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Section 134 (Engine): Disassembly: Engine

WARNING: This page is about a different car, the 2005 Lincoln Navigator and 2005 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL DESCRIPTION

G03905604
 Remover, Crankshaft Rear Slinger 303-514 (T95P-6701-AH)
G03886718
 Remover, Crankshaft Rear Seal 303-519 (T95P-6701-EH)
G03885061
 Slide Hammer 100-001 (T50T-100-A)
G03905862
 Installer, Connecting Rod 303-442 (T93P-6136-A)
G03886657
 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
G03905746
 Remover, Crankshaft Front Seal 303-107 (T74P-6700-A)
G03920369
 Locking Tool, Camshaft Phaser Sprocket 303-1046
G03886005
 Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
G03920070
 Compressor, Valve Spring 303-1039
G03886715
 Modular Engine Lift Bracket 303-F047 (014-00073)
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft Metal Surface Prep ZC-31 -
Silicone Gasket Remover ZC-30 -
CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
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: The flexplate, crankshaft rear seal and the crankshaft rear oil slinger must be removed before mounting the engine on the engine stand.
NOTE: For additional information, refer to Figure-Figure.
  1. Remove the bolts and the flexplate.
    Fig 1: Removing Flexplate/Flywheel Retainer 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: Removing 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
    G03920205Courtesy of FORD MOTOR CO.
  7. Remove the 3 bolts and the RH engine support insulators.
    Fig 6: Removing RH Engine Support Insulator
    G03933620Courtesy of FORD MOTOR CO.
    8. NOTE: LH shown, RH similar.
    Fig 7: Removing Cylinder Block Drain Plugs
    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.
    Fig 8: Installing Cylinder Block Drain Plugs
    G03885619Courtesy of FORD MOTOR CO.
  9. Install the cylinder block drain plugs.
    • Tighten to 24 Nm (18 lb-ft).
  10. Disconnect the RH camshaft position (CMP) sensor electrical connector.
    Fig 9: Disconnecting RH CMP Sensor Electrical Connector
    G03919909Courtesy of FORD MOTOR CO.
  11. Remove the stud bolt and the RH radio ignition interference capacitor.
    Fig 10: Removing RH Radio Ignition Interference Capacitor
    G03920219Courtesy of FORD MOTOR CO.
  12. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
    Fig 11: Disconnecting RH VCT Solenoid Electrical Connector
    G03920220Courtesy of FORD MOTOR CO.
  13. Disconnect the 2 engine wiring harness retainers from the RH valve cover studs.
    Fig 12: Disconnecting Engine Wiring Harness Retainers From RH Valve Cover
    G03920221Courtesy of FORD MOTOR CO.
  14. Disconnect the electrical connector retainer from the coolant tube.
    Fig 13: Disconnecting Electrical Connector Retainer From Coolant Tube Support Bracket
    G03919850Courtesy of FORD MOTOR CO.
  15. Disconnect the 4 RH ignition coil electrical connectors.
    Fig 14: Disconnecting RH Ignition Coil Electrical Connectors
    G03920223Courtesy of FORD MOTOR CO.
  16. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 15: Disconnecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03920224Courtesy of FORD MOTOR CO.
  17. Disconnect the 2 engine wiring harness retainers from the LH valve cover studs.
    Fig 16: Disconnecting Engine Wiring Harness Retainers From LH Valve Cover Studs
    G03933745Courtesy of FORD MOTOR CO.
  18. Remove the stud bolt and the LH radio ignition interference capacitor.
    Fig 17: Removing LH Radio Ignition Interference Capacitor
    G03920225Courtesy of FORD MOTOR CO.
    19. NOTE: LH shown, RH similar.
    Fig 18: Removing Ignition Coils
    G03920226Courtesy of FORD MOTOR CO.
  19. Remove the 8 bolts and the 8 ignition coils.
  20. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 19: Disconnecting CKP Sensor Electrical Connector
    G04612789Courtesy of FORD MOTOR CO.
  21. Remove the engine wiring harness from the engine assembly.
  22. Remove the 2 bolts and the 2 knock sensors (KS).
    Fig 20: Removing Knock Sensors (KS)
    G03920293Courtesy of FORD MOTOR CO.
  23. Remove the stud bolt and the coolant tube.
    • Discard the O-ring seal.
    Fig 21: Removing Coolant Tube
    G03920263Courtesy of FORD MOTOR CO.
  24. Remove the bolt and the oil level indicator tube.
    • Discard the O-ring seal.
    Fig 22: Removing Oil Level Indicator Tube
    G03933683Courtesy of FORD MOTOR CO.
  25. Remove the bolt and the RH CMP sensor.
    Fig 23: Removing RH CMP Sensor
    G03920013Courtesy of FORD MOTOR CO.
