig 12: Identifying EGR Vacuum Regulator Solenoid Electrical & Vacuum Connections
    G01307935Courtesy of FORD MOTOR CO.
  16. Disconnect the vacuum hose.
    Fig 13: Identifying Vacuum Hose
    G01307936Courtesy of FORD MOTOR CO.
  17. Remove the bolts and the upper intake manifold spacer.
    Fig 14: Identifying Upper Intake Manifold Spacer Bolt
    G01307937Courtesy of FORD MOTOR CO.
  18. Disconnect the oil pressure sensor electrical connector.
    Fig 15: Locating Oil Pressure Sensor Electrical Connector
    G01307938Courtesy of FORD MOTOR CO.
  19. Disconnect the camshaft position (CMP) sensor and the intake manifold runner control (IMRC) electrical connectors.
    Fig 16: Locating Camshaft Position (CMP) Sensor & Intake Manifold Runner Control (IMRC) Electrical Connectors
    G01307939Courtesy of FORD MOTOR CO.
  20. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 17: Locating Engine Coolant Temperature (ECT) Sensor Electrical Connector
    G01307940Courtesy of FORD MOTOR CO.
  21. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 18: Locating Crankshaft Position (CKP) Sensor Electrical Connector
    G01307941Courtesy of FORD MOTOR CO.
  22. Remove the ignition coil electrical connector.
    Fig 19: Locating Ignition Coil Electrical Connector
    G01307942Courtesy of FORD MOTOR CO.
  23. Disconnect the EGR valve vacuum hose.
    Fig 20: Identifying EGR Valve Vacuum Hose
    G01307943Courtesy of FORD MOTOR CO.
  24. Remove the four bolts and the fuel injection supply manifold.
    Fig 21: Identifying Fuel Injection Supply Manifold Bolt
    G01307944Courtesy of FORD MOTOR CO.
  25. Remove the bolts and the water bypass tube.
    Fig 22: Identifying Water Bypass Tube Bolt
    G01307945Courtesy of FORD MOTOR CO.
  26. Disconnect the EGR tube from the EGR valve.
    Fig 23: Identifying EGR Tube
    G01307946Courtesy of FORD MOTOR CO.
  27. Remove the bolts and the lower intake manifold assembly.
    Fig 24: Identifying Lower Intake Manifold Assembly Bolt
    G01307947Courtesy of FORD MOTOR CO.
  28. Remove and discard the lower intake manifold sealing components.
    Fig 25: Removing Lower Intake Manifold Sealing Components
    G01307948Courtesy of FORD MOTOR CO.
  29. Remove the bolt and the oil level indicator and tube.
    Fig 26: Removing Oil Level Indicator Tube
    G01307949Courtesy of FORD MOTOR CO.
  30. Disconnect the spark plug wires.
    Fig 27: Identifying Spark Plug Wires
    G01307950Courtesy of FORD MOTOR CO.
  31. Remove the bolts and the ignition coil.
    Fig 28: Identifying Ignition Coil Bolt
    G01307951Courtesy of FORD MOTOR CO.
  32. Remove the nuts and the RH exhaust manifold.
    Fig 29: Identifying RH Exhaust Manifold Nuts
    G01307952Courtesy of FORD MOTOR CO.
  33. Loosen the nut and remove the EGR tube.
    Fig 30: Identifying EGR Tube Nut
    G01307953Courtesy of FORD MOTOR CO.
  34. Remove the nuts and the LH exhaust manifold.
    Fig 31: Identifying LH Exhaust Manifold Nuts
    G01307954Courtesy of FORD MOTOR CO.
  35. Remove the PCV valve and tube assembly.
    Fig 32: Identifying PCV Valve
    G01307955Courtesy of FORD MOTOR CO.
  36. Remove the PCV tube.
    Fig 33: Identifying PCV Tube
    G01307956Courtesy of FORD MOTOR CO.
  37. Remove the LH valve cover.
    1. Remove the bolts.
    2. Remove the stud bolts.
    3. Remove the LH valve cover.
      Fig 34: Removing LH Valve Cover
      G01307957Courtesy of FORD MOTOR CO.
  38. Remove the RH valve cover.
    1. Remove the bolts.
    2. Remove the stud bolts.
    3. Remove the RH valve cover.
      Fig 35: Removing RH Valve Cover
      G01307958Courtesy of FORD MOTOR CO.
  39. Inspect the valve cover gaskets. Install new valve cover gaskets if necessary.
    CAUTION: If the components are to be reinstalled, they must be installed into the same position. Mark the components for location.
