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Section 1153 (Engine -- 4.0L SOHC): Disassembly: Engine

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL SPECIFICATIONS

G03947213Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Vibration Damper 303-101 (T74P-3616-A)
G03913789Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Vibration Damper 303-773
G03885361Courtesy of FORD MOTOR CO.
 Compressor, Valve Spring 303-581 (T97T-6565-A)
G03983738Courtesy of FORD MOTOR CO.
 Holding Tool, Camshaft Sprocket 303-564 (T97T-6256-B)
G03913863Courtesy of FORD MOTOR CO.
 Adapter for 303-564 303-578 (T97T-6256-A)
G03889585Courtesy of FORD MOTOR CO.
 Strap Wrench 303-D055 (D85L-6000-A) or equivalent
G03947336Courtesy of FORD MOTOR CO.
 Lifting Eyes 303-050 (D81L-6001-D) or equivalent
G03947220Courtesy of FORD MOTOR CO.
 Crankshaft Socket 303-674
G03886430Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
GENERAL EQUIPMENT SPECIFICATIONS

8-mm x 1.25 x 100-mm bolts (2 required)
CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
CAUTION: If the fuel rail is used as a leverage device, it can be damaged. Care must be taken when working around the fuel rail.
NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation.
NOTE: For additional information, refer to the exploded views under ASSEMBLY .

    All engines 

  1. Remove the bolts and the flexplate.
    Fig 1: Removing Bolts And Flexplate
    G03947222Courtesy of FORD MOTOR CO.
  2. Remove the spacer plate and the flexplate spacer.
  3. Install the engine on a suitable stand.
  4. Remove the nuts and the A/C hose.
    Fig 2: Removing Nuts And A/C Hose
    G03947223Courtesy of FORD MOTOR CO.
  5. Remove the bolts.
    Fig 3: Removing Bolts
    G03947224Courtesy of FORD MOTOR CO.
  6. Disconnect the A/C compressor electrical connector and wire harness retainer.
    Fig 4: Disconnecting A/C Compressor Electrical Connector And Wire Harness Retainer
    G03947225Courtesy of FORD MOTOR CO.
  7. Remove the bolts and the accessory bracket.
    Fig 5: Removing Bolts And Accessory Bracket
    G03947226Courtesy of FORD MOTOR CO.
  8. Disconnect the generator electrical connectors and wire harness retainer.
    Fig 6: Disconnecting Generator Electrical Connectors And Wire Harness Retainer
    G03947227Courtesy of FORD MOTOR CO.
  9. Remove the generator mounting bracket.
    1. Remove the bolt and the drive belt tensioner.
    2. Remove the generator mounting bracket bolts.
      Fig 7: Removing Generator Mounting Bracket
      G03947228Courtesy of FORD MOTOR CO.
  10. Disconnect the following electrical connectors:
    • Camshaft position (CMP) sensor.
    • Ignition coil.
    • Engine coolant temperature (ECT) sensor.
    • Ignition radio interference capacitor.
    • Fuel pressure and temperature sensor.
      Fig 8: Disconnecting Electrical Connectors
      G03947229Courtesy of FORD MOTOR CO.
    11. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.
    NOTE: RH shown; LH similar.
    NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them.
    Fig 9: Removing Spark Plug Wires
    G03947230Courtesy of FORD MOTOR CO.
  11. Remove the spark plug wires.
  12. Remove the bolts and the coil and bracket assembly.
    Fig 10: Removing Bolts And Coil And Bracket Assembly
    G03947447Courtesy of FORD MOTOR CO.

    13. Engines equipped with an engine oil cooler 

  13. Remove the oil cooler hose bracket bolts.
    Fig 11: Removing Oil Cooler Hose Bracket Bolts
    G03947232Courtesy of FORD MOTOR CO.
  14. Remove the oil cooler and hoses.
    Fig 12: Removing Oil Cooler And Hoses
    G03947233Courtesy of FORD MOTOR CO.

