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Engine Mechanical: Mechanical: Engine: Disassembly: Engine

SPECIAL TOOL(S)

G04652177Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04652178Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04652179Courtesy of FORD MOTOR CO.
 Locking Tool, Flywheel
303-103 (T74P-8375-A)
G04652180Courtesy of FORD MOTOR CO.
 Engine Stand
014-00232 or equivalent
G04652181Courtesy of FORD MOTOR CO.
 Alignment Plate, Camshaft
303-465 (T94P-6256-CH)
G04652182Courtesy of FORD MOTOR CO.
 Timing Peg, Crankshaft
303-507
G04652183Courtesy of FORD MOTOR CO.
 Holding Fixture, Drive Pinion Flange
205-126 (T78P-4851-A)
G04652184Courtesy of FORD MOTOR CO.
 Adapter for 205-126 (205-072-02)
G04652185Courtesy of FORD MOTOR CO.
 Remover, Oil Seal
303-409 (T92C-6700-CH)
CAUTION: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
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.
CAUTION: Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.
NOTE: For additional information, refer to the exploded view under the assembly procedure in this article.

    Vehicles equipped with a manual transmission 

    WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury.
    CAUTION: Loosen the bolts evenly to prevent pressure plate damage.
    Fig 1: Locating Clutch Pressure Plate Bolts
    G04652186Courtesy of FORD MOTOR CO.
  1. Remove the 7 bolts, clutch pressure plate and clutch disc.

    2. All vehicles 

  2. Install the special tool and remove the flywheel or flexplate.
    Fig 2: Identifying Special Tool (303-103)
    G04652187Courtesy of FORD MOTOR CO.
  3. Mount the engine on a suitable engine stand.
  4. Disconnect the crankshaft position (CKP) sensor and the wiring harness pin-type retainers.
    Fig 3: Locating Crankshaft Position Sensor And Wiring Harness Pin-Type Retainers
    G04652188Courtesy of FORD MOTOR CO.
  5. Remove the 3 nuts and the generator heat shield.
    Fig 4: Locating Generator Heat Shield And Nuts
    G04652189Courtesy of FORD MOTOR CO.
  6. Remove the nut and disconnect the generator electrical connections and wiring harness retainer.
    Fig 5: Locating Generator Electrical Connections And Wiring Harness Retainer
    G04652190Courtesy of FORD MOTOR CO.
  7. Remove the nut and the wiring harness retainer.
    Fig 6: Locating Wiring Harness Retainer And Nut
    G04652191Courtesy of FORD MOTOR CO.
  8. Remove the bolt, the 2 stud bolts and the generator.
    Fig 7: Locating Generator And Bolts
    G04652192Courtesy of FORD MOTOR CO.
  9. Remove the 2 bolts and the accessory drive belt tensioner.
    Fig 8: Locating Accessory Drive Belt Tensioner Bolts
    G04652193Courtesy of FORD MOTOR CO.
  10. Loosen the bolt and remove the accessory drivebelt idler pulley.
    Fig 9: Locating Accessory Drivebelt Idler Pulley And Bolt
    G04652194Courtesy of FORD MOTOR CO.
  11. If equipped, loosen the bolt and remove the accessory drive belt idler pulley.
    Fig 10: Locating Accessory Drive Belt Idler Pulley And Bolt
    G04652195Courtesy of FORD MOTOR CO.
  12. Remove the 3 bolts and the coolant pump pulley.
    Fig 11: Locating Coolant Pump Pulley Bolts
    G03897969Courtesy of FORD MOTOR CO.
  13. Remove the 3 bolts and the coolant pump.
    Fig 12: Locating Coolant Pump Bolts
    G03897970Courtesy of FORD MOTOR CO.
  14. Disconnect the heater hose from the thermostat housing.
    Fig 13: Locating Heater Hose
    G04652198Courtesy of FORD MOTOR CO.
  15. Remove the 3 bolts and the thermostat housing.
    Fig 14: Locating Thermostat Housing Bolts
    G04652199Courtesy of FORD MOTOR CO.
  16. Disconnect the oil pressure sensor electrical connector.
    Fig 15: Locating Oil Pressure Sensor Electrical Connector
    G04652200Courtesy of FORD MOTOR CO.
  17. Remove the engine oil filter.
    Fig 16: Locating Engine Oil Filter
    G04652201Courtesy of FORD MOTOR CO.
  18. Remove the 4 bolts and the oil filter adapter.
    • Discard the gasket.
      Fig 17: Locating Oil Filter Adapter And Bolts
      G04652202Courtesy of FORD MOTOR CO.
  19. Disconnect the knock sensor (KS) electrical connector and pin-type retainer.
    Fig 18: Locating Knock Sensor Electrical Connector And Pin-Type Retainer
    G04652203Courtesy of FORD MOTOR CO.
  20. Remove the lower intake manifold bolt.
    Fig 19: Locating Lower Intake Manifold Bolt
    G04652204Courtesy of FORD MOTOR CO.
  21. Disconnect the throttle position (TP) sensor electrical connector and wiring harness pin-type retainer.
    Fig 20: Locating Throttle Position Sensor Electrical Connector And Wiring Harness Pin-Type Retainer
    G04652205Courtesy of FORD MOTOR CO.
  22. Disconnect the idle air control (IAC) valve electrical connector and wiring harness pin-type retainer.
    Fig 21: Locating Idle Air Control Valve Electrical Connector And Wiring Harness Pin-Type Retainer
    G04652206Courtesy of FORD MOTOR CO.
  23. Disconnect the fuel rail pressure and temperature sensor vacuum hose.
    Fig 22: Locating Fuel Rail Pressure And Temperature Sensor Vacuum Hose
    G04652207Courtesy of FORD MOTOR CO.
  24. Detach the wiring harness pin-type retainer.
    Fig 23: Locating Wiring Harness Pin-Type Retainer
    G04652208Courtesy of FORD MOTOR CO.
  25. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
    Fig 24: Locating Intake Manifold Runner Control Actuator Electrical Connector
    G04652209Courtesy of FORD MOTOR CO.
  26. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
    Fig 25: Locating Manifold Absolute Pressure Sensor Electrical Connector
    G04652210Courtesy of FORD MOTOR CO.

