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WARNING: This page is about a different car, the 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the spacer plate.
    Fig 1: Locating Spacer Plate
    GF0002498Courtesy of FORD MOTOR CO.
  2. Using the special tools, remove the crankshaft rear seal.
    Fig 2: Removing Crankshaft Rear Seal
    GF0002440Courtesy of FORD MOTOR CO.
  3. Mount the engine on a suitable stand.
  4. Disconnect and detach the heated oxygen sensor (HO2S) electrical connector. Remove the nut and the ground wire.
    Fig 3: Removing Nut And Ground Wire
    GF0002499Courtesy of FORD MOTOR CO.
  5. Disconnect the heated positive crankcase ventilation (PCV) valve and the radio interference capacitor electrical connectors.
    Fig 4: Disconnecting Heated Positive Crankcase Ventilation (PCV) Valve And Radio Interference Capacitor Electrical Connectors
    GF0002500Courtesy of FORD MOTOR CO.
  6. Remove the bolt and the accessory drive belt idler pulley.
    Fig 5: Removing Bolt And Accessory Drive Belt Idler Pulley
    GF0002501Courtesy of FORD MOTOR CO.
  7. Remove the 4 bolts and the generator mounting bracket, the generator, the accessory drive belt tensioner and the idler pulley as an assembly.
    Fig 6: Locating Generator Mounting Bracket Bolts
    GF0002502Courtesy of FORD MOTOR CO.
  8. Disconnect the crankshaft position (CKP) sensor and the camshaft position (CMP) electrical connectors.
    • Detach the 2 wiring harness retainers.
    Fig 7: Disconnecting Crankshaft Position (CKP) Sensor And Camshaft Position (CMP) Electrical Connectors
    GF0002503Courtesy of FORD MOTOR CO.
  9. If equipped, disconnect the A/C compressor clutch electrical connector and detach the wiring harness retainer.
    Fig 8: Identifying A/C Compressor Clutch Electrical Connector
    GF0002504Courtesy of FORD MOTOR CO.
  10. Remove the 2 nuts, the 2 bolts and the A/C compressor and power steering pump bracket brace.
    Fig 9: Identifying A/C Compressor And Power Steering Pump Bracket Brace Nuts & Bolts
    GF0002505Courtesy of FORD MOTOR CO.
  11. Remove the bolt and the A/C compressor and power steering pump bracket and, if equipped, the A/C compressor.
    Fig 10: Identifying A/C Compressor And Power Steering Pump Bracket Bolt
    GF0002506Courtesy of FORD MOTOR CO.
  12. Disconnect the oil pressure sender electrical connector and detach the wiring harness retainer.
    Fig 11: Disconnecting Oil Pressure Sender Electrical Connector And Detaching Wiring Harness Retainer
    GF0002507Courtesy of FORD MOTOR CO.
  13. 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 12: Disconnecting HO2S Electrical Connector, Knock Sensor (KS) And Cylinder Head Temperature (CHT) Sensor Electrical Connectors
    GF0002508Courtesy of FORD MOTOR CO.
  14. Remove the 4 bolts and the coolant pump pulley.
    Fig 13: Identifying Coolant Pump Pulley Bolts
    GF0002396Courtesy of FORD MOTOR CO.
  15. Release the clamp and disconnect the bypass hose. Remove the bolt and the heater outlet tube.
    Fig 14: Disconnecting Bypass Hose
    GF0002509Courtesy of FORD MOTOR CO.
  16. Remove the 14 bolts and the lower intake manifold.
    • Remove and discard the 2 gaskets and 2 end seals.
    Fig 15: Locating Lower Intake Manifold Bolts
    GF0002510Courtesy of FORD MOTOR CO.
  17. Remove the 3 bolts, 2 stud bolts and the LH valve cover.
    • Remove and discard the gasket.
    Fig 16: Removing LH Valve Cover Bolts
    GF0002511Courtesy of FORD MOTOR CO.
  18. Remove the bolt and the oil level indicator and tube.
    Fig 17: Removing Bolt And Oil Level Indicator And Tube
    GF0002512Courtesy of FORD MOTOR CO.
  19. Remove the 6 nuts and the LH exhaust manifold.
    • Remove and discard the nuts and the gasket.
    Fig 18: Locating LH Exhaust Manifold Nuts
    GF0002513Courtesy of FORD MOTOR CO.
    20. NOTE: Note the locations of the 2 long studs.
  20. Remove and discard the 6 LH exhaust manifold studs.
  21. Remove the bolts and the engine support insulator bracket. Remove the oil pressure sender.
    Fig 19: Locating Engine Support Insulator Bracket Bolts
    GF0002514Courtesy of FORD MOTOR CO.