  40. Remove the rocker arms.
    1. Remove the bolts.
    2. Remove the rocker arms.
      Fig 36: Identifying Rocker Arms & Bolt
      G01307959Courtesy of FORD MOTOR CO.
  41. Remove the push rods.
    Fig 37: Identifying Push Rods
    G01307960Courtesy of FORD MOTOR CO.
  42. Remove the lower exhaust manifold studs from both cylinder heads.
    Fig 38: Identifying Lower Exhaust Manifold Studs
    G01307961Courtesy of FORD MOTOR CO.
    43. NOTE: Record the location of long and short bolts.
    Fig 39: Identifying Head Bolt
    G01307962Courtesy of FORD MOTOR CO.
  43. Remove and discard the bolts.
  44. Remove the LH cylinder head and the gasket. Discard the gasket.
    Fig 40: Removing LH Cylinder Head
    G01307963Courtesy of FORD MOTOR CO.
  45. Remove the RH cylinder head and the gasket. Discard the gasket.
    Fig 41: Removing RH Cylinder Head
    G01307964Courtesy of FORD MOTOR CO.
  46. Remove the oil filter.
    Fig 42: Identifying Oil Filter
    G01307965Courtesy of FORD MOTOR CO.
  47. Remove the oil pressure sensor.
    Fig 43: Locating Oil Pressure Sensor
    G01307966Courtesy of FORD MOTOR CO.
  48. Remove the bolts and the oil pan.
    Fig 44: Removing Oil Pan Bolts
    G01307967Courtesy of FORD MOTOR CO.
  49. Remove the water pump.
    • Remove the stud bolts.
    • Remove the water pump.
    • Discard the water pump housing gasket.
      Fig 45: Identifying Water Pump Bolt
      G01307968Courtesy of FORD MOTOR CO.
  50. Remove the bolt and the camshaft synchronizer.
    Fig 46: Identifying Camshaft Synchronizer Bolt
    G01307969Courtesy of FORD MOTOR CO.
  51. Using the special tools, remove the crankshaft damper and pulley assembly.
    Fig 47: Removing Crankshaft Damper & Pulley Assembly
    G01307970Courtesy of FORD MOTOR CO.
  52. Remove the nuts and the crankshaft position (CKP) sensor.
    Fig 48: Identifying Crankshaft Position (CKP) Sensor Nuts
    G01307971Courtesy of FORD MOTOR CO.
  53. Using the special tool, remove the crankshaft front seal. Discard the seal.
    Fig 49: Removing Crankshaft Front Seal
    G01307972Courtesy of FORD MOTOR CO.
  54. Remove the engine oil pump and the front cover assembly and the engine front cover gasket.
    1. Remove the stud bolts.
    2. Remove the bolt.
      3. CAUTION: The cap screw is hidden; make sure to remove it or the engine front cover will be damaged.
    3. Remove the screw.
    4. Slide the engine front cover and engine front cover gasket from the dowels. Discard the engine front cover gasket.
      Fig 50: Identifying Engine Oil Pump Stud Bolt
      G01307973Courtesy of FORD MOTOR CO.
  55. Remove the camshaft position sensor drive gear.
    1. Remove the bolt.
    2. Remove the camshaft position sensor drive gear.
      Fig 51: Identifying Camshaft Position Sensor Drive Gear
      G01307974Courtesy of FORD MOTOR CO.
  56. Compress and install a retaining pin to hold the timing chain tensioner.
    Fig 52: Installing Retaining Pin To Hold Timing Chain Tensioner
    G01307975Courtesy of FORD MOTOR CO.
  57. Remove the camshaft sprocket, the crankshaft sprocket and the timing chain as an assembly.
    Fig 53: Removing Crankshaft Sprocket & Timing Chain
    G01307976Courtesy of FORD MOTOR CO.
  58. Remove the timing chain tensioner.
    1. Remove the bolts.
    2. Remove the timing chain tensioner.
      Fig 54: Identifying Timing Chain Tensioner Bolt
      G01307977Courtesy of FORD MOTOR CO.
  59. Remove the valve tappets.
    1. Remove the bolts.
    2. Remove the tappet guide plate and retainer.
    3. Remove the valve tappets.
      Fig 55: Removing Valve Tappets
      G01307978Courtesy of FORD MOTOR CO.
