Engine Mechanical: Mechanical: Engine: Disassembly: Engine

Illustration	Tool Name	Tool Number
	Heavy Duty Floor Crane	014-00071 or equivalent
	Spreader Bar	303-D089 (D93P-6001-A3) or equivalent
	Locking Tool, Flywheel	303-103 (T74P-8375-A)
	Engine Stand	014-00232 or equivalent
	Alignment Plate, Camshaft	303-465 (T94P-6256-CH)
	Timing Peg, Crankshaft	303-507
	Holding Fixture, Drive Pinion Flange	205-126 (T78P-4851-A)
	Adapter for 205-126	(205-072-02)
	Remover, Oil Seal	303-409 (T92C-6700-CH)

Vehicles equipped with a manual transmission 

WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury.
CAUTION: Loosen the bolts evenly to prevent pressure plate damage.
1. Remove the 7 bolts, clutch pressure plate and clutch disc.
Fig 1: Locating Clutch Pressure Plate Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

2. Install the special tool and remove the flywheel or flexplate.
Fig 2: Identifying Special Tool (303-103)
Courtesy of FORD MOTOR CO.
3. Mount the engine on a suitable engine stand.
4. Disconnect the crankshaft position (CKP) sensor and the wiring harness pin-type retainers.
Fig 3: Locating Crankshaft Position Sensor And Wiring Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
5. Remove the 3 nuts and the generator heat shield.
Fig 4: Locating Generator Heat Shield And Nuts
Courtesy of FORD MOTOR CO.
6. Remove the nut and disconnect the generator electrical connections and wiring harness retainer.
Fig 5: Locating Generator Electrical Connections And Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
7. Remove the nut and the wiring harness retainer.
Fig 6: Locating Wiring Harness Retainer And Nut
Courtesy of FORD MOTOR CO.
8. Remove the bolt, the 2 stud bolts and the generator.
Fig 7: Locating Generator And Bolts
Courtesy of FORD MOTOR CO.
9. Remove the 2 bolts and the accessory drive belt tensioner.
Fig 8: Locating Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
10. Loosen the bolt and remove the accessory drivebelt idler pulley.
Fig 9: Locating Accessory Drivebelt Idler Pulley And Bolt
Courtesy of FORD MOTOR CO.
11. If equipped, loosen the bolt and remove the accessory drive belt idler pulley.
Fig 10: Locating Accessory Drive Belt Idler Pulley And Bolt
Courtesy of FORD MOTOR CO.
12. Remove the 3 bolts and the coolant pump pulley.
Fig 11: Locating Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
13. Remove the 3 bolts and the coolant pump.
Fig 12: Locating Coolant Pump Bolts
Courtesy of FORD MOTOR CO.
14. Disconnect the heater hose from the thermostat housing.
Fig 13: Locating Heater Hose
Courtesy of FORD MOTOR CO.
15. Remove the 3 bolts and the thermostat housing.
Fig 14: Locating Thermostat Housing Bolts
Courtesy of FORD MOTOR CO.
16. Disconnect the oil pressure sensor electrical connector.
Fig 15: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
17. Remove the engine oil filter.
Fig 16: Locating Engine Oil Filter
Courtesy of FORD MOTOR CO.
18. Remove the 4 bolts and the oil filter adapter.
    • Discard the gasket.
Fig 17: Locating Oil Filter Adapter And Bolts
Courtesy of FORD MOTOR CO.
19. Disconnect the knock sensor (KS) electrical connector and pin-type retainer.
Fig 18: Locating Knock Sensor Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.
20. Remove the lower intake manifold bolt.
Fig 19: Locating Lower Intake Manifold Bolt
Courtesy of FORD MOTOR CO.
21. Disconnect the throttle position (TP) sensor electrical connector and wiring harness pin-type retainer.
Fig 20: Locating Throttle Position Sensor Electrical Connector And Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
22. Disconnect the idle air control (IAC) valve electrical connector and wiring harness pin-type retainer.
Fig 21: Locating Idle Air Control Valve Electrical Connector And Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
23. Disconnect the fuel rail pressure and temperature sensor vacuum hose.
Fig 22: Locating Fuel Rail Pressure And Temperature Sensor Vacuum Hose
Courtesy of FORD MOTOR CO.
24. Detach the wiring harness pin-type retainer.
Fig 23: Locating Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
25. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
Fig 24: Locating Intake Manifold Runner Control Actuator Electrical Connector
Courtesy of FORD MOTOR CO.
26. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
Fig 25: Locating Manifold Absolute Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.