  26. Remove the bolt and the LH CMP sensor.
    Fig 24: Removing LH CMP Sensor
    G03933753Courtesy of FORD MOTOR CO.
  27. Remove the bolt and the CKP sensor.
    Fig 25: Removing Crankshaft Position (CKP) Sensor
    G03920231Courtesy of FORD MOTOR CO.
    28. 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    CAUTION: When removing the valve cover, make sure to avoid damaging the VCT solenoid.
    NOTE: The fasteners are part of the valve cover and should not be removed.
    NOTE: LH shown, RH similar.
    Fig 26: Removing Valve Covers
    G03920232Courtesy of FORD MOTOR CO.
  28. 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.
  29. Remove the 8 nuts and the RH exhaust manifold.
    Fig 27: Remove RH Exhaust Manifold
    G03920262Courtesy of FORD MOTOR CO.
  30. Remove the bolts and the LH engine support insulator.
    Fig 28: Removing LH Engine Support Insulator
    G03933757Courtesy of FORD MOTOR CO.
  31. Remove the 8 nuts and the LH exhaust manifold.
    Fig 29: Removing LH Exhaust Manifold
    G03920260Courtesy of FORD MOTOR CO.
  32. Remove the bolts and the oil filter adapter.
    • Discard the gasket.
    Fig 30: Removing Oil Filter Adapter
    G03933759Courtesy of FORD MOTOR CO.
  33. Remove the bolts, the coolant pump pulley and the 3 accessory drive belt idler pulleys.
    Fig 31: Removing Coolant Pump Pulley And Accessory Drive Belt Idler Pulley
    G03933688Courtesy of FORD MOTOR CO.
  34. Remove the bolts and the accessory drive belt tensioner.
    Fig 32: Removing Accessory Drive Belt Tensioner
    G03920234Courtesy of FORD MOTOR CO.
  35. Remove the coolant pump bolts.
    Fig 33: Removing Coolant Pump Bolts
    G03885825Courtesy of FORD MOTOR CO.
  36. Remove the coolant pump from the cylinder block.
    • Discard the O-ring seal.
    Fig 34: Removing Coolant Pump
    G03885759Courtesy of FORD MOTOR CO.
  37. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
    Fig 35: Removing Crankshaft Pulley Using Special Tool
    G03919906Courtesy of FORD MOTOR CO.
  38. Using the special tool, remove and discard the crankshaft front seal.
    Fig 36: Removing Crankshaft Front Seal Using Special Tool
    G03919889Courtesy of FORD MOTOR CO.
  39. Remove the bolts, oil pan and discard the oil pan gasket.
    Fig 37: Removing Oil Pan
    G03885459Courtesy of FORD MOTOR CO.
    40. NOTE: Correct fastener location is essential for the assembly procedure. Record fastener location.
    Fig 38: Removing Front Cover Fasteners
    G03933693Courtesy of FORD MOTOR CO.
  40. Remove the fasteners.
  41. Remove the engine front cover from the cylinder block.
    Fig 39: Removing Engine Front Cover From Cylinder Block
    G03885740Courtesy of FORD MOTOR CO.
  42. Remove the crankshaft sensor ring from the crankshaft.
    Fig 40: Removing Crankshaft Sensor Ring
    G04583449Courtesy of FORD MOTOR CO.
  43. Position the crankshaft keyway at the 12 o'clock position.
    Fig 41: Positioning Crankshaft Keyway At 12 O'Clock Position
    G03919943Courtesy of FORD MOTOR CO.
    44. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.
    Fig 42: Positioning Camshaft Lobes
    G03919944Courtesy of FORD MOTOR CO.
  44. 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.
    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: Removing 3 RH Cylinder Head Camshaft Roller Followers
    G03919945Courtesy of FORD MOTOR CO.
  45. Remove only the 3 camshaft roller followers shown in the illustration from the RH 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 Valve Spring With Special Tool
    G03919946Courtesy of FORD MOTOR CO.
  46. Using the special tool, remove the 3 designated camshaft roller followers in the previous step from the RH cylinder head.
    47. 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 45: Removing 3 LH Cylinder Head Camshaft Roller Followers
    G03919947Courtesy of FORD MOTOR CO.
  47. Remove only the 3 camshaft roller followers shown in the illustration from the LH cylinder head.
    48. 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 46: Compressing Spring Using Special Tool
    G03919948Courtesy of FORD MOTOR CO.
  48. Using the special tool, remove the 3 designated camshaft roller followers in the previous step from the LH cylinder head.
    49. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set.
    Fig 47: Positioning Crankshaft Keyway To 6 O'Clock Position
    G03919949Courtesy of FORD MOTOR CO.
