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Engine Disassembly Procedure

WARNING: This page is about a different car, the 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Separate the engine control sensor wiring connectors from the upper intake manifold.
    Fig 1: Separating Engine Control Sensor Wiring Connectors
    G03429883Courtesy of FORD MOTOR CO.
  2. Disconnect the idle air control valve and the throttle position sensor.
    Fig 2: Disconnecting Idle Air Control Valve & Throttle Position Sensor
    G03429884Courtesy of FORD MOTOR CO.
  3. Disconnect the exhaust gas recirculation (EGR) vacuum regulator and the differential pressure feedback EGR electrical connectors.
    Fig 3: Disconnecting Exhaust Gas Recirculation (EGR) Vacuum Regulator
    G03429885Courtesy of FORD MOTOR CO.
  4. Remove the positive crankcase ventilation (PCV) tube.
    Fig 4: Removing Positive Crankcase Ventilation (PCV) Tube
    G03429886Courtesy of FORD MOTOR CO.
  5. Disconnect the vacuum line from the fuel pressure regulator.
    Fig 5: Disconnecting Vacuum Line From Fuel Pressure Regulator
    G03429887Courtesy of FORD MOTOR CO.
  6. Disconnect and remove the engine control wire harness.
    Fig 6: Disconnecting & Removing Engine Control Wire Harness
    G03429888Courtesy of FORD MOTOR CO.
  7. Remove the bolts and upper intake manifold.
    Fig 7: Removing Bolts & Upper Intake Manifold
    G03429889Courtesy of FORD MOTOR CO.
  8. Disconnect the crankshaft and camshaft position sensors.
    Fig 8: Disconnecting Crankshaft & Camshaft Position Sensors
    G03429890Courtesy of FORD MOTOR CO.
  9. Disconnect the radio ignition interference capacitor.
    Fig 9: Disconnecting Radio Ignition Interference Capacitor
    G03429891Courtesy of FORD MOTOR CO.
  10. Disconnect the remaining electrical connectors and harness retainers and remove the harness.
    • coils-on-plugs
    • fuel injectors
    Fig 10: Disconnecting Electrical Connectors & Harness Retainers
    G03429892Courtesy of FORD MOTOR CO.
  11. Remove the bolts and the six coil-on-plugs.
    Fig 11: Removing Bolts & Six Coil-On-Plugs
    G03429893Courtesy of FORD MOTOR CO.
  12. Disconnect the coolant temperature sensor and the oil pressure switch.
    Fig 12: Disconnecting Coolant Temperature Sensor
    G03429894Courtesy of FORD MOTOR CO.
  13. Remove the fuel charging wire harness.
    Fig 13: Removing Fuel Charging Wire Harness
    G03429895Courtesy of FORD MOTOR CO.
  14. Remove the lower intake manifold.
    Fig 14: Removing Lower Intake Manifold
    G03429896Courtesy of FORD MOTOR CO.
  15. Remove the radio interference capacitor.
    • Remove the nut.
    Fig 15: Removing Radio Interference Capacitor
    G03429897Courtesy of FORD MOTOR CO.
  16. Remove the RH valve cover.
    • Remove and discard the gasket if damaged.
    Fig 16: Identifying Bolt
    G03429898Courtesy of FORD MOTOR CO.
  17. Remove the engine lift bracket.
    Fig 17: Removing Engine Lift Bracket
    G03429899Courtesy of FORD MOTOR CO.
  18. Remove the LH exhaust manifold.
    Fig 18: Removing LH Exhaust Manifold
    G03429900Courtesy of FORD MOTOR CO.
  19. Remove the RH exhaust manifold.
    Fig 19: Removing RH Exhaust Manifold
    G03429901Courtesy of FORD MOTOR CO.
  20. Remove the knock sensor.
    Fig 20: Locating Knock Sensor
    G03429902Courtesy of FORD MOTOR CO.
  21. Remove the LH valve cover.
    • Remove and discard the gasket.
    Fig 21: Removing LH Valve Cover
    G03429903Courtesy of FORD MOTOR CO.
  22. Disconnect the hoses.
    Fig 22: Disconnecting Hoses
    G03429904Courtesy of FORD MOTOR CO.
  23. Remove the water pump assembly.
    Fig 23: Removing Water Pump Assembly
    G03429905Courtesy of FORD MOTOR CO.