  22. Remove the 2 bolts, 3 stud bolts and the RH valve cover.
    • Remove and discard the gasket.
    Fig 20: Removing 2 Bolts, 3 Stud Bolts And RH Valve Cover
    GF0002515Courtesy of FORD MOTOR CO.
  23. Remove the 6 nuts and the RH exhaust manifold.
    • Remove and discard the nuts and the gasket.
    Fig 21: Locating RH Exhaust Manifold Nuts
    GF0002516Courtesy of FORD MOTOR CO.
    24. NOTE: Note the locations of the 2 long studs.
  24. Remove and discard the 6 RH exhaust manifold studs.
  25. Remove the bolts and the RH engine support insulator brackets.
    Fig 22: Locating RH Engine Support Insulator Brackets Bolts
    GF0002517Courtesy of FORD MOTOR CO.
    26. CAUTION: If the rocker arms are to be reinstalled, they must be installed into their original positions. Mark the rocker arms for location.
    Fig 23: Removing Bolts, Rocker Arm Pivots And Rocker Arms
    GF0002518Courtesy of FORD MOTOR CO.
  26. Remove the 6 bolts, the 6 rocker arm pivots and the 6 rocker arms from both cylinder heads.
    27. CAUTION: If the push rods are to be reinstalled, they must be installed into their original positions. Mark the push rods for location.
    Fig 24: Removing Push Rods From Both Cylinder Heads
    GF0002519Courtesy of FORD MOTOR CO.
  27. Remove the 6 push rods from both cylinder heads.
  28. Remove the 8 cylinder head bolts from both cylinder heads.
    Fig 25: Removing Cylinder Head Bolts From Both Cylinder Heads
    GF0002520Courtesy of FORD MOTOR CO.
  29. Remove both cylinder heads.
    • Remove and discard both cylinder head gaskets.
    Fig 26: Removing Cylinder Heads
    GF0002521Courtesy of FORD MOTOR CO.
    30. NOTE: The 2 oil pan-to-engine front cover bolts are unique and must be installed in the correct positions.
    Fig 27: Locating Oil Pan Bolts
    GF0002522Courtesy of FORD MOTOR CO.
  30. Remove the 17 bolts and the oil pan.
    • Remove and discard the oil pan rear seal.
  31. 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 28: Removing CMP Sensor And Camshaft Synchronizer
    GF0002523Courtesy of FORD MOTOR CO.
  32. Using the special tool to prevent the crankshaft rotation, remove the crankshaft pulley bolt and washer.
    Fig 29: Removing Crankshaft Pulley Bolt And Washer
    GF0002383Courtesy of FORD MOTOR CO.
  33. Using the special tools, remove the crankshaft pulley.
    Fig 30: Removing Crankshaft Pulley
    GF0002384Courtesy of FORD MOTOR CO.
  34. Using the special tool, remove the crankshaft front seal.
    • Discard the crankshaft front seal.
    Fig 31: Removing Crankshaft Front Seal
    GF0002387Courtesy of FORD MOTOR CO.
  35. Remove the 4 nuts, 4 bolts, the stud bolt, the coolant pump and the gasket.
    • Discard the gasket.
    Fig 32: Removing Coolant Pump
    GF0002524Courtesy of FORD MOTOR CO.
  36. Remove the engine front cover and oil pump assembly and the engine front cover gasket.
    • Remove the 2 stud bolts.
    • Remove the bolt.
      CAUTION: The cap screw is hidden. Make sure to remove it or the engine front cover will be damaged.
    • Remove the cap screw.
    • Slide the engine front cover and engine front cover gasket from the dowels.
      • Discard the gasket.
    • Remove the studs.
    Fig 33: Removing Engine Front Cover And Oil Pump Assembly And Engine Front Cover Gasket
    GF0002525Courtesy of FORD MOTOR CO.
  37. Remove the bolt and the camshaft synchronizer drive gear.
    Fig 34: Locating Camshaft Synchronizer Drive Gear Bolt
    GF0002409Courtesy of FORD MOTOR CO.
  38. Compress the timing chain tensioner and install a retaining pin.
    Fig 35: Installing Retaining Pin To Hold Timing Chain Tensioner
    GF0002526Courtesy of FORD MOTOR CO.
  39. Remove the crankshaft gear, the camshaft gear and the timing chain as an assembly.
    Fig 36: Identifying Timing Chain And Sprockets
    G03962031Courtesy of FORD MOTOR CO.
