Engine Mechanical: Mechanical: Engine: Disassembly: Engine

Special Tool(s) 

Fig 1: Identifying Special Tool(s) (1 Of 2)

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Special Tool(s) (2 Of 2)

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1. Install the engine on the Engine Stand or equivalent using the Heavy Duty Floor Crane.
2. Loosen the bolts retaining the water pump pulley.
3. Remove the drive belt (8620). For additional information, refer to REMOVAL AND INSTALLATION .
4. Remove the water pump pulley.
5. Disconnect the fuel charging wiring (9D930) from the oil control solenoid.
   • On early production vehicles, remove the connector cover from the engine appearance cover.
   • Disconnect the oil control solenoid.
6. On early production vehicles, remove the engine appearance cover.
   Fig 3: Removing Engine Appearance Cover Bolt

   Courtesy of FORD MOTOR CO.
7. Remove the ignition wires.
   Fig 4: Removing Ignition Wires

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8. Remove the A/C compressor (19703). For additional information, refer to REMOVAL AND INSTALLATION .
9. Remove the battery ground cable (14301).
10. Remove the generator (GEN) (10300). For additional information, refer to GENERATOR .
11. Remove the generator mounting bracket (10153). For additional information, refer to GENERATOR .
12. Disconnect the fuel charging wiring from the fuel temperature sensor and fuel pressure sensor.
13. Remove the exhaust manifold heat shield.
    Fig 5: Removing Exhaust Manifold Heat Shield Bolts

    Courtesy of FORD MOTOR CO.
14. Remove the exhaust manifold (9430).
    • Remove the nine nuts in the sequence shown in Fig 6.
    • Remove the exhaust manifold.
    • Remove the exhaust manifold gasket (9448).
    Fig 6: Removing Exhaust Manifold Nuts In Sequence

    Courtesy of FORD MOTOR CO.
15. Remove the throttle body. For additional information, refer to REMOVAL & INSTALLATION .
16. Remove the fuel injection supply manifold (9F792). For additional information, refer to REMOVAL & INSTALLATION .
17. Remove the intake manifold.
    • Remove the two nuts and seven bolts in the sequence shown in Fig 7.
    • Remove the intake manifold (9424).
    Fig 7: Removing Intake Manifold Nuts/Bolts In Sequence

    Courtesy of FORD MOTOR CO.
18. Remove the water thermostat housing. For additional information, refer to REMOVAL .
19. Remove the crankcase ventilation tube (6758).
20. Remove the water bypass tube.
    Fig 8: Removing Water Bypass Tube

    Courtesy of FORD MOTOR CO.
21. Remove the oil separator.
    • Remove the bolts.
    • Remove the oil separator.
    • Remove the oil separator to cylinder block gasket (6B752) and discard.
    Fig 9: Removing Oil Separator

    Courtesy of FORD MOTOR CO.
22. Remove the oil level indicator tube.
    Fig 10: Removing Oil Level Indicator Tube

    Courtesy of FORD MOTOR CO.
23. Remove the fuel charging wiring.
24. Remove the lower radiator hose (8286).
25. Remove the ignition coil (12029), the radio ignition interference capacitor (18801) and the bracket.
26. Remove the steering pump and brackets. For additional information, refer to REMOVAL and REMOVAL .
    Fig 11: Removing Steering Pump And Brackets

    Courtesy of FORD MOTOR CO.
27. Remove the upper timing belt cover.
    Fig 12: Removing Upper Timing Belt Cover

    Courtesy of FORD MOTOR CO.
28. Remove the valve cover (6582).
    • Remove the bolts and grommets.
    • Remove the spacers.
    • Remove the O-rings.
    • Remove the valve cover.
    • Remove the valve cover gasket (6584).
    Fig 13: Removing Bolts And Grommets

    Courtesy of FORD MOTOR CO.
NOTE: Identify spark plug location if new spark plugs are not going to be installed. Original spark plugs must be installed in their original locations.
Fig 14: Identifying Spark Plug
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29. Remove the spark plugs (12405).
30. Remove the camshaft position sensor (CMP sensor) (6B288).
    Fig 15: Removing Camshaft Position Sensor

    Courtesy of FORD MOTOR CO.
31. Remove the knock sensor.
    Fig 16: Removing Knock Sensor

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32. Remove the center timing belt cover.
    Fig 17: Removing Center Timing Belt Cover

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NOTE: Hold the camshaft (6250) with a wrench to prevent camshaft rotation.
Fig 18: Removing Oil Plug On Variable Camshaft Timing Assembly
Courtesy of FORD MOTOR CO.
33. Remove the oil plug on the variable camshaft timing assembly.
34. Remove the bolt then remove the crankshaft pulley (6312).
    Fig 19: Removing Crankshaft Pulley

    Courtesy of FORD MOTOR CO.
35. Remove the lower timing belt cover.
    Fig 20: Removing Lower Timing Belt Cover

    Courtesy of FORD MOTOR CO.
36. Remove the timing belt tensioner.
    Fig 21: Removing Timing Belt Tensioner

    Courtesy of FORD MOTOR CO.
37. Remove the timing belt.
NOTE: Hold the camshafts with a wrench to prevent camshaft rotation.
Fig 22: Removing Camshaft Sprockets (1 Of 2)
Courtesy of FORD MOTOR CO.
Fig 23: Removing Camshaft Sprockets (2 Of 2)
Courtesy of FORD MOTOR CO.
38. Remove the camshaft sprockets (6256).
39. Remove the idler pulley.
    Fig 24: Removing Idler Pulley

