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Section 463 (Engine - 4.0L SOHC): Disassembly: Engine

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tools
G03274726Courtesy of FORD MOTOR CO.
GENERAL EQUIPMENT

8 mm x 1.25 x 100 mm bolts (2 req'd)
CAUTION: If the fuel supply manifold is used as a leverage device, damage can occur to the supply manifold. Care must be taken when working around the fuel supply manifold.

    ALL VEHICLES 

  1. Remove the flywheel.
    Fig 2: Removing Flywheel
    G03274727Courtesy of FORD MOTOR CO.
  2. Using the special tool, remove the crankshaft rear oil seal.
    Fig 3: Removing Crankshaft Rear Oil Seal
    G03274728Courtesy of FORD MOTOR CO.
  3. Install the engine on a suitable engine stand.
  4. Remove the floor crane, spreader bar and the lifting eyes.
  5. Remove the generator mounting bracket.
    1. Remove drive belt tensioner bolt.
    2. Remove the generator mounting bracket bolts.
      Fig 4: Removing Generator Mounting Bracket
      G03274729Courtesy of FORD MOTOR CO.
  6. Disconnect the idle air control (IAC) valve, throttle position (TP) sensor electrical connectors and the TP sensor wiring pin - type retainer.
    Fig 5: Disconnecting IAC Valve, TP Sensor Electrical Connectors
    G03274730Courtesy of FORD MOTOR CO.
  7. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose and tube fitting.
    Fig 6: Disconnecting EGR Valve Vacuum Hose And Tube Fitting
    G03274731Courtesy of FORD MOTOR CO.
  8. Disconnect the EGR vacuum regulator solenoid valve electrical and vacuum connections.
    Fig 7: Disconnecting EGR Vacuum Regulator Solenoid Valve Electrical And Vacuum Connections
    G03274732Courtesy of FORD MOTOR CO.
  9. Disconnect the camshaft position (CMP) sensor and differential pressure feedback EGR system electrical connectors. Release the wiring harness pin-type retainer.
    Fig 8: Disconnecting CMP Sensor And Differential Pressure Feedback EGR System Electrical Connectors
    G03274733Courtesy of FORD MOTOR CO.
  10. Remove the bolt and disconnect the radio ignition interference capacitor electrical connector.
    Fig 9: Disconnecting Radio Ignition Interference Capacitor Electrical Connector
    G03274734Courtesy of FORD MOTOR CO.
    11. CAUTION: Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
    Fig 10: Removing Spark Plug Wires
    G03274735Courtesy of FORD MOTOR CO.
  11. Using the special tool, remove the spark plug wires from the spark plugs and all routing clips.
  12. Disconnect the ignition coil electrical connector.
    Fig 11: Disconnecting Ignition Coil Electrical Connector
    G03274736Courtesy of FORD MOTOR CO.
  13. Remove the ignition coil bracket lower bolts.
    Fig 12: Removing Ignition Coil Bracket Lower Bolts
    G03274737Courtesy of FORD MOTOR CO.
  14. Remove the ignition coil bracket upper bolts and the ignition coil assembly.
    Fig 13: Removing Ignition Coil Bracket Upper Bolts And Ignition Coil Assembly
    G03274738Courtesy of FORD MOTOR CO.
  15. Disconnect the vacuum hoses.
    Fig 14: Disconnecting Vacuum Hoses
    G03274739Courtesy of FORD MOTOR CO.
  16. Detach the pin-type retainer and disconnect the knock sensor electrical connector.
    Fig 15: Disconnecting KS Electrical Connector
    G03274740Courtesy of FORD MOTOR CO.
  17. Remove the intake manifold bolts and lift up the intake manifold.
    Fig 16: Removing Intake Manifold
    G03274741Courtesy of FORD MOTOR CO.
  18. Remove the heated positive crankcase ventilation (PCV) hose retainers and remove the heated PCV fitting.
    Fig 17: Removing Heated Positive Crankcase Ventilation Hose Retainers
    G03274742Courtesy of FORD MOTOR CO.
  19. Remove the intake manifold.
  20. Disconnect the coolant hose.
    Fig 18: Disconnecting Coolant Hose
    G03274743Courtesy of FORD MOTOR CO.
  21. Remove the coolant tube bracket retaining bolts.
    Fig 19: Removing Coolant Tube Bracket Retaining Bolts
    G03274744Courtesy of FORD MOTOR CO.
  22. Disconnect the coolant hoses.
    Fig 20: Disconnecting Coolant Hoses
    G03274745Courtesy of FORD MOTOR CO.
  23. Detach the wiring harness retainer and remove the coolant tube and bracket assembly.
    Fig 21: Removing Wiring Harness Retainer And Coolant Tube
    G03274746Courtesy of FORD MOTOR CO.
  24. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 22: Disconnecting CKP Sensor Electrical Connector
    G03274747Courtesy of FORD MOTOR CO.
  25. Disconnect the wiring harness retainers.
    Fig 23: Disconnecting Wiring Harness Retainers
    G03274748Courtesy of FORD MOTOR CO.
  26. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
    Fig 24: Disconnecting Water Temperature Indicator Sender Unit & ECT Sensor Connectors
    G03274749Courtesy of FORD MOTOR CO.
  27. Disconnect the fuel pulse damper vacuum hose.
    Fig 25: Disconnecting Fuel Pulse Damper Vacuum Hose
    G03274750Courtesy of FORD MOTOR CO.
    28. NOTE: The LH side is shown, the RH side is similar.
    Fig 26: Disconnecting Six Fuel Injector Electrical Connectors
    G03274751Courtesy of FORD MOTOR CO.
  28. Disconnect the six fuel injector electrical connectors.
  29. Remove the fuel charging wiring harness.
    Fig 27: Removing Fuel Charging Wiring Harness
    G03274752Courtesy of FORD MOTOR CO.
  30. Disconnect and remove the EGR tube from the exhaust manifold.
    Fig 28: Removing EGR Tube From Exhaust Manifold
    G03274753Courtesy of FORD MOTOR CO.
  31. Remove the fuel supply tube upper bracket bolt.
    Fig 29: Removing Fuel Supply Tube Upper Bracket Bolt
    G03274754Courtesy of FORD MOTOR CO.
  32. Remove the fuel supply tube lower bracket bolt.
    Fig 30: Removing Fuel Supply Tube Lower Bracket Bolt
    G03274755Courtesy of FORD MOTOR CO.
  33. Remove the fuel injection supply manifold.
    1. Remove the fuel supply tube from the fuel manifold. Remove the fuel supply tube from the engine.
    2. Remove the fuel injection supply manifold bolts and the supply manifold and the fuel injectors as an assembly.
      Fig 31: Removing Fuel Injection Supply Manifold
      G03274756Courtesy of FORD MOTOR CO.

