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Section 551 (Engine - 4.0L): Disassembly: Engine

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tool(s)
G03180735Courtesy of FORD MOTOR CO.
GENERAL EQUIPMENT

8-mm x 1.25 x 100-mm bolts (2 req'd)
CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
CAUTION: If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold.
NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation.
NOTE: For additional information, refer to the exploded views under DESCRIPTION AND OPERATION .
  1. Remove the bolts and the flexplate.
    Fig 2: Removing Bolts And Flexplate
    G03180736Courtesy of FORD MOTOR CO.
  2. Remove the spacer plate.
  3. Install the engine on a suitable stand.
  4. Remove the nuts and the A/C hose.
    Fig 3: Removing Nuts And A/C Hose
    G03180737Courtesy of FORD MOTOR CO.
  5. Remove the bolts.
    Fig 4: Removing Bolts
    G03180738Courtesy of FORD MOTOR CO.
  6. Disconnect the A/C compressor electrical connector and wire harness retainer.
    Fig 5: Disconnecting A/C Compressor Electrical Connector And Wire Harness
    G03180739Courtesy of FORD MOTOR CO.
  7. Remove the bolts and the accessory bracket.
    Fig 6: Removing Bolts And Accessory Bracket
    G03180740Courtesy of FORD MOTOR CO.
  8. Disconnect the generator electrical connectors and wire harness retainers.
    Fig 7: Disconnecting Generator Electrical Connectors And Wire Harness Retainers
    G03180741Courtesy of FORD MOTOR CO.
  9. Remove the generator mounting bracket.
    1. Remove the bolt and the drive belt tensioner.
    2. Remove the generator mounting bracket bolts.
    Fig 8: Removing Generator Mounting Bracket Bolts
    G03180742Courtesy of FORD MOTOR CO.
  10. Disconnect the following electrical connectors:
    • Camshaft position (CMP) sensor.
    • Ignition coil.
    • Engine coolant temperature (ECT) sensor.
    • Ignition radio interference capacitor.
    • Fuel pressure and temperature sensor.
    Fig 9: Disconnecting Electrical Connectors
    G03180743Courtesy of FORD MOTOR CO.
    11. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.
    NOTE: RH shown; LH similar.
    NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them.
    Fig 10: Removing Spark Plug Wires
    G03180744Courtesy of FORD MOTOR CO.
  11. Remove the spark plug wires.
  12. Remove the bolts and the coil and bracket assembly.
    Fig 11: Removing Bolts And Coil And Bracket Assembly
    G03180745Courtesy of FORD MOTOR CO.

    13. Engines equipped with an engine oil cooler 

  13. Remove the oil cooler hose bracket bolts.
    Fig 12: Removing Oil Cooler Hose Bracket Bolts
    G03180746Courtesy of FORD MOTOR CO.
  14. Remove the oil cooler and hoses.
    Fig 13: Removing Oil Cooler And Hoses
    G03180747Courtesy of FORD MOTOR CO.