    15. All engines 

  15. Position aside the fuel tube.
    Fig 13: Positioning Aside Fuel Tube
    G03947234Courtesy of FORD MOTOR CO.
  16. Disconnect the knock sensor (KS) electrical connector.
    • Detach the wiring harness pin-type retainer.
      Fig 14: Disconnecting Knock Sensor Electrical Connector
      G03947235Courtesy of FORD MOTOR CO.
  17. Disconnect the electronic throttle body and throttle position (TP) sensor electrical connectors.
    Fig 15: Disconnecting Electronic Throttle Body And Throttle Position Sensor Electrical Connectors
    G03947236Courtesy of FORD MOTOR CO.
  18. Disconnect the exhaust gas recirculation (EGR) system module vacuum hose and electrical connector.
    • Detach the wiring harness pin-type retainer.
      Fig 16: Disconnecting Exhaust Gas Recirculation System Module Vacuum Hose And Electrical Connector
      G03947237Courtesy of FORD MOTOR CO.
  19. Remove the bolts and the intake manifold and gaskets.
    Fig 17: Removing Bolts And Intake Manifold And Gaskets
    G03947238Courtesy of FORD MOTOR CO.
  20. Disconnect the 6 fuel injector electrical connectors.
    Fig 18: Disconnecting Fuel Injector Electrical Connectors
    G03947239Courtesy of FORD MOTOR CO.
  21. Disconnect the crankshaft position (CKP) sensor electrical connector and the wiring anchors. Discard the wiring anchors.
    Fig 19: Disconnecting Crankshaft Position Sensor Electrical Connector And Wiring Anchors
    G03947240Courtesy of FORD MOTOR CO.
  22. Remove the engine wiring harness retainer bolts.
    Fig 20: Removing Engine Wiring Harness Retainer Bolts
    G03947241Courtesy of FORD MOTOR CO.
  23. Remove the engine wiring harness.
    Fig 21: Removing Engine Wiring Harness
    G03947242Courtesy of FORD MOTOR CO.
  24. Disconnect the fuel pressure and temperature sensor vacuum hose fitting.
    • Remove the vacuum harness.
      Fig 22: Removing Vacuum Harness
      G03947243Courtesy of FORD MOTOR CO.
  25. Disconnect the oil pressure switch electrical connector and remove the battery cable and harness.
    Fig 23: Disconnecting Oil Pressure Switch Electrical Connector
    G03947244Courtesy of FORD MOTOR CO.
  26. Remove the oil pressure switch.
    Fig 24: Removing Oil Pressure Switch
    G03947245Courtesy of FORD MOTOR CO.
    27. NOTE: LH shown; RH similar.
    Fig 25: Removing RH And LH Insulator Bolts And Brackets
    G03947246Courtesy of FORD MOTOR CO.
  27. Remove the RH and the LH insulator bolts and brackets.
  28. Remove the bolts and the fuel rail.
    Fig 26: Removing Bolts And Fuel Rail
    G03947247Courtesy of FORD MOTOR CO.
  29. Remove the fuel injectors.
    • Remove and discard the O-ring seals.
      Fig 27: Removing Fuel Injectors
      G03947248Courtesy of FORD MOTOR CO.
    30. NOTE: RH shown; LH similar.
    Fig 28: Removing Valve Covers
    G03914179Courtesy of FORD MOTOR CO.
  30. Loosen the bolts and remove the valve covers.
  31. Remove the thermostat housing.
    1. Remove the bolts.
    2. Release the bypass hose clamp and remove the thermostat housing.
      Fig 29: Removing Thermostat Housing
      G03947250Courtesy of FORD MOTOR CO.
  32. Remove the bolt and the oil level indicator tube.
    Fig 30: Locating Bolt And Oil Level Indicator Tube
    G03913929Courtesy of FORD MOTOR CO.
  33. Remove the bolt and the knock sensor (KS).
    Fig 31: Removing Bolt And Knock Sensor
    G03914181Courtesy of FORD MOTOR CO.
  34. Remove the bolts and the RH exhaust manifold and gasket.
    Fig 32: Removing Bolts And RH Exhaust Manifold And Gasket
    G03947253Courtesy of FORD MOTOR CO.
  35. Remove the bolts and the LH exhaust manifold and gasket.
    Fig 33: Removing Bolts And LH Exhaust Manifold And Gasket
    G03947254Courtesy of FORD MOTOR CO.
  36. Using the special tool to hold the crankshaft pulley, remove the bolt.
    Fig 34: Removing Bolt Using Special Tool
    G03946937Courtesy of FORD MOTOR CO.
    37. NOTE: If the pulley bolt is not installed, the tool will bottom out before the pulley is off.
  37. Install the crankshaft pulley bolt 2 to 3 turns Using the special tools and the 2 8-mm bolt! remove the crankshaft pulley.
    • Discard the crankshaft pulley bolt.
      Fig 35: Removing Crankshaft Pulley
      G03946938Courtesy of FORD MOTOR CO.
  38. Remove the bolts and the coolant pump pulley.
