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Section 1322 (Engine Mechanical - 5.4L (4V)): Disassembly: Engine

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000311Courtesy of FORD MOTOR CO.
 3-Jaw Puller 303-D121 or equivalent
GF0000433Courtesy of FORD MOTOR CO.
 Compressor, Valve Spring 303-452 (T93P-6565-AR)
GF0000351Courtesy of FORD MOTOR CO.
 Installer, Connecting Rod 303-442 (T93P-6136-A)
GF0000344Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
GF0000319Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH)
GF0000317Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
GF0000218Courtesy of FORD MOTOR CO.
 Slide Hammer 100-001 (T50T-100-A)
GF0000246Courtesy of FORD MOTOR CO.
 Strap Wrench 303-D055 (D85L-6000-A) or equivalent
Material

Item Specification
Motorcraft Metal Surface Prep
ZC-31-A		 -
Silicone Gasket Remover
ZC-30		 -
NOTE: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
NOTE: The flywheel, crankshaft rear oil slinger, crankshaft rear seal and crankshaft rear seal retainer plate must be removed before mounting the engine on the engine stand.
NOTE: For additional information, refer to the exploded view under the ASSEMBLY .
  1. Remove the 8 flywheel bolts.
    2. NOTE: The flywheel is a press fit on the crankshaft pilot. Do not use screwdrivers or prybars to remove the flywheel or damage to the flywheel or engine may occur.
  2. Remove the flywheel.
    • Install 2 of the removed flywheel bolts in the 2 holes shown on the flywheel flange.
    • Tighten the 2 bolts evenly to push the flywheel off the crankshaft pilot.
    3. Fig 1: Identifying Flywheel Bolts
    GF0046355Courtesy of FORD MOTOR CO.
  3. Remove the engine/transmission spacer plate.
  4. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove the crankshaft rear oil slinger.
    5. Fig 2: Removing Crankshaft Rear Oil Seal Slinger
    G03920149Courtesy of FORD MOTOR CO.
  5. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove the crankshaft rear seal.
    6. Fig 3: Removing Crankshaft Rear Seal
    G03920150Courtesy of FORD MOTOR CO.
  6. Remove the 8 bolts and the rear seal retainer plate.
      NOTE: 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.
    • Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the mating surfaces.
    7. Fig 4: Identifying Crankshaft Rear Seal Retainer Plate Bolts
    GF0000352Courtesy of FORD MOTOR CO.
  7. Mount the engine on a suitable work stand.
    8. Fig 5: Mounting Engine On Suitable Work Stand
    GF0000466Courtesy of FORD MOTOR CO.
  8. Disconnect the coolant hose from the thermostat housing.
    9. Fig 6: Locating Coolant Hose From Thermostat Housing
    GF0000467Courtesy of FORD MOTOR CO.
  9. Remove the coolant tube bracket nut.
    10. Fig 7: Locating Coolant Tube Bracket Nut
    GF0000468Courtesy of FORD MOTOR CO.
  10. Disconnect the 2 coolant vent hoses from the intake manifold.
    11. Fig 8: Locating Coolant Vent Hoses From Intake Manifold
    GF0000469Courtesy of FORD MOTOR CO.
  11. Disconnect the 2 upper radiator hoses from the intake manifold.
    12. Fig 9: Locating Upper Radiator Hoses From Intake Manifold
    GF0000470Courtesy of FORD MOTOR CO.
  12. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
    13. Fig 10: Locating Engine Coolant Temperature (ECT) Sensor Electrical Connector
    GF0000471Courtesy of FORD MOTOR CO.
  13. Remove the 2 nuts and the thermostat housing assembly.
    14. Fig 11: Locating Thermostat Housing Assembly Nuts
    GF0000472Courtesy of FORD MOTOR CO.
  14. Disconnect the coolant hose from the Charge Air Cooler (CAC).
    15. Fig 12: Locating Coolant Hose From Charge Air Cooler (CAC)
    GF0000473Courtesy of FORD MOTOR CO.