2.0L engines 

27. If equipped, disconnect the secondary air injection (AIR) vacuum supply hose.
Fig 26: Locating Secondary Air Injection Vacuum Supply Hose
Courtesy of FORD MOTOR CO.
28. Disconnect the swirl control valve electrical connector.
Fig 27: Locating Swirl Control Valve Electrical Connector
Courtesy of FORD MOTOR CO.
29. Remove the bolt and the oil level indicator tube.
Fig 28: Locating Bolt And Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
NOTE: There are 3 different size bolts used. Mark the location of the bolts to make sure of correct installation.
30. Remove the 7 intake manifold bolts.
Fig 29: Locating Intake Manifold Bolts
Courtesy of FORD MOTOR CO.

2.3L engines 

31. Disconnect the swirl valve electrical connectors and pin-type retainers.
Fig 30: Locating Swirl Valve Electrical Connectors And Pin-Type Retainers
Courtesy of FORD MOTOR CO.
32. Remove the 2 bolts and the oil level indicator and tube.
Fig 31: Locating Oil Level Indicator Tube Bolts
Courtesy of FORD MOTOR CO.
NOTE: There are 3 different size bolts used. Mark the location of the bolts to make sure of correct installation.
33. Remove the 7 intake manifold bolts.
Fig 32: Locating Intake Manifold Bolts
Courtesy of FORD MOTOR CO.