    27. 2.0L engines 

  27. If equipped, disconnect the secondary air injection (AIR) vacuum supply hose.
    Fig 26: Locating Secondary Air Injection (AIR) Vacuum Supply Hose
    G04652211Courtesy of FORD MOTOR CO.
  28. Disconnect the swirl control valve electrical connector.
    Fig 27: Locating Swirl Control Valve Electrical Connector
    G04652212Courtesy of FORD MOTOR CO.
  29. Remove the bolt and the oil level indicator tube.
    Fig 28: Locating Oil Level Indicator Tube Bolt
    G04652213Courtesy of FORD MOTOR CO.
    30. NOTE: There are 3 different size bolts used. Mark the location of the bolts to make sure of correct installation.
    Fig 29: Locating Intake Manifold Bolts
    G04652214Courtesy of FORD MOTOR CO.
  30. Remove the 7 intake manifold bolts.

    31. 2.3L engines 

  31. Disconnect the swirl valve electrical connectors and pin-type retainers.
    Fig 30: Locating Swirl Valve Electrical Connectors And Pin-Type Retainers
    G04652215Courtesy of FORD MOTOR CO.
  32. Remove the 2 bolts and the oil level indicator and tube.
    Fig 31: Locating Oil Level Indicator Tube Bolts
    G04652216Courtesy of FORD MOTOR CO.
    33. NOTE: There are 3 different size bolts used. Mark the location of the bolts to make sure of correct installation.
    Fig 32: Locating Intake Manifold Bolts
    G04652217Courtesy of FORD MOTOR CO.
  33. Remove the 7 intake manifold bolts.