    34. EARLY BUILD VEHICLES 

  34. Disconnect the PCV hose.
    Fig 32: Disconnecting PCV Hose
    G03274757Courtesy of FORD MOTOR CO.

    35. LATE BUILD VEHICLES 

  35. Disconnect the PCV hose from the valve.
    Fig 33: Disconnecting PCV Hose From Valve
    G03274758Courtesy of FORD MOTOR CO.

    36. ALL VEHICLES 

  36. Remove the PCV valve from the valve cover. Remove the PCV system from the engine.
    Fig 34: Removing PCV Valve
    G03274759Courtesy of FORD MOTOR CO.
  37. Remove the LH valve cover and the gasket.
    Fig 35: Removing LH Valve Cover And Gasket
    G03274760Courtesy of FORD MOTOR CO.
  38. Remove the RH valve cover and the gasket.
    Fig 36: Removing RH Valve Cover And Gasket
    G03274761Courtesy of FORD MOTOR CO.
  39. Remove the thermostat housing.
    1. Remove the bolts.
    2. Release the bypass hose clamp and remove the housing.
      Fig 37: Removing Thermostat Housing
      G03274762Courtesy of FORD MOTOR CO.
  40. Remove the bolt and the oil level indicator tube.
    Fig 38: Removing Oil Level Indicator Tube
    G03274763Courtesy of FORD MOTOR CO.
  41. Remove the bolt and the knock sensor (KS).
    Fig 39: Removing Knock Sensor
    G03274764Courtesy of FORD MOTOR CO.
  42. Remove the retainers, LH exhaust manifold and the gasket.
    Fig 40: Removing LH Exhaust Manifold And Gasket
    G03274765Courtesy of FORD MOTOR CO.
  43. Remove the retainers, RH exhaust manifold and the gasket.
    Fig 41: Removing RH Exhaust Manifold And Gasket
    G03274766Courtesy of FORD MOTOR CO.
  44. Remove the coolant pump.
    Fig 42: Removing Coolant Pump
    G03274767Courtesy of FORD MOTOR CO.