  24. Disconnect the coolant hoses at the oil cooler.
    Fig 24: Disconnecting Coolant Hoses At Oil Cooler
    G03429906Courtesy of FORD MOTOR CO.
  25. Remove the bolt.
    Fig 25: Removing Crankshaft Damper Bolt
    G03429907Courtesy of FORD MOTOR CO.
  26. Using the special tool, remove the crankshaft damper.
    Fig 26: Removing Crankshaft Damper
    G03429908Courtesy of FORD MOTOR CO.
  27. Remove the power steering pump pulley.
    Fig 27: Removing Power Steering Pump Pulley
    G03429909Courtesy of FORD MOTOR CO.
  28. Remove the oil filter.
    Fig 28: Removing Oil Filter
    G03429910Courtesy of FORD MOTOR CO.
  29. Remove the power steering pump.
    Fig 29: Removing Power Steering Pump
    G03429911Courtesy of FORD MOTOR CO.
  30. Remove the generator support bracket.
    Fig 30: Removing Generator Support Bracket
    G03429912Courtesy of FORD MOTOR CO.
  31. Remove the oil cooler.
    Fig 31: Removing Oil Cooler
    G03429913Courtesy of FORD MOTOR CO.
  32. Remove the oil pressure sender and the block heater.
    Fig 32: Removing Oil Pressure Sender & Block Heater
    G03429914Courtesy of FORD MOTOR CO.
  33. Remove the bolts and studs and the oil pan.
    • Discard the gasket.
    Fig 33: Removing Bolts & Studs & Oil Pan
    G03429915Courtesy of FORD MOTOR CO.
  34. Remove the bolts, nut and the oil pick up tube and screen.
    Fig 34: Removing Bolts & Nut
    G03429916Courtesy of FORD MOTOR CO.
  35. Remove the nuts and the oil pan baffle.
    Fig 35: Removing Nuts & Oil Pan Baffle
    G03429917Courtesy of FORD MOTOR CO.
  36. Remove the stud and the oil level indicator and tube.
    Fig 36: Removing Stud & Oil Level Indicator & Tube
    G03429918Courtesy of FORD MOTOR CO.
    37. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
    Fig 37: Removing Bolts, Studs, & Front Cover
    G03429919Courtesy of FORD MOTOR CO.
  37. Clean all sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A.

    Remove the bolts, studs, and the front cover.

    • Discard the gasket.

  38. Remove the crankshaft front seal from the front cover.
    Fig 38: Removing Crankshaft Front Seal
    G03429920Courtesy of FORD MOTOR CO.
    39. CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped 20-25-34Y-30M (Color Blue).
    Fig 39: Removing Ignition Pulse Wheel
    G03429921Courtesy of FORD MOTOR CO.
  39. Remove the ignition pulse wheel.
  40. Install the damper bolt.
    Fig 40: Installing Damper Bolt
    G03429922Courtesy of FORD MOTOR CO.
    41. NOTE: RH shown; LH similar.
    Fig 41: Removing LH & RH Spark Plugs
    G03429923Courtesy of FORD MOTOR CO.
  41. Remove the LH and RH spark plugs.
  42. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number one cylinder at top dead center (TDC).
    • Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
    Fig 42: Verifying Camshafts
    G03429924Courtesy of FORD MOTOR CO.
  43. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.
    Fig 43: Rotating Crankshaft Clockwise
    G03429925Courtesy of FORD MOTOR CO.
  44. Verify that the RH camshafts are correctly positioned.
    Fig 44: Verifying RH Camshafts
    G03429926Courtesy of FORD MOTOR CO.
  45. Remove the RH timing chain tensioner arm.
    1. Remove the bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
    Fig 45: Removing Bolts & Tensioner
    G03429927Courtesy of FORD MOTOR CO.
  46. Remove the bolts, RH timing chain guide and the timing chain.
    Fig 46: Removing Timing Chain Guide Bolts
    G03429928Courtesy of FORD MOTOR CO.
  47. Rotate the crankshaft clockwise 600 degrees (1-2/3 times) to position the crankshaft keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
    Fig 47: Rotating Crankshaft Clockwise
    G03429929Courtesy of FORD MOTOR CO.
  48. Verify the LH camshafts are in the neutral position.
    Fig 48: Verifying LH Camshafts Are In Neutral Position
    G03429930Courtesy of FORD MOTOR CO.