    Fig 36: Removing Bolts And Coolant Pump Pulley
    G03947405Courtesy of FORD MOTOR CO.
  39. Remove the bolts and the coolant pump.
    Fig 37: Removing Bolts And Coolant Pump
    G03914184Courtesy of FORD MOTOR CO.
  40. Rotate the crankshaft until the cam lobe of the cylinder being serviced is in the UP position.
    Fig 38: Identifying Cam Lobe Position
    G03947421Courtesy of FORD MOTOR CO.
    41. NOTE: Mark each camshaft roller follower to make sure it is installed in its original position during reassembly.
    Fig 39: Removing Camshaft Roller Using Special Tool
    G03947260Courtesy of FORD MOTOR CO.
  41. Using the special tool, remove the camshaft roller followers.
  42. Remove the RH hydraulic chain tensioner.
    Fig 40: Removing RH Hydraulic Chain Tensioner
    G03913936Courtesy of FORD MOTOR CO.
  43. Install the special tools on the RH cylinder head and tighten the top 2 clamp bolts.
    Fig 41: Identifying Special Holding Tool
    G03946909Courtesy of FORD MOTOR CO.
    44. CAUTION: The RH camshaft sprocket bolt is a LH threaded bolt.
    Fig 42: Identifying RH Camshaft Sprocket Bolt
    G03913961Courtesy of FORD MOTOR CO.
  44. Remove the RH camshaft sprocket bolt.
  45. Remove the bolt.
    Fig 43: Removing Bolt
    G03913939Courtesy of FORD MOTOR CO.
  46. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.
    Fig 44: Removing Camshaft Sprocket From Camshaft
    G03914195Courtesy of FORD MOTOR CO.
  47. Remove the LH hydraulic chain tensioner.
    Fig 45: Identifying LH Camshaft Tensioner
    G03913851Courtesy of FORD MOTOR CO.
  48. Install the special tools on the LH cylinder head.
    Fig 46: Identifying Special Holding Tool
    G03946909Courtesy of FORD MOTOR CO.
  49. Remove the LH camshaft sprocket bolt.
    Fig 47: Removing LH Camshaft Sprocket Bolt
    G03913853Courtesy of FORD MOTOR CO.
  50. Remove the bolt.
    Fig 48: Identifying LH Cassette Upper Bolt
    G03913945Courtesy of FORD MOTOR CO.
  51. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.
    Fig 49: Removing Camshaft Sprocket From Camshaft
    G03914195Courtesy of FORD MOTOR CO.
    52. NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
  52. Remove the bolts in the sequence shown in Fig 50 and remove the cylinder heads.
    • Discard the gaskets and the bolts.
      Fig 50: Identifying Removing Sequence Of LH Cylinder Head Bolts
      G03913941Courtesy of FORD MOTOR CO.
    53. 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 cylinder head gasket.
  53. Clean and inspect the cylinder head sealing surfaces. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  54. Using the special tool, remove the crankshaft front oil seal.
    Fig 51: Removing Crankshaft Front Oil Seal Using Special Tool
    G03946929Courtesy of FORD MOTOR CO.
  55. Remove the bolts and the engine front cover.
    Fig 52: Removing Bolts And Engine Front Cover
    G03913813Courtesy of FORD MOTOR CO.
  56. Remove the bolts and the oil pan.
    Fig 53: Removing Bolts And Oil Pan
    G03947274Courtesy of FORD MOTOR CO.
  57. Remove the bolt and the oil pump screen cover and tube.
    Fig 54: Removing Bolt And Oil Pump Screen Cover And Tube
    G03914200Courtesy of FORD MOTOR CO.
    58. NOTE: Note the location of the 2 silver-colored bolts with the washer seals. These bolts must be installed in the same position from which they were removed with new washer seals.
    Fig 55: Removing Cylinder Block Cradle Inner Bolts
    G03914202Courtesy of FORD MOTOR CO.
  58. Remove the cylinder block cradle inner bolts. Remove and discard the 2 washer seals.
  59. Remove the cylinder block cradle Torx bolts.
    Fig 56: Removing Cylinder Block Cradle Torx Bolts
    G03914201Courtesy of FORD MOTOR CO.
  60. Remove the 15 bolts and the 2 nuts. Remove the cylinder block cradle.
    Fig 57: Locating Outer Bolts
    G03914037Courtesy of FORD MOTOR CO.
  61. Remove the oil pump pickup tube, the oil pump and the oil pump intermediate shaft.
    Fig 58: Removing Oil Pump Pickup Tube, Oil Pump And Oil Pump Intermediate Shaft
    G03947279Courtesy of FORD MOTOR CO.
  62. Remove the oil filter adapter.
    Fig 59: Removing Oil Filter Adapter
    G03947280Courtesy of FORD MOTOR CO.
  63. Inspect and install new O-ring seals if necessary.
    Fig 60: Installing O-Ring Seals
    G03914206Courtesy of FORD MOTOR CO.
  64. Remove the jackshaft rear plug.
