Engine Mechanical: Mechanical: Engine: Disassembly: Engine

Fig 1: Identifying Special Tool(s)

Courtesy of FORD MOTOR CO.

CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

1. Remove the flexplate and the spacer plate.
   Fig 2: Removing Flexplate And Spacer Plate

   Courtesy of FORD MOTOR CO.
2. Using the special tools, remove the crankshaft oil slinger.
   Fig 3: Removing Crankshaft Oil Slinger

   Courtesy of FORD MOTOR CO.
3. Using the special tools, remove the crankshaft rear seal.
   Fig 4: Removing Crankshaft Rear Seal

   Courtesy of FORD MOTOR CO.
4. Remove the rear seal retainer plate.
   Fig 5: Removing Rear Seal Retainer Plate

   Courtesy of FORD MOTOR CO.
5. Mount the engine on a suitable engine stand.
   Fig 6: Mounting Engine On A Suitable Engine Stand

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6. Remove the two bolts and the pin-type retainer from the power steering reservoir bracket.
   Fig 7: Removing Two Bolts And Pin-Type Retainer From Power Steering Reservoir Bracket

   Courtesy of FORD MOTOR CO.
7. Remove the power steering reservoir and bracket.
   • Disconnect the hose from the power steering pump.
   • Remove the bolt and the reservoir and bracket.
   Fig 8: Removing Reservoir And Bracket

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8. Disconnect the battery cable harness ground.
   Fig 9: Disconnecting Battery Cable Harness Ground

   Courtesy of FORD MOTOR CO.
9. Disconnect the electrical connector and the battery cable from the alternator.
   Fig 10: Disconnecting Electrical Connector And Battery Cable From Alternator

   Courtesy of FORD MOTOR CO.
10. Disconnect the two retainers from the engine front cover studs.
    Fig 11: Disconnecting Two Retainers From Engine Front Cover Studs

    Courtesy of FORD MOTOR CO.
11. Disconnect the two retainers from the A/C compressor.
    Fig 12: Disconnecting Two Retainers From A/C Compressor

    Courtesy of FORD MOTOR CO.
12. Remove the bolt and the battery cable harness from the RH engine mount.
    Fig 13: Removing Bolt And Battery Cable Harness From RH Engine Mount

    Courtesy of FORD MOTOR CO.
13. Disconnect the electrical connector and the vacuum hose from the fuel pressure sensor.
    Fig 14: Disconnecting Electrical Connector And Vacuum Hose From Fuel Pressure Sensor

    Courtesy of FORD MOTOR CO.
14. Disconnect the vacuum harness from the intake manifold and remove the harness.
    Fig 15: Disconnecting Vacuum Harness From Intake Manifold

    Courtesy of FORD MOTOR CO.
NOTE: LH shown; RH similar.
Fig 16: Removing LH And RH Coil Covers
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15. Remove the LH and RH coil covers.
NOTE: LH shown; RH similar.
Fig 17: Disconnecting Rh And LH Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
16. Disconnect the RH and LH ignition coil electrical connectors.
17. Disconnect the radio interference capacitor electrical connector.
    Fig 18: Disconnecting Radio Interference Capacitor Electrical Connector

    Courtesy of FORD MOTOR CO.
18. Disconnect the eight fuel injector electrical connectors.
    Fig 19: Disconnecting Eight Fuel Injector Electrical Connectors

    Courtesy of FORD MOTOR CO.
19. Separate the fuel charging wiring harness retainers from the fuel injection supply manifold.
    Fig 20: Identifying Wiring Harness Retainers From Fuel Injection Supply Manifold

    Courtesy of FORD MOTOR CO.
20. Disconnect the camshaft position (CMP) sensor electrical connector and the two retainers from the valve cover.
    Fig 21: Disconnecting Camshaft Position (CMP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
21. Disconnect the oil pressure sensor electrical connector.
    Fig 22: Disconnecting Oil Pressure Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
22. Disconnect the pin-type retainers from the back of the engine in the locations shown.
    Fig 23: Disconnecting Pin-Type Retainers From Back Of Engine