  49. Remove the LH timing chain and tensioner arm.
    1. Remove the bolts.
    2. Remove the tensioner.
    3. Remove the tensioner arm.
    Fig 49: Removing Bolts & Tensioner
    G03429931Courtesy of FORD MOTOR CO.
  50. Remove the LH timing chain and timing chain guide.
    Fig 50: Removing LH Timing Chain & Timing Chain Guide
    G03429932Courtesy of FORD MOTOR CO.
  51. Remove the damper bolt and the crankshaft sprockets.
    Fig 51: Removing Damper Bolt & Crankshaft Sprockets
    G03429933Courtesy of FORD MOTOR CO.
    52. NOTE: RH shown; LH similar.
    NOTE: The camshaft caps have alignment dowels.
    Fig 52: Loosening LH & RH Camshaft Cap Bolts In Sequence
    G03429934Courtesy of FORD MOTOR CO.
  52. Loosen the LH and RH camshaft cap bolts in the indicated sequence and remove the camshaft caps.
    • Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.
  53. Remove the LH and RH camshafts.
    54. CAUTION: The camshaft followers must be installed in the original position.
    NOTE: RH shown; LH similar.
    Fig 53: Removing LH & RH Camshaft Followers
    G03429935Courtesy of FORD MOTOR CO.
  54. Remove the LH and RH camshaft followers.
    • Mark the location of the followers using a permanent-type marker.
  55. Remove the coolant by pass tube.
    Fig 54: Removing Coolant By Pass Tube
    G03429936Courtesy of FORD MOTOR CO.
    56. NOTE: RH shown; LH similar.
    Fig 55: Removing Gaskets
    G03429937Courtesy of FORD MOTOR CO.
  56. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
    • Discard the gaskets.
    57. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
  57. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge and feeler gauge. 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) deep.
  58. Remove the power steering/engine support bracket.
    Fig 56: Removing Power Steering/Engine Support Bracket
    G03429938Courtesy of FORD MOTOR CO.
  59. Remove the oil separator.
    Fig 57: Removing Oil Separator
    G03429939Courtesy of FORD MOTOR CO.
  60. Remove the bolts in the indicated sequence and remove the oil pump.
    Fig 58: Removing Bolts In Indicated Sequence & Removing Oil Pump
    G03429940Courtesy of FORD MOTOR CO.
  61. Using the special tool, remove the cylinder ridge.
    Fig 59: Removing Cylinder Ridge Using Special Tool
    G03429941Courtesy of FORD MOTOR CO.
  62. Remove the connecting rod cap bolts. Hold the piston/rod assembly to keep it from falling from the engine block.
    Fig 60: Removing Connecting Rod Cap Bolts
    G03429942Courtesy of FORD MOTOR CO.
  63. Using the special tool, remove the piston/rod assembly from the engine block.
    • Remove the connecting rod bearings.
    Fig 61: Removing Connecting Rod Bearings
    G03429943Courtesy of FORD MOTOR CO.
  64. Remove the engine block from the stand and place it on a workbench.
  65. Remove the bolts and the flexplate.
    Fig 62: Removing Bolts & Flexplate
    G03429944Courtesy of FORD MOTOR CO.
  66. Remove the bolts and studs in the indicated sequence and remove the lower cylinder block.
    Fig 63: Lower Cylinder Block Bolts & Studs Removal Sequence
    G03429945Courtesy of FORD MOTOR CO.
  67. Remove the crankshaft rear main seal and remove the crankshaft.
    Fig 64: Removing Crankshaft Rear Main Seal & Remove Crankshaft
    G03429946Courtesy of FORD MOTOR CO.
  68. Remove the crankshaft key.
    Fig 65: Removing Crankshaft Key
    G03429947Courtesy of FORD MOTOR CO.
  69. Remove the crankshaft thrust bearing from the cylinder block.
    Fig 66: Removing Crankshaft Thrust Bearing From Cylinder Block
    G03429948Courtesy of FORD MOTOR CO.
  70. Remove the bearings from the lower cylinder block.
    Fig 67: Removing Bearings From Lower Cylinder Block
    G03429949Courtesy of FORD MOTOR CO.
  71. Remove the crankshaft main bearings from the cylinder block.
    Fig 68: Removing Crankshaft Main Bearings From Cylinder Block
    G03429950Courtesy of FORD MOTOR CO.
  72. Inspect the cylinder block, lower cylinder block, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION for basic mechanical concerns.
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