    15. All engines 

  15. Position aside the fuel tube.
    Fig 14: Positioning Aside Fuel Tube
    G03180748Courtesy of FORD MOTOR CO.
  16. Disconnect the vacuum harness.
    Fig 15: Disconnecting Vacuum Harness
    G03180749Courtesy of FORD MOTOR CO.
  17. Disconnect the knock sensor (KS) electrical connector.
    • Detach the wiring harness pin-type retainer.
    Fig 16: Disconnecting Knock Sensor (KS) Electrical Connector
    G03180750Courtesy of FORD MOTOR CO.
  18. Disconnect the electronic throttle body and throttle position (TP) sensor electrical connectors.
    Fig 17: Disconnecting Electronic Throttle Body And Throttle Position (TP) Sensor Electrical Connectors
    G03180751Courtesy of FORD MOTOR CO.
  19. Disconnect the exhaust gas recirculation (EGR) system module vacuum hose and electrical connector.
    • Detach the wiring harness pin-type retainer.
    Fig 18: Disconnecting Exhaust Gas Recirculation (EGR) System Module Vacuum Hose And Electrical Connector
    G03180752Courtesy of FORD MOTOR CO.
  20. Remove the bolts and the intake manifold and gaskets.
    Fig 19: Removing Bolts And Intake Manifold And Gaskets
    G03180753Courtesy of FORD MOTOR CO.
  21. Disconnect the six fuel injector electrical connectors.
    Fig 20: Disconnecting Six Fuel Injector Electrical Connectors
    G03180754Courtesy of FORD MOTOR CO.
  22. Disconnect the crankshaft position (CKP) sensor electrical connector and the wiring anchors.
    Fig 21: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector And Wiring Anchors
    G03180755Courtesy of FORD MOTOR CO.
  23. Remove the engine wiring harness retainer bolts.
    Fig 22: Removing Engine Wiring Harness Retainer Bolts
    G03180756Courtesy of FORD MOTOR CO.
  24. Remove the engine wiring harness.
    Fig 23: Removing Engine Wiring Harness
    G03180757Courtesy of FORD MOTOR CO.
  25. Disconnect the fuel pulse damper and the fuel pressure and temperature sensor vacuum hose fittings.
    • Remove the vacuum harness.
    Fig 24: Removing Vacuum Harness
    G03180758Courtesy of FORD MOTOR CO.
  26. Disconnect the oil pressure switch electrical connector and remove the battery cable and harness.
    Fig 25: Disconnecting Oil Pressure Switch Electrical Connector
    G03180759Courtesy of FORD MOTOR CO.
  27. Remove the oil pressure switch.
    Fig 26: Removing Oil Pressure Switch
    G03180760Courtesy of FORD MOTOR CO.
    28. NOTE: LH shown; RH similar.
    Fig 27: Removing RH And LH Insulator Bolts And Brackets
    G03180761Courtesy of FORD MOTOR CO.
  28. Remove the RH and the LH insulator bolts and brackets.
  29. Remove the bolts and the fuel injection supply manifold.
    Fig 28: Removing Bolts And Fuel Injection Supply Manifold
    G03180762Courtesy of FORD MOTOR CO.
  30. Remove the fuel injectors.
    • Remove and discard the O-rings.
    Fig 29: Removing And Discard O-Rings
    G03180763Courtesy of FORD MOTOR CO.
    31. NOTE: RH shown; LH similar.
    Fig 30: Removing Valve Covers
    G03180764Courtesy of FORD MOTOR CO.
  31. Loosen the bolts and remove the valve covers.
  32. Remove the thermostat housing.
    1. Remove the bolts.
    2. Release the bypass hose clamp and remove the thermostat housing.
    Fig 31: Removing Thermostat Housing
    G03180765Courtesy of FORD MOTOR CO.
  33. Remove the bolt and the oil level indicator tube.
    Fig 32: Removing Bolt And Oil Level Indicator Tube
    G03180766Courtesy of FORD MOTOR CO.
  34. Remove the bolt and the knock sensor (KS).
    Fig 33: Removing Bolt And Knock Sensor (KS)
    G03180767Courtesy of FORD MOTOR CO.
  35. Remove the bolts and the RH exhaust manifold and gasket.
    Fig 34: Removing Bolts And RH Exhaust Manifold And Gasket
    G03180768Courtesy of FORD MOTOR CO.
  36. Remove the bolts and the LH exhaust manifold and gasket.
    Fig 35: Removing Bolts And LH Exhaust Manifold And Gasket
    G03180769Courtesy of FORD MOTOR CO.
    37. NOTE: Late build pulley shown, early build pulley similar.
    Fig 36: Removing Pulley Bolt
    G03180770Courtesy of FORD MOTOR CO.
  37. Remove the bolt.

    38. Engines equipped with early build pulley 

  38. Using the special tool, remove the crankshaft pulley.
    Fig 37: Removing Crankshaft Pulley
    G03180771Courtesy of FORD MOTOR CO.

    39. Engines equipped with late build pulley 

  39. Using the special tool and two 8-mm x 1.25 x 100-mm bolts, remove the crankshaft pulley.
    Fig 38: Removing Crankshaft Pulley
    G03180772Courtesy of FORD MOTOR CO.