    34. All engines 

  34. Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.
    Fig 33: Locating Positive Crankcase Ventilation Hose
    G04652218Courtesy of FORD MOTOR CO.
  35. Remove the exhaust gas recirculation (EGR) tube.
    Fig 34: Locating Exhaust Gas Recirculation Tube
    G04652219Courtesy of FORD MOTOR CO.
  36. Remove the radio interference capacitor bracket bolt and position the bracket aside.
    Fig 35: Locating Radio Interference Capacitor Bracket Bolt
    G04652220Courtesy of FORD MOTOR CO.
  37. Disconnect the wiring harness retainers from the valve cover studs and position aside.
    Fig 36: Locating Wiring Harness Retainers
    G04652221Courtesy of FORD MOTOR CO.
  38. Disconnect the fuel charging wiring harness.
    • Disconnect the fuel rail pressure and temperature sensor electrical connector.
    • Disconnect the 4 fuel injector electrical connectors.
    • Detach the wiring harness retainers.
      Fig 37: Locating Fuel Charging Wiring Harness
      G04652222Courtesy of FORD MOTOR CO.
  39. Remove the 2 bolts and the fuel rail with the fuel injectors.
    Fig 38: Locating Fuel Rail Bolts And Fuel Rail
    G04652223Courtesy of FORD MOTOR CO.
  40. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
    Fig 39: Locating Camshaft Position Sensor Electrical Connectors And Coil-On-Plug
    G04652224Courtesy of FORD MOTOR CO.
  41. Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor electrical connector. Remove the wiring harness from the engine.
    Fig 40: Locating Cylinder Head Temperature Sensor Electrical Connector And Rubber Boot
    G04652225Courtesy of FORD MOTOR CO.
  42. Disconnect and remove the coolant hose.
    Fig 41: Locating Coolant Hose
    G04652226Courtesy of FORD MOTOR CO.
  43. Disconnect the coolant bypass hose.
    Fig 42: Locating Coolant Bypass Hose
    G04652227Courtesy of FORD MOTOR CO.
  44. Remove the 4 bolts and the coolant bypass.
    Fig 43: Locating Coolant Bypass And Bolts
    G04652228Courtesy of FORD MOTOR CO.
  45. Disconnect and remove the coolant bypass hose.
    Fig 44: Locating Coolant Bypass Hose
    G04652229Courtesy of FORD MOTOR CO.
  46. Remove the bolt and the KS.
    Fig 45: Locating KS And Bolt
    G04652230Courtesy of FORD MOTOR CO.
  47. Remove the 8 bolts and the crankcase vent oil separator.
    Fig 46: Locating Crankcase Vent Oil Separator And Bolts
    G04652231Courtesy of FORD MOTOR CO.
  48. If equipped, remove the block heater.
    Fig 47: Locating Block Heater
    G04652232Courtesy of FORD MOTOR CO.
  49. Remove the crankcase vent tube and the coil-on-plugs.
    Fig 48: Locating Crankcase Vent Tube And Coil-On-Plugs
    G04652233Courtesy of FORD MOTOR CO.
    50. CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
  50. Remove the spark plugs and the CHT sensor.
    • Discard the CHT.
      Fig 49: Locating Spark Plugs And CHT Sensor
      G04652234Courtesy of FORD MOTOR CO.
  51. Remove the bolts and the valve cover.
    Fig 50: Locating Valve Cover And Bolts
    G04652235Courtesy of FORD MOTOR CO.
    52. CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
  52. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
    • The hole in the crankshaft pulley should be in the 6 o'clock position.
      Fig 51: Turning Crankshaft Clockwise
      G04652236Courtesy of FORD MOTOR CO.
    53. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    NOTE: The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
    Fig 52: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  53. Install the special tool in the slots on the rear of both camshafts.
  54. Remove the engine plug bolt.
    Fig 53: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    55. NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during disassembly.
    Fig 54: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
  55. Install the special tool.
  56. Assemble the special tools using 4 hardened washers in the locations shown.
    Fig 55: Assembling Special Tools (205-072-02 And 205-126)
    G04652240Courtesy of FORD MOTOR CO.
    57. CAUTION: The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
    CAUTION: If the crankshaft sprocket diamond washer comes off with the crankshaft pulley, it must be installed back onto the crankshaft.
  57. Using the special tools and an air impact wrench, remove the crankshaft pulley.
    • Remove and discard the crankshaft pulley bolt and washer.
    • Remove the crankshaft pulley.
      Fig 56: Identifying Special Tools Assembly (205-072-02/205-126) And Crankshaft Pulley Bolt
      G04652241Courtesy of FORD MOTOR CO.
    58. CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.
    Fig 57: Identifying Special Tool (303-409) And Crankshaft Front Oil Seal
    G04652242Courtesy of FORD MOTOR CO.
  58. Using the special tool, remove the crankshaft front oil seal.
    59. NOTE: Whenever the CKP sensor is removed, a new one must be installed using the alignment jig supplied with the new part.
    Fig 58: Locating CKP Sensor
    G03898012Courtesy of FORD MOTOR CO.
  59. Remove and discard the CKP sensor.
  60. Remove the 22 bolts and the engine front cover.
    Fig 59: Locating Engine Front Cover Bolts
    G03897743Courtesy of FORD MOTOR CO.
  61. Remove the timing chain tensioner.
    1. Compress the timing chain tensioner, and insert a paper clip into the hole to retain the tensioner.
    2. Remove the 2 bolts and timing chain tensioner.
      Fig 60: Identifying Timing Chain Tensioner Bolts And Paper Clips
      G04652245Courtesy of FORD MOTOR CO.
  62. Remove the RH timing chain guide.
    Fig 61: Locating RH Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
  63. Remove the timing chain.
    Fig 62: View Of Timing Chain
    G03897779Courtesy of FORD MOTOR CO.
  64. Remove the 2 bolts and the LH timing chain guide.
    Fig 63: Identifying Bolts And LH Timing Chain Guide
    G03897780Courtesy of FORD MOTOR CO.
    65. CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
    Fig 64: Locating Cam Holding Area And Sprocket Bolt
    G03897781Courtesy of FORD MOTOR CO.
  65. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
  66. Remove the oil pump chain tensioner and guide.
    1. Release the tension on the tensioner spring.
    2. Remove the tensioner and the shoulder bolt.
    3. Remove the guide.
      Fig 65: Identifying Tensioner Spring, Shoulder Bolt And Guide
      G04652250Courtesy of FORD MOTOR CO.
    67. NOTE: Remove the crankshaft sprocket diamond washers located in front of and behind the crankshaft sprocket.
    NOTE: The oil pump chain sprocket must be held in place.
  67. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain and sprockets.
      Fig 66: Identifying Bolt, Chain And Sprockets
      G04652251Courtesy of FORD MOTOR CO.
  68. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
    Fig 67: Locating Camshaft Lobe
    G03898791Courtesy of FORD MOTOR CO.
    69. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
  69. Remove the camshafts from the engine.
    • Loosen the camshaft bearing bolts in the sequence shown, one turn at a time. Repeat until all the tension is released.
    • Remove the camshaft bearing caps.
    • Remove the camshafts.
      Fig 68: Identifying Loosening/Tightening Sequence Of Camshaft Bearing Bolts
      G03897808Courtesy of FORD MOTOR CO.
  70. Remove the cylinder head.
    • Remove and discard the 10 cylinder head bolts.
    • Remove the cylinder head.
    • Remove and discard the cylinder head gasket.
      Fig 69: Locating Cylinder Head Bolts
      G04652254Courtesy of FORD MOTOR CO.
  71. Remove the cylinder head alignment dowels.
    Fig 70: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
  72. Remove the 13 bolts and the oil pan.
    Fig 71: Locating Oil Pan Bolts
    G04652256Courtesy of FORD MOTOR CO.
  73. Remove the 6 bolts and the rear crankshaft seal.
    Fig 72: Locating Bolts
    G04652257Courtesy of FORD MOTOR CO.
  74. Remove the 2 bolts, oil pump pickup tube and gasket.
    Fig 73: Locating Oil Pump Pickup Tube Bolts
    G04652258Courtesy of FORD MOTOR CO.
  75. Remove the 4 bolts and the oil pump.
    Fig 74: Locating Oil Pump Bolts
    G04652259Courtesy of FORD MOTOR CO.
  76. Remove the 3 bolts and the intermediate shaft bearing bracket.
    Fig 75: Locating Intermediate Shaft Bearing Bracket And Bolts
    G04652260Courtesy of FORD MOTOR CO.

