Engine Mechanical: Mechanical: Engine: Disassembly: Engine

SPECIAL TOOL(S)

Courtesy of FORD MOTOR CO.	Impact Slide Hammer 100-001 (T50T-100-A)
Courtesy of FORD MOTOR CO.	Remover, Crankshaft Rear Seal 303-519 (T95P-6701-EH)
Courtesy of FORD MOTOR CO.	Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
Courtesy of FORD MOTOR CO.	Remover, Oil Seal 303-409 (T92C-6700-CH)
Courtesy of FORD MOTOR CO.	Remover, Crankshaft Vibration Damper 303-176 (T82L-6316-B)

MATERIALS

Item	Specification
Silicone Gasket Remover ZC-30	-
Motorcraft Metal Surface Prep ZC-31	-

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 views in ENGINE ASSEMBLY  .

1. Remove the 6 bolts and the flywheel.
   Fig 1: Locating Flywheel Bolts

   Courtesy of FORD MOTOR CO.
2. Using the special tools, remove the crankshaft rear seal.
   Fig 2: Identifying Special Tools (100-001) And (303-519)

   Courtesy of FORD MOTOR CO.
3. Mount the engine on a suitable stand.
4. Remove the 4 bolts and the coolant pump pulley.
   Fig 3: Locating Coolant Pump Pulley Bolts

   Courtesy of FORD MOTOR CO.
5. Remove the accessory drive belt idler pulley.
   Fig 4: Locating Accessory Drive Belt Idler Pulley

   Courtesy of FORD MOTOR CO.
6. Disconnect the generator.
   • Remove the B+ wire terminal.
   • Disconnect the generator electrical connector.
     Fig 5: Locating Generator Electrical Connector

     Courtesy of FORD MOTOR CO.
7. Remove the 3 bolts and the generator.
   Fig 6: Locating Generator Bolts

   Courtesy of FORD MOTOR CO.
8. Remove the bolt and the coolant pump extension tube and bracket.
   Fig 7: Locating Coolant Pump Extension Tube And Bracket Bolt

   Courtesy of FORD MOTOR CO.
9. Remove the 4 bolts and the A/C compressor mounting bracket brace and generator mounting bracket as an assembly.
   Fig 8: Locating A/C Compressor Mounting Bracket Bolts

   Courtesy of FORD MOTOR CO.
10. Remove the 4 bolts and the A/C compressor bracket.
    Fig 9: Locating A/C Compressor Bracket Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Remove and discard the coolant pump outlet tube O-ring.
11. Remove the coolant pump outlet tube.
    • Disconnect the 3 coolant hoses.
      • Reposition the clamps.
    • Remove the 2 bolts and the coolant pump outlet tube.
      Fig 10: Locating Coolant Pump Outlet Tube Bolts

      Courtesy of FORD MOTOR CO.
12. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 11: Locating Accessory Drive Belt Tensioner Bolts

    Courtesy of FORD MOTOR CO.
13. Remove the 4 bolts and the power steering pump bracket.
    Fig 12: Locating Power Steering Pump Bracket Bolts

    Courtesy of FORD MOTOR CO.
14. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 13: Locating Crankshaft Position Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
15. Remove the catalyst monitor sensor electrical connector mounting bracket.
    Fig 14: Locating Catalyst Monitor Sensor Electrical Connector Mounting Bracket

    Courtesy of FORD MOTOR CO.
16. Remove the 4 bolts and the RH engine mount bracket.
    Fig 15: Locating RH Engine Mount Bracket Bolts

    Courtesy of FORD MOTOR CO.
17. Disconnect the oil pressure sensor electrical connector and remove the engine harness pin-type retainer.
    Fig 16: Locating Oil Pressure Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
18. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 17: Locating Camshaft Position Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
19. Disconnect the intake manifold runner control (IMRC) electrical connector.
    Fig 18: Locating Intake Manifold Runner Control Electrical Connector

    Courtesy of FORD MOTOR CO.
20. Disconnect the crankcase vent hose valve electrical connector and quick-connect the crankcase vent hose.
    Fig 19: Locating Crankcase Vent Hose Valve Electrical Connector

    Courtesy of FORD MOTOR CO.
21. Disconnect the quick connect crankcase vent hose from the intake manifold and remove.
    Fig 20: Locating Quick Connect Crankcase Vent Hose

