Section 986 (Engine - 4.2L -- F150 Pickup): Disassembly: Engine

	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)
	Strap Wrench 303-D055 (D85L-6000-A) or equivalent

Vehicles equipped with a manual transmission

CAUTION: Loosen the bolts evenly to prevent pressure plate damage.
NOTE: If the parts are to be reused, mark the clutch pressure plate and the flywheel for assembly reference.
Fig 1: Removing 6 Bolts, Clutch Pressure Plate And Clutch Disc
Courtesy of FORD MOTOR CO.
1. Remove the 6 bolts, the clutch pressure plate and the clutch disc.
2. Remove the 6 bolts and the flywheel.
   Fig 2: Removing 6 Bolts And Flywheel

   Courtesy of FORD MOTOR CO.

   Vehicles equipped with an automatic transmission

3. Remove the 6 bolts and the flexplate.
   Fig 3: Removing 6 Bolts And Flexplate

   Courtesy of FORD MOTOR CO.

All vehicles 

4. Remove the spacer plate.
   Fig 4: Removing Spacer Plate

   Courtesy of FORD MOTOR CO.
5. Using the special tools, remove the crankshaft rear seal.
   Fig 5: Using Special Tools To Remove Crankshaft Rear Seal

   Courtesy of FORD MOTOR CO.
6. Mount the engine on a suitable stand.
7. Disconnect and detach the heated oxygen sensor (HO2S) electrical connector. Remove the nut and the ground wire.
   Fig 6: Removing Nut And Ground Wire

   Courtesy of FORD MOTOR CO.
8. Disconnect the heated positive crankcase ventilation (PCV) valve and the radio interference capacitor electrical connectors.
   Fig 7: Disconnecting Heated Positive Crankcase Ventilation (PCV) Valve And Radio Interference Capacitor Electrical Connectors

   Courtesy of FORD MOTOR CO.
9. Remove the bolt and the accessory drive belt idler pulley.
   Fig 8: Removing Bolt And Accessory Drive Belt Idler Pulley

   Courtesy of FORD MOTOR CO.
10. Remove the 4 bolts and the generator mounting bracket, the generator, the accessory drive belt tensioner and the idler pulley as an assembly.
    Fig 9: Removing 4 Bolts And Generator Mounting Bracket, Generator, Accessory Drive Belt Tensioner And Idler Pulley As An Assembly

    Courtesy of FORD MOTOR CO.
11. Disconnect the crankshaft position (CKP) sensor and the camshaft position (CMP) electrical connectors.
    • Detach the 2 wiring harness retainers.
    Fig 10: Disconnecting Crankshaft Position (CKP) Sensor And Camshaft Position (CMP) Electrical Connectors

    Courtesy of FORD MOTOR CO.
12. If equipped, disconnect the A/C compressor clutch electrical connector.
    Fig 11: Disconnecting A/C Compressor Clutch Electrical Connector

    Courtesy of FORD MOTOR CO.
13. Remove the 2 nuts, the 2 bolts and the A/C compressor and power steering pump bracket brace.
    Fig 12: Removing 2 Nuts, 2 Bolts And A/C Compressor And Power Steering Pump Bracket Brace

    Courtesy of FORD MOTOR CO.
14. Remove the bolt and the A/C compressor and power steering pump bracket and, if equipped, the A/C compressor.
    Fig 13: Removing Bolt, A/C Compressor, Power Steering Pump Bracket And A/C Compressor

    Courtesy of FORD MOTOR CO.
15. Disconnect the oil pressure sender electrical connector and detach the wiring harness retainer.
    Fig 14: Disconnecting Oil Pressure Sender Electrical Connector And Detaching Wiring Harness Retainer

    Courtesy of FORD MOTOR CO.
16. Disconnect and detach the HO2S electrical connector. Disconnect the knock sensor (KS) and the cylinder head temperature (CHT) sensor electrical connectors.
    • Remove the engine wiring harness.
    Fig 15: Disconnecting HO2S Electrical Connector, Knock Sensor (KS) And Cylinder Head Temperature (CHT) Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
17. Remove the 4 bolts and the coolant pump pulley.
    Fig 16: Removing Bolts And Coolant Pump Pulley

    Courtesy of FORD MOTOR CO.
18. Release the clamp and disconnect the bypass hose. Remove the bolt and the heater outlet tube.
    Fig 17: Removing Bolt And Heater Outlet Tube

    Courtesy of FORD MOTOR CO.
19. Remove the 14 bolts and the lower intake manifold.
    • Remove and discard the 2 gaskets and 2 end seals.
    Fig 18: Removing 14 Bolts And Lower Intake Manifold