  60. Remove the engine balance shaft drive gear.
    1. Remove the camshaft key.
    2. Remove the gear.
      Fig 56: Identifying Camshaft Key & Gear
      G01307979Courtesy of FORD MOTOR CO.
  61. Remove the engine dynamic balance shaft.
    • Remove the bolts.
    • Remove the balance shaft driven gear, thrust plate and engine dynamic balance shaft as an assembly.
      Fig 57: Identifying Engine Dynamic Balance Shaft Bolt
      G01307980Courtesy of FORD MOTOR CO.
  62. Remove the camshaft.
    1. Remove the bolts.
    2. Remove the camshaft thrust plate.
    3. Remove the spacer.
    4. Remove the camshaft.
      Fig 58: Removing Camshaft Spacer
      G01307981Courtesy of FORD MOTOR CO.
  63. Remove the bearing covers.
    1. Remove the engine dynamic balance shaft bearing cover.
    2. Remove the camshaft bearing cover.
      Fig 59: Identifying Bearing Covers
      G01307982Courtesy of FORD MOTOR CO.
  64. Remove the oil pump screen cover and tube.
    • Remove the nut.
    • Remove the bolts.
      Fig 60: Identifying Oil Pump Screen Nut Cover & Tube Bolts
      G01307983Courtesy of FORD MOTOR CO.
  65. Remove the nuts and the oil pan baffle.
    Fig 61: Identifying Oil Pan Baffle Nut
    G01307984Courtesy of FORD MOTOR CO.
  66. If necessary, remove the ridge at the top of the cylinder.
    67. CAUTION: The connecting rods and bearings are matched to the crankshaft journals. Make sure the components are marked and installed in the correct location.
    CAUTION: Each connecting rod and connecting rod cap are matched sets. They will fit together only one way. Mark them before removing.
    CAUTION: Do not damage the connecting rod and the connecting rod cap fractured joint face surface or engine damage can occur.
  67. Remove the piston.
    1. Make sure the piston being removed is at the bottom of the cylinder bore.
    2. Remove the bolts.
    3. Remove the connecting rod cap and the lower connecting rod bearing.
      4. CAUTION: Do not damage the cylinder wall when removing the piston.
      Fig 62: Identifying Connecting Rod Bolts
      G01307985Courtesy of FORD MOTOR CO.
    4. Push the piston and the connecting rod out of the cylinder.
  68. Repeat the piston removal steps for the remaining pistons.
    69. CAUTION: The crankshaft main bearings and the main bearing caps are matched to the crankshaft journals. Make sure the components are marked for position.
    NOTE: The crankshaft main bearing located at the main bearing cap is the thrust bearing.
  69. Remove the four main bearing caps and lower crankshaft main bearings.
    1. Remove the stud bolts.
    2. Remove the main bearing cap and lower crankshaft main bearing.
      Fig 63: Identifying Main Bearing Cap Stud Bolts
      G01307986Courtesy of FORD MOTOR CO.
  70. Repeat the main bearing cap and the lower bearing removal steps for the remaining main bearing caps and the lower crankshaft main bearings.
    71. CAUTION: The crankshaft journals must be protected from damage when the crankshaft is removed.
    Fig 64: Identifying Crankshaft & Crankshaft Rear Seal
    G01307987Courtesy of FORD MOTOR CO.
  71. Remove the crankshaft and the crankshaft rear seal.
    72. NOTE: For ease in reassembly, record the location of the crankshaft upper thrust bearing.
    Fig 65: Identifying Upper Crankshaft Main Bearings & Crankshaft Upper Thrust Bearing
    G01307988Courtesy of FORD MOTOR CO.
  72. Remove the upper crankshaft main bearings and the crankshaft upper thrust bearing.
  73. Remove the camshaft bearings.
    Fig 66: Identifying Camshaft Bearings
    G01307989Courtesy of FORD MOTOR CO.
  74. Remove the engine dynamic balance shaft bearings.
    Fig 67: Identifying Engine Dynamic Balance Shaft Bearings
    G01307990Courtesy of FORD MOTOR CO.
  75. If equipped, remove the engine coolant heater. For additional information, refer to ENGINE COOLING .
    76. NOTE: For cleaning purposes, the plugs should be removed.
  76. If necessary, remove the following:
    1. The cylinder block dowels.
    2. The oil gallery plugs.
    3. The water jacket plugs.
      Fig 68: Identifying Cylinder Block Dowels, Oil Gallery Plugs & Water Jacket Plugs
      G01307991Courtesy of FORD MOTOR CO.
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