  40. Remove the 2 bolts and the timing chain tensioner.
    Fig 37: Locating Timing Chain Tensioner Bolts
    GF0002405Courtesy of FORD MOTOR CO.
    41. NOTE: If the valve tappets are to be reinstalled, they must be installed into their original locations. Mark the valve tappets for location.
    Fig 38: Removing Valve Tappets
    GF0002527Courtesy of FORD MOTOR CO.
  41. Remove the 12 valve tappets.
    • Remove the 4 bolts.
    • Remove the valve tappet guide plate and retainer.
    • Remove the 12 valve tappets.
  42. Remove the engine balance shaft drive gear and the camshaft key.
    Fig 39: Locating Engine Balance Shaft Drive Gear And Camshaft Key
    GF0002528Courtesy of FORD MOTOR CO.
  43. Remove the 2 bolts and the balance shaft driven gear, thrust plate and engine dynamic balance shaft as an assembly.
    Fig 40: Removing Bolts And Balance Shaft Driven Gear, Thrust Plate And Engine Dynamic Balance Shaft As An Assembly
    GF0002529Courtesy of FORD MOTOR CO.
  44. Remove the camshaft.
    • Remove the 2 bolts.
    • Remove the camshaft thrust plate.
    • Remove the spacer.
    • Remove the camshaft.
    Fig 41: Identifying Camshaft Bolts, Camshaft Thrust Plate And Spacer
    GF0002530Courtesy of FORD MOTOR CO.
  45. Remove the bearing covers.
    • Remove the engine dynamic balance shaft bearing cover.
    • Remove the camshaft bearing cover.
    Fig 42: Removing Bearing Covers
    GF0002531Courtesy of FORD MOTOR CO.
  46. Remove the nut, the 2 bolts and the oil pump screen cover and tube.
    Fig 43: Removing Nut, Bolts And Oil Pump Screen Cover And Tube
    GF0002532Courtesy of FORD MOTOR CO.
  47. Remove the 5 nuts and the oil pan baffle.
    Fig 44: Locating Oil Pan Baffle Nuts
    GF0002533Courtesy of FORD MOTOR CO.
  48. 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.
    49. 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.
  49. Remove the piston.
    • Make sure the piston being removed is at the bottom of the cylinder bore.
    • Remove the 2 bolts.
    • Remove the connecting rod cap and the lower connecting rod bearing.
      CAUTION: Do not damage the cylinder wall when removing the piston.
    • Push the piston and the connecting rod out of the cylinder.
  50. Repeat the piston removal steps for the remaining pistons.
    Fig 45: Removing Piston
    GF0002534Courtesy of FORD MOTOR CO.
    51. 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 46: Locating Bolts, Main Bearing Caps And Lower Crankshaft Main Bearings
    GF0002535Courtesy of FORD MOTOR CO.
  51. Remove the 4 main bearing caps and lower crankshaft main bearings.
    • Remove the bolts and stud bolts.
    • Remove the 4 main bearing caps and lower crankshaft main bearings.
    52. CAUTION: The crankshaft journals must be protected from damage when the crankshaft is removed.
    Fig 47: Removing Crankshaft
    GF0002536Courtesy of FORD MOTOR CO.
  52. Remove the crankshaft.
    53. NOTE: For ease in reassembly, record the locations of the crankshaft upper thrust bearings.
    Fig 48: Removing Upper Crankshaft Main Bearings And Crankshaft Upper Thrust Bearing
    GF0002537Courtesy of FORD MOTOR CO.
  53. Remove the 3 upper crankshaft main bearings and the crankshaft upper thrust bearing.
  54. Remove the camshaft bearings.
    Fig 49: Removing Camshaft Bearings
    GF0002538Courtesy of FORD MOTOR CO.
  55. Remove the engine dynamic balance shaft bearings.
    Fig 50: Removing Engine Dynamic Balance Shaft Bearings
    GF0002539Courtesy of FORD MOTOR CO.
  56. If equipped, remove the engine block heater.
    Fig 51: Locating Engine Block Heater
    GF0002540Courtesy of FORD MOTOR CO.
    57. NOTE: For cleaning purposes, the plugs should be removed.
    Fig 52: Identifying Cylinder Block Dowels, Oil Gallery Plugs And Water Jacket Plugs
    GF0002541Courtesy of FORD MOTOR CO.
  57. If necessary, remove the following:
    • Cylinder block dowels.
    • Oil gallery plugs.
    • Water jacket plugs.
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