    40. All engines 

  40. Remove the bolts and the coolant pump pulley.
    Fig 39: Removing Bolts And Coolant Pump Pulley
    G03180773Courtesy of FORD MOTOR CO.
  41. Remove the bolts and the coolant pump.
    Fig 40: Removing Bolts And Coolant Pump
    G03180774Courtesy of FORD MOTOR CO.
  42. Rotate the crankshaft until the cam lobe is in the up position.
    Fig 41: Rotating Crankshaft Until Cam Lobe Is In Up Position
    G03180775Courtesy of FORD MOTOR CO.
    43. NOTE: Mark each camshaft roller follower to make sure it is installed in its original position during reassembly.
    Fig 42: Using Special Tool Remove Camshaft Roller
    G03180776Courtesy of FORD MOTOR CO.
  43. Using the special tool, remove the camshaft roller followers.
  44. Remove the RH hydraulic chain tensioner.
    Fig 43: Removing RH Hydraulic Chain Tensioner
    G03180777Courtesy of FORD MOTOR CO.
  45. Install the special tools on the RH cylinder head and tighten the top two clamp bolts.
    Fig 44: Installing Special Tools On RH Cylinder Head
    G03180778Courtesy of FORD MOTOR CO.
    46. CAUTION: The RH camshaft sprocket bolt is a LH threaded bolt.
    Fig 45: Removing RH Camshaft Sprocket
    G03180779Courtesy of FORD MOTOR CO.
  46. Remove the RH camshaft sprocket bolt.
  47. Remove the bolt.
    Fig 46: Removing Bolt
    G03180780Courtesy of FORD MOTOR CO.
  48. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.
    Fig 47: Removing Camshaft Sprocket From Camshaft
    G03180781Courtesy of FORD MOTOR CO.
  49. Remove the LH hydraulic chain tensioner.
    Fig 48: Removing LH Hydraulic Chain Tensioner
    G03180782Courtesy of FORD MOTOR CO.
  50. Install the special tools on the LH cylinder head.
    Fig 49: Installing Special Tools On LH Cylinder Head
    G03180783Courtesy of FORD MOTOR CO.
  51. Remove the LH camshaft sprocket bolt.
    Fig 50: Removing LH Camshaft Sprocket Bolt
    G03180784Courtesy of FORD MOTOR CO.
  52. Remove the bolt.
    Fig 51: Removing Bolt
    G03180785Courtesy of FORD MOTOR CO.
  53. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.
    Fig 52: Removing Camshaft Sprocket From Camshaft
    G03180786Courtesy of FORD MOTOR CO.
    54. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
    Fig 53: Discarding Gaskets And Bolts
    G03180787Courtesy of FORD MOTOR CO.
  54. Remove the bolts in the sequence shown and remove the cylinder heads.
    • Discard the gaskets and the bolts.
    55. 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 (6051).
  55. Clean and inspect the sealing surfaces. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  56. Using the special tool, remove the crankshaft front oil seal.
    Fig 54: Removing Crankshaft Front Oil Seal
    G03180788Courtesy of FORD MOTOR CO.
  57. Remove the bolts and the engine front cover.
    Fig 55: Removing Bolts And Engine Front Cover
    G03180789Courtesy of FORD MOTOR CO.
  58. Remove the bolts and the oil pan.
    Fig 56: Removing Bolts And Oil Pan
    G03180790Courtesy of FORD MOTOR CO.
  59. Remove the bolt and the oil pump screen cover and tube.
    Fig 57: Removing Bolt And Oil Pump Screen Cover And Tube
    G03180791Courtesy of FORD MOTOR CO.
  60. Remove the bolts.
    Fig 58: Removing Bolts
    G03180792Courtesy of FORD MOTOR CO.
  61. Remove the lower block cradle bolts.
    Fig 59: Removing Lower Block Cradle Bolts
    G03180793Courtesy of FORD MOTOR CO.
  62. Remove the 15 bolts and the two nuts. Remove the lower block cradle.
    Fig 60: Removing Lower Block Cradle
    G03180794Courtesy of FORD MOTOR CO.
  63. Remove the oil pump pick-up tube, the oil pump, and the oil pump intermediate shaft.
    Fig 61: Removing Oil Pump Pick-Up Tube Oil Pump
    G03180795Courtesy of FORD MOTOR CO.
  64. Remove the oil filter adapter.
    Fig 62: Removing Oil Filter Adapter
    G03180796Courtesy of FORD MOTOR CO.
  65. Inspect and install new O-ring seals if necessary.
    Fig 63: Installing New O-Ring Seals
    G03180797Courtesy of FORD MOTOR CO.
  66. Remove the rear jackshaft plug.
    Fig 64: Removing The Rear Jackshaft Plug
    G03180798Courtesy of FORD MOTOR CO.
  67. Using the special tool, hold the crankshaft.