  15. Loosen the 4 coolant pump pulley bolts.
    16. Fig 13: Locating Coolant Pump Pulley Bolts
    GF0000393Courtesy of FORD MOTOR CO.
  16. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.
    17. Fig 14: Rotating Accessory Drive Belt Tensioner Clockwise & Removing Accessory Drive Belt
    GF0046335Courtesy of FORD MOTOR CO.
  17. Remove the bolt, Supercharger (SC) drive belt tensioner and the SC drive belt.
    18. Fig 15: Locating Bolt, Supercharger (SC) Drive Belt Tensioner & SC Drive Belt
    GF0000474Courtesy of FORD MOTOR CO.
  18. Remove the power steering tube bracket nut.
    19. Fig 16: Locating Power Steering Tube Bracket Nut
    GF0000475Courtesy of FORD MOTOR CO.
  19. Remove the power steering tube bracket bolt.
    20. Fig 17: Locating Power Steering Tube Bracket Bolt
    GF0000477Courtesy of FORD MOTOR CO.
  20. Remove the 2 power steering reservoir bracket bolts.
    21. Fig 18: Locating Power Steering Reservoir Bracket Bolts
    GF0000478Courtesy of FORD MOTOR CO.
  21. Remove the 3 bolts and the power steering pump and reservoir assembly.
    22. Fig 19: Locating Power Steering Pump & Reservoir Assembly Bolts
    GF0000479Courtesy of FORD MOTOR CO.
  22. Disconnect the generator electrical connector.
    23. Fig 20: Locating Generator Electrical Connector
    GF0046358Courtesy of FORD MOTOR CO.
  23. Remove the stud bolt, 2 bolts and the generator.
    24. Fig 21: Locating Stud Bolt, Bolts & Alternator
    GF0000482Courtesy of FORD MOTOR CO.
  24. Remove the bolt and the accessory drive belt tensioner.
    25. Fig 22: Locating Accessory Drive Belt Tensioner Bolt
    GF0000483Courtesy of FORD MOTOR CO.
  25. Remove the stud bolt and the accessory drive belt idler pulley (smooth).
    26. Fig 23: Locating Stud Bolt & Accessory Drive Belt Idler Pulley
    GF0000484Courtesy of FORD MOTOR CO.
  26. Remove the bolt and the accessory drive belt idler pulley (grooved).
    27. Fig 24: Locating Accessory Drive Belt Idler Pulley Bolt
    GF0000485Courtesy of FORD MOTOR CO.
  27. Remove the 4 bolts and the coolant pump pulley.
    28. Fig 25: Locating Coolant Pump Pulley Bolts
    GF0000486Courtesy of FORD MOTOR CO.
  28. Remove the 3 bolts and the 3 SC drive belt idler pulleys.
    29. Fig 26: Locating SC Drive Belt Idler Pulley Bolts
    GF0000487Courtesy of FORD MOTOR CO.
  29. Disconnect the 2 EGR tube fittings.
    • Remove the EGR tube.
    30. Fig 27: Locating Exhaust Gas Recirculation (EGR) Tube Fittings
    GF0000488Courtesy of FORD MOTOR CO.
  30. Disconnect and remove the crankcase ventilation tube.
    31. Fig 28: Locating Crankcase Ventilation Tube
    GF0000489Courtesy of FORD MOTOR CO.
  31. Disconnect the Throttle Position (TP) sensor electrical connector.
    32. Fig 29: Locating Throttle Position (TP) Sensor Electrical Connector
    GF0000490Courtesy of FORD MOTOR CO.
  32. Disconnect the electronic throttle control electrical connector.
    33. Fig 30: Locating Throttle Body (TB) Control Electrical Connector
    GF0000491Courtesy of FORD MOTOR CO.
  33. Remove the 4 bolts and the TB and spacer assembly.
    34. Fig 31: Locating TB & Spacer Assembly Bolts
    GF0000492Courtesy of FORD MOTOR CO.
  34. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
    35. Fig 32: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    GF0000493Courtesy of FORD MOTOR CO.
  35. Detach the 2 wiring harness pin-type retainers (1 shown) from the coolant tube assembly bracket.
    36. Fig 33: Detaching Wiring Harness Pin-Type Retainer From Coolant Tube Assembly Bracket
    GF0000494Courtesy of FORD MOTOR CO.
  36. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector and pin-type retainer.
    37. Fig 34: Locating LH Heated Oxygen Sensor (HO2S) Electrical Connector & Pin-Type Retainer
    GF0000495Courtesy of FORD MOTOR CO.
  37. Disconnect the bubbler tube from the SC.
    38. Fig 35: Disconnecting Bubbler Tube From SC
    GF0000497Courtesy of FORD MOTOR CO.
  38. Remove the 2 bolts and the wiring harness retaining bracket.
    39. Fig 36: Locating Wiring Harness Retaining Bracket & Bolts
    GF0000498Courtesy of FORD MOTOR CO.
  39. Detach the 2 wiring harness pin-type retainers.
    40. Fig 37: Locating Wiring Harness Pin-Type Retainers
    GF0046359Courtesy of FORD MOTOR CO.
  40. Disconnect the PCV valve electrical connector.
    41. Fig 38: Locating Positive Crankcase Ventilation (PCV) Valve Electrical Connector
    GF0000500Courtesy of FORD MOTOR CO.
  41. Disconnect the 4 RH fuel injector electrical connectors.
    42. Fig 39: Locating RH Fuel Injector Electrical Connectors
    GF0000501Courtesy of FORD MOTOR CO.
  42. Disconnect the fuel rail pressure and temperature sensor electrical connector.
    43. Fig 40: Locating Fuel Rail Pressure & Temperature Sensor Electrical Connector
    GF0000502Courtesy of FORD MOTOR CO.
  43. Remove the nut and the RH radio interference capacitor.
    44. Fig 41: Removing Nut & RH Radio Interference Capacitor
    GF0000503Courtesy of FORD MOTOR CO.
  44. Disconnect the EGR valve electrical connector.
    45. Fig 42: Disconnecting EGR Valve Electrical Connector
    GF0000504Courtesy of FORD MOTOR CO.
  45. Detach the wiring harness from the RH coil-on-plug cover stud bolt.
    46. Fig 43: Detaching Wiring Harness From RH Coil-On-Plug Cover Stud Bolt
    GF0000505Courtesy of FORD MOTOR CO.
  46. Detach the wiring harness retainers from the RH valve cover stud bolts.
    47. Fig 44: Detaching Wiring Harness Retainers From RH Valve Cover Stud Bolts
    GF0000506Courtesy of FORD MOTOR CO.
  47. Remove the bolt, stud bolt and the RH coil-on-plug cover.
    48. Fig 45: Locating RH Coil-On-Plug Cover Bolt & Stud Bolt
    GF0000507Courtesy of FORD MOTOR CO.
  48. Disconnect the 4 RH coil-on-plug electrical connectors.
    • Remove the 4 RH coil-on-plugs.
    49. Fig 46: Locating RH Coil-On-Plug Electrical Connectors
    GF0000508Courtesy of FORD MOTOR CO.
  49. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness pin-type retainers.
    50. Fig 47: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector
    GF0000509Courtesy of FORD MOTOR CO.
  50. Disconnect the Camshaft Position (CMP) sensor electrical connector.
    51. Fig 48: Locating Camshaft Position (CMP) Sensor Electrical Connector
    GF0000510Courtesy of FORD MOTOR CO.
  51. Disconnect the Intake Air Temperature 2 (IAT2) sensor electrical connector.
    52. Fig 49: Locating Intake Air Temperature (IAT) Sensor Electrical Connector
    GF0000511Courtesy of FORD MOTOR CO.
  52. Disconnect the 4 LH fuel injector electrical connectors.
    53. Fig 50: Locating LH Fuel Injector Electrical Connectors
    GF0000512Courtesy of FORD MOTOR CO.
  53. Remove the nut and the LH radio interference capacitor.
    54. Fig 51: Locating LH Radio Interference Capacitor Nut
    GF0000513Courtesy of FORD MOTOR CO.