    Courtesy of FORD MOTOR CO.
40. Remove the crankshaft sprocket (6306) and timing belt guide.
    Fig 25: Removing Crankshaft Sprocket And Timing Belt Guide

    Courtesy of FORD MOTOR CO.
41. Remove the camshaft timing belt guide pulleys.
42. Remove the timing cover back plate.
    Fig 26: Removing Timing Cover Back Plate

    Courtesy of FORD MOTOR CO.
43. Remove the water pump housing.
    Fig 27: Removing Water Pump Housing

    Courtesy of FORD MOTOR CO.
44. Remove the bolts.
    Fig 28: Removing Bolts

    Courtesy of FORD MOTOR CO.
45. Rotate the oil control solenoid assembly 90 degrees.
    Fig 29: Rotating Oil Control Solenoid Assembly 90 Degrees

    Courtesy of FORD MOTOR CO.
CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to be sure they are assembled in their original positions. Keep camshaft journal caps with the cylinder head from which they were removed. Do not mix with camshaft journal caps from another cylinder head.
Fig 30: Removing Camshaft Journal Cap Bolts
Courtesy of FORD MOTOR CO.
46. Remove the camshaft journal caps.
    • Loosen the bolts in several two-turn steps in the sequence shown in Fig 30.
    • Remove the bolts.
47. Remove camshaft front oil seals.
NOTE: The oil control solenoid assembly and exhaust camshafts are removed as an assembly.
Fig 31: Removing Camshafts
Courtesy of FORD MOTOR CO.
48. Remove the camshafts.
NOTE: If valve tappets (6500) are being reused the valve tappet must be installed in its original position or engine damage may occur.
Fig 32: Removing Valve Tappets
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49. Remove valve tappets.
CAUTION: The bolts are torque-to-yield, new bolts must be installed or possible engine damage may occur.
Fig 33: Removing Cylinder Head And Head Gasket
Courtesy of FORD MOTOR CO.
50. Remove the cylinder head (6049) and the head gasket (6051).
51. If the cylinder head is to be repaired. For additional information, refer to CYLINDER HEAD .
52. Turn the engine upside down on the engine stand.
53. Remove the crankshaft position sensor (CKP sensor) (6C315) and the bushing.
    Fig 34: Removing Crankshaft Position Sensor

    Courtesy of FORD MOTOR CO.
54. Remove the oil pan (6675).
    • Remove the bolts.
    • Remove the oil pan.
    • Clean sealing surfaces with a non-abrasive cleaner.
    Fig 35: Removing Oil Pan Bolts

    Courtesy of FORD MOTOR CO.
55. Remove the oil pump cover and screen.
    • Remove the bolts.
    • Remove the oil pump cover and screen.
    • Remove and discard the oil pump inlet tube gasket (6626).
    Fig 36: Removing Bolts

    Courtesy of FORD MOTOR CO.
56. Remove the cylinder block cradle (6010) shims, if equipped.
57. Remove the cylinder block cradle and the gasket.
    Fig 37: Removing Cylinder Block Cradle And Gasket

    Courtesy of FORD MOTOR CO.
58. Remove the crankshaft front seal (6700). For additional information, refer to CRANKSHAFT FRONT OIL SEAL .
59. Remove the oil pump (6600).
    • Remove the bolts.
    • Remove the oil pump.
    • Remove the oil pump to cylinder block gasket (6659).
    Fig 38: Removing Oil Pump Bolts

    Courtesy of FORD MOTOR CO.
60. Remove the rear main oil seal retainer assembly and discard the gasket.
    Fig 39: Removing Rear Main Oil Seal Retainer Assembly

    Courtesy of FORD MOTOR CO.
CAUTION: The connecting rods and connecting rod caps must be correctly oriented, the interlocking tangs on the same side of the connecting rod or possible engine damage may occur.
CAUTION: The connecting rod bolts are torque-to-yield. Discard the connecting rod bolts.
Fig 40: Removing Connecting Rod Caps
Courtesy of FORD MOTOR CO.
61. Remove the four connecting rod caps.
62. If the connecting rod bearings are to be revised, each one must be identified so that it can be installed in its original location. Remove the four upper and four lower connecting rod bearings (6211).
    Fig 41: Removing Upper And Four Lower Connecting Rod Bearings

    Courtesy of FORD MOTOR CO.
63. Remove the four piston and connecting rod assemblies.
    Fig 42: Removing Piston And Connecting Rod Assemblies

    Courtesy of FORD MOTOR CO.
CAUTION: Make sure the main bearing caps are installed in their original position or possible engine damage may occur.
Fig 43: Removing Crankshaft Main Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
64. Remove the crankshaft main bearing caps.
    • Remove the bolts.
    • Remove the crankshaft main bearing caps.
    • Remove the lower crankshaft main bearings (6333).
65. Remove the crankshaft (6303).
    Fig 44: Removing Crankshaft

    Courtesy of FORD MOTOR CO.
66. Remove the upper crankshaft main bearing.
    Fig 45: Removing Upper Crankshaft Main Bearings

    Courtesy of FORD MOTOR CO.
67. Remove the upper crankshaft main bearing and the upper crankshaft thrust main bearing (6337).
68. Remove the crankshaft key.
    Fig 46: Removing Crankshaft Key

    Courtesy of FORD MOTOR CO.
69. If required, remove all the pipe plugs and alignment dowels.