All engines 

34. Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.
Fig 33: Locating Positive Crankcase Ventilation Hose
Courtesy of FORD MOTOR CO.
35. Remove the exhaust gas recirculation (EGR) tube.
Fig 34: Locating Exhaust Gas Recirculation Tube
Courtesy of FORD MOTOR CO.
36. Remove the radio interference capacitor bracket bolt and position the bracket aside.
Fig 35: Locating Radio Interference Capacitor Bracket Bolt
Courtesy of FORD MOTOR CO.
37. Disconnect the wiring harness retainers from the valve cover studs and position aside.
Fig 36: Locating Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
38. Disconnect the fuel charging wiring harness.
    • Disconnect the fuel rail pressure and temperature sensor electrical connector.
    • Disconnect the 4 fuel injector electrical connectors.
    • Detach the wiring harness retainers.
Fig 37: Locating Fuel Charging Wiring Harness
Courtesy of FORD MOTOR CO.
39. Remove the 2 bolts and the fuel rail with the fuel injectors.
Fig 38: Locating Fuel Rail Bolts And Fuel Rail
Courtesy of FORD MOTOR CO.
40. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
Fig 39: Locating Camshaft Position Sensor Electrical Connectors And Coil-On-Plug
Courtesy of FORD MOTOR CO.
41. Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor electrical connector. Remove the wiring harness from the engine.
Fig 40: Locating Cylinder Head Temperature Sensor Electrical Connector And Rubber Boot
Courtesy of FORD MOTOR CO.
42. Disconnect and remove the coolant hose.
Fig 41: Locating Coolant Hose
Courtesy of FORD MOTOR CO.
43. Disconnect the coolant bypass hose.
Fig 42: Locating Coolant Bypass Hose
Courtesy of FORD MOTOR CO.
44. Remove the 4 bolts and the coolant bypass.
Fig 43: Locating Coolant Bypass And Bolts
Courtesy of FORD MOTOR CO.
45. Disconnect and remove the coolant bypass hose.
Fig 44: Locating Coolant Bypass Hose
Courtesy of FORD MOTOR CO.
46. Remove the bolt and the KS.
Fig 45: Locating KS And Bolt
Courtesy of FORD MOTOR CO.
47. Remove the 8 bolts and the crankcase vent oil separator.
Fig 46: Locating Crankcase Vent Oil Separator And Bolts
Courtesy of FORD MOTOR CO.
48. If equipped, remove the block heater.
Fig 47: Locating Block Heater
Courtesy of FORD MOTOR CO.
49. Remove the crankcase vent tube and the coil-on-plugs.
Fig 48: Locating Crankcase Vent Tube And Coil-On-Plugs
Courtesy of FORD MOTOR CO.
CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
50. Remove the spark plugs and the CHT sensor.
    • Discard the CHT.
Fig 49: Locating Cylinder Head Temperature Sensor And Spark Plugs
Courtesy of FORD MOTOR CO.
51. Remove the bolts and the valve cover.
Fig 50: Locating Valve Cover Bolts
Courtesy of FORD MOTOR CO.
CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
52. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
    • The hole in the crankshaft pulley should be in the 6 o'clock position.
Fig 51: Turning Crankshaft Clockwise
Courtesy of FORD MOTOR CO.
CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
NOTE: The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
53. Install the special tool in the slots on the rear of both camshafts.
Fig 52: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
54. Remove the engine plug bolt.
Fig 53: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.
NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during disassembly.
55. Install the special tool.
Fig 54: Identifying Special Tool (303-507)
Courtesy of FORD MOTOR CO.
56. Assemble the special tools using 4 hardened washers in the locations shown.
Fig 55: Assembling Special Tools (205-126 And 205-072-02) And Hardened Washers
Courtesy of FORD MOTOR CO.
CAUTION: The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
CAUTION: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced; remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur.
57. Using the special tools and an air impact wrench, remove the crankshaft pulley.
    • Remove and discard the crankshaft pulley bolt and washer.
    • Remove the crankshaft pulley.
    • Remove the diamond washer and discard.
Fig 56: Using Special Tools (205-126 And 205-072-02)
Courtesy of FORD MOTOR CO.
CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.
58. Using the special tool, remove the crankshaft front oil seal.
Fig 57: Identifying Special Tool (303-409) And Crankshaft Front Oil Seal
Courtesy of FORD MOTOR CO.
NOTE: Whenever the CKP sensor is removed, a new one must be installed using the alignment jig supplied with the new part.
59. Remove and discard the CKP sensor.
Fig 58: Locating CKP Sensor
Courtesy of FORD MOTOR CO.
60. Remove the 22 bolts and the engine front cover.
Fig 59: Locating Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
61. Remove the timing chain tensioner.
    1. Compress the timing chain tensioner, and insert a paper clip into the hole to retain the tensioner.
    2. Remove the 2 bolts and timing chain tensioner.
Fig 60: Identifying Paper Clip Into Hole And Bolts
Courtesy of FORD MOTOR CO.
62. Remove the RH timing chain guide.
Fig 61: Locating RH Timing Chain Guide
Courtesy of FORD MOTOR CO.
63. Remove the timing chain.
Fig 62: View Of Timing Chain
Courtesy of FORD MOTOR CO.
64. Remove the 2 bolts and the LH timing chain guide.
Fig 63: Identifying Bolts And LH Timing Chain Guide
Courtesy of FORD MOTOR CO.
CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
65. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
Fig 64: Locating Cam Holding Area And Sprocket Bolt
Courtesy of FORD MOTOR CO.

Early build vehicles 

66. Remove the oil pump drive chain tensioner and guide.
    1. Release the tension on the tensioner spring.
    2. Remove the tensioner and the shoulder bolt.
    3. Remove the guide.
Fig 65: Locating Oil Pump Bolts
Courtesy of FORD MOTOR CO.