  49. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
    50. 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 48: Removing LH Timing Chain Tensioner & Tensioner Arm
    G03919950Courtesy of FORD MOTOR CO.
  50. Remove the bolts, the LH timing chain tensioner and tensioner arm.
    51. 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 49: Removing RH Timing Chain Tensioner & Tensioner Arm
    G03919951Courtesy of FORD MOTOR CO.
  51. Remove the bolts, the RH timing chain tensioner and tensioner arm.
  52. 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 50: Removing Timing Chains
    G03919952Courtesy of FORD MOTOR CO.
    53. NOTE: RH shown, LH similar.
    Fig 51: Removing Timing Chain Guides
    G03919953Courtesy of FORD MOTOR CO.
  53. Remove the LH and RH timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
    54. CAUTION: Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    CAUTION: Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.
    Fig 52: Removing RH VCT Phaser Sprocket Assembly
    G03919954Courtesy of FORD MOTOR CO.
  54. Using the special tool, remove the bolt and the RH VCT phaser sprocket assembly.
    • Discard the VCT phaser sprocket bolt.
    55. CAUTION: Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    CAUTION: Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.
    Fig 53: Removing LH VCT Phaser Sprocket Assembly
    G03919955Courtesy of FORD MOTOR CO.
  55. Using the special tool, remove the bolt and the LH VCT phaser sprocket assembly.
    • Discard the VCT phaser sprocket bolt.
  56. Install the special tool onto the LH cylinder head.
    Fig 54: Installing Special Tool Onto LH Cylinder Head
    G03920258Courtesy of FORD MOTOR CO.
  57. Install the special tool onto the RH cylinder head.
    Fig 55: Installing Special Tool Onto RH Cylinder Head
    G03920261Courtesy of FORD MOTOR CO.
    58. 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 Sequence
    G03919956Courtesy of FORD MOTOR CO.
  58. Remove the bolts in the sequence shown and remove the RH cylinder head front camshaft bearing cap and then the remaining bearing caps.
  59. 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 57: Identifying Camshaft Front Thrust Bearing Cap Oil Metering Groove
    G03919957Courtesy of FORD MOTOR CO.
  60. Remove the RH camshaft.
    61. 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.
  61. Remove the remaining camshaft roller followers from the RH cylinder head.
    62. 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.
  62. Remove the hydraulic lash adjusters from the RH cylinder head.
    63. 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 58: Identifying Camshaft Bearing Cap Bolt Loosening Sequence
    G03919956Courtesy of FORD MOTOR CO.
  63. Remove the bolts in the sequence shown and remove the LH cylinder head front camshaft bearing cap and then the remaining bearing caps.
  64. 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 59: Identifying Camshaft Front Thrust Bearing Cap Oil Metering Groove
    G03919957Courtesy of FORD MOTOR CO.
  65. Remove the LH camshaft.
    66. 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.
  66. Remove the remaining camshaft roller followers from the LH cylinder head.
    67. 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.
  67. Remove the hydraulic lash adjusters from the LH cylinder head.
    68. CAUTION: 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.
    CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
    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: 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.
    Fig 60: Removing Cylinder Head
    G03885651Courtesy of FORD MOTOR CO.
  68. Remove the bolts and the cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
    69. 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.
  69. 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.
    70. NOTE: 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.
    NOTE: 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.
    NOTE: LH shown, RH similar.
    Fig 61: Identifying Oil Pressure Feed Area
    G03885653Courtesy of FORD MOTOR CO.
  70. 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).
  71. Remove the bolts, the oil pump screen and pickup tube and the spacer.
    Fig 62: Removing Oil Pump Screen, Pickup Tube & Spacer
    G03920339Courtesy of FORD MOTOR CO.
  72. Remove the 3 bolts and the oil pump.
    Fig 63: Removing Oil Pump
    G04638972Courtesy of FORD MOTOR CO.
  73. 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.
    74. 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 64: Removing Connecting Rod Caps
    G04583770Courtesy of FORD MOTOR CO.
  74. Remove the bolts and the connecting rod caps.

    Discard the bolts.

    75. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 65: Removing Piston Through Top Of Cylinder Block
    G03920342Courtesy of FORD MOTOR CO.
  75. Use the special tool to push the piston through the top of the cylinder block.
  76. Disassemble the 8 pistons. For additional information, refer to PISTON .
  77. 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 66: Removing Main Bearing Cap Fasteners
    G03920343Courtesy of FORD MOTOR CO.
  78. Remove the 5 main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
    Fig 67: Removing Main Bearing Caps
    G03920344Courtesy of FORD MOTOR CO.
  79. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.
    Fig 68: Removing Crankshaft And Upper Main Bearings
    G03881879Courtesy of FORD MOTOR CO.
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