    Courtesy of FORD MOTOR CO.
20. Remove the 3 bolts, 2 stud bolts and the LH valve cover.
    • Remove and discard the gasket.
    Fig 19: Removing 3 Bolts, 2 Stud Bolts And LH Valve Cover

    Courtesy of FORD MOTOR CO.
21. Remove the bolt and the oil level indicator and tube.
    Fig 20: Removing Bolt And Oil Level Indicator And Tube

    Courtesy of FORD MOTOR CO.
22. Remove the 6 nuts and the LH exhaust manifold.
    • Remove and discard the gasket.
    Fig 21: Removing 6 Nuts And LH Exhaust Manifold

    Courtesy of FORD MOTOR CO.
23. Remove the bolts and the engine support insulator bracket. Remove the oil pressure sender.
    Fig 22: Removing Bolts And Engine Support Insulator Bracket

    Courtesy of FORD MOTOR CO.
24. Remove the 2 bolts, 3 stud bolts and the RH valve cover.
    • Remove and discard the gasket.
    Fig 23: Removing 2 Bolts, 3 Stud Bolts And RH Valve Cover

    Courtesy of FORD MOTOR CO.
25. Remove the 6 nuts and the RH exhaust manifold.
    • Remove and discard the gasket.
    Fig 24: Removing 6 Nuts And RH Exhaust Manifold

    Courtesy of FORD MOTOR CO.
26. Remove the bolts and the RH engine support insulator brackets.
    Fig 25: Removing Bolts And RH Engine Support Insulator Brackets

    Courtesy of FORD MOTOR CO.
CAUTION: If the rocker arms are to be reinstalled, they must be installed into their original positions. Mark the rocker arms for location.
Fig 26: Removing 6 Bolts, 6 Rocker Arm Pivots And 6 Rocker Arms From Both Cylinder Heads
Courtesy of FORD MOTOR CO.
27. Remove the 6 bolts, the 6 rocker arm pivots and the 6 rocker arms from both cylinder heads.
CAUTION: If the push rods are to be reinstalled, they must be installed into their original positions. Mark the push rods for location.
Fig 27: Removing 6 Push Rods From Both Cylinder Heads
Courtesy of FORD MOTOR CO.
28. Remove the 6 push rods from both cylinder heads.
29. Remove the 3 lower exhaust manifold studs from both cylinder heads.
    Fig 28: Removing 3 Lower Exhaust Manifold Studs From Both Cylinder Heads

    Courtesy of FORD MOTOR CO.
30. Remove the 8 cylinder head bolts from both cylinder heads.
    Fig 29: Removing 8 Cylinder Head Bolts From Both Cylinder Heads

    Courtesy of FORD MOTOR CO.
31. Remove both cylinder heads.
    • Remove and discard both cylinder head gaskets.
    Fig 30: Removing Both Cylinder Heads

    Courtesy of FORD MOTOR CO.
32. Remove the 17 bolts and the oil pan.
    • Remove and discard the oil pan rear seal.
    Fig 31: Removing 17 Bolts And Oil Pan

    Courtesy of FORD MOTOR CO.
33. Remove the CMP sensor and the camshaft synchronizer.
    1. Remove the 2 bolts and the CMP sensor.
    2. Remove the bolt and washer assembly.
    3. Remove the camshaft synchronizer.
    Fig 32: Removing CMP Sensor And Camshaft Synchronizer

    Courtesy of FORD MOTOR CO.
34. Using the special tool to prevent the crankshaft rotation, remove the crankshaft pulley bolt and washer.
    Fig 33: Using Special Tool To Prevent Crankshaft Rotation And Remove Crankshaft Pulley Bolt And Washer

    Courtesy of FORD MOTOR CO.
35. Using the special tools, remove the crankshaft pulley.
    Fig 34: Using Special Tools To Remove Crankshaft Pulley

    Courtesy of FORD MOTOR CO.
36. Using the special tool, remove the crankshaft front seal.
    • Discard the crankshaft front seal.
    Fig 35: Using Special Tool To Remove Crankshaft Front Seal

    Courtesy of FORD MOTOR CO.
37. Remove the 4 nuts, 4 bolts, the stud bolt, the coolant pump and the gasket.
    • Discard the gasket.
    Fig 36: Removing 4 Nuts, 4 Bolts, Stud Bolt, Coolant Pump And Gasket

    Courtesy of FORD MOTOR CO.
38. 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 cap screw is hidden. Make sure to remove it or the engine front cover will be damaged.
    3. Remove the cap screw.
    4. Slide the engine front cover and engine front cover gasket from the dowels.
       • Discard the gasket.
    5. Remove the studs.
    Fig 37: Removing Engine Front Cover And Oil Pump Assembly And Engine Front Cover Gasket