Late build vehicles 

67. Remove the oil pump drive chain tensioner.
    1. Release the tension on the tensioner spring.
    2. Remove the tensioner and the 2 shoulder bolts.
Fig 66: Locating Shoulder Bolts & Tensioner
Courtesy of FORD MOTOR CO.

All vehicles 

NOTE: Remove and discard the crankshaft sprocket diamond washer located behind the crankshaft sprocket.
NOTE: The oil pump chain sprocket must be held in place.
68. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain and sprockets.
Fig 67: Identifying Bolt, Chain And Sprockets
Courtesy of FORD MOTOR CO.
69. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
Fig 68: Locating Camshaft Lobe
Courtesy of FORD MOTOR CO.
CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
NOTE: Mark the location and orientation of each camshaft bearing cap.
70. Remove the camshafts from the engine.
    • Loosen the camshaft bearing bolts in the sequence shown, one turn at a time. Repeat until all the tension is released.
    • Remove the camshaft bearing caps.
    • Remove the camshafts.
Fig 69: Identifying Loosening/Tightening Sequence Of Camshaft Bearing Bolts
Courtesy of FORD MOTOR CO.
71. Remove the cylinder head.
    • Remove and discard the 10 cylinder head bolts.
    • Remove the cylinder head.
    • Remove and discard the cylinder head gasket.
Fig 70: Locating Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
72. Remove the cylinder head alignment dowels.
Fig 71: Identifying Cylinder Head Alignment Dowels
Courtesy of FORD MOTOR CO.
73. Remove the 13 bolts and the oil pan.
Fig 72: Locating Oil Pan Bolts
Courtesy of FORD MOTOR CO.
74. Remove the 6 bolts and the rear crankshaft seal.
Fig 73: Locating Rear Crankshaft Seal Bolts
Courtesy of FORD MOTOR CO.
75. Remove the 2 bolts, oil pump pickup tube and gasket.
Fig 74: Locating Oil Pump Pickup Tube Bolts
Courtesy of FORD MOTOR CO.
76. Remove the 4 bolts and the oil pump.
Fig 75: Locating Oil Pump Assembly & Bolts
Courtesy of FORD MOTOR CO.
77. Remove the 3 bolts and the intermediate shaft bearing bracket.
Fig 76: Locating Intermediate Shaft Bearing Bracket And Bolts
Courtesy of FORD MOTOR CO.

2.3L engines 

78. Make sure the Crankshaft TDC  Timing Peg is still installed and the engine is still at Top Dead Center (TDC).
    • Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC  Timing Peg.
    Fig 77: Installing Crankshaft TDC Timing Peg

    
79. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC  .
    Fig 78: Locating Balancer Unit And Shafts Reference Mark

    
80. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.

    Remove the 4 bolts and the balancer unit.

    Fig 79: Locating Balancer Unit Bolts

    

All vehicles 

81. Remove the Crankshaft TDC  Timing Peg.
    Fig 80: Installing Crankshaft TDC Timing Peg

    
82. 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 manufacturer's instructions.
83. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.

    Remove the connecting rod cap bolts and cap.

    Fig 81: Locating Connecting Rod Cap Bolts

    
84. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

    Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.

    • Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
    Fig 82: Identifying Connecting Rod Installer

    
85. Remove the bolts in the sequence shown.
    • Remove the main bearing beam.
    • Discard the bolts.
    Fig 83: Identifying Crankshaft Cap Bolts Removing Sequence

    
86. Remove the crankshaft from the engine block.
    Fig 84: Locating Crankshaft

    
87. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.

    Remove the main bearings from the main bearing beam.

    Fig 85: Locating Main Bearings

    
88. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
    NOTE: The center bulkhead has the thrust bearing.

    Remove the main bearings from the cylinder block.

    Fig 86: Locating Main Bearings

    
89. NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly.
    NOTE: The front bulkhead does not have an oil squirter.

    Remove the 4 oil squirters.

    Fig 87: Locating Oil Squirters

    
90. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .