Section 875 (Engine - 4.0L (SOHC)): Disassembly: Engine

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools

Illustration	Tool Name	Tool Number
	Crankshaft Damper Remover	303-101 (T74P-6316-A)
	Cylinder Ridge Reamer	303-016 (T64L-6011-EA)
	Heavy Duty Floor Crane	014-00071
	Lifting Bracket, Engine	303-050 (T70P-6000)
	Rear Jackshaft Socket	303-634
	Remover, Crankshaft Vibration Damper	303-773
	Seal Remover	303-409 (T92C-6700-CH)
	Spreader Bar	303-106 (T74P-6666-A)
	Strap Wrench	303-D055 (D85L-6000-A) or equivalent
	Valve Spring Compressor	303-581 (T97T-6565-A)

General Equipment

8 mm x 1.25 x 100 mm bolts (2 required)

CAUTION: If used as a leverage device, the fuel rail may be damaged. Care must be taken when working around the fuel rail.

Remove the flywheel or flexplate.
Remove the crankshaft spacer plate.
Remove the crankshaft spacer.

Fig 1: Locating Crankshaft Spacer
Courtesy of FORD MOTOR CO.

NOTE: The crankshaft rear seal may have a metal speedy sleeve. This sleeve must be removed before attempting to remove the seal.

Fig 2: Locating Speedy Sleeve

Courtesy of FORD MOTOR CO.

If necessary, remove the speedy sleeve using 2 screwdrivers or small pry bars.
Using the special tool, remove the crankshaft rear seal.

Fig 3: Removing Crankshaft Rear Seal Using Special Tool (303-409)
Courtesy of FORD MOTOR CO.
Install the engine on a suitable engine stand.
Remove the floor crane, Spreader Bar and the Engine Lifting Brackets.
Remove the generator mounting bracket.

Fig 4: Identifying Generator Mounting Bracket Bolts
Courtesy of FORD MOTOR CO.
- Remove drive belt tensioner bolt.
- Remove the generator mounting bracket bolts.
Remove the bolt and the engine ground strap. Detach the electrical connector.

Fig 5: Locating Bolt & Engine Ground Strap
Courtesy of FORD MOTOR CO.
Disconnect the PCV valve hose and electrical connector.

Fig 6: Locating PCV Valve Hose & Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the camshaft position (CMP) sensor and differential pressure feedback EGR system electrical connectors. Detach the wiring harness pin-type retainer. Remove the electrical connector bracket bolt.

Fig 7: Locating Camshaft Position (CMP) Sensor
Courtesy of FORD MOTOR CO.
Disconnect the 6 fuel injector electrical connectors and detach the 2 wiring harness retainers.

Fig 8: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the engine coolant temperature (ECT) sensor and knock sensor electrical connectors.

Fig 9: Locating Engine Coolant Temperature (ECT) Sensor
Courtesy of FORD MOTOR CO.
Remove the bracket bolt.

Fig 10: Locating Bracket Bolt
Courtesy of FORD MOTOR CO.
Disconnect the coolant hose.

Fig 11: Locating Coolant Hose
Courtesy of FORD MOTOR CO.
Remove the coolant tube bracket retaining bolts.

Fig 12: Locating Coolant Tube Bracket Retaining Bolts
Courtesy of FORD MOTOR CO.
Disconnect the coolant hose.

Fig 13: Locating Coolant Hose
Courtesy of FORD MOTOR CO.
Detach the wiring harness retainer and remove the coolant tube and bracket, the PCV hose-to intake manifold fitting and the PCV hose as an assembly.

Fig 14: Detaching Wiring Harness Retainer And Removing Coolant Tube And Bracket Assembly
Courtesy of FORD MOTOR CO.
Disconnect the crankshaft position (CKP) sensor electrical connector.

Fig 15: Locating Crankshaft Position (CKP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove and discard the wiring anchors.

Fig 16: Locating Wiring Harness Anchors
Courtesy of FORD MOTOR CO.
Remove the engine wiring harness.
Disconnect and remove the EGR tube from the exhaust manifold.

Fig 17: Locating EGR Tube From Exhaust Manifold
Courtesy of FORD MOTOR CO.
Remove the fuel rail bolts, fuel rail and the fuel injectors as an assembly.

Fig 18: Locating Fuel Rail Bolts
Courtesy of FORD MOTOR CO.
Remove the bolts, the LH valve cover and the gasket.