    45. EARLY BUILD VEHICLES 

    CAUTION: This bolt is a torque-to-yield design and cannot be reused.
    Fig 43: Removing Crankshaft Pulley Bolt
    G03274768Courtesy of FORD MOTOR CO.
  45. Using the special tool, remove the crankshaft pulley bolt.
  46. Using the special tool, remove the crankshaft pulley.
    Fig 44: Removing Crankshaft Pulley
    G03274769Courtesy of FORD MOTOR CO.

    47. LATE BUILD VEHICLES 

    CAUTION: This bolt is a torque-to-yield design and cannot be reused.
    Fig 45: Removing Crankshaft Pulley Bolt
    G03274770Courtesy of FORD MOTOR CO.
  47. Using the special tool, remove the crankshaft pulley bolt.
    48. NOTE: If the crankshaft pulley bolt is not installed, the special tool will bottom out before the pulley is off.
    Fig 46: Removing Pulley
    G03274771Courtesy of FORD MOTOR CO.
  48. Install the crankshaft pulley bolt 2-3 turns. Using the special tool and the 8 mm x 1.25 x 100 mm bolts, remove the pulley.

    49. ALL VEHICLES 

    NOTE: Mark each of the roller followers to ensure it is installed in its original position during reassembly.
    Fig 47: Removing Camshaft Roller Followers
    G03274772Courtesy of FORD MOTOR CO.
  49. Using the special tool, remove the camshaft roller followers.
  50. Remove the RH hydraulic chain tensioner.
    Fig 48: Removing RH Hydraulic Chain Tensioner
    G03274773Courtesy of FORD MOTOR CO.
  51. Remove the RH chain guide bolt.
    Fig 49: Removing RH Chain Guide Bolt
    G03274774Courtesy of FORD MOTOR CO.
    52. CAUTION: The right-hand camshaft sprocket bolt is a left -hand threaded bolt.
    NOTE: Secure the chain to the camshaft drive cassette with a rubber band to aid in the removal of the cylinder head.
    Fig 50: Removing RH Camshaft Sprocket Bolt And Sprocket
    G03274775Courtesy of FORD MOTOR CO.
  52. Remove the RH camshaft sprocket bolt and sprocket.
  53. Remove the LH hydraulic chain tensioner.
    Fig 51: Removing LH Hydraulic Chain Tensioner
    G03274776Courtesy of FORD MOTOR CO.
  54. Remove the LH chain guide bolt.
    Fig 52: Removing LH Chain Guide Bolt
    G03274777Courtesy of FORD MOTOR CO.
    55. NOTE: Secure the chain to the camshaft drive cassette with a rubber band to aid in the removal of the cylinder head.
    Fig 53: Removing LH Camshaft Sprocket Bolt And Sprocket
    G03274778Courtesy of FORD MOTOR CO.
  55. Remove the LH camshaft sprocket bolt and sprocket.
  56. Remove the bolts in the sequence shown and remove the LH cylinder head.
    Fig 54: LH Cylinder Head Bolts Removal Sequence
    G03274779Courtesy of FORD MOTOR CO.
  57. Remove the bolts in the sequence shown and remove the RH cylinder head.
    Fig 55: RH Cylinder Head Bolts Removal Sequence
    G03274780Courtesy of FORD MOTOR CO.
  58. Remove the bolts and the engine front cover.
    Fig 56: Removing Engine Front Cover
    G03274781Courtesy of FORD MOTOR CO.
  59. Remove the bolts and the oil pan.
    Fig 57: Removing Oil Pan
    G03274782Courtesy of FORD MOTOR CO.
  60. Remove the oil pump screen cover and tube.
    Fig 58: Removing Oil Pump Screen Cover And Tube
    G03274783Courtesy of FORD MOTOR CO.
  61. Remove the rear cylinder block cradle bolts.
    Fig 59: Removing Rear Cylinder Block Cradle Bolts
    G03274784Courtesy of FORD MOTOR CO.
  62. Remove the eight inner cylinder block cradle bolts. Discard the washer seals.
    Fig 60: Removing Eight Inner Cylinder Block Cradle Bolts
    G03274785Courtesy of FORD MOTOR CO.
  63. Remove the 15 bolts and the two nuts. Remove the cylinder block cradle and gasket.
    Fig 61: Removing Cylinder Block Cradle And Gasket
    G03274786Courtesy of FORD MOTOR CO.
  64. Remove the bolts and the oil pump.
    Fig 62: Removing Bolts And Oil Pump