    Courtesy of FORD MOTOR CO.
23. Disconnect the knock sensor (KS) electrical connector and the pin-type retainer.
    Fig 24: Disconnecting Knock Sensor (KS) Electrical Connector And Pin-Type Retainer

    Courtesy of FORD MOTOR CO.
24. Disconnect the wiring harness retainer from the stud on the cylinder head.
    Fig 25: Disconnecting Wiring Harness Retainer From Stud On Cylinder Head

    Courtesy of FORD MOTOR CO.
25. Disconnect the intake manifold runner control (IMRC) electrical connector.
    Fig 26: Disconnecting Intake Manifold Runner Control (IMRC) Electrical Connector

    Courtesy of FORD MOTOR CO.
26. Disconnect the exhaust gas recirculation (EGR) system module tube nut from the exhaust manifold.
    Fig 27: Disconnecting Exhaust Gas Recirculation (EGR) System Module Tube Nut From Exhaust Manifold

    Courtesy of FORD MOTOR CO.
27. Disconnect the cylinder head temperature (CHT) sensor electrical connector and the two pin-type retainers.
    Fig 28: Disconnecting Cylinder Head Temperature (CHT) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
28. Disconnect the positive crankcase ventilation (PCV) electrical connector.
    Fig 29: Disconnecting Positive Crankcase Ventilation (PCV) Electrical Connector

    Courtesy of FORD MOTOR CO.
29. Remove the PCV tube.
    Fig 30: Removing PCV Tube

    Courtesy of FORD MOTOR CO.
30. Disconnect the RH radio interference capacitor electrical connector and the pin-type retainer.
    Fig 31: Disconnecting RH Radio Interference Capacitor Electrical Connector

    Courtesy of FORD MOTOR CO.
31. Disconnect the throttle position (TP) sensor and the idle air control (IAC) sensor electrical connectors.
    Fig 32: Disconnecting Throttle Position (TP) Sensor And Idle Air Control (IAC) Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
32. Disconnect the two retainers from the RH valve cover studs.
    Fig 33: Disconnecting Two Retainers From RH Valve Cover Studs

    Courtesy of FORD MOTOR CO.
33. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 34: Disconnecting Engine Coolant Temperature (ECT) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
34. Disconnect the A/C compressor and the crankshaft position (CKP) sensor electrical connectors.
    Fig 35: Disconnecting A/C Compressor And Crankshaft Position (CKP) Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
35. Remove the upper radiator hose.
    Fig 36: Removing Upper Radiator Hose

    Courtesy of FORD MOTOR CO.
36. Remove the coolant bypass-to-thermostat housing hose.
    Fig 37: Removing Coolant Bypass-To-Thermostat Housing Hose

    Courtesy of FORD MOTOR CO.
37. Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE BELT, TENSIONER AND PULLEY .
38. Remove the bolts and the generator support bracket.
    Fig 38: Removing Generator Support Bracket

    Courtesy of FORD MOTOR CO.
39. Remove the bolts and the generator.
    Fig 39: Removing Generator

    Courtesy of FORD MOTOR CO.
40. Remove the crossover tube.
    1. Disconnect the coolant hose.
    2. Remove the retainers and the crossover tube.
    Fig 40: Removing Crossover Tube

    Courtesy of FORD MOTOR CO.
41. Remove the eight ignition coils.
    Fig 41: Removing Ignition Coils

    Courtesy of FORD MOTOR CO.
42. Remove the nut and the bolt from the oil level indicator tube and position the tube aside.
    Fig 42: Removing Oil Level Indicator Tube

    Courtesy of FORD MOTOR CO.
NOTE: RH shown; LH similar.
Fig 43: Removing Engine Lifting Eyes
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43. Remove the engine lifting eyes.
44. Remove the bolts and the LH valve cover.
    Fig 44: Removing LH Valve Cover

    Courtesy of FORD MOTOR CO.
45. Remove the coolant hose retainers from the RH valve cover.
    Fig 45: Removing Coolant Hose Retainers From RH Valve Cover

    Courtesy of FORD MOTOR CO.
46. Remove the bolts and the RH valve cover.
    Fig 46: Removing RH Valve Cover