  54. Detach the wiring harness retainers from the LH valve cover stud bolts.
    55. Fig 52: Detaching Wiring Harness Retainers From LH Valve Cover Stud Bolts
    GF0000514Courtesy of FORD MOTOR CO.
  55. Remove the 2 bolts and the LH coil-on-plug cover.
    56. Fig 53: Locating LH Coil-On-Plug Cover Bolts
    GF0000515Courtesy of FORD MOTOR CO.
  56. Disconnect the 4 LH coil-on-plug electrical connectors.
    • Remove the 4 LH coil-on-plugs.
    57. Fig 54: Disconnecting LH Coil-On-Plug Electrical Connectors
    GF0000516Courtesy of FORD MOTOR CO.
  57. Remove the wiring harness assembly from the engine.
  58. Disconnect the intake manifold-to-coolant tube assembly hose.
    59. Fig 55: Disconnecting Intake Manifold-To-Coolant Tube Assembly Hose
    GF0000517Courtesy of FORD MOTOR CO.
  59. Remove the 14 bolts and the intake manifold assembly.
    • Remove and discard the 2 intake manifold gaskets.
    60. Fig 56: Locating Intake Manifold Assembly & Bolts
    GF0000518Courtesy of FORD MOTOR CO.
  60. Remove the stud bolt, 3 bolts and the RH engine support insulator bracket.
    61. Fig 57: Locating RH Engine Support Insulator Bracket Bolts & Stud Bolt
    GF0000523Courtesy of FORD MOTOR CO.
  61. Remove 8 nuts and the RH exhaust manifold.
    • Discard the nuts and gaskets.
    62. Fig 58: Identifying RH Exhaust Manifold Nuts
    GF0000533Courtesy of FORD MOTOR CO.
  62. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  63. Remove and discard the 8 RH exhaust manifold studs.
  64. Remove the 4 bolts and the LH engine support insulator bracket.
    65. Fig 59: Identifying LH Engine Support Insulator Bracket Bolts
    GF0000576Courtesy of FORD MOTOR CO.
  65. Remove 8 nuts and the LH exhaust manifold.
    • Discard the nuts and gaskets.
    66. Fig 60: Identifying LH Exhaust Manifold Nuts
    GF0000532Courtesy of FORD MOTOR CO.
  66. Clean and inspect the LH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  67. Remove and discard the 8 LH exhaust manifold studs.
  68. Remove the 3 coolant tube assembly bolts.
    69. Fig 61: Identifying Coolant Tube Assembly Bolts
    GF0000577Courtesy of FORD MOTOR CO.
  69. Remove the oil level indicator, the bolt and the oil level indicator tube.
    • Remove and discard the oil level indicator tube O-ring seal.
    70. Fig 62: Identifying Oil Level Indicator Tube & Bolt
    GF0000578Courtesy of FORD MOTOR CO.
  70. Remove the 3 bolts and the coolant tube assembly.
    71. Fig 63: Identifying Coolant Tube Assembly Bolts
    GF0000534Courtesy of FORD MOTOR CO.
    NOTE: A new oil cooler must be installed or severe damage to the engine can occur.
  71. Remove the 6 bolts and the oil cooler.
    • Discard the oil cooler and the gaskets.
    72. Fig 64: Identifying Oil Cooler Bolts
    GF0000520Courtesy of FORD MOTOR CO.
  72. Remove the 8 bolts and the oil filter adapter.
    • Discard the oil filter adapter gasket.
    73. Fig 65: Identifying Oil Filter Adapter Bolts
    GF0000521Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  73. Remove the LH and RH block drain plugs.
    74. Fig 66: Locating LH & RH Block Drain Plugs
    GF0000524Courtesy of FORD MOTOR CO.
    NOTE: 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.
  74. Remove the 14 bolts, 2 stud bolts and the oil pan.
    • Remove and discard the oil pan gasket.
    • Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the mating surfaces.
    75. Fig 67: Inspecting Mating Surfaces
    GF0000580Courtesy of FORD MOTOR CO.