Fig 19: Locating LH Valve Cover & Gasket
Courtesy of FORD MOTOR CO.
Remove the bolts, the RH valve cover and the gasket.

Fig 20: Locating Valve Covers & Gasket
Courtesy of FORD MOTOR CO.
Remove the thermostat housing.
- Remove the bolts.
- Release the bypass hose clamp and remove the housing.
  
  Fig 21: Identifying Bypass Hose Clamp & Housing
  Courtesy of FORD MOTOR CO.
Remove the bolt and the oil level indicator tube.

Fig 22: Locating Oil Level Indicator Tube Bolt
Courtesy of FORD MOTOR CO.
Remove the bolt and the knock sensor (KS).

Fig 23: Locating Knock Sensor (KS) Bolt
Courtesy of FORD MOTOR CO.
Remove the nuts, LH exhaust manifold and the gasket.
- Discard the nuts and gasket.
Remove and discard the 6 LH exhaust manifold studs.

Fig 24: Locating LH Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
Remove the nuts, RH exhaust manifold and the gasket.

Fig 25: Locating RH Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
- Discard the nuts and gasket.
Remove and discard the 6 RH exhaust manifold studs.
Remove the bolts and the coolant pump.

Fig 26: Locating Coolant Pump Bolts
Courtesy of FORD MOTOR CO.

NOTE: This bolt is a torque-to-yield design and cannot be reused.

Fig 27: Holding Crankshaft Pulley Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, remove and discard the crankshaft pulley bolt.

NOTE: If the crankshaft pulley bolt is not installed, the special tool will bottom out before the pulley is off.

Fig 28: Removing Crankshaft Pulley Using Special Tool

Courtesy of FORD MOTOR CO.

Install the crankshaft pulley bolt 2-3 turns. Using the special tools and the 8 mm x 1.25 x 100 mm bolts, remove the pulley.
Rotate the crankshaft until the cam lobe of the cylinder being serviced is in the UP position.

Fig 29: Locating Crankshaft Lobe
Courtesy of FORD MOTOR CO.

NOTE: Mark each of the roller followers to make sure it is installed in its original position during reassembly.

Fig 30: Locating Camshaft Roller Follower And Special Tools

Courtesy of FORD MOTOR CO.

Using the special tool, remove the camshaft roller followers.
Remove the RH hydraulic chain tensioner.

Fig 31: Locating RH Hydraulic Chain Tensioner
Courtesy of FORD MOTOR CO.
Remove the RH chain guide bolt.

Fig 32: Locating RH Chain Guide Bolt
Courtesy of FORD MOTOR CO.

NOTE: 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 33: Locating RH Camshaft Sprocket Bolt & Sprocket

Courtesy of FORD MOTOR CO.

Remove the RH camshaft sprocket bolt and sprocket.
Remove the LH hydraulic chain tensioner.

Fig 34: Locating LH Hydraulic Chain Tensioner
Courtesy of FORD MOTOR CO.
Remove the LH chain guide bolt.

Fig 35: Locating LH Chain Guide Bolt
Courtesy of FORD MOTOR CO.

NOTE: Secure the chain to the camshaft drive cassette with a rubber band to aid in the removal of the cylinder head.

Fig 36: Locating LH Camshaft Sprocket Bolt & Sprocket

Courtesy of FORD MOTOR CO.

Remove the LH camshaft sprocket bolt and sprocket.

NOTE: New cylinder head bolts must be installed. They are torque-to-yield design and cannot be reused.

Fig 37: Identifying Cylinder Head Bolts Removing Sequence

Courtesy of FORD MOTOR CO.

Remove the bolts in the sequence shown and remove the LH cylinder head.
- Discard the gasket and bolts.

NOTE: New cylinder head bolts must be installed. They are torque-to-yield design and cannot be reused.

Fig 38: Identifying Cylinder Head Bolts Removing Sequence

Courtesy of FORD MOTOR CO.

Remove the bolts in the sequence shown and remove the RH cylinder head.
- Discard the gasket and bolts.
Remove the bolts and the engine front cover.

Fig 39: Locating Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
Remove the bolts and the oil pan.

Fig 40: Locating Oil Pan Bolts
Courtesy of FORD MOTOR CO.
Remove the bolt and the oil pump screen cover and tube.

