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Section 1154 (Engine -- 4.6L (2V)): 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 CHART

G03886657
 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
G03905862
 Installer, Connecting Rod 303-442 (T93P-6136-A)
G03905746
 Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
G03886005
 Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
G03947903
 Compressor, Valve Spring 303-567 (T97P-6565-AH)
G03885376
 Spacer, Valve Spring Compressor 303-382 (T91P-6565-AH)
G03886718
 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
G03905604
 Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH)
G03885061
 Slide Hammer 100-001 (T50T-100-A)
MATERIAL CHART

Item Specification
Motorcraft Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
NOTE: For additional information, refer to the exploded views under ENGINE .
  1. Remove the bolts and the flexplate.
    Fig 1: Identifying Bolts And Flexplate
    G03885612Courtesy of FORD MOTOR CO.
  2. Remove the spacer plate.
    Fig 2: Removing Spacer Plate
    G03947909Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove the crankshaft rear oil slinger.
    Fig 3: Removing Crankshaft Rear Oil Seal Slinger
    G03920149Courtesy of FORD MOTOR CO.
  4. Using the special tools, remove the crankshaft rear seal.
    Fig 4: Removing Crankshaft Rear Seal
    G03920150Courtesy of FORD MOTOR CO.
  5. Remove the bolts and the rear seal retainer plate.
    Fig 5: Identifying Bolts And Crankshaft Rear Seal Retainer Plate
    G03885716Courtesy of FORD MOTOR CO.
  6. Install the engine on a suitable engine stand.
  7. Rotate the belt tensioner and remove the accessory drive belt.
    Fig 6: Rotating Accessory Drive Belt Tensioner Clockwise
    G03886148Courtesy of FORD MOTOR CO.
  8. Remove the nuts and position the wiring harness bracket aside.
    Fig 7: Removing Wiring Harness Bracket
    G03947735Courtesy of FORD MOTOR CO.
  9. Remove the oil filter.
    10. NOTE: Lower radiator hose removed for clarity.
    Fig 8: Removing Oil Filter
    G03947915Courtesy of FORD MOTOR CO.
  10. Disconnect the oil pressure switch electrical connector and remove the bolts and the oil filter adapter.
  11. Remove the power steering hose support bracket.
    Fig 9: Removing Power Steering Hose Support Bracket
    G03947620Courtesy of FORD MOTOR CO.
  12. Disconnect the return and pressure hoses from the power steering pump.
    Fig 10: Disconnecting Return And Pressure Hoses
    G03947737Courtesy of FORD MOTOR CO.
  13. Remove the bolts and the power steering pump.
    Fig 11: Removing Power Steering Pump
    G03947738Courtesy of FORD MOTOR CO.
  14. Remove the nut and position the radio interference capacitor and ground cable aside. Remove the power steering reservoir and bracket from the stud bolt.
    Fig 12: Removing Power Steering Reservoir And Bracket From Stud Bolt
    G03947739Courtesy of FORD MOTOR CO.
  15. Disconnect the A/C compressor and crankshaft position (CKP) sensor electrical connectors.
    Fig 13: Disconnecting A/C Compressor And Crankshaft Position (CKP) Sensor Electrical Connectors
    G03947920Courtesy of FORD MOTOR CO.
  16. Disconnect the wiring harness retainers.
    Fig 14: Disconnecting Wiring Harness Retainers
    G03947742Courtesy of FORD MOTOR CO.
  17. Detach the wiring harness retainer from the A/C tube.
    Fig 15: Removing Wiring Harness Retainer From A/C Tube
    G03947743Courtesy of FORD MOTOR CO.
  18. Remove the bolt and position the wiring harness aside.
    Fig 16: Removing Bolt
    G03947744Courtesy of FORD MOTOR CO.
  19. Remove the crankcase air inlet tube.
    Fig 17: Removing Crankcase Air Inlet Tube
    G03947745Courtesy of FORD MOTOR CO.
  20. Remove the studs and the A/C compressor.
    Fig 18: Removing Studs And A/C Compressor
    G03885760Courtesy of FORD MOTOR CO.
  21. Remove the nut and the upper radiator hose bracket and position the radio interference capacitor aside.
    Fig 19: Removing Upper Radiator Hose Bracket
    G03947621Courtesy of FORD MOTOR CO.
  22. Remove the bolts and the idler pulleys.
    Fig 20: Removing Idler Pulleys
    G03947747Courtesy of FORD MOTOR CO.
  23. Disconnect the generator electrical connectors and pin-type retainer.
    Fig 21: Disconnecting Generator Electrical Connectors
    G03947748Courtesy of FORD MOTOR CO.
