Section 855 (Engine - 4.6L (2V) - F-150): Disassembly: Engine

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.

Special Tools

Illustration	Tool Name	Tool Number
	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)

Material

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 section.

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: Locating Flexplate Bolts

Courtesy of FORD MOTOR CO.

Remove the spacer plate.

Fig 2: Locating 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

Courtesy of FORD MOTOR CO.

Using the special tools, remove and discard the crankshaft rear seal.

Fig 4: Removing Crankshaft Rear Seal

Courtesy of FORD MOTOR CO.

Remove the bolts, oil pan and oil pan gasket.
- Clean and inspect the sealing surfaces.

Fig 5: Locating Oil Pan And Oil Pan Gasket Bolts

Courtesy of FORD MOTOR CO.

Remove the bolts and the crankshaft rear seal retainer plate.
- Clean and inspect the sealing surfaces.

Fig 6: Locating Crankshaft Rear Seal Retainer Plate Bolts

Courtesy of FORD MOTOR CO.

Mount the engine on a suitable workstand.
Remove the 3 bolts and the RH engine support insulator.

Fig 7: Locating RH Engine Support Insulator Bolts

Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

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

Fig 8: Locating Cylinder Block Drain Plug

Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Install the cylinder block drain plugs.
- Tighten to 24 Nm (18 lb-ft).

Fig 9: Locating Cylinder Block Drain Plug

Courtesy of FORD MOTOR CO.

Disconnect the engine oil pressure (EOP) sensor electrical connector.

Fig 10: Locating Engine Oil Pressure 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: Locating Camshaft Position (CMP) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the LH radio ignition interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.

Fig 13: Locating 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 14: Locating 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 15: Locating Upper Radiator Hose Bracket Nut

Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Remove the nuts and the 2 radio interference capacitors.

Fig 16: Identifying Radio Frequency Interference Capacitors

Courtesy of FORD MOTOR CO.

Remove the bolt and the CMP sensor.

Fig 17: Locating Bolt And LH CMP Sensor

Courtesy of FORD MOTOR CO.

Remove the bolt and the crankshaft position (CKP) sensor.

Fig 18: Locating Crankshaft Position (CKP) Sensor Bolt

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.

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.

Fig 19: Locating Valve Cover

Courtesy of FORD MOTOR CO.

Remove the bolts, the coolant pump pulley and the accessory drive belt idler pulleys.

Fig 20: Locating Coolant Pump Pulley And Accessory Drive Belt Idler Pulley Bolts

Courtesy of FORD MOTOR CO.

Remove the bolts and the accessory drive belt tensioner.

Fig 21: Identifying Accessory Drive Belt Tensioner Bolts

Courtesy of FORD MOTOR CO.

Remove the bolts.

Fig 22: Locating Bolts

Courtesy of FORD MOTOR CO.

Remove the coolant pump from the cylinder block.

Fig 23: Identifying Coolant Pump

Courtesy of FORD MOTOR CO.

Remove and discard the crankshaft pulley bolt.
Use the special tool to remove the crankshaft pulley.

Fig 24: Removing Crankshaft Pulley Using Special Tool

Courtesy of FORD MOTOR CO.

Use the special tool to remove and discard the crankshaft front seal.

Fig 25: 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.

Remove the fasteners.

Fig 26: Locating Fasteners

Courtesy of FORD MOTOR CO.

Remove the engine front cover from the cylinder block.

Fig 27: Removing Engine Front Cover From Cylinder Block

Courtesy of FORD MOTOR CO.

NOTE: Camshaft roller follower is shown removed for clarity.

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

Fig 28: Installing Special Tool Between Valve Spring Coils

Courtesy of FORD MOTOR CO.

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.

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

Fig 29: Using Special Tool To Compress Valve Springs And Remove Camshaft Roller Follower

Courtesy of FORD MOTOR CO.

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 30: View Of Crankshaft Sensor Ring At Crankshaft

Courtesy of FORD MOTOR CO.

Position the crankshaft with the keyway at the 12 o'clock position.

Fig 31: 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 seal integrity. If cracks, tears or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

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 32: Identifying Timing Chain Tensioning System

Courtesy of FORD MOTOR CO.

Remove the timing chains and crankshaft sprocket.

Fig 33: View Of Left And Right Timing Chains, Sprockets And Crankshaft Gear

Courtesy of FORD MOTOR CO.

Remove the timing chain guides.
- Remove the bolts.
- Remove the LH timing chain guide.
- Remove the bolts.
- Remove the RH timing chain guide.

Fig 34: Identifying Timing Chain Guides

Courtesy of FORD MOTOR CO.

Remove the RH exhaust manifold.
1. Remove and discard the nuts.
2. Remove the RH exhaust manifold.
3. Remove and discard the RH exhaust manifold gasket.

Fig 35: Locating Exhaust Manifold

Courtesy of FORD MOTOR CO.

Remove the LH exhaust manifold.
1. Remove and discard the nuts.
2. Remove the LH exhaust manifold.
3. Remove and discard the LH exhaust manifold gasket.

Fig 36: Identifying LH Exhaust Manifold

Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Remove and discard the 16 exhaust manifold-to-cylinder head studs.

Fig 37: Locating Exhaust Manifold-To-Cylinder Head Studs

Courtesy of FORD MOTOR CO.

Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
Remove the bolt and the oil level indicator tube.

Fig 38: Locating Oil Level Indicator Tube Bolts

Courtesy of FORD MOTOR CO.

Install the special tools on both ends of the cylinder head.

Fig 39: Identifying Special Tool

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.

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

Fig 40: Identifying Cylinder Heads Gasket And Bolts

Courtesy of FORD MOTOR CO.

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.
- Remove any large deposits of silicone or gasket material with a plastic scraper.
- Apply silicone gasket remover, following package directions, and allow to set for several minutes.
- 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.
- 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.

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).

Fig 41: Identifying Cylinder Head/Cylinder Block Oil Pressure Feed Areas

Courtesy of FORD MOTOR CO.

Remove the bolts and the LH engine support insulator.

Fig 42: Locating LH Engine Support Insulator Bolts

Courtesy of FORD MOTOR CO.

Remove the bolts and the oil filter adapter.
- Discard the gasket.

Fig 43: Locating Oil Filter Adapter Bolts

Courtesy of FORD MOTOR CO.

Clean the gasket surfaces at the cylinder block and the oil filter adapter.

Fig 44: 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 45: Locating Oil Pump Screen Bolts, Pickup Tube And Spacer

Courtesy of FORD MOTOR CO.

Remove the 3 bolts and the oil pump.

Fig 46: Locating Oil Pump Bolts

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.

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

Fig 47: Locating Connecting Rod Caps

Courtesy of FORD MOTOR CO.

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

Use the special tool to push the piston through the top of the cylinder block.

Fig 48: Pushing Piston Through Top Of Cylinder Block

Courtesy of FORD MOTOR CO.

Disassemble the 8 pistons. For additional information, refer to Piston in this article.

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

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.

Fig 49: Locating Crankshaft Bearing Cap Fasteners

Courtesy of FORD MOTOR CO.

Remove the 5 main bearing caps, the lower crankshaft main bearings and the lower thrust washer.

Fig 50: Locating 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 51: Removing Crankshaft, Upper Crankshaft Main Bearings And Upper Thrust Washers From Cylinder Block

Courtesy of FORD MOTOR CO.