  75. Remove the 3 bolts and the oil pump screen and pickup tube assembly.
    • Discard the O-ring seal.
    76. Fig 68: Identifying Bolts, Oil Pump Screen & Pickup Tube Assembly
    GF0000456Courtesy of FORD MOTOR CO.
  76. Remove the spacer, 7 nuts and the windage tray.
    77. Fig 69: Identifying Windage Tray Spacer & Nuts
    GF0000581Courtesy of FORD MOTOR CO.
    NOTE: 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.
  77. Remove the bolts, stud bolts and RH valve cover.
    • Remove and discard the gaskets.
    • Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the mating surfaces.
    78. Fig 70: Identifying RH Valve Cover Bolts & Stud Bolts
    GF0000582Courtesy of FORD MOTOR CO.
    NOTE: 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.
  78. Remove the bolts, stud bolts and LH valve cover.
    • Remove and discard the gaskets.
    • Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the mating surfaces.
    79. Fig 71: Locating Valve Covers Bolts
    GF0000525Courtesy of FORD MOTOR CO.
  79. Remove the bolt and the Crankshaft Position (CKP) sensor.
    80. Fig 72: Locating Crankshaft Position (CKP) Sensor Bolt
    GF0000526Courtesy of FORD MOTOR CO.
  80. Remove the bolt and the CMP sensor.
    81. Fig 73: Locating CMP Sensor Bolt
    GF0000527Courtesy of FORD MOTOR CO.
  81. Remove the 4 bolts and the coolant pump.
    82. Fig 74: Locating Coolant Pump Bolts
    GF0000528Courtesy of FORD MOTOR CO.
  82. Using the Strap Wrench, remove the crankshaft pulley bolt and the washer.
    • Discard the bolt.
    83. Fig 75: Removing Crankshaft Pulley Bolt & Washer Using Strap Wrench
    GF0046336Courtesy of FORD MOTOR CO.
  83. Using the 3-Jaw Puller, remove the crankshaft pulley.
    84. Fig 76: Removing Crankshaft Pulley Using 3-Jaw Puller
    GF0046337Courtesy of FORD MOTOR CO.
  84. Using the Crankshaft Front Oil Seal Remover, remove the crankshaft front seal.
    85. Fig 77: Removing Crankshaft Front Seal Using Special Tool
    G03919889Courtesy of FORD MOTOR CO.
    NOTE: 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.
  85. Remove the 16 bolts and the engine front cover.
    • Remove and discard the engine front cover gaskets.
    • Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the mating surfaces.
    86. Fig 78: Inspecting Mating Surfaces
    GF0000395Courtesy of FORD MOTOR CO.
    NOTE: Only use hand tools when removing or installing the spark plugs, or damage may occur to the cylinder head or spark plugs.
    NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.
    NOTE: RH shown, LH similar.
  86. Remove the 8 spark plugs.
    87. Fig 79: Identifying Spark Plugs
    GF0000530Courtesy of FORD MOTOR CO.
    NOTE: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
  87. Using the Valve Spring Compressor, compress the valve spring and remove the roller follower.
    88. Fig 80: Compressing Valve Spring & Removing Valve Spring Retainer Keys Using Special Tool (303-452)
    GF0000437Courtesy of FORD MOTOR CO.
  88. Repeat the previous step to remove each of the roller followers. Inspect the roller followers. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
    89. NOTE: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
  89. Remove the hydraulic lash adjusters.
    90. Fig 81: Identifying Hydraulic Lash Adjusters
    GF0000531Courtesy of FORD MOTOR CO.
  90. Remove the crankshaft sensor ring.
    91. Fig 82: Locating Crankshaft Sensor Ring
    GF0000401Courtesy of FORD MOTOR CO.
  91. Remove the crankshaft washer.
    92. Fig 83: Locating Crankshaft Washer
    GF0046344Courtesy of FORD MOTOR CO.
  92. Remove the 2 bolts and the RH primary timing chain tensioner.
    93. Fig 84: Locating RH Primary Timing Chain Tensioner Bolts
    GF0000402Courtesy of FORD MOTOR CO.
