Engine Mechanical: Mechanical: Engine: Disassembly: Engine

Special Tools

Illustration	Tool Name	Tool Number
	Impact Slide Hammer	100-001 (T50T-100-A)
	Remover, Crankshaft Rear Seal	303-519 (T95P-6701-EH)
	Remover, Crankshaft Vibration Damper	303-009 (T58P-6316-D)
	Remover, Oil Seal	303-409 (T92C-6700-CH)
	Remover, Crankshaft Vibration Damper	303-176 (T82L-6316-B)

Material

Item	Specification
Silicone Gasket Remover ZC-30	-
Motorcraft Metal Surface Prep ZC-31	-

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: For additional information, refer to the exploded views in Engine Assembly.

1. Remove the 6 bolts and the flywheel.
Fig 1: Flexplate Bolts
Courtesy of FORD MOTOR CO.
2. Using the special tools, remove the crankshaft rear seal.
Fig 2: Removing Crankshaft Rear Seal
Courtesy of FORD MOTOR CO.
3. Mount the engine on a suitable stand.
4. Remove the 4 bolts and the coolant pump pulley.
Fig 3: Identifying Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
5. Remove the accessory drive belt idler pulley.
Fig 4: Locating Accessory Drive Belt Idler Pulley
Courtesy of FORD MOTOR CO.
6. Disconnect the generator.
   • Remove the B+ wire terminal.
   • Disconnect the generator electrical connector.
Fig 5: Locating Generator Electrical Connector
Courtesy of FORD MOTOR CO.
7. Remove the 3 bolts and the generator.
Fig 6: Locating Generator Bolts
Courtesy of FORD MOTOR CO.
8. Remove the bolt and the coolant pump extension tube and bracket.
Fig 7: Locating Coolant Pump Extension Tube And Bracket Bolt
Courtesy of FORD MOTOR CO.
9. Remove the 4 bolts and the A/C compressor mounting bracket brace and generator mounting bracket as an assembly.
Fig 8: Locating A/C Compressor Mounting Bracket Bolts
Courtesy of FORD MOTOR CO.
10. Remove the 4 bolts and the A/C compressor bracket.
Fig 9: Locating A/C Compressor Bracket Bolts
Courtesy of FORD MOTOR CO.
NOTE: Remove and discard the coolant pump outlet tube O-ring.
11. Remove the coolant pump outlet tube.
    • Disconnect the 3 coolant hoses.
      • Reposition the clamps.
    • Remove the 2 bolts and the coolant pump outlet tube.
Fig 10: Locating Coolant Pump Outlet Tube Bolts
Courtesy of FORD MOTOR CO.
12. Remove the 3 bolts and the accessory drive belt tensioner.
Fig 11: Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
13. Remove the 4 bolts and the power steering pump bracket.
Fig 12: Power Steering Pump Bracket Bolts
Courtesy of FORD MOTOR CO.
14. Disconnect the crankshaft position (CKP) sensor electrical connector.
Fig 13: Crankshaft Position (CKP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
15. Remove the catalyst monitor sensor electrical connector mounting bracket.
Fig 14: Locating Catalyst Monitor Sensor Electrical Connector Bracket Nut
Courtesy of FORD MOTOR CO.
16. Remove the 4 bolts and the RH engine mount bracket.
Fig 15: Locating RH Engine Mount Bracket Bolts
Courtesy of FORD MOTOR CO.
17. Disconnect the oil pressure sensor electrical connector and remove the engine harness pin-type retainer.
Fig 16: Locating Oil Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
18. Disconnect the camshaft position (CMP) sensor electrical connector.
Fig 17: Locating Camshaft Position Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
19. Disconnect the intake manifold runner control (IMRC) electrical connector.
Fig 18: Locating Intake Manifold Runner Control Electrical Connector