    G03274787Courtesy of FORD MOTOR CO.
  65. Remove the oil filter.
  66. Remove the oil filter adapter.
    Fig 63: Removing Oil Filter Adapter
    G03274788Courtesy of FORD MOTOR CO.
  67. Inspect and install new O-ring seals if necessary.
    Fig 64: Installing New O-Ring Seals
    G03274789Courtesy of FORD MOTOR CO.
  68. Remove the bolts and the jackshaft chain tensioner.
    Fig 65: Removing Jackshaft Chain Tensioner
    G03274790Courtesy of FORD MOTOR CO.
  69. Remove the bolts and the jackshaft chain guide.
    Fig 66: Removing Jackshaft Chain Guide
    G03274791Courtesy of FORD MOTOR CO.
  70. Remove the jackshaft rear plug.
    Fig 67: Removing Jackshaft Rear Plug
    G03274792Courtesy of FORD MOTOR CO.
  71. Install the special tool on the rear of the jackshaft.
    Fig 68: Installing Special Tool On Rear Of Jackshaft
    G03274793Courtesy of FORD MOTOR CO.
  72. Loosen the jackshaft sprocket bolt.
    Fig 69: Loosening Jackshaft Sprocket Bolt
    G03274794Courtesy of FORD MOTOR CO.
  73. With the special tool still in place, loosen the rear sprocket retaining bolt.
    74. NOTE: It may be required to hold the oil pump intermediate shaft, using an E-12 external TORX® socket, in order to remove the bolts if bolts do not turn out easily at this time.
    Fig 70: Removing Jackshaft Sprocket Bolt
    G03274795Courtesy of FORD MOTOR CO.
  74. Remove the jackshaft sprocket bolt.
  75. Remove the jackshaft sprocket and chain.
    Fig 71: Removing Jackshaft Sprocket And Chain
    G03274796Courtesy of FORD MOTOR CO.
  76. Remove the bolt and the LH camshaft drive cassette.
    Fig 72: Removing Bolt And LH Camshaft Drive Cassette
    G03274797Courtesy of FORD MOTOR CO.
  77. Remove the RH camshaft drive cassette bolt and spacer.
    Fig 73: Removing RH Camshaft Drive Cassette Bolt And Spacer
    G03274798Courtesy of FORD MOTOR CO.
  78. Remove the sprocket bolt and the RH camshaft drive cassette.
    Fig 74: Removing Sprocket Bolt And RH Camshaft Drive Cassette
    G03274799Courtesy of FORD MOTOR CO.
  79. Remove the hold down and the oil pump drive.
    Fig 75: Removing Hold Down And Oil Pump Drive
    G03274800Courtesy of FORD MOTOR CO.
  80. Remove the bolts and the jackshaft thrust plate.
    Fig 76: Removing Bolts And Jackshaft Thrust Plate
    G03274801Courtesy of FORD MOTOR CO.
  81. Remove the jackshaft.
    Fig 77: Removing Jackshaft
    G03274802Courtesy of FORD MOTOR CO.
  82. Remove the jackshaft spacer.
    Fig 78: Removing Jackshaft Spacer
    G03274803Courtesy of FORD MOTOR CO.
  83. Using the cylinder ridge reamer, remove the ridge and carbon deposits from the top of each cylinder.
    Fig 79: Removing Ridge And Carbon Deposits From Top Of Each Cylinder
    G03274804Courtesy of FORD MOTOR CO.
  84. Remove connecting rod caps.
    1. Remove the connecting rod nuts.
    2. Remove the connecting rod cap.
      Fig 80: Removing Connecting Rod Caps
      G03274805Courtesy of FORD MOTOR CO.
  85. Install rubber hose pieces on the bolts to protect the crankshaft and remove the piston and connecting rod assemblies.
    Fig 81: Installing Rubber Hose Pieces On Bolts To Protect Crankshaft
    G03274806Courtesy of FORD MOTOR CO.
  86. Remove the crankshaft main bearing cap bolts.
    Fig 82: Removing Crankshaft Main Bearing Cap Bolts
    G03274807Courtesy of FORD MOTOR CO.
  87. Remove the crankshaft main bearing caps.
    Fig 83: Removing Crankshaft Main Bearing Caps
    G03274808Courtesy of FORD MOTOR CO.
  88. Remove the crankshaft.
    Fig 84: Removing Crankshaft
    G03274809Courtesy of FORD MOTOR CO.
  89. Remove the crankshaft main bearings and the thrust bearing.
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