    77. 2.3L engines 

  77. Make sure the Crankshaft TDC  Timing Peg is still installed and the engine is still at Top Dead Center (TDC).
    • Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC  Timing Peg.
    Fig 76: Installing Crankshaft TDC Timing Peg
    G06262183
  78. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC  .
    Fig 77: Locating Balancer Unit And Shafts Reference Mark
    G06262184
  79. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.

    Remove the 4 bolts and the balancer unit.

    Fig 78: Locating Balancer Unit Bolts
    G06262185

    80. All engines 

  80. Remove the Crankshaft TDC  Timing Peg.
    Fig 79: Installing Crankshaft TDC Timing Peg
    G06262186
  81. 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, following manufacturer's instructions.
  82. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.

    Remove the connecting rod cap bolts and cap.

    Fig 80: Locating Connecting Rod Cap Bolts
    G06262187
  83. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

    Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.

    • Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
    Fig 81: Identifying Connecting Rod Installer
    G06262188
  84. Remove the bolts in the sequence shown.
    • Remove the main bearing beam.
    • Discard the bolts.
    Fig 82: Identifying Crankshaft Cap Bolts Removing Sequence
    G06262189
  85. Remove the crankshaft from the engine block.
    Fig 83: Locating Crankshaft
    G06262190
  86. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.

    Remove the main bearings from the main bearing beam.

    Fig 84: Locating Main Bearings
    G06262191
  87. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
    NOTE: The center bulkhead has the thrust bearing.

    Remove the main bearings from the cylinder block.

    Fig 85: Locating Main Bearings
    G06262192
  88. NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly.
    NOTE: The front bulkhead does not have an oil squirter.

    Remove the 4 oil squirters.

    Fig 86: Locating Oil Squirters
    G06262193
  89. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
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