Courtesy of FORD MOTOR CO.
20. Disconnect the crankcase vent hose valve electrical connector and quick-connect the crankcase vent hose.
Fig 19: Locating Crankcase Vent Hose Valve Electrical Connector
Courtesy of FORD MOTOR CO.
21. Disconnect the quick connect crankcase vent hose from the intake manifold and remove.
Fig 20: Locating Quick Connect Crankcase Vent Hose
Courtesy of FORD MOTOR CO.
22. Remove the bolt and the oil level indicator and tube.
Fig 21: Oil Level Indicator Tube Bolt
Courtesy of FORD MOTOR CO.
CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire.
NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them.
23. Disconnect and remove the spark plug wires and retainers as an assembly.
Fig 22: Locating Spark Plug Wires & Retainers
Courtesy of FORD MOTOR CO.
24. Remove the 4 engine harness pin-type retainers.
Fig 23: Locating Engine Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
25. Disconnect the knock sensor (KS) electrical connector.
Fig 24: Locating Knock Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
26. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
Fig 25: Locating Cylinder Head Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
27. Disconnect the following.
    1. Idle air control (IAC) electrical connector
    2. Throttle position (TP) sensor electrical connector
    3. Exhaust gas recirculation (EGR) system module electrical connector
    4. EGR system module vacuum connector
    5. EGR system module-to-exhaust manifold tube upper fitting
Fig 26: Identifying EGR System Module Vacuum Connector & Throttle Position Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
28. Detach the wire retainer from the TP sensor stud bolt.
Fig 27: Locating Wire Retainer
Courtesy of FORD MOTOR CO.
29. Loosen the nut and remove the EGR system module-to-exhaust manifold tube.
Fig 28: EGR System Module-To-Exhaust Manifold Tube
Courtesy of FORD MOTOR CO.
30. Disconnect the ignition coil electrical connector and remove the engine harness pin-type retainer.
Fig 29: Locating Ignition Coil Electrical Connector
Courtesy of FORD MOTOR CO.
31. Remove the 3 bolts and the ignition coil.
Fig 30: Locating Ignition Coil Bolts
Courtesy of FORD MOTOR CO.
32. Disconnect the vacuum harness connection and remove the vacuum harness from the engine.
Fig 31: Locating Vacuum Harness
Courtesy of FORD MOTOR CO.
33. Disconnect the engine harness-to-fuel charging harness electrical connector and remove the engine harness from the engine.
Fig 32: Locating Engine Harness-To-Fuel Charging Harness Electrical Connector
Courtesy of FORD MOTOR CO.
34. Remove the upper intake manifold and discard the gaskets.
Fig 33: Locating Upper Intake Manifold
Courtesy of FORD MOTOR CO.
35. Remove the bolts and the fuel rail, fuel injectors and fuel charging harness as an assembly.
Fig 34: Locating Fuel Rail, Fuel Injectors And Fuel Charging Harness
Courtesy of FORD MOTOR CO.
36. Remove the fuel injector clips and fuel injectors.
Fig 35: Fuel Injectors & Clips
Courtesy of FORD MOTOR CO.
37. Remove and discard the fuel injector O-rings.
Fig 36: Fuel Injector O-Rings
Courtesy of FORD MOTOR CO.
NOTE: Record the location of the 6 long bolts and the 8 short bolts.
38. Remove the bolts and the lower intake manifold assembly.
Fig 37: Locating Lower Intake Manifold Assembly Bolts
Courtesy of FORD MOTOR CO.
39. Remove and discard the lower intake manifold sealing components.