  24. Remove the bolts and the bracket.
    Fig 22: Removing Bolts And Bracket
    G03947929Courtesy of FORD MOTOR CO.
  25. Remove the bolts and the generator.
    Fig 23: Removing Bolts And Generator
    G03947750Courtesy of FORD MOTOR CO.
  26. Disconnect the electrical connector and remove the bolt and the camshaft position (CMP) sensor.
    Fig 24: Disconnecting Electrical Connector
    G03947751Courtesy of FORD MOTOR CO.
  27. Remove the bolts and the drive belt tensioner.
    Fig 25: Removing Drive Belt Tensioner
    G03947932Courtesy of FORD MOTOR CO.
  28. Remove the bolt and the CKP sensor.
    Fig 26: Removing CKP Sensor
    G03947933Courtesy of FORD MOTOR CO.
  29. Remove the bolts and the coolant pump pulley.
    Fig 27: Removing Coolant Pump Pulley
    G03947934Courtesy of FORD MOTOR CO.
  30. Remove the bolts.
    Fig 28: Identifying Coolant Pump Bolts
    G03885825Courtesy of FORD MOTOR CO.
  31. Remove the coolant pump from the cylinder block.
    • Discard the O-ring seal.
      Fig 29: Identifying Coolant Pump
      G03885759Courtesy of FORD MOTOR CO.
  32. Remove the exhaust gas recirculation (EGR) tube from the exhaust manifold.
    Fig 30: Removing Exhaust Gas Recirculation (EGR) Tube From Exhaust Manifold
    G03947752Courtesy of FORD MOTOR CO.
  33. Remove the bolts and the RH exhaust manifold heat shield.
    Fig 31: Removing RH Exhaust Manifold Heat Shield
    G03947753Courtesy of FORD MOTOR CO.
  34. Remove the RH exhaust manifold.
    1. Remove the 8 nuts.
    2. Remove the RH exhaust manifold.
    3. Remove and discard the RH exhaust manifold gasket.
      Fig 32: Removing RH Exhaust Manifold
      G03947754Courtesy of FORD MOTOR CO.
  35. Remove the LH exhaust manifold heat shield.
    Fig 33: Removing LH Exhaust Manifold Heat Shield
    G03947755Courtesy of FORD MOTOR CO.
  36. Remove the LH exhaust manifold.
    1. Remove the 8 nuts.
    2. Remove the LH exhaust manifold.
    3. Remove and discard the LH exhaust manifold gasket.
      Fig 34: Removing LH Exhaust Manifold
      G03947756Courtesy of FORD MOTOR CO.
  37. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  38. Remove the bolt and the oil level indicator tube.
    Fig 35: Locating Oil Level Indicator Tube Mounting Bolt
    G03906387Courtesy of FORD MOTOR CO.
  39. Remove the bolt and the brake booster vacuum hose.
    Fig 36: Removing Brake Booster Vacuum Hose
    G03947758Courtesy of FORD MOTOR CO.
  40. Disconnect the throttle position (TP) sensor and the electronic throttle body electrical connectors.
    Fig 37: Disconnecting Throttle Position (TP) Sensor
    G03947759Courtesy of FORD MOTOR CO.
  41. Remove the positive crankcase ventilation (PCV) tube and disconnect the vacuum tube from the throttle body adapter.
    Fig 38: Removing Positive Crankcase Ventilation (PCV) Tube
    G03947760Courtesy of FORD MOTOR CO.
  42. Disconnect the EGR system module and fuel pressure sensor vacuum fittings.
    • Remove the vacuum harness from the engine.
      Fig 39: Removing Vacuum Harness From Engine
      G03947558Courtesy of FORD MOTOR CO.
  43. Disconnect the EGR system module and fuel pressure sensor electrical connectors.
    Fig 40: Disconnecting EGR System Module And Fuel Pressure Sensor Electrical Connectors
    G03947762Courtesy of FORD MOTOR CO.
  44. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 41: Disconnecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03947763Courtesy of FORD MOTOR CO.
  45. Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.
    Fig 42: Locating Knock Sensor (KS) Electrical Connector
    G03881828Courtesy of FORD MOTOR CO.
  46. Disconnect the coolant hoses.
    Fig 43: Disconnecting Coolant Hoses
    G03947765Courtesy of FORD MOTOR CO.
  47. Disconnect the coolant hose.
    Fig 44: Disconnecting Coolant Hose
    G03947766Courtesy of FORD MOTOR CO.
  48. Remove the bolts and the throttle body adapter.
    Fig 45: Removing Throttle Body Adapter
    G03947767Courtesy of FORD MOTOR CO.
