Section 972 (Engine - 4.6L (2V) - F150 Pickup): Disassembly: Engine

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOLS

	Remover, Crankshaft Rear Slinger 303-514 (T95P-6701-AH)
	Remover, Crankshaft Rear Seal 303-519 (T95P-6701-EH)
	Slide Hammer 100-001 (T50T-100-A)
	Installer, Connecting Rod 303-442 (T93P-6136-A)
	Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
	Remover, Crankshaft Front Seal 303-107 (T74P-6700-A)
	Remover, Crankshaft Rear Seal 303-519 (T95P-6701-DH)
	Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
	Compressor, Valve Spring 303-452 (T97P-6565-AH)
	Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH)
	Holding Tool, Crankshaft 303-448 (T93P-6303-A)

MATERIALS

Item	Specification
Motorcraft Metal Surface Prep ZC-31	-
Silicone Gasket Remover ZC-30	-

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 in the ASSEMBLY portion of this article.

NOTE: The crankshaft rear seal, the rear oil seal slinger and the crankshaft rear seal retainer plate must be removed before mounting the engine on the engine stand.

Remove the bolts and the flexplate.

Fig 1: Removing Bolts And Flexplate
Courtesy of FORD MOTOR CO.
Remove the spacer plate.

Fig 2: Removing Spacer Plate
Courtesy of FORD MOTOR CO.
Using the special tools, remove and discard the crankshaft rear oil slinger.

Fig 3: Removing Crankshaft Rear Oil Seal Slinger Using Special Tools
Courtesy of FORD MOTOR CO.
Using the special tools, remove and discard the crankshaft rear seal.

Fig 4: Removing Crankshaft Rear Seal Using Special Tools
Courtesy of FORD MOTOR CO.
Remove the bolts, oil pan and oil pan gasket.
- Clean and inspect the sealing surfaces.
Fig 5: Removing Bolts, Oil Pan And Oil Pan Gasket
Courtesy of FORD MOTOR CO.
Remove the bolts and the crankshaft rear seal retainer plate.
- Clean and inspect the sealing surfaces.
Fig 6: Removing Bolts And Crankshaft Rear Seal Retainer Plate
Courtesy of FORD MOTOR CO.
Mount the engine on a suitable work stand.
Remove the 3 bolts and the RH engine support insulator.

Fig 7: Removing Bolts And RH Engine Support Insulator
Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 8: Removing Cylinder Block Drain Plugs

Courtesy of FORD MOTOR CO.

Remove the cylinder block drain plugs and drain the coolant into a suitable container.

NOTE: LH shown, RH similar.

Fig 9: Locating Cylinder Block Drain Plugs

Courtesy of FORD MOTOR CO.

Install the cylinder block drain plugs.
- Tighten to 24 Nm (18 lb-ft).
Disconnect the engine oil pressure (EOP) sensor electrical connector.

Fig 10: Disconnecting Engine Oil Pressure (EOP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.

Fig 11: Disconnecting Knock Sensor (KS) Electrical Connector And Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Disconnect the camshaft position (CMP) sensor electrical connector.

Fig 12: Disconnecting Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the crankshaft position (CKP) sensor electrical connector.

Fig 13: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the LH radio ignition interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.

Fig 14: Disconnecting LH Radio Ignition Interference Capacitor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the RH radio ignition interference capacitor electrical connector.

Fig 15: Disconnecting RH Radio Ignition Interference Capacitor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the engine wiring harness retainers from the valve cover studs and remove the electrical harness from the engine assembly.
Remove the nut and the upper radiator hose bracket.

Fig 16: Removing Nut And Upper Radiator Hose Bracket
Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Fig 17: Removing Nuts And 2 Radio Interference Capacitors

Courtesy of FORD MOTOR CO.

Remove the nuts and the 2 radio interference capacitors.
Remove the bolt and the CMP sensor.

Fig 18: Removing Bolt And CMP Sensor
Courtesy of FORD MOTOR CO.
Remove the bolt and the CKP sensor.

Fig 19: Removing Bolt And CKP Sensor
Courtesy of FORD MOTOR CO.

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. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: The fasteners are part of the valve cover and should not be removed.

NOTE: LH shown, RH similar.

Fig 20: Removing LH Valve Cover

Courtesy of FORD MOTOR CO.

Remove the valve covers.
- Fully loosen the fasteners and remove the valve covers.
- Clean the valve cover mating surface of the cylinder heads with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
Remove the bolts, the coolant pump pulley and the accessory drive belt idler pulleys.

Fig 21: Removing Bolts Coolant Pump Pulley And Accessory Drive Belt Idler Pulleys
Courtesy of FORD MOTOR CO.
Disconnect the coolant hoses from the heater outlet tube.

Fig 22: Disconnecting Coolant Hoses From Heater Outlet Tube
Courtesy of FORD MOTOR CO.
Remove the heater outlet tube studs.

Fig 23: Removing Heater Outlet Tube Studs
Courtesy of FORD MOTOR CO.
Remove the heater outlet tube and discard the O-ring seal.

Fig 24: Removing Heater Outlet Tube
Courtesy of FORD MOTOR CO.
Remove the bolts and the accessory drive belt tensioner.

Fig 25: Removing Bolts And Accessory Drive Belt Tensioner
Courtesy of FORD MOTOR CO.
Remove the bolts.

Fig 26: Removing Bolts
Courtesy of FORD MOTOR CO.
Remove the coolant pump from the cylinder block.