    Courtesy of FORD MOTOR CO.
39. Remove the bolt and the camshaft synchronizer drive gear.
    Fig 38: Removing Bolt And Camshaft Synchronizer Drive Gear

    Courtesy of FORD MOTOR CO.
40. Compress the timing chain tensioner and install a retaining pin.
    Fig 39: Compressing Timing Chain Tensioner And Installing Retaining Pin

    Courtesy of FORD MOTOR CO.
41. Remove the crankshaft gear, the camshaft gear and the timing chain as an assembly.
    Fig 40: Removing Crankshaft Gear, Camshaft Gear And Timing Chain As An Assembly

    Courtesy of FORD MOTOR CO.
42. Remove the 2 bolts and the timing chain tensioner.
    Fig 41: Removing 2 Bolts And Timing Chain Tensioner

    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 location.
Fig 42: Removing 12 Valve Tappets
Courtesy of FORD MOTOR CO.
43. Remove the 12 valve tappets.
    1. Remove the 4 bolts.
    2. Remove the valve tappet guide plate and retainer.
    3. Remove the 12 valve tappets.
44. Remove the engine balance shaft drive gear and the camshaft key.
    Fig 43: Removing Engine Balance Shaft Drive Gear And Camshaft Key

    Courtesy of FORD MOTOR CO.
45. Remove the 2 bolts and the balance shaft driven gear, thrust plate and engine dynamic balance shaft as an assembly.
    Fig 44: Removing 2 Bolts And Balance Shaft Driven Gear, Thrust Plate And Engine Dynamic Balance Shaft As An Assembly

    Courtesy of FORD MOTOR CO.
46. Remove the camshaft.
    1. Remove the 2 bolts.
    2. Remove the camshaft thrust plate.
    3. Remove the spacer.
    4. Remove the camshaft.
    Fig 45: Removing Camshaft

    Courtesy of FORD MOTOR CO.
47. Remove the bearing covers.
    1. Remove the engine dynamic balance shaft bearing cover.
    2. Remove the camshaft bearing cover.
    Fig 46: Removing Bearing Covers

    Courtesy of FORD MOTOR CO.
48. Remove the nut, the 2 bolts and the oil pump screen cover and tube.
    Fig 47: Removing Nut, 2 Bolts And Oil Pump Screen Cover And Tube

    Courtesy of FORD MOTOR CO.
49. Remove the 5 nuts and the oil pan baffle.
    Fig 48: Removing 5 Nuts And Oil Pan Baffle

    Courtesy of FORD MOTOR CO.
50. 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's instructions.
CAUTION: The connecting rods and bearings are matched to the crankshaft journals. Make sure the components are marked and installed in the correct locations.
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.
Fig 49: Removing Piston
Courtesy of FORD MOTOR CO.
51. 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.
52. 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 number 3 main bearing cap is the thrust bearing.
Fig 50: Removing Main Bearing Caps And Lower Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
53. Remove the 4 main bearing caps and lower crankshaft main bearings.
    1. Remove the bolts and stud bolts.
    2. Remove the 4 main bearing caps and lower crankshaft main bearings.
CAUTION: The crankshaft journals must be protected from damage when the crankshaft is removed.
Fig 51: Removing Crankshaft
Courtesy of FORD MOTOR CO.
54. Remove the crankshaft.
NOTE: For ease in reassembly, record the locations of the crankshaft upper thrust bearings.
Fig 52: Removing Upper Crankshaft Main Bearings And Crankshaft Upper Thrust Bearing
Courtesy of FORD MOTOR CO.
55. Remove the 3 upper crankshaft main bearings and the crankshaft upper thrust bearing.
56. Remove the camshaft bearings.
    Fig 53: Removing Camshaft Bearings

    Courtesy of FORD MOTOR CO.
57. Remove the engine dynamic balance shaft bearings.
    Fig 54: Removing Engine Dynamic Balance Shaft Bearings

    Courtesy of FORD MOTOR CO.
58. If equipped, remove the engine block heater.
    Fig 55: Removing Engine Block Heater

    Courtesy of FORD MOTOR CO.
NOTE: For cleaning purposes, the plugs should be removed.
Fig 56: Removing Cylinder Block Dowels, Oil Gallery Plugs, Water Jacket Plugs
Courtesy of FORD MOTOR CO.
59. If necessary, remove the following:
    1. Cylinder block dowels.
    2. Oil gallery plugs.
    3. Water jacket plugs.