    Item	Part Number	Description
    1	9439	RH intake manifold gasket
    2	9439	LH intake manifold gasket
    3	9A424	Intake manifold rear end seal (part of 9439)
    4	9A425	Intake manifold front end seal (part of 9439)

Fig 38: Lower Intake Manifold Gaskets
Courtesy of FORD MOTOR CO.
40. Remove the 3 nuts and the heat shield.
Fig 39: Locating Heat Shield Nuts
Courtesy of FORD MOTOR CO.
41. Remove the 6 nuts and the RH exhaust manifold.
Fig 40: Locating RH Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
42. Remove the 6 nuts and the LH exhaust manifold.
Fig 41: Locating LH Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
43. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
44. Remove the LH valve cover.
    1. Remove the 3 bolts.
    2. Remove the 2 stud bolts.
    3. Remove the LH valve cover.
Fig 42: Identifying LH Valve Cover
Courtesy of FORD MOTOR CO.
45. Remove the RH valve cover.
    1. Remove the 3 stud bolts.
    2. Remove the 2 bolts.
    3. Remove the RH valve cover.
Fig 43: Identifying RH Valve Cover
Courtesy of FORD MOTOR CO.
CAUTION: If the components are to be reinstalled, they must be installed into the same position. Mark the components for location.
NOTE: If the rocker arms are to be reinstalled, they must be installed into their original locations. Mark the rocker arms for location.
46. Remove the rocker arms.
    1. Remove the bolts.
    2. Remove the rocker arms and pivots.
Fig 44: Identifying Rocker Arms And Pivots
Courtesy of FORD MOTOR CO.
NOTE: If the push rods are to be reinstalled, they must be installed into their original locations. Mark the push rods for location.
47. Remove the 12 push rods.
Fig 45: Pushrods
Courtesy of FORD MOTOR CO.
48. Remove the lower 3 exhaust manifold studs from both cylinder heads.
Fig 46: Lower Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
NOTE: Record the location of long and short bolts.
49. Remove and discard all the cylinder head bolts.
Fig 47: Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
50. Remove the RH and LH cylinder heads and the gaskets. Discard the gasket.
Fig 48: Cylinder Head & Gasket
Courtesy of FORD MOTOR CO.
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.
51. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads 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 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.
52. Inspect the cylinder heads for distortion. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
53. Remove and discard the engine oil filter.
Fig 49: Engine Oil Filter
Courtesy of FORD MOTOR CO.
CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
54. If equipped, remove the oil cooler and tube assembly bolt.
    • Discard the oil cooler and tube assembly.
Fig 50: Locating Oil Cooler/Tube Assembly & Bolt
Courtesy of FORD MOTOR CO.
55. Remove the oil pressure sensor.
Fig 51: Locating Oil Pressure Sensor
Courtesy of FORD MOTOR CO.
NOTE: Discard the oil pan rear seal.
56. Remove the 17 bolts and the oil pan.
Fig 52: Locating Oil Pan Bolts
Courtesy of FORD MOTOR CO.
NOTE: In some cases the oil pump intermediate shaft may not come out with the synchronizer assembly. If so, retrieve the intermediate shaft before proceeding.
57. Remove the bolt and the camshaft synchronizer assembly.
Fig 53: Camshaft Synchronizer Assembly & Bolt
Courtesy of FORD MOTOR CO.
58. Using the special tool, remove the crankshaft damper and pulley assembly.
Fig 54: Removing Crankshaft Pulley
Courtesy of FORD MOTOR CO.
59. Using the special tool, remove the crankshaft front seal. Discard the seal.
Fig 55: Removing Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
60. Remove the coolant pump.
    • Remove the 4 nuts, 4 bolts and the stud bolt.
    • Remove the coolant pump.
    • Discard the coolant pump housing gasket.
Fig 56: Coolant Pump
Courtesy of FORD MOTOR CO.
61. Remove the engine front cover and oil pump assembly and the engine front cover gasket.
    1. Remove the 2 stud bolts.
    2. Remove the bolt.
    CAUTION: The capscrew is hidden; make sure to remove it or the engine front cover will be damaged.
    3. Remove the capscrew.
    4. Slide the engine front cover and engine front cover gasket from the dowels. Discard the engine front cover gasket.
    5. Remove the 4 studs.
Fig 57: Identifying Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
62. Remove the camshaft synchronizer drive gear.
    1. Remove the bolt.
    2. Remove the camshaft synchronizer drive gear.
Fig 58: Camshaft Synchronizer Drive Gear & Bolt
Courtesy of FORD MOTOR CO.
63. Compress and install a retaining pin to hold the timing chain tensioner.
Fig 59: Compressing Timing Chain Tensioner And Installing Retaining Pin
Courtesy of FORD MOTOR CO.
64. Remove the camshaft gear, the crankshaft gear and the timing chain as an assembly.
Fig 60: Identifying Timing Chain And Sprockets
Courtesy of FORD MOTOR CO.
65. Remove the bolts and the timing chain tensioner.
Fig 61: Locating Timing Chain Tensioner Bolts
Courtesy of FORD MOTOR CO.
NOTE: If the valve tappets are to be reinstalled, they must be installed into their original locations. Mark the valve tappets for installation.
66. Remove the 12 valve tappets.
    1. Remove the 2 bolts.
    2. Remove the tappet guide plate and retainer.
    3. Remove the 12 valve tappets.
Fig 62: Identifying Valve Tappets
Courtesy of FORD MOTOR CO.
67. Remove the engine balance shaft drive gear and camshaft key.
Fig 63: Locating Engine Balance Shaft Drive Gear & Camshaft Key
Courtesy of FORD MOTOR CO.
68. Remove the engine dynamic balance shaft.
    • Remove the 2 bolts.
    • Remove the balance shaft driven gear, thrust plate and engine dynamic balance shaft as an assembly.
Fig 64: Balance Shaft Driven Gear, Thrust Plate & Bolts
Courtesy of FORD MOTOR CO.
69. Remove the camshaft.
    1. Remove the 2 bolts.
    2. Remove the camshaft thrust plate.
    3. Remove the spacer.
    4. Remove the camshaft.
Fig 65: Camshaft, Spacer, Thrust Plate & Bolts
Courtesy of FORD MOTOR CO.
70. Remove the bearing covers.
    1. Remove the engine dynamic balance shaft bearing cover.
    2. Remove the camshaft bearing cover.
Fig 66: Identifying Engine Dynamic Balance Shaft Bearing Cover & Camshaft Bearing Cover
Courtesy of FORD MOTOR CO.
71. Remove the oil pump screen cover and tube.
    • Remove the nut.
    • Remove the 2 bolts.
Fig 67: Locating Oil Pump Screen Cover Bolts & Nuts
Courtesy of FORD MOTOR CO.
72. Remove the 5 nuts and the oil pan baffle.
Fig 68: Locating Oil Pan Baffle Nuts
Courtesy of FORD MOTOR CO.
73. If necessary, remove the ridge at the top of the cylinder.
CAUTION: The connecting rods and bearings are matched to the crankshaft journals. Make sure the components are marked and installed in the correct location.
CAUTION: Each connecting rod and connecting rod cap are matched sets. They will fit together only one way. Mark them before removing.
CAUTION: Do not damage the connecting rod and the connecting rod cap fractured joint face surface or engine damage can occur.
74. Remove the piston.
    1. Make sure the piston being removed is at the bottom of the cylinder bore.
    2. Remove the 2 bolts.
    3. Remove the connecting rod cap and the lower connecting rod bearing.
    CAUTION: Do not damage the cylinder wall when removing the piston.
    4. Push the piston and the connecting rod out of the cylinder.
Fig 69: Removing Piston
Courtesy of FORD MOTOR CO.
75. Repeat the piston removal steps for the remaining pistons.
CAUTION: The crankshaft main bearings and the main bearing caps are matched to the crankshaft journals. Make sure the components are marked for position.
NOTE: The crankshaft main bearing located at the main bearing cap is the thrust bearing.
76. Remove the 4 main bearing caps and lower crankshaft main bearings.
    1. Remove the 2 stud bolts.
    2. Remove the main bearing cap and lower crankshaft main bearing.
Fig 70: Main Bearing Cap & Bolts
Courtesy of FORD MOTOR CO.
77. Repeat the main bearing cap and the lower bearing removal steps for the remaining main bearing caps and the lower crankshaft main bearings.
CAUTION: The crankshaft journals must be protected from damage when the crankshaft is removed.
78. Remove the crankshaft.
Fig 71: Locating Crankshaft
Courtesy of FORD MOTOR CO.
NOTE: For ease in reassembly, record the location of the crankshaft upper thrust bearing.
79. Remove the upper 4 crankshaft main bearings and the crankshaft upper thrust bearing.
Fig 72: Identifying Crankshaft Upper Main Bearings And Upper Thrust Main Bearing
Courtesy of FORD MOTOR CO.
80. Remove the 4 camshaft bearings.
Fig 73: Identifying Camshaft Bearings
Courtesy of FORD MOTOR CO.
81. Remove the 2 engine dynamic balance shaft bearings.
Fig 74: Identifying Engine Dynamic Balance Shaft Bearings
Courtesy of FORD MOTOR CO.
82. If equipped, remove the engine block heater.
Fig 75: Locating Engine Block Heater
Courtesy of FORD MOTOR CO.
NOTE: For cleaning purposes, the plugs should be removed.
83. If necessary, remove the following:
    1. Cylinder block dowels
    2. Oil gallery plugs
    3. Coolant jacket plugs
Fig 76: Identifying Cylinder Block Dowels, Oil Gallery Plugs & Coolant Jacket Plugs
Courtesy of FORD MOTOR CO.