  49. Disconnect the RH fuel injector, coil and ground electrical connectors and the wiring harness retainers.
    Fig 46: Disconnecting RH Fuel Injector, Coil And Ground Electrical Connectors
    G03947561Courtesy of FORD MOTOR CO.
  50. Disconnect the LH fuel injector and coil pack electrical connectors and the fuel charging wiring harness retainers.
    Fig 47: Disconnecting LH Fuel Injector And Coil Pack Electrical Connectors
    G03947562Courtesy of FORD MOTOR CO.
  51. Disconnect the wiring harness retainers.
    Fig 48: Disconnecting Wiring Harness Retainers
    G03947770Courtesy of FORD MOTOR CO.
  52. Disconnect the ground wire.
    Fig 49: Disconnecting Ground Wire
    G03947560Courtesy of FORD MOTOR CO.
  53. Disconnect all remaining wiring harness retainers and remove the fuel charging wiring harness.
    54. NOTE: LH is shown, RH is similar.
    Fig 50: Removing Bolts And Ignition Coils
    G03947564Courtesy of FORD MOTOR CO.
  54. Remove the bolts and all 8 ignition coils.
  55. Remove the bolts and the thermostat housing.
    Fig 51: Removing Thermostat Housing
    G03947773Courtesy of FORD MOTOR CO.
  56. Remove the 9 bolts and the intake manifold.
    Fig 52: Removing Intake Manifold
    G03947774Courtesy of FORD MOTOR CO.
  57. Remove the intake manifold gaskets.
    Fig 53: Removing Intake Manifold Gaskets
    G03947775Courtesy of FORD MOTOR CO.
    58. 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 which make leak paths.
  58. Clean the sealing surfaces.
  59. Remove the bolt and the ground wire.
    Fig 54: Removing Bolt And Ground Wire
    G03947961Courtesy of FORD MOTOR CO.
  60. Remove the heater hose if necessary.
    Fig 55: Removing Heater Hose
    G03947962Courtesy of FORD MOTOR CO.
  61. Remove the bolts and the KS.
    Fig 56: Removing Bolts And KS
    G03947963Courtesy of FORD MOTOR CO.
  62. Remove the nut and the coolant tube.
    Fig 57: Removing Coolant Tube
    G03947794Courtesy of FORD MOTOR CO.
  63. Remove the bolts and the LH engine mount.
    Fig 58: Removing LH Engine Mount
    G03947776Courtesy of FORD MOTOR CO.
  64. Remove the bolts and the RH engine mount.
    Fig 59: Removing RH Engine Mount
    G03947777Courtesy of FORD MOTOR CO.
  65. Remove the RH cylinder block drain plug.
    • Reinstall the drain plug after draining the coolant.
      Fig 60: Removing RH Cylinder Block Drain Plug
      G03947778Courtesy of FORD MOTOR CO.
  66. Remove the LH cylinder block drain plug.
    • Reinstall the drain plug after draining the coolant.
      Fig 61: Removing LH Cylinder Block Drain Plug
      G03947779Courtesy of FORD MOTOR CO.
    67. 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 which make leak paths.
    NOTE: There are several kinds of bolts used in fastening the valve cover. The bolts must be installed in their original locations.
  67. Loosen the bolts and remove the LH valve cover.
    • Clean and inspect the mating surfaces and, if necessary, install new gaskets.
      Fig 62: Removing LH Valve Cover
      G03947781Courtesy of FORD MOTOR CO.
    68. 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 which make leak paths.
    NOTE: There are several kinds of bolts used in fastening the valve cover. The bolts must be installed in their original locations.
  68. Loosen the bolts and remove the RH valve cover.
    • Clean and inspect the mating surfaces and, if necessary, install new gaskets.
      Fig 63: Removing RH Valve Cover
      G03947780Courtesy of FORD MOTOR CO.
    69. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
  69. Remove the spark plugs.
  70. Position the lobe of the camshaft upward.
    Fig 64: Positioning Lobe Of Camshaft Upward
    G04002231Courtesy of FORD MOTOR CO.
  71. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 65: Installing Special Tool Between Valve Spring Coils
    G03947787Courtesy of FORD MOTOR CO.
    72. NOTE: The roller followers are positional. Mark the followers for installation in their original locations.
    Fig 66: Compressing Valve Springs And Remove Camshaft Roller Followers
    G03947788Courtesy of FORD MOTOR CO.
  72. Using the special tool, compress the valve springs and remove the camshaft roller followers.
  73. Remove the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
    Fig 67: Removing Crankshaft Pulley Using Special Tool
    G03919906Courtesy of FORD MOTOR CO.
  74. Using the special tool, remove the crankshaft front oil seal.
    Fig 68: Removing Crankshaft Front Seal Using Special Tool
    G03919889Courtesy of FORD MOTOR CO.
