Engine Mechanical: Mechanical: Engine: Disassembly: Engine

For information on Ford Color Coded Illustrations refer to OEM Color Coding .

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-142 (T80T-4000-J) Installer, Differential Bearing Cone
Courtesy of FORD MOTOR COMPANY	205-150 (T80T-4000-S) Installer, Spindle Bearing
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1655 Tool, Camshaft Holding
Courtesy of FORD MOTOR COMPANY	303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH
Knife
Puller

Materials 

1. • Loosen the coolant hose fitting.
   • Release the clamps and remove the coolant hoses.

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2. Release the clamps and disconnect the coolant hoses.

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3. • Remove the coolant hose retainer nut and bolt.
   • Release the coolant hose retainer.
   • Remove the coolant hose retainer nut.

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4. Release the clamp and remove the coolant hoses.

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5. Remove the nut and position the coolant hoses and retainer aside.

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6. Remove the bolts and the thermostat housing and hoses.

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7. Remove and discard the thermostat housing O-ring seal and gasket.

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8. Disconnect the EOP sensor wiring harness electrical connector and retainer.

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9. • Remove the wiring harness retainer bolt.
   • Remove the CKP sensor cover.
   • Disconnect the CKP sensor wiring harness electrical connector.
   • Detach the wiring harness retainer.

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10. Remove the ground wire stud bolt.

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11. • Disconnect the ignition coil-on-plug electrical connectors.
    • Disconnect the CMP sensor electrical connectors.
    • Disconnect the VCT unit electrical connectors.
    • Detach the wiring harness retainers and position the wiring harness aside.

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12. Remove the retainers and the heat shield.

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13. • Disconnect the direct injector fuel rail harness electrical connectors.
    • Disconnect the CMP sensor electrical connectors.
    • Disconnect the CHT sensor electrical connectors.
    • Detach the wiring harness retainers and position the wiring harness aside.

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14. • Disconnect the KS sensor electrical connector.
    • Disconnect the port injector fuel rail harness electrical connectors.
    • Remove the ground wire stud bolt.

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15. • Disconnect the ignition coil-on-plug electrical connectors.
    • Disconnect the VCT unit electrical connectors.
    • Disconnect the high pressure fuel pump electrical connector.
    • Detach the wiring harness retainers and remove the engine wiring harness.

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16. Disconnect the quick release coupling and remove the fuel inlet tube. Refer to: Quick Release Coupling .

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17. Disconnect the secondary latches and position aside.

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18. • Detach the high-pressure fuel pump supply line retainers.
    • Disconnect the spring lock couplings and remove the high-pressure fuel pump supply line. Refer to: Spring Lock Couplings .

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19. • Remove and discard the high-pressure fuel pump to fuel rail high-pressure fuel tube retaining bolts.
    • Disconnect the high-pressure fuel pump to fuel rail high-pressure fuel tube flare nuts.
    • Remove and discard the high-pressure fuel pump to fuel rail high-pressure fuel tube.

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20. NOTE: Alternately loosen the high-pressure fuel pump bolts one complete revolution at a time.

    Remove the bolts and the high-pressure fuel pump.

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21. Remove and discard the high-pressure fuel pump O-ring seal.

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22. Remove the high-pressure fuel pump roller tappet.

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23. • Inspect the high-pressure fuel pump roller tappet. If any flat spots or scoring are found, especially in the indicated areas.
    • Inspect the high-pressure fuel pump and the high-pressure fuel pump roller tappet drive lobe.
    • Install new components as needed.

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24. Loosen the bolt and remove the high-pressure fuel pump mounting plate.

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25. NOTE: Use compressed air to remove any foreign material from the ignition coil-on-plugs and surrounding area before removing the ignition coil-on-plugs.
    NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

    Remove the bolts and the RH ignition coil-on-plugs.

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26. NOTE: Use compressed air to remove any foreign material from the ignition coil-on-plugs and surrounding area before removing the ignition coil-on-plugs.
    NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

    Remove the bolts and the LH ignition coil-on-plugs.

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27. Loosen the stud bolts, bolts and remove the LH valve cover.

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28. Remove and discard the valve cover gasket.

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29. NOTE: Inspect the VCT oil control solenoid seals. Remove any damaged seals.

    If necessary, using the special tools, remove the VCT oil control solenoid seals. Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone, 205-153 (T80T-4000-W) Handle.

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30. NOTE: Inspect the spark plug tube seals. Remove any damaged seals.

    If necessary, using the special tools, remove the spark plug tube seals. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer, 205-153 (T80T-4000-W) Handle.

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31. Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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32. Loosen the stud bolts, bolts and remove the RH valve cover.

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33. Remove and discard the valve cover gasket.