Fig 27: Removing Coolant Pump From Cylinder Block
Courtesy of FORD MOTOR CO.
Remove and discard the crankshaft pulley bolt.
Use the special tool to remove the crankshaft pulley.

Fig 28: Using Special Tool To Remove Crankshaft Pulley
Courtesy of FORD MOTOR CO.
Use the special tool to remove and discard the crankshaft front seal.

Fig 29: Removing Crankshaft Front Seal Using Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Correct fastener location is essential for assembly procedure. Record the fastener location.

Fig 30: Removing Fasteners

Courtesy of FORD MOTOR CO.

Remove the fasteners.
Remove the engine front cover from the cylinder block.

Fig 31: Removing Engine Front Cover From Cylinder Block
Courtesy of FORD MOTOR CO.

NOTE: Camshaft roller follower is shown removed for clarity.

Fig 32: Installing Special Tool Between Valve Spring Coils To Prevent Valve Stem Seal Damage

Courtesy of FORD MOTOR CO.

Install the special tool between the valve spring coils to prevent valve stem seal damage.

NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.

NOTE: Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.

Fig 33: Using Special Tool To Compress Valve Springs And Remove Camshaft Roller Follower

Courtesy of FORD MOTOR CO.

Using the special tool, compress the valve springs and remove the camshaft roller follower.

NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.

Repeat the previous 3 steps for each camshaft roller follower.
Remove the crankshaft sensor ring from the crankshaft.

Fig 34: Removing Crankshaft Sensor Ring From Crankshaft
Courtesy of FORD MOTOR CO.
Position the crankshaft with the keyway at the 12 o'clock position.

Fig 35: Positioning Crankshaft With Keyway At 12 O'clock Position
Courtesy of FORD MOTOR CO.

CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seat integrity. If cracks, tears or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

Fig 36: Removing Timing Chain Tensioning System From Both Timing Chains

Courtesy of FORD MOTOR CO.

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.
Remove the timing chains and crankshaft sprocket.

Fig 37: Removing Timing Chain And Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Remove the timing chain guides.
1. Remove the bolts.
2. Remove the LH timing chain guide.
3. Remove the bolts.
4. Remove the RH timing chain guide.
Fig 38: Removing Timing Chain Guides
Courtesy of FORD MOTOR CO.
Remove the RH exhaust manifold.
1. Remove the nut.
2. Remove the RH exhaust manifold.
3. Remove and discard the RH exhaust manifold gasket.
Fig 39: Removing RH Exhaust Manifold
Courtesy of FORD MOTOR CO.
Remove the LH exhaust manifold.
1. Remove the nut.
2. Remove the LH exhaust manifold.
3. Remove and discard the LH exhaust manifold gasket.
Fig 40: Removing LH Exhaust Manifold
Courtesy of FORD MOTOR CO.
Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
Remove the bolt and the oil level indicator tube.

Fig 41: Removing Bolt And Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
Install the special tools on both ends of the cylinder head.

Fig 42: Installing Special Tools On Both Ends Of Cylinder Head
Courtesy of FORD MOTOR CO.

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 must be installed. They are tighten-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: LH shown, RH similar.

Fig 43: Removing Bolts And Cylinder Heads

Courtesy of FORD MOTOR CO.

Remove the bolts and the cylinder heads.
- Discard the cylinder head gasket.
- Discard the cylinder head bolts.

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.

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 staining of the metal surfaces is normal.

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 machine edge must be flat with 0.010 mm (0.0004 in) from end to end.

NOTE: LH shown, RH similar.

Fig 44: Identifying Oil Pressure Feed Area Of Deck Face Surface

Courtesy of FORD MOTOR CO.

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).
Remove the bolts and the LH engine support insulator.

Fig 45: Removing Bolts And LH Engine Support Insulator
Courtesy of FORD MOTOR CO.
Remove the bolts and the oil filter adapter.
- Discard the gasket.
Fig 46: Removing Bolts And Oil Filter Adapter
Courtesy of FORD MOTOR CO.
Clean the gasket surfaces at the cylinder block and the oil filter adapter.

Fig 47: Cleaning Gasket Surfaces At Cylinder Block And Oil Filter Adapter
Courtesy of FORD MOTOR CO.
Remove the bolts, the oil pump screen and pickup tube and the spacer.

Fig 48: Removing Bolts, Oil Pump Screen, Pickup Tube And Spacer
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the oil pump.

Fig 49: Removing Bolts And Oil Pump
Courtesy of FORD MOTOR CO.
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 instructions.

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 50: Removing Bolts And Connecting Rod Caps

Courtesy of FORD MOTOR CO.

Remove the bolts and the connecting rod caps. Discard the bolts.

CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Fig 51: Using Special Tool To Push Piston Through Top Of Cylinder Block

Courtesy of FORD MOTOR CO.

Use the special tool to push the piston through the top of the cylinder block.
Disassemble the 8 pistons. For additional information, refer to PISTON .

CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

Fig 52: Removing Crankshaft Bearing Cap Fasteners

Courtesy of FORD MOTOR CO.

Remove the crankshaft bearing cap fasteners.
1. Remove and discard the cross-mounted main cap bolts.
2. Loosen the jack screws.
3. Remove and discard the main cap bolts.
Remove the 5 main bearing caps, the lower crankshaft main bearings and the lower thrust washer.

Fig 53: Removing Main Bearing Caps, Lower Crankshaft Main Bearings And Lower Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.

Fig 54: Removing Crankshaft, Upper Crankshaft Main Bearings And Upper Thrust Washers From Cylinder Block
Courtesy of FORD MOTOR CO.