    Courtesy of FORD MOTOR CO.
47. Remove the retainers and the upper-to-lower intake bracket.
    Fig 47: Removing Retainers And Upper-To-Lower Intake Bracket

    Courtesy of FORD MOTOR CO.
NOTE: Upper intake shown removed for clarity.
Fig 48: Bolt Removal Sequence
Courtesy of FORD MOTOR CO.
48. Remove the bolts in the sequence shown and remove the upper and lower intake.
49. Remove the bolt and the coolant bypass tube.
    Fig 49: Removing Bolt And Coolant Bypass Tube

    Courtesy of FORD MOTOR CO.
50. Remove the bolts and the KS.
    Fig 50: Removing Bolts And KS

    Courtesy of FORD MOTOR CO.
NOTE: LH shown; RH similar.
Fig 51: Removing Exhaust Manifolds
Courtesy of FORD MOTOR CO.
51. Remove the exhaust manifolds.
    1. Remove the 16 nuts.
    2. Remove the exhaust manifolds.
    3. Remove the exhaust manifold gaskets.
52. Remove the oil level indicator tube.
NOTE: LH shown; RH similar.
Fig 52: Removing LH And RH Engine Mounts
Courtesy of FORD MOTOR CO.
53. Remove the LH and RH engine mounts.
NOTE: RH shown, LH similar.
Fig 53: Removing Drain Plugs From Engine Block
Courtesy of FORD MOTOR CO.
54. Remove the drain plugs from the engine block. Allow the coolant to completely drain.
55. Remove the four bolts and the oil filter adapter.
    • Discard the oil filter.
    • Discard the gasket.
    Fig 54: Removing Oil Filter Adapter

    Courtesy of FORD MOTOR CO.
56. Clean and inspect the oil filter adapter.
    • Flush the adapter with parts cleaner. If metal particles are present, install a new oil filter adapter.
57. Remove the three remaining bolts and the power steering pump.
    Fig 55: Removing Power Steering Pump

    Courtesy of FORD MOTOR CO.
58. Remove the bolts and the A/C Compressor.
    Fig 56: Removing A/C Compressor

    Courtesy of FORD MOTOR CO.
59. Install the special tool.
    1. Loosen the bolts.
    Fig 57: Installing Special Tool

    Courtesy of FORD MOTOR CO.
60. Remove the coolant pump pulley.
    1. Remove the bolts.
    2. Remove the coolant pump pulley.
    Fig 58: Removing Coolant Pump Pulley

    Courtesy of FORD MOTOR CO.
61. Remove the coolant pump from the cylinder block.
    • Clean and inspect the sealing surfaces.
    Fig 59: Removing Coolant Pump From Cylinder Block

    Courtesy of FORD MOTOR CO.
62. To remove the crankshaft pulley bolt, remove the upper fan shroud and electric fan. For additional information, refer to ENGINE COOLING .
63. Using the special tool to prevent the crankshaft pulley from turning, remove the pulley bolt.
    Fig 60: Using Special Tool To Prevent Crankshaft Pulley From Turning

    Courtesy of FORD MOTOR CO.
64. Remove the bolt.
    Fig 61: Removing Pulley Bolt

    Courtesy of FORD MOTOR CO.
65. Using the special tool, remove the crankshaft vibration damper.
    Fig 62: Removing Crankshaft Vibration Damper

    Courtesy of FORD MOTOR CO.
66. Using the special tool, remove the crankshaft front seal.
    Fig 63: Removing Crankshaft Front Seal

    Courtesy of FORD MOTOR CO.
67. Remove the bolt and the belt idler pulley.
    Fig 64: Removing Bolt And Belt Idler Pulley

    Courtesy of FORD MOTOR CO.
68. Remove the four front oil pan-to-timing cover bolts.
    Fig 65: Removing Four Front Oil Pan-To-Timing Cover Bolts

    Courtesy of FORD MOTOR CO.
69. Remove the engine front cover fasteners in the sequence shown.
    Fig 66: Engine Front Cover Fastener Removal Sequence

