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Section 432 (Engine): Disassembly: Engine

WARNING: This page is about a different car, the 2006 Lincoln Navigator and 2006 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G04627272Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Rear Slinger
303-514 (T95P-6701-AH)
G04627273Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Rear Seal
303-519 (T95P-6701-EH)
G04627274Courtesy of FORD MOTOR CO.
 Slide Hammer
100-001 (T50T-100-A)
G04627275Courtesy of FORD MOTOR CO.
 Installer, Connecting Rod
303-442 (T93P-6136-A)
G04627276Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Vibration Damper
303-009 (T58P-6316-D)
G04627277Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Front Seal
303-107 (T74P-6700-A)
G04627278Courtesy of FORD MOTOR CO.
 Locking Tool, Camshaft Phaser Sprocket
303-1046
G04627279Courtesy of FORD MOTOR CO.
 Remover/Installer, Cylinder Head
303-572 (T97T-6000-A)
G04627280Courtesy of FORD MOTOR CO.
 Compressor, Valve Spring
303-1039
G04627281Courtesy of FORD MOTOR CO.
 Modular Engine Lift Bracket
303-F047 (014-00073)
MATERIALS

Item Specification
Motorcraft Metal Surface Prep
ZC-31		 -
Silicone Gasket Remover
ZC-30		 -
CAUTION:
  1. Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
  2. 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:
  1. The flexplate, crankshaft rear seal and the crankshaft rear oil slinger must be removed before mounting the engine on the engine stand.
  2. For additional information, refer to Figure under the assembly procedure in this article.
  1. Remove the bolts and the flexplate.
    Fig 1: Locating Flexplate Bolts
    G03885481Courtesy of FORD MOTOR CO.
  2. Using the special tools, remove and discard the crankshaft rear oil slinger.
    Fig 2: Removing Crankshaft Rear Oil Seal Slinger
    G03920149Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove and discard the crankshaft rear seal.
    Fig 3: Removing Crankshaft Rear Seal
    G03920150Courtesy of FORD MOTOR CO.
  4. Remove the 8 bolts and the crankshaft rear seal retainer plate.
    Fig 4: Identifying Bolts And Crankshaft Rear Seal Retainer Plate
    G03885716Courtesy of FORD MOTOR CO.
  5. Mount the engine on a suitable work stand.
  6. Remove the special tool.
    Fig 5: Identifying Special Tool (303-F047)
    G03920205Courtesy of FORD MOTOR CO.
  7. Remove the 3 bolts and the RH engine support insulators.
    Fig 6: Identifying RH Engine Support Insulator Bolts
    G03933620Courtesy of FORD MOTOR CO.
    8. NOTE: LH shown, RH similar.
    Fig 7: Locating Cylinder Block Drain Plug
    G03885619Courtesy of FORD MOTOR CO.
  8. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
    9. NOTE: LH shown, RH similar.
  9. Install the cylinder block drain plugs.
    • Tighten to 24 N.m (18 lb-ft).
      Fig 8: Locating Cylinder Block Drain Plug
      G03885619Courtesy of FORD MOTOR CO.
  10. Disconnect the RH camshaft position (CMP) sensor electrical connector.
    Fig 9: Identifying RH CMP Sensor Electrical Connector
    G03919909Courtesy of FORD MOTOR CO.
  11. Remove the stud bolt and the RH radio ignition interference capacitor.
    Fig 10: Identifying RH Radio Ignition Interference Capacitor Stud Bolt
    G03920219Courtesy of FORD MOTOR CO.
  12. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
    Fig 11: Locating Camshaft Timing (VCT) Solenoid Electrical Connectors
    G03920220Courtesy of FORD MOTOR CO.
  13. Disconnect the 2 engine wiring harness retainers from the RH valve cover studs.
    Fig 12: Locating Engine Wiring Harness Retainers At RH Valve Cover
    G03920221Courtesy of FORD MOTOR CO.
  14. Disconnect the electrical connector retainer from the coolant tube.
    Fig 13: Locating Electrical Connector Retainer At Coolant Tube Support Bracket
    G03919850Courtesy of FORD MOTOR CO.
  15. Disconnect the 4 RH ignition coil electrical connectors.
    Fig 14: Locating Ignition Coil Electrical Connectors
    G03920223Courtesy of FORD MOTOR CO.
  16. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 15: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03920224Courtesy of FORD MOTOR CO.
  17. Remove the stud bolt and the LH radio ignition interference capacitor.
    Fig 16: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt
    G03920225Courtesy of FORD MOTOR CO.
    18. NOTE: LH shown, RH similar.
    Fig 17: Identifying Ignition Coils And Bolts
    G03920226Courtesy of FORD MOTOR CO.
  18. Remove the 8 bolts and the 8 ignition coils.
  19. Remove the engine wiring harness from the engine assembly.
  20. Remove the 2 bolts and the 2 knock sensors (KS).
    Fig 18: Identifying Knock Sensors (KS)
    G03920293Courtesy of FORD MOTOR CO.
  21. Remove the stud bolt and the coolant tube.
    • Discard the O-ring seal.
      Fig 19: Identifying Coolant Tube Stud Bolt
      G03920263Courtesy of FORD MOTOR CO.
  22. Remove the bolt and the oil level indicator tube.
    • Discard the O-ring seal.
      Fig 20: Locating Oil Level Indicator Tube Bolt
      G04627301Courtesy of FORD MOTOR CO.
  23. Remove the bolt and the RH CMP sensor.
    Fig 21: Locating Camshaft (CMP) Sensor Bolt
    G03920013Courtesy of FORD MOTOR CO.
  24. Remove the bolt and the LH CMP sensor.
    Fig 22: Locating Bolt And LH CMP Sensor
    G03919989Courtesy of FORD MOTOR CO.
  25. Remove the bolt and the CKP sensor.
    Fig 23: Locating Crankshaft Position (CKP) Sensor Bolt
    G03920231Courtesy of FORD MOTOR CO.
    26. CAUTION:
    1. 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    2. When removing the valve cover, make sure to avoid damaging the VCT solenoid.
    NOTE:
    1. The fasteners are part of the valve cover and should not be removed.
    2. LH shown, RH similar.
  26. Loosen the fasteners and remove the valve covers.
    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
      Fig 24: Locating Valve Cover Bolts
      G04627305Courtesy of FORD MOTOR CO.
  27. Remove the 8 nuts and the RH exhaust manifold.
  28. Remove the bolts and the LH engine support insulator.
    Fig 26: Locating LH Engine Support Insulator Bolts
    G04627307Courtesy of FORD MOTOR CO.
  29. Remove the 8 nuts and the LH exhaust manifold.
  30. Remove the bolts and the oil filter adapter.
    • Discard the gasket.
      Fig 28: Locating Oil Filter Adapter With Bolts
      G04627309Courtesy of FORD MOTOR CO.
  31. Remove the bolts, the coolant pump pulley and the 3 accessory drive belt idler pulleys.
    Fig 29: Locating Coolant Pump Pulley And Accessory Drive Belt Idler Pulley Bolts
    G03933688Courtesy of FORD MOTOR CO.
  32. Remove the bolts and the accessory drive belt tensioner.
    Fig 30: Identifying Accessory Drive Belt Tensioner Bolts
    G03920234Courtesy of FORD MOTOR CO.
  33. Remove the coolant pump bolts.
    Fig 31: Identifying Coolant Pump Bolts
    G03885825Courtesy of FORD MOTOR CO.
  34. Remove the coolant pump from the cylinder block.
    • Discard the O-ring seal.
      Fig 32: Identifying Coolant Pump
      G03885759Courtesy of FORD MOTOR CO.
  35. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
    Fig 33: Removing Crankshaft Pulley Using Special Tool
    G03919906Courtesy of FORD MOTOR CO.
  36. Using the special tool, remove and discard the crankshaft front seal.
    Fig 34: Removing Crankshaft Front Seal Using Special Tool
    G03919889Courtesy of FORD MOTOR CO.
  37. Remove the bolts, oil pan and discard the oil pan gasket.
    Fig 35: Identifying Oil Pan Bolts
    G03885459Courtesy of FORD MOTOR CO.
    38. NOTE: Correct fastener location is essential for the assembly procedure. Record fastener location.
    Fig 36: Identifying Engine Block Fastener Location
    G04627317Courtesy of FORD MOTOR CO.
  38. Remove the fasteners.
  39. Remove the engine front cover from the cylinder block.
    Fig 37: Locating Engine Front Cover
    G03885740Courtesy of FORD MOTOR CO.
  40. Remove the crankshaft sensor ring from the crankshaft.
    Fig 38: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
  41. Position the crankshaft key way at the 12 o'clock position.
    Fig 39: Positioning Crankshaft Keyway At 12 O'Clock Position
    G03919943Courtesy of FORD MOTOR CO.
    42. NOTE: If the camshaft lobes are not exactly positioned as shown in Fig 40, the crankshaft will require one full additional rotation to 12 o'clock.
    Fig 40: Identifying Camshaft Lobe Position
    G03919944Courtesy of FORD MOTOR CO.
  42. The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder.
    43. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
    Fig 41: Identifying RH Cylinder Head Camshaft Roller Followers And Bolts
    G03919945Courtesy of FORD MOTOR CO.
  43. Remove only the 3 camshaft roller followers shown in Fig 41 from the RH cylinder head.
    44. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.
    NOTE: It may be necessary to push the valve down while compressing the spring.
    Fig 42: Identifying Special Tool For Removing/Installing Camshaft Roller Followers
    G03919946Courtesy of FORD MOTOR CO.
  44. Using the special tool, remove the 3 designated camshaft roller followers in the previous step from the RH cylinder head.
    45. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
    Fig 43: Locating LH Cylinder Head Camshaft Roller Followers And Bolts
    G03919947Courtesy of FORD MOTOR CO.
  45. Remove only the 3 camshaft roller followers shown in Fig 43 from the LH cylinder head.
    46. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.
    NOTE: It may be necessary to push the valve down while compressing the spring.
    Fig 44: Compressing Spring Using Special Tool
    G03919948Courtesy of FORD MOTOR CO.
  46. Using the special tool, remove the 3 designated camshaft roller followers in the previous step from the LH cylinder head.
    47. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set.
    Fig 45: Crankshaft Positioned With Keyway At 6 O'clock Position
    G03919949Courtesy of FORD MOTOR CO.
  47. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
    48. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
    Fig 46: Identifying LH Timing Chain Tensioner & Tensioner Arm
    G03919950Courtesy of FORD MOTOR CO.
  48. Remove the bolts, the LH timing chain tensioner and tensioner arm.
    49. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
    Fig 47: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts
    G03919951Courtesy of FORD MOTOR CO.
  49. Remove the bolts, the RH timing chain tensioner and tensioner arm.
  50. Remove the RH and LH timing chains and the crankshaft sprocket.
    • Remove the RH timing chain from the camshaft sprocket.
    • Remove the RH timing chain from the crankshaft sprocket.
    • Remove the LH timing chain from the camshaft sprocket.
    • Remove the LH timing chain and crankshaft sprocket.
      Fig 48: Identifying RH/LH Timing Chains
      G03919952Courtesy of FORD MOTOR CO.
    51. NOTE: RH shown, LH similar.
  51. Remove the LH and RH timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
      Fig 49: Identifying Timing Chain Guide And Mounting Bolts
      G03919953Courtesy of FORD MOTOR CO.
    52. CAUTION:
    1. Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    2. Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.
  52. Using the special tool, remove the bolt and the RH VCT phaser sprocket assembly.
    • Discard the VCT phaser sprocket bolt.
      Fig 50: Identifying VCT Phaser Sprocket Bolt And Holder Tool
      G03919954Courtesy of FORD MOTOR CO.
    53. CAUTION:
    1. Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    2. Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.
  53. Using the special tool, remove the bolt and the LH VCT phaser sprocket assembly.
    • Discard the VCT phaser sprocket bolt.
      Fig 51: Identifying Special Sprocket Phaser Tool
      G03919955Courtesy of FORD MOTOR CO.
  54. Install the special tool onto the LH cylinder head.
    Fig 52: Identifying Special Tool Onto Cylinder Head
    G03920258Courtesy of FORD MOTOR CO.
  55. Install the special tool onto the RH cylinder head.
    Fig 53: Identifying Special Tool On Cylinder Head
    G03920261Courtesy of FORD MOTOR CO.
    56. CAUTION: When removing the front thrust camshaft bearing cap, use care as the cap may be damaged from sideloading when removing the cam unequally in height from the bearing towers.
    NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.
    Fig 54: Identifying Camshaft Bearing Cap Bolt Loosening/Tightening Sequence
    G03919956Courtesy of FORD MOTOR CO.
  56. Remove the bolts in the sequence shown in Fig 54 and remove the RH cylinder head front camshaft bearing cap and then the remaining bearing caps.
  57. Clean and inspect the RH camshaft bearing caps.
    • The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
      Fig 55: Identifying Camshaft Front Thrust Bearing Cap Oil Metering Groove
      G03919957Courtesy of FORD MOTOR CO.
  58. Remove the RH camshaft.
    59. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
  59. Remove the remaining camshaft roller followers from the RH cylinder head.
    60. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
  60. Remove the hydraulic lash adjusters from the RH cylinder head.
    61. CAUTION: When removing the front thrust camshaft bearing cap, use care as the cap may be damaged from sideloading when removing the cam unequally in height from the bearing towers.
    NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.
    Fig 56: Identifying Camshaft Bearing Cap Bolt Loosening/Tightening Sequence
    G03919956Courtesy of FORD MOTOR CO.
  61. Remove the bolts in the sequence shown in Fig 56 and remove the LH cylinder head front camshaft bearing cap and then the remaining bearing caps.
  62. Clean and inspect the LH camshaft bearing caps.
    • The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
      Fig 57: Locating LH Camshaft Bearing Caps
      G04627338Courtesy of FORD MOTOR CO.
  63. Remove the LH camshaft.
    64. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
  64. Remove the remaining camshaft roller followers from the LH cylinder head.
    65. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
  65. Remove the hydraulic lash adjusters from the LH cylinder head.
    66. CAUTION:
    1. The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
    2. Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    3. The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
    4. 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.
    5. Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    NOTE: RH shown, LH similar.
  66. Remove the bolts and the cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 58: Locating Cylinder Head Bolts
      G03885651Courtesy of FORD MOTOR CO.
    67. CAUTION:
    1. 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.
    2. 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.
  67. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head 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 remaining 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.
    68. NOTE:
    1. Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.
    2. Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.
    3. LH shown, RH similar.
    Fig 59: Identifying Cylinder Head/Cylinder Block Oil Pressure Feed Areas
    G03885653Courtesy of FORD MOTOR CO.
  68. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches longer than 0.0254 mm (0.001 in).
  69. Remove the bolts, the oil pump screen and pickup tube and the spacer.
    Fig 60: Removing Bolts, Pump Screen & Pickup Tube
    G04627341Courtesy of FORD MOTOR CO.
  70. Remove the 3 bolts and the oil pump.
    Fig 61: Locating Oil Pump Bolts
    G04638972Courtesy of FORD MOTOR CO.
  71. 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 the manufacturer instructions.
    72. CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for correct orientation.
    Fig 62: Identifying Bolts And Connecting Rod Caps
    G04583770Courtesy of FORD MOTOR CO.
  72. Remove the bolts and the connecting rod caps. Discard the bolts.
    73. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 63: Pushing Piston Through Top Of Cylinder Block
    G03920342Courtesy of FORD MOTOR CO.
  73. Use the special tool to push the piston through the top of the cylinder block.
  74. Disassemble the 8 pistons. For additional information, refer to PISTON .
  75. Remove the fasteners.
    1. Remove and discard the cross-mounted main cap bolts.
    2. Remove the dowels.
    3. Remove and discard the main bearing cap bolts.
      Fig 64: Removing Main Bearing Cap Bolts
      G04627345Courtesy of FORD MOTOR CO.
  76. Remove the 5 main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
    Fig 65: Identifying Main Bearing Caps
    G03920344Courtesy of FORD MOTOR CO.
  77. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.
    Fig 66: Identifying Crankshaft And Main Bearings
    G03881879Courtesy of FORD MOTOR CO.
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