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34. NOTE: Inspect the VCT solenoid seals. Remove any damaged seals.

    If necessary, using the special tools, remove the VCT solenoid seals. Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone, 205-153 (T80T-4000-W) Handle.

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35. NOTE: Inspect the spark plug tube seals. Remove any damaged seals.

    If necessary, using the special tools, remove the spark plug tube seals. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer, 205-153 (T80T-4000-W) Handle.

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36. Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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37. Cut and discard the coolant pump belt. Use the General Equipment: Knife

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38. Remove the bolt and the coolant pump belt idler pulley.

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39. Remove the bolts and the coolant pump belt idler pulley bracket.

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40. Remove and bolts and the coolant pump.

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41. Remove and discard the coolant pump O-ring seal and gasket.

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42. Remove the crankshaft bolt and washer.

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43. Remove the crankshaft pulley bolts.

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44. Using a Puller and 2 bolts, remove the crankshaft pulley. Use the General Equipment: Puller

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45. Install the original crankshaft pulley bolt and washer.

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46. Using the special tool, remove and discard the crankshaft front seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.

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47. NOTE: Retain the original crankshaft pulley bolt for turning the crankshaft while the pulley is removed.

    Remove the original crankshaft pulley bolt and washer.

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48. Remove the nuts and the coolant hose retainer bracket.

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49. Remove the engine front cover bolts.

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50. Using a pry tool on the pry pads shown, remove the engine front cover.

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51. Using the special tools, remove and discard the engine front cover to coolant pipe seal. Use Special Service Tool: 205-150 (T80T-4000-S) Installer, Spindle Bearing, 205-153 (T80T-4000-W) Handle.

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52. Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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53. Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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54. • Remove the bolts and the LH engine mount bracket.
    • Discard the bolts.

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55. Remove the bolts and the EOP sensor cover plate.

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56. Remove and discard cover plate gasket.

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57. Remove the bolts and the oil pump tube.

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58. Remove and discard the O-ring seals.

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59. Remove the bolts and the oil pump support bracket.

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60. Remove the bolts and the oil pump assembly.

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61. Remove and discard the gasket and O-ring seal.

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62. • Remove the bolts and the RH engine mount bracket.
    • Discard the bolts.

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63. Install the original crankshaft pulley bolt and washer.

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64. 1. Rotate the crankshaft clockwise.
    2. Position the crankshaft sprocket keyway at the 11 o'clock position.
    3. Verify the timing marks on the VCT units are at the 11 o'clock (exhaust) and 12:30 (intake) positions.

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65. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install Special Service Tool: 303-1655 Tool, Camshaft Holding.

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66. Remove the bolts and the RH timing chain tensioner.

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67. Remove the RH timing chain tensioner arm.

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68. Remove the bolts and the RH timing chain guide.

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69. Remove the RH timing chain.

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70. Verify the timing marks on the VCT units are at the 11:30 (intake) and 1:00 o'clock (exhaust) positions.

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71. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install Special Service Tool: 303-1655 Tool, Camshaft Holding.

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72. Remove the stud bolt, bolt and the LH timing chain tensioner.

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73. Remove the LH timing chain tensioner arm.

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74. Remove the bolts and the LH timing chain guide.

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75. Remove the LH timing chain.

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76. Remove the original crankshaft pulley bolt and washer.

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77. Remove the timing chain sprocket.

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78. NOTE: Make sure the camshaft holding tool is in position.
    • Remove the bolts and the exhaust and intake VCT units.
    • Discard the bolts.

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79. NOTE: Make sure the camshaft holding tool is in position.
    • Remove the bolts and the exhaust and intake VCT units.
    • Discard the bolts.

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80. Remove Special Service Tool: 303-1655 Tool, Camshaft Holding.

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81. NOTE: The front camshaft bearing mega cap must be removed first. Failure to follow this direction may result in damage to the engine.

    Remove the bolts and the front camshaft bearing mega cap.

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82. Remove the bolts and the camshaft bearing caps.

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83. Remove the intake and exhaust camshaft.

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84. NOTE: Mark the location of the roller follower and the hydraulic lash adjuster assembly before removal.
    1. Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
    2. Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
    3. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Replace damaged components as necessary.

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85. Remove Special Service Tool: 303-1655 Tool, Camshaft Holding.

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86. NOTE: The front camshaft bearing mega cap must be removed first. Failure to follow this direction may result in damage to the engine.

    Remove the bolts and the front camshaft bearing mega cap.

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87. Remove the bolts and the camshaft bearing caps.

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88. Remove the intake and exhaust camshaft.

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89. NOTE: Mark the location of the roller follower and the hydraulic lash adjuster assembly before removal.
    1. Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
    2. Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
    3. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Replace damaged components as necessary.