    Courtesy of FORD MOTOR CO.
22. Remove the bolt and the oil level indicator and tube.
    Fig 21: Removing Oil Level Indicator And Tube

    Courtesy of FORD MOTOR CO.
CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them.
Fig 22: Locating Spark Plug Wires And Retainers
Courtesy of FORD MOTOR CO.
23. Disconnect and remove the spark plug wires and retainers as an assembly.
24. Remove the 4 engine harness pin-type retainers.
    Fig 23: Locating Engine Harness Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
25. Disconnect the knock sensor (KS) electrical connector.
    Fig 24: Locating Knock Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
26. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 25: Locating Cylinder Head Temperature Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
27. Disconnect the following.
    1. Idle air control (IAC) electrical connector
    2. Throttle position (TP) sensor electrical connector
    3. Exhaust gas recirculation (EGR) system module electrical connector
    4. EGR system module vacuum connector
    5. EGR system module (ESM)-to-exhaust manifold tube upper fitting (the MAP/Baro sensor is an integral part of the ESM)
       Fig 26: Identifying EGR System Module (ESM)Vacuum Connector And Throttle Position Sensor Electrical Connector

       Courtesy of FORD MOTOR CO.
28. Detach the wire retainer from the TP sensor stud bolt.
    Fig 27: Locating Wire Retainer

    Courtesy of FORD MOTOR CO.
29. Loosen the nut and remove the EGR system module-to-exhaust manifold tube.
    Fig 28: Removing EGR System Module-To-Exhaust Manifold Tube

    Courtesy of FORD MOTOR CO.
30. Disconnect the ignition coil electrical connector and remove the engine harness pin-type retainer.
    Fig 29: Locating Ignition Coil Electrical Connector

    Courtesy of FORD MOTOR CO.
31. Remove the 3 bolts and the ignition coil.
    Fig 30: Locating Ignition Coil Bolts

    Courtesy of FORD MOTOR CO.
32. Disconnect the vacuum harness connection and remove the vacuum harness from the engine.
    Fig 31: Locating Vacuum Harness

    Courtesy of FORD MOTOR CO.
33. Disconnect the engine harness-to-fuel charging harness electrical connector and remove the engine harness from the engine.
    Fig 32: Locating Engine Harness-To-Fuel Charging Harness Electrical Connector

    Courtesy of FORD MOTOR CO.
34. Remove the upper intake manifold and discard the gaskets.
    Fig 33: Locating Upper Intake Manifold

    Courtesy of FORD MOTOR CO.
35. Remove the bolts and the fuel rail, fuel injectors and fuel charging harness as an assembly.
    Fig 34: Locating Fuel Rail, Fuel Injectors And Fuel Charging Harness

    Courtesy of FORD MOTOR CO.
36. Remove the fuel injector clips and fuel injectors.
    Fig 35: Locating Fuel Injector Clips And Fuel Injectors

    Courtesy of FORD MOTOR CO.
37. Remove and discard the fuel injector O-rings.
    Fig 36: Locating Fuel Injector O-Rings

    Courtesy of FORD MOTOR CO.
NOTE: Record the location of the 6 long bolts and the 8 short bolts.
Fig 37: Locating Lower Intake Manifold Assembly Bolts
Courtesy of FORD MOTOR CO.
38. Remove the bolts and the lower intake manifold assembly.
39. Remove and discard the lower intake manifold sealing components.
    Fig 38: Identifying Lower Intake Manifold Sealing Components

    Courtesy of FORD MOTOR CO.
40. Remove the 3 nuts and the heat shield.
    Fig 39: Locating Heat Shield Nuts

    Courtesy of FORD MOTOR CO.
41. Remove the 6 nuts and the RH exhaust manifold.
    Fig 40: Locating RH Exhaust Manifold Nuts

    Courtesy of FORD MOTOR CO.
42. Remove the 6 nuts and the LH exhaust manifold.
    Fig 41: Locating LH Exhaust Manifold Nuts

    Courtesy of FORD MOTOR CO.
43. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
44. Remove the LH valve cover.
    1. Remove the 3 bolts.
    2. Remove the 2 stud bolts.
    3. Remove the LH valve cover.
       Fig 42: Identifying LH Valve Cover

       Courtesy of FORD MOTOR CO.
45. Remove the RH valve cover.
    1. Remove the 3 stud bolts.
    2. Remove the 2 bolts.
    3. Remove the RH valve cover.
       Fig 43: Identifying RH Valve Cover