    Fig 65: Using special tool hold crankshaft
    G03180799Courtesy of FORD MOTOR CO.
  68. Remove the rear jackshaft sprocket-retaining bolt.
    Fig 66: Removing Rear Jackshaft Sprocket-Retaining
    G03180800Courtesy of FORD MOTOR CO.
  69. Remove the rear bolt and spacer.
    Fig 67: Removing Rear Bolt And Spacer
    G03180801Courtesy of FORD MOTOR CO.
  70. Remove the cassette.
    Fig 68: Removing Cassette
    G03180802Courtesy of FORD MOTOR CO.
  71. Remove the oil pump bolt and retainer and then remove the oil pump drive.
    Fig 69: Removing Oil Pump Bolt And Retainer And Remove Oil Pump Drive
    G03180803Courtesy of FORD MOTOR CO.
  72. Using the special tool, loosen the front sprocket retaining bolt.
    Fig 70: Removing Front Sprocket
    G03180804Courtesy of FORD MOTOR CO.
  73. Remove the bolts and the chain tensioner.
    Fig 71: Removing Bolts And Chain Tensioner
    G03180805Courtesy of FORD MOTOR CO.
  74. Remove the chain guide.
    Fig 72: Removing Chain Guide
    G03180806Courtesy of FORD MOTOR CO.
  75. Remove the bolt.
    Fig 73: Removing Bolt
    G03180807Courtesy of FORD MOTOR CO.
  76. Remove the jackshaft sprocket and chain.
    Fig 74: Removing Jackshaft Sprocket And Chain
    G03180808Courtesy of FORD MOTOR CO.
  77. Remove the bolt and the front cassette.
    Fig 75: Removing Bolt And Front Cassette
    G03180809Courtesy of FORD MOTOR CO.
  78. Remove the jackshaft thrust plate.
    Fig 76: Removing Jackshaft Thrust Plate
    G03180810Courtesy of FORD MOTOR CO.
  79. Remove the jackshaft.
    Fig 77: Removing Jackshaft
    G03180811Courtesy of FORD MOTOR CO.
  80. Remove the balance shaft tensioner.
    1. Install a pin in the balance shaft tensioner.
    2. Remove the bolts.
    3. Remove the balance shaft tensioner.
    Fig 78: Removing Balance Shaft Tensioner
    G03180812Courtesy of FORD MOTOR CO.
  81. Remove the two bolts and the balance shaft chain guide.
    82. NOTE: DO NOT remove the balance shaft sprocket bolt.
    Fig 79: Removing Balance Shaft Chain And Crankshaft Sprocket
    G03180813Courtesy of FORD MOTOR CO.
  82. Remove the balance shaft chain and crankshaft sprocket.
  83. Remove the balance shaft.
    1. Remove the bolts.
    2. Remove the balance shaft.
    Fig 80: Removing Balance Shaft
    G03180814Courtesy of FORD MOTOR CO.
  84. Using the cylinder ridge reamer, remove the ridge and carbon deposits from the top of each cylinder.
    Fig 81: Removing Ridge And Carbon Deposits From Top Of Each Cylinder
    G03180815Courtesy of FORD MOTOR CO.
    85. NOTE: Clearly mark the connecting rods and rod caps in numerical order for correct reassembly.
    Fig 82: Removing Connecting Rod Cap
    G03180816Courtesy of FORD MOTOR CO.
  85. Remove the connecting rod caps.
    1. Remove the connecting rod nuts.
    2. Remove the connecting rod cap.
  86. Install rubber hose pieces on the bolts to protect the crankshaft and remove the pistons.
    Fig 83: Removing Pistons
    G03180817Courtesy of FORD MOTOR CO.
  87. Remove the connecting rod bearings.
    Fig 84: Removing Connecting Rod Bearings
    G03180818Courtesy of FORD MOTOR CO.
  88. Remove the piston rings.
    Fig 85: Removing Piston Rings
    G03180819Courtesy of FORD MOTOR CO.
  89. Clean and inspect the pistons. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
    90. CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
    Fig 86: Removing Crankshaft
    G03180820Courtesy of FORD MOTOR CO.
  90. Remove the bolts.
    91. NOTE: Number (or mark) the crankshaft bearing caps before removing them.
    Fig 87: Removing Crankshaft Main Bearing Caps
    G03180821Courtesy of FORD MOTOR CO.
  91. Remove the crankshaft main bearing caps.
  92. Remove the crankshaft rear oil seal from the crankshaft.
    Fig 88: Removing Crankshaft Rear Oil Seal From Crankshaft
    G03180822Courtesy of FORD MOTOR CO.
  93. Remove the crankshaft.
    Fig 89: Removing Crankshaft
    G03180823Courtesy of FORD MOTOR CO.
  94. Remove the crankshaft main bearings and the thrust bearing.
    Fig 90: Removing Crankshaft Main Bearings And Thrust Bearing
    G03180824Courtesy of FORD MOTOR CO.
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