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90. Disconnect the secondary latches and position aside.

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91. Disconnect the spring lock couplings and remove the fuel rail to fuel rail fuel supply line. Refer to: Spring Lock Couplings .

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92. NOTE: To release the fuel pressure in the fuel rail to fuel rail high-pressure fuel tube, wrap the fuel rail to fuel rail high-pressure fuel tube flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of the fuel rail to fuel rail high-pressure fuel tube flare nuts.

    Disconnect the fuel rail to fuel rail high-pressure fuel tube flare nuts and remove and discard the fuel rail to fuel rail high-pressure fuel tube.

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93. Remove the LH block coolant drain and allow coolant to drain from the cylinder block.

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94. Remove the RH block coolant drain and allow coolant to drain from the cylinder block.

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95. Remove and discard the RH cylinder head M6 bolt.

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96. NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
    NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
    • Remove and discard the bolts from the RH cylinder head.
    • Remove the cylinder head.

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97. Remove and discard the RH cylinder head gasket.

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98. NOTE: 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.
    NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    • Clean and inspect the cylinder block mating surface.
    • Check the cylinder head distortion. Refer to: Cylinder Block Distortion .

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99. NOTE: 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.
    NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    • Clean and inspect the cylinder block mating surface.
    • Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion. Refer to: Cylinder Head Distortion .

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100. Remove and discard the LH cylinder head M6 bolt.

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101. NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
     NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface
     NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
     • Remove and discard the bolts from the LH cylinder head.
     • Remove the cylinder head.

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102. Remove and discard the LH cylinder head gasket.

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103. NOTE: 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.
     NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
     • Clean and inspect the cylinder block mating surface.
     • Check the cylinder head distortion. Refer to: Cylinder Block Distortion .

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104. NOTE: 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.
     NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
     • Clean and inspect the cylinder block mating surface.
     • Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion. Refer to: Cylinder Head Distortion .

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105. Remove the bolts and the KS.

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106. Remove the bolts and the channel cover plate.

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107. Remove and discard the gasket.

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108. Remove the bolt and the coolant hose retainer bracket.

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109. Remove the oil pan bolts.

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110. Using a pry tool on the pry pads, release the oil pan seal.

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111. NOTE: 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, may cause engine failure.

     Slide the oil pan to the side to release the oil transfer tube and filter from the oil pan and remove the oil pan.

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112. Remove and oil transfer tube and filter.

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113. Remove and discard the oil transfer tube and filter O-ring seals.

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114. 1. Inspect the oil transfer tube and filter for debris.
     2. Clean the oil transfer tube and filter.

        Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

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115. Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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116. 1. Inspect the oil transfer tube and filter bore on the oil pan for wear.
     2. Measure the oil transfer tube and filter bore, if the bore diameter exceeds 31.80 mm (1.252 in) the oil pan must be replaced.

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117. Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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118. Remove the bolts and the oil manifold.

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119. Remove and discard the oil manifold gasket.

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120. Remove the bolt and the CKP sensor.

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121. • Remove the bolts and the crankshaft rear seal retainer.
     • Discard the crankshaft rear seal retainer.

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122. Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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123. • 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.

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124. • Remove and discard the bolts in sequence shown.
     • Remove the main bearing cap support brace.

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125. NOTE: The connecting rod cap bolts are a torque-to-yield design.
     NOTE: Clearly mark the position and orientation of the connecting rods, connecting rod caps and connecting rod bearings for reassembly.
     • Remove the connecting rod cap bolts and caps.
     • Discard the connecting rod cap bolts.

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126. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod while removing the pistons.

     Remove the piston/rod assembly from the engine block.

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127. Inspect the pistons. Refer to: Piston Inspection .
128. NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.

     Remove and discard the bolts in sequence shown.

     Fig 1: Main Bearing Cap Bolts Loosening Sequence

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129. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
     NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.

     Remove the main bearing caps.

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130. Remove the lower crankshaft thrust washer from the back side of the No. 4 rear main bearing cap.

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131. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

     Remove the crankshaft main bearings from the main bearing caps.

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132. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.

     Remove the crankshaft.

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133. Remove the crankshaft thrust bearings from the rear main bearing bulkhead.

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134. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

     Remove the crankshaft main bearings from the cylinder block.

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135. • Remove the piston cooling jets bolts.
     • NOTE: Do not remove by grasping the tubes.

       By grasping the main hub, remove the piston cooling jets.

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136. • Inspect the piston cooling jets for debris, bent or damaged tubes.
     • Replace as necessary.

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137. • Inspect the piston cooling jets O-ring seal for damage.
     • Replace as necessary.

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