  93. Remove the RH primary timing chain tensioner arm.
    94. Fig 85: Locating RH Primary Timing Chain Tensioner Arm
    GF0000403Courtesy of FORD MOTOR CO.
  94. Remove the RH primary timing chain.
    95. Fig 86: Identifying RH Primary Timing Chain
    GF0000404Courtesy of FORD MOTOR CO.
  95. Remove the 2 bolts and the RH primary timing chain guide.
    96. Fig 87: Locating RH Primary Timing Chain Guide Bolts
    GF0000405Courtesy of FORD MOTOR CO.
  96. Remove the 2 bolts and the LH primary timing chain tensioner.
    97. Fig 88: Locating LH Primary Timing Chain Tensioner Bolts
    GF0000406Courtesy of FORD MOTOR CO.
  97. Remove the LH primary timing chain tensioner arm.
    98. Fig 89: Locating LH Primary Timing Chain Tensioner Arm
    GF0000407Courtesy of FORD MOTOR CO.
  98. Remove the LH primary timing chain.
    99. Fig 90: Locating LH Primary Timing Chain
    GF0000408Courtesy of FORD MOTOR CO.
  99. Remove the 2 bolts and the LH primary timing chain guide.
    100. Fig 91: Locating LH Primary Timing Chain Guide Bolts
    GF0000409Courtesy of FORD MOTOR CO.
  100. Remove the crankshaft sprocket.
    101. Fig 92: Locating Crankshaft Sprocket
    GF0000410Courtesy of FORD MOTOR CO.
  101. Remove the 3 bolts and the oil pump.
    102. Fig 93: Identifying Oil Pump & Bolts
    GF0000454Courtesy of FORD MOTOR CO.
    NOTE: 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.
    NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
    NOTE: 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.
    NOTE: 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.
  102. Remove the bolts, the RH cylinder head and the LH cylinder head.
    • Discard the bolts.
    • Remove and discard the cylinder head gaskets.
    103. Fig 94: Identifying Cylinder Head Bolts
    GF0000535Courtesy of FORD MOTOR CO.
    NOTE: 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.
    NOTE: 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.
  103. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence.
    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.
    104. 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 within 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 within 0.010 mm (0.0004 in) from end to end.
    NOTE: LH shown, RH similar.
  104. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
    105. Fig 95: Identifying Cylinder Head/Cylinder Block Oil Pressure Feed Areas
    G03885653Courtesy of FORD MOTOR CO.
  105. 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 manufacturer's instructions.
    106. NOTE: 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
  106. Remove the bolts and the connecting rod caps for pistons No. 1 and No. 6.
    • Carefully tap the connecting rod bolts out of the connecting rod caps. Avoid damaging the rod caps.
    107. Fig 96: Identifying Rod Caps & Rod Bolts
    GF0000583Courtesy of FORD MOTOR CO.
    NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
  107. Using the Connecting Rod Installer, push pistons 1 through 6 through the top of the cylinder block.
    108. Fig 97: Pushing Piston Through Top Of Cylinder Block
    G03920342Courtesy of FORD MOTOR CO.
  108. To remove pistons 2, 3, 4, 5, 7 and 8, turn the crankshaft 90 degrees and repeat the previous steps.
    109. NOTE: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
  109. Remove the crankshaft main bearing cap fasteners.
    1. Remove and discard the side bolts.
    2. Remove and discard the main bearing cap bolts.
    3. Remove the dowel pins.
    110. Fig 98: Locating Main Bearing Cap Bolts
    GF0000584Courtesy of FORD MOTOR CO.
  110. Remove the main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
    111. Fig 99: Identifying Main Bearing Caps, Lower Crankshaft Main Bearings & Lower Thrust Washer
    GF0046362Courtesy of FORD MOTOR CO.
  111. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.
    112. Fig 100: Identifying Crankshaft, Upper Crankshaft Main Bearings & Upper Thrust Washers
    GF0046363Courtesy of FORD MOTOR CO.
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