  75. Remove the 4 oil pan bolts.
    Fig 69: Locating (Four) Front Oil Pan Bolts
    G03885291Courtesy of FORD MOTOR CO.
    76. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 70: Identifying Front Cover Fasteners
    G03885685Courtesy of FORD MOTOR CO.
  76. Remove the fasteners.
  77. Remove the engine front cover from the cylinder block.
    Fig 71: Removing Engine Front Cover From Cylinder Block
    G03885740Courtesy of FORD MOTOR CO.
  78. Remove the crankshaft sensor ring from the crankshaft.
    Fig 72: Removing Crankshaft Sensor Ring From Crankshaft
    G03947786Courtesy of FORD MOTOR CO.
    79. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
  79. Remove the timing chain tensioning system from both timing chains.
    1. Remove the bolts.
    2. Remove the timing chain tensioners.
    3. Remove the timing chain tensioner arms.
      Fig 73: Removing Timing Chain Tensioner Arms
      G03947789Courtesy of FORD MOTOR CO.
  80. Remove the LH and RH timing chains and the crankshaft sprocket.
    Fig 74: Removing Timing Chain
    G03885313Courtesy of FORD MOTOR CO.
  81. Remove both timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
      Fig 75: Removing Timing Chain Guides
      G03885314Courtesy of FORD MOTOR CO.
  82. Install the special tool on both ends of the cylinder head.
    Fig 76: Installing Special Tool On Both Ends Of Cylinder Head
    G04671899Courtesy of FORD MOTOR CO.
    83. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
    CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are torque-to-yield designed and cannot be reused.
    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: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    NOTE: RH is shown, LH is similar.
  83. Remove the bolts and discard.
    • Remove the cylinder heads.
      Fig 77: Locating Cylinder Head Bolts
      G03885651Courtesy of FORD MOTOR CO.
  84. Remove and discard the cylinder head gaskets.
    Fig 78: Removing Cylinder Head Gaskets
    G03947985Courtesy of FORD MOTOR CO.
    85. 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.
  85. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head 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 remaining 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 straining of the metal surfaces is normal.
    86. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.
    NOTE: Use a straightedge that is calibrated by the manufacturer to be flat with 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.
    NOTE: LH is shown, RH is similar.
    Fig 79: Identifying Oil Pressure Feed Area Of Deck Face Surface
    G03885653Courtesy of FORD MOTOR CO.
  86. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area or scratches more than 0.0254 mm (0.001 in).
  87. 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.
  88. Remove the oil pan.
    • Remove the bolts.
    • Remove the oil pan.
    • Remove the oil pan gasket.
      Fig 80: Removing Oil Pan
      G03947987Courtesy of FORD MOTOR CO.
  89. Remove the bolts and the oil pump screen cover and tube.
    Fig 81: Removing Oil Pump Screen Cover And Tube
    G03885762Courtesy of FORD MOTOR CO.
  90. Remove the oil pump screen cover and tube spacer.
    Fig 82: Removing Oil Pump Screen Cover And Tube Spacer
    G03885763Courtesy of FORD MOTOR CO.
  91. Remove the bolts and the oil pump.
    Fig 83: Removing Bolts And Oil Pump
    G03947990Courtesy of FORD MOTOR CO.
    92. CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for correct orientation.
    Fig 84: Identifying Bolts And Connecting Rod Caps
    G04583770Courtesy of FORD MOTOR CO.
  92. Remove the bolts and the connecting rod cap. Discard the bolts.
    93. CAUTION: Do not scratch the cylinder walls or crankshaft journal with the connecting rod.
    Fig 85: Pushing Piston Through Top Of Cylinder Block
    G03920342Courtesy of FORD MOTOR CO.
  93. Use the Connecting Rod Installer to push the piston through the top of the cylinder block.
  94. Remove the piston rings.
    Fig 86: Identifying Piston Rings
    G03947302Courtesy of FORD MOTOR CO.
  95. Clean and inspect the piston and connecting rods. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
    96. CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
    Fig 87: Removing Side Bolts
    G03947994Courtesy of FORD MOTOR CO.
  96. Remove the side bolts.
  97. Remove and discard the bolts.
    Fig 88: Removing Bolts
    G03947995Courtesy of FORD MOTOR CO.
  98. Remove the 5 main bearing caps and the lower crankshaft main bearings.
    Fig 89: Removing Main Bearing Caps
    G03920344Courtesy of FORD MOTOR CO.
  99. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.
    Fig 90: Removing Crankshaft And Main Bearings From Cylinder Block
    G03881879Courtesy of FORD MOTOR CO.
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