Fig 41: Locating Oil Pump Screen Cover And Bolt
Courtesy of FORD MOTOR CO.
Remove the rear cylinder block cradle bolts.

Fig 42: Locating Rear Cylinder Block Cradle Bolts
Courtesy of FORD MOTOR CO.
Remove the 8 inner cylinder block cradle bolts. Discard the washer seals.

Fig 43: Locating Inner Cylinder Block Cradle Bolts
Courtesy of FORD MOTOR CO.
Remove the 15 bolts and the 2 nuts. Remove the cylinder block cradle and gasket.

Fig 44: Locating Cylinder Block Cradle & Gasket
Courtesy of FORD MOTOR CO.
Remove the bolts and the oil pump.

Fig 45: Locating Oil Pump Bolts
Courtesy of FORD MOTOR CO.
Remove the oil filter adapter.

Fig 46: Locating Oil Filter Adapter
Courtesy of FORD MOTOR CO.
Inspect and install new O-ring seals if necessary.

Fig 47: Locating O-Ring Seals
Courtesy of FORD MOTOR CO.
Remove the bolts and the jackshaft chain tensioner.

Fig 48: Locating Jackshaft Chain Tensioner Bolts
Courtesy of FORD MOTOR CO.
Remove the bolts and the jackshaft chain guide.

Fig 49: Locating Jackshaft Chain Guide Bolts
Courtesy of FORD MOTOR CO.
Remove the jackshaft rear plug.

Fig 50: Locating Jackshaft Rear Plug
Courtesy of FORD MOTOR CO.
Install the special tool on the rear of the jackshaft.

Fig 51: Identifying Special Tool (303-634)
Courtesy of FORD MOTOR CO.
Loosen the jackshaft sprocket bolt.

Fig 52: Locating Jackshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
With the special tool still in place, loosen the rear sprocket retaining bolt.

NOTE: It may be necessary 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 53: Locating Jackshaft Sprocket Bolt

Courtesy of FORD MOTOR CO.

Remove the jackshaft sprocket bolt.
Remove the jackshaft sprocket and chain.

Fig 54: Locating Jackshaft Chain And Sprockets
Courtesy of FORD MOTOR CO.
Remove the bolt and the LH camshaft drive cassette.

Fig 55: Locating LH Camshaft Drive Cassette Bolt
Courtesy of FORD MOTOR CO.
Remove the RH camshaft drive cassette bolt and spacer.

Fig 56: Locating RH Camshaft Drive Cassette Bolt & Spacer
Courtesy of FORD MOTOR CO.
Remove the sprocket bolt and the RH camshaft drive cassette.

Fig 57: Locating RH Camshaft Drive Cassette Bolt
Courtesy of FORD MOTOR CO.
Remove the hold down and the oil pump drive.

Fig 58: Locating Oil Pump Drive
Courtesy of FORD MOTOR CO.
Remove the bolts and the jackshaft thrust plate.

Fig 59: Locating Jackshaft Thrust Plate Bolts
Courtesy of FORD MOTOR CO.
Remove the jackshaft.

Fig 60: Locating Jackshaft
Courtesy of FORD MOTOR CO.
Remove the jackshaft spacer.

Fig 61: Locating Jackshaft Spacer
Courtesy of FORD MOTOR CO.
Using the cylinder ridge reamer, remove the ridge and carbon deposits from the top of each cylinder.

Fig 62: Removing Ridge & Carbon Deposits Using Cylinder Ridge Reamer
Courtesy of FORD MOTOR CO.
Remove connecting rod caps.

Fig 63: Identifying Connecting Rod Caps Nuts
Courtesy of FORD MOTOR CO.
- Remove the connecting rod nuts.
- Remove the connecting rod cap.
Install rubber hose pieces on the bolts to protect the crankshaft and remove the piston and connecting rod assemblies.

Fig 64: Locating Rubber Hose Pieces On Bolts
Courtesy of FORD MOTOR CO.
Remove the crankshaft main bearing cap bolts.

Fig 65: Locating Crankshaft Main Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
Remove the crankshaft main bearing caps.

Fig 66: Locating Crankshaft Main Bearing Caps
Courtesy of FORD MOTOR CO.
Remove the crankshaft.
Remove the crankshaft main bearings and the thrust bearing.

Fig 67: Locating Crankshaft Main Bearings & Thrust Bearing
Courtesy of FORD MOTOR CO.