    Courtesy of FORD MOTOR CO.
NOTE: Be careful when removing the gasket. It is reusable if not damaged.
Fig 67: Removing Oil Pan And Gasket
Courtesy of FORD MOTOR CO.
70. Remove the oil pan and the gasket.
71. Remove the crankshaft position sensor pulse wheel.
    Fig 68: Removing Crankshaft Position Sensor Pulse Wheel

    Courtesy of FORD MOTOR CO.
72. Position the piston of the cylinder in which the roller followers are being removed at the bottom of the stroke and camshaft lobe at the base circle.
73. Using the special tool, compress the intake valve spring and remove the roller follower.
    Fig 69: Compressing Intake Valve Spring

    Courtesy of FORD MOTOR CO.
74. Using the special tool, compress the exhaust valve spring and remove the roller follower.
    Fig 70: Compressing Exhaust Valve Spring

    Courtesy of FORD MOTOR CO.
75. Repeat the above steps to remove all the roller followers.
76. Remove the bolts and the RH and LH timing chain tensioners.
    Fig 71: Removing RH And LH Timing Chain Tensioners

    Courtesy of FORD MOTOR CO.
77. Remove the RH and LH timing chain tensioner arms.
    Fig 72: Removing RH And LH Timing Chain Tensioner Arms

    Courtesy of FORD MOTOR CO.
78. Remove the RH and the LH timing chains and the crankshaft sprocket.
    Fig 73: Removing RH And LH Timing Chains And Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
79. Remove the RH and LH timing chain guides.
    Fig 74: Removing RH And LH Timing Chain Guides

    Courtesy of FORD MOTOR CO.
80. Remove the RH and LH cylinder heads.
    • Discard the cylinder head bolts.
    Fig 75: Removing RH And LH Cylinder Head Bolts

    Courtesy of FORD MOTOR CO.
81. Remove the bolts and the oil pump screen and pickup tube.
    Fig 76: Removing Oil Pump Screen And Pickup Tube

    Courtesy of FORD MOTOR CO.
82. Remove the oil pump screen and pickup tube spacer.
    Fig 77: Removing Oil Pump Screen And Pickup Tube Spacer

    Courtesy of FORD MOTOR CO.
83. Remove the spacers and the windage tray.
    Fig 78: Removing Spacers And Windage Tray

    Courtesy of FORD MOTOR CO.
84. Remove the bolts and the oil pump.
    Fig 79: Removing Oil Pump

    Courtesy of FORD MOTOR CO.
CAUTION: Do not stamp the top of pistons, as ring land damage can occur.
NOTE: Connecting rods and rod caps should be numbered to keep the correct orientation in the following sequence.
Fig 80: Removing Connecting Rod Caps For Pistons 1 And 6
Courtesy of FORD MOTOR CO.
85. Remove the connecting rod caps for piston numbers 1 and 6.
    • Discard the bolts.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE: Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer following manufacturer's instructions.
Fig 81: Pushing Piston 1 And 6 Through Top Of Cylinder Block
Courtesy of FORD MOTOR CO.
86. Using the special tool, push piston numbers 1 and 6 through the top of the cylinder block.
87. To remove pistons 3 and 5, 4 and 7, 2 and 8, turn the crankshaft 90 degrees and repeat the previous two steps.
    CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
88. Remove the side bolts.
    Fig 82: Removing Side Bolts

    Courtesy of FORD MOTOR CO.
89. Remove and discard the bolts.
    Fig 83: Removing And Bolts

    Courtesy of FORD MOTOR CO.
90. Remove the main bearing cap and the crankshaft lower main bearings from the cylinder block.
    Fig 84: Removing Main Bearing Cap And Crankshaft Lower Main Bearings From Cylinder Block

    Courtesy of FORD MOTOR CO.
91. Remove the crankshaft, the crankshaft thrust washer, and the crankshaft upper main bearings from the cylinder block.
    Fig 85: Removing Crankshaft Thrust Washer And Crankshaft Upper Main Bearings From Cylinder Block

    Courtesy of FORD MOTOR CO.