       Courtesy of FORD MOTOR CO.
       CAUTION: If the components are to be reinstalled, they must be installed into the same position. Mark the components for location.
NOTE: If the rocker arms are to be reinstalled, they must be installed into their original locations. Mark the rocker arms for location.
46. Remove the rocker arms.
    1. Remove the bolts.
    2. Remove the rocker arms and pivots.
       Fig 44: Identifying Rocker Arms And Pivots

       Courtesy of FORD MOTOR CO.
NOTE: If the push rods are to be reinstalled, they must be installed into their original locations. Mark the push rods for location.
Fig 45: Locating Push Rods
Courtesy of FORD MOTOR CO.
47. Remove the 12 push rods.
48. Remove the lower 3 exhaust manifold studs from both cylinder heads.
    Fig 46: Locating Lower Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.
NOTE: Record the location of long and short bolts.
Fig 47: Locating Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
49. Remove and discard all the cylinder head bolts.
NOTE: RH shown, LH similar.
Fig 48: Removing Cylinder Head
Courtesy of FORD MOTOR CO.
50. Remove the RH and LH cylinder heads and the gaskets. Discard the gasket.
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.
51. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads 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 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 staining of the metal surfaces is normal.
52. Inspect the cylinder heads for distortion. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
53. Remove and discard the engine oil filter.
    Fig 49: Locating Engine Oil Filter

    Courtesy of FORD MOTOR CO.
CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
54. If equipped, remove the oil cooler and tube assembly bolt.
    • Discard the oil cooler and tube assembly.
      Fig 50: Locating Oil Cooler And Tube Assembly

      Courtesy of FORD MOTOR CO.
55. Remove the oil pressure sensor.
    Fig 51: Locating Oil Pressure Sensor

    Courtesy of FORD MOTOR CO.
NOTE: Discard the oil pan rear seal.
Fig 52: Locating Oil Pan Bolts
Courtesy of FORD MOTOR CO.
56. Remove the 17 bolts and the oil pan.
NOTE: In some cases the oil pump intermediate shaft may not come out with the synchronizer assembly. If so, retrieve the intermediate shaft before proceeding.
Fig 53: Identifying Camshaft Synchronizer Assembly
Courtesy of FORD MOTOR CO.
57. Remove the bolt and the camshaft synchronizer assembly.
58. Using the special tool, remove the crankshaft damper and pulley assembly.
    Fig 54: Removing Crankshaft Damper And Pulley Using Special Tools (303-009) And (303-176)

    Courtesy of FORD MOTOR CO.
59. Using the special tool, remove the crankshaft front seal. Discard the seal.
    Fig 55: Using Special Tool (303-409) To Remove Front Crankshaft Seal

    Courtesy of FORD MOTOR CO.
60. Remove the coolant pump.
    • Remove the 4 nuts, 4 bolts and the stud bolt.
    • Remove the coolant pump.
    • Discard the coolant pump housing gasket.
      Fig 56: Locating Coolant Pump Bolts

      Courtesy of FORD MOTOR CO.
61. Remove the engine front cover and oil pump assembly and the engine front cover gasket.
    1. Remove the 2 stud bolts.
    2. Remove the bolt.
    CAUTION: The capscrew is hidden; make sure to remove it or the engine front cover will be damaged.
    3. Remove the capscrew.
    4. Slide the engine front cover and engine front cover gasket from the dowels. Discard the engine front cover gasket.
    5. Remove the 4 studs.
       Fig 57: Identifying Engine Front Cover Bolts

       Courtesy of FORD MOTOR CO.
62. Remove the camshaft synchronizer drive gear.
    1. Remove the bolt.
    2. Remove the camshaft synchronizer drive gear.
       Fig 58: Identifying Camshaft Synchronizer Drive Gear

       Courtesy of FORD MOTOR CO.
63. Compress and install a retaining pin to hold the timing chain tensioner.
    Fig 59: Identifying Timing Chain Tensioner Retaining Pin

    Courtesy of FORD MOTOR CO.
64. Remove the camshaft gear, the crankshaft gear and the timing chain as an assembly.
    Fig 60: Identifying Timing Chain And Sprockets

    Courtesy of FORD MOTOR CO.
65. Remove the bolts and the timing chain tensioner.
    Fig 61: Locating Timing Chain Tensioner Bolts

    Courtesy of FORD MOTOR CO.
NOTE: If the valve tappets are to be reinstalled, they must be installed into their original locations. Mark the valve tappets for installation.
66. Remove the 12 valve tappets.
    1. Remove the 2 bolts.
    2. Remove the tappet guide plate and retainer.
    3. Remove the 12 valve tappets.
       Fig 62: Identifying Valve Tappets

       Courtesy of FORD MOTOR CO.
67. Remove the engine balance shaft drive gear and camshaft key.
    Fig 63: Locating Engine Balance Shaft Drive Gear And Camshaft Key

    Courtesy of FORD MOTOR CO.
68. Remove the engine dynamic balance shaft.
    • Remove the 2 bolts.
    • Remove the balance shaft driven gear, thrust plate and engine dynamic balance shaft as an assembly.
      Fig 64: Locating Balance Shaft Driven Gear And Thrust Plate

      Courtesy of FORD MOTOR CO.
69. Remove the camshaft.
    1. Remove the 2 bolts.
    2. Remove the camshaft thrust plate.
    3. Remove the spacer.
    4. Remove the camshaft.
       Fig 65: Removing Camshaft

       Courtesy of FORD MOTOR CO.
70. Remove the bearing covers.
    1. Remove the engine dynamic balance shaft bearing cover.
    2. Remove the camshaft bearing cover.
       Fig 66: Identifying Engine Dynamic Balance Shaft Bearing Cover And Camshaft Bearing Cover

       Courtesy of FORD MOTOR CO.
71. Remove the oil pump screen cover and tube.
    • Remove the nut.
    • Remove the 2 bolts.
      Fig 67: Locating Oil Pump Screen Cover And Tube Bolts

      Courtesy of FORD MOTOR CO.
72. Remove the 5 nuts and the oil pan baffle.
    Fig 68: Locating Oil Pan Baffle Nuts

    Courtesy of FORD MOTOR CO.
73. If necessary, remove the ridge at the top of the cylinder.
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.
74. Remove the piston.
    1. Make sure the piston being removed is at the bottom of the cylinder bore.
    2. Remove the 2 bolts.
    3. Remove the connecting rod cap and the lower connecting rod bearing.
    CAUTION: Do not damage the cylinder wall when removing the piston.
    Fig 69: Removing Piston
    Courtesy of FORD MOTOR CO.
    4. Push the piston and the connecting rod out of the cylinder.
75. Repeat the piston removal steps for the remaining pistons.
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.
76. Remove the 4 main bearing caps and lower crankshaft main bearings.
    1. Remove the 2 stud bolts.
    2. Remove the main bearing cap and lower crankshaft main bearing.
       Fig 70: Identifying Main Bearing Cap

       Courtesy of FORD MOTOR CO.
77. Repeat the main bearing cap and the lower bearing removal steps for the remaining main bearing caps and the lower crankshaft main bearings.
CAUTION: The crankshaft journals must be protected from damage when the crankshaft is removed.
Fig 71: Locating Crankshaft
Courtesy of FORD MOTOR CO.
78. Remove the crankshaft.
NOTE: For ease in reassembly, record the location of the crankshaft upper thrust bearing.
Fig 72: Locating Upper Crankshaft Main Bearings And Crankshaft Upper Thrust Bearing
Courtesy of FORD MOTOR CO.
79. Remove the upper 4 crankshaft main bearings and the crankshaft upper thrust bearing.
80. Remove the 4 camshaft bearings.
    Fig 73: Locating Camshaft Bearings

    Courtesy of FORD MOTOR CO.
81. Remove the 2 engine dynamic balance shaft bearings.
    Fig 74: Locating Engine Dynamic Balance Shaft Bearings

    Courtesy of FORD MOTOR CO.
82. If equipped, remove the engine block heater.
    Fig 75: Locating Engine Block Heater

    Courtesy of FORD MOTOR CO.
NOTE: For cleaning purposes, the plugs should be removed.
83. If necessary, remove the following:
    1. Cylinder block dowels
    2. Oil gallery plugs
    3. Coolant jacket plugs
       Fig 76: Identifying Cylinder Block Dowels, Oil Gallery Plugs And Coolant Jacket Plugs

       Courtesy of FORD MOTOR CO.