    Fig 61: Removing Jackshaft Rear Plug
    G03914209Courtesy of FORD MOTOR CO.
  65. Using the special tool, hold the crankshaft.
    Fig 62: Holding Crankshaft Using Special Tool
    G03947283Courtesy of FORD MOTOR CO.
  66. Remove the jackshaft sprocket rear bolt.
    Fig 63: Removing Jackshaft Sprocket Rear Bolt
    G03947284Courtesy of FORD MOTOR CO.
  67. Remove the RH cassette bolt.
    Fig 64: Removing RH Cassette Bolt
    G03914215Courtesy of FORD MOTOR CO.
  68. Remove the RH cassette.
    Fig 65: Removing RH Cassette
    G03914195Courtesy of FORD MOTOR CO.
  69. Remove the oil pump bolt and retainer and then remove the oil pump drive.
    Fig 66: Removing Oil Pump Bolt And Retainer
    G03914217Courtesy of FORD MOTOR CO.
  70. Using the special tool to hold the crankshaft, loosen the front sprocket retaining bolt.
    Fig 67: Loosening Front Sprocket Retaining Bolt Using Special Tool
    G03947031Courtesy of FORD MOTOR CO.
  71. Remove the bolts and the chain tensioner.
    Fig 68: Removing Bolts And Chain Tensioner
    G03914207Courtesy of FORD MOTOR CO.
  72. Remove the chain guide.
    Fig 69: Removing Chain Guide
    G03914208Courtesy of FORD MOTOR CO.
  73. Remove the bolt.
    Fig 70: Locating Jackshaft Sprocket Bolt
    G03914212Courtesy of FORD MOTOR CO.
  74. Remove the jackshaft and crankshaft sprockets and the chain.
    • Remove the crankshaft key.
      Fig 71: Removing Jackshaft And Crankshaft Sprockets And Chain
      G03947292Courtesy of FORD MOTOR CO.
  75. Remove the bolt and the front cassette.
    Fig 72: Removing Bolt And Front Cassette
    G03914214Courtesy of FORD MOTOR CO.
  76. Remove the jackshaft thrust plate.
    Fig 73: Removing Jackshaft Thrust Plate
    G03914218Courtesy of FORD MOTOR CO.
  77. Remove the jackshaft.
    Fig 74: Removing Jackshaft
    G03914279Courtesy of FORD MOTOR CO.
  78. Remove the balance shaft tensioner.
    1. Install a pin in the balance shaft tensioner.
    2. Remove the bolts.
    3. Remove the balance shaft tensioner.
      Fig 75: Removing Balance Shaft Tensioner
      G03914220Courtesy of FORD MOTOR CO.
  79. Remove the 2 bolts and the balance shaft chain guide.
    80. NOTE: DO NOT remove the balance shaft sprocket bolt.
    Fig 76: Removing Balance Shaft Chain And Crankshaft Sprocket
    G03914221Courtesy of FORD MOTOR CO.
  80. Remove the balance shaft chain and crankshaft sprocket.
  81. Remove the balance shaft.
    1. Remove the bolts.
    2. Remove the balance shaft.
      Fig 77: Removing Balance Shaft
      G03914222Courtesy of FORD MOTOR CO.
  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 the manufacturer's instructions.
    83. NOTE: Clearly mark the connecting rods and rod caps in numerical order for correct reassembly.
  83. Remove the connecting rod caps.
    1. Remove the connecting rod nuts.
    2. Remove the connecting rod cap.
      Fig 78: Removing Connecting Rod Caps
      G03947299Courtesy of FORD MOTOR CO.
  84. Install rubber hose pieces on the bolts to protect the crankshaft and remove the pistons.
    Fig 79: Installing Rubber Hose Pieces On Bolts
    G03914225Courtesy of FORD MOTOR CO.
  85. Remove the connecting rod bearings.
    Fig 80: Removing Connecting Rod Bearings
    G03947301Courtesy of FORD MOTOR CO.
  86. Remove the piston rings.
    Fig 81: Identifying Piston Rings
    G03947302Courtesy of FORD MOTOR CO.
  87. Clean and inspect the pistons. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
    88. CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
    Fig 82: Removing Bolts
    G03914226Courtesy of FORD MOTOR CO.
  88. Remove the bolts.
    89. NOTE: Number (or mark) the crankshaft bearing caps before removing them.
    Fig 83: Removing Crankshaft Main Bearing Caps
    G03914227Courtesy of FORD MOTOR CO.
  89. Remove the crankshaft main bearing caps.
  90. Remove the crankshaft rear oil seal from the crankshaft.
    Fig 84: Removing Crankshaft Rear Oil Seal From Crankshaft
    G03914228Courtesy of FORD MOTOR CO.
  91. Remove the crankshaft.
    Fig 85: Removing Crankshaft
    G03914229Courtesy of FORD MOTOR CO.
  92. Remove the crankshaft main bearings and the thrust bearing.
    Fig 86: Removing Crankshaft Main Bearings And Thrust Bearing
    G03947307Courtesy of FORD MOTOR CO.
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