Section 16 (Engine - 5.2L 32V Ti-VCT - Supercharged): Disassembly: Engine

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	100-001 (T50T-100-A)Slide Hammer
Courtesy of FORD MOTOR COMPANY	205-142 (T80T-4000-J)Installer, Differential Bearing Cone
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W)Handle
Courtesy of FORD MOTOR COMPANY	303-1247VCT Spark Plug Tube Seal Remover and InstallerTKIT-2006UF-FLMTKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-409 (T92C-6700-CH)Remover, Crankshaft SealTKIT-1992-FH/FMH/FLMHTKIT-1993-LMH/MH
Courtesy of FORD MOTOR COMPANY	303-448 (T93P-6303-A)Holding Tool, CrankshaftTKIT-1993-FLMTKIT-1993-LM
Courtesy of FORD MOTOR COMPANY	303-519 (T95P-6701-EH)Remover, Crankshaft Rear Oil SealTKIT-1995-FH/FLMHTKIT-1995-LMH/MH
Courtesy of FORD MOTOR COMPANY	303-F047Lifting Bracket, Engine
Floor Crane
Mounting Stand
Plastic Scraper
Puller

1. NOTE: The flywheel bolts are torque-to-yield design and are not reusable

   Remove and discard the flywheel bolts.

   • Remove the flywheel.

   Courtesy of FORD MOTOR COMPANY

2. Remove the crankshaft sensor ring and the engine-to-transmission spacer plate.

   Courtesy of FORD MOTOR COMPANY

3. Inspect the crankshaft sensor ring for damage. If the crankshaft sensor ring has been dropped or has any visual damage, it must be discarded.

   Courtesy of FORD MOTOR COMPANY

4. Using the special tools, remove and discard the crankshaft rear seal. Use Special Service Tool: 303-519 (T95P-6701-EH) Remover, Crankshaft Rear Oil Seal., 100-001 (T50T-100-A) Slide Hammer.

   Courtesy of FORD MOTOR COMPANY

5. Using a floor crane, install the engine on a mounting stand and remove the special tool. Remove Special Service Tool: 303-F047 Lifting Bracket, Engine.Use the General Equipment: Floor CraneUse the General Equipment: Mounting Stand

   Courtesy of FORD MOTOR COMPANY

6. • Reposition the wiring harness electrical connector insulators.
   • Disconnect the engine wiring harness electrical connectors.
   • Detach the engine wiring harness retainers and position the harness aside.

   Courtesy of FORD MOTOR COMPANY

7. • Remove the nut and the ground cable.
   • Reposition the wiring harness electrical connector insulator.
   • Disconnect the engine wiring harness electrical connectors.
   • Detach the engine wiring harness retainers and position the harness aside.

   Courtesy of FORD MOTOR COMPANY

8. • Disconnect the engine wiring harness electrical connector.
   • Detach the engine wiring harness retainers and position the harness aside.

   Courtesy of FORD MOTOR COMPANY

   1. Reposition the wiring harness electrical connector insulator.

9. Detach the engine wiring harness retainer.

   Courtesy of FORD MOTOR COMPANY

10. Disconnect the engine wiring harness electrical connectors.

    Courtesy of FORD MOTOR COMPANY

11. Remove the LH spark plug cover.

    Courtesy of FORD MOTOR COMPANY

12. • Disconnect the engine wiring harness electrical connectors.
    • Detach the engine wiring harness retainers and position the harness aside.

    Courtesy of FORD MOTOR COMPANY

13. Remove the RH spark plug cover.

    Courtesy of FORD MOTOR COMPANY

14. • Disconnect the engine wiring harness electrical connectors.
    • Detach the engine wiring harness retainers and position the harness aside.

    Courtesy of FORD MOTOR COMPANY

15. • Remove the nut and the ground wire.
    • Remove the wiring harness from the engine.

    Courtesy of FORD MOTOR COMPANY

16. NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease removal.

    Remove the bolts and the ignition coils.

    Courtesy of FORD MOTOR COMPANY

17. NOTE: Do not remove the spark plugs when the engine is hot or cold soaked. Spark plug thread or cylinder head damage can occur. Make sure the engine is warm (hand touch after cooling down) prior to spark plug removal.
    NOTE: If a spark plug is dropped, internal damage may result and the spark plug must be discarded. The use of a damaged spark plug may cause cylinder misfire resulting in engine damage.
    NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.

    Remove the spark plugs.

    Courtesy of FORD MOTOR COMPANY

18. Loosen the bolts and remove the valve cover.

    Courtesy of FORD MOTOR COMPANY

19. NOTE: Clean the valve cover gasket groove with soap and water or a suitable solvent.

    Remove and discard the gasket.

    Courtesy of FORD MOTOR COMPANY

20. Inspect the VCT variable force solenoid seals. Remove any damaged seals using the special tools. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-142 (T80T-4000-J) Installer, Differential Bearing Cone.

    Courtesy of FORD MOTOR COMPANY

21. Inspect the spark plug seals. Remove any damaged seals using the special tools. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

    Courtesy of FORD MOTOR COMPANY

22. 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.

    Make sure that the mating faces are clean and free of foreign material. Use the General Equipment: Plastic Scraper

    Courtesy of FORD MOTOR COMPANY

23. 1. Remove the oil level indicator.
    2. Remove the bolt and the upper oil level indicator tube.

    Courtesy of FORD MOTOR COMPANY

24. Inspect the O-ring seals and replace as necessary.

    Courtesy of FORD MOTOR COMPANY

25. 1. Depress the tab.
    2. Rotate the oil level indicator lower tube counterclockwise.
    3. Pull the oil level indicator lower tube from the engine.

    Courtesy of FORD MOTOR COMPANY

26. Inspect the O-ring seal and replace as necessary.

    Courtesy of FORD MOTOR COMPANY

27. Loosen the bolts and remove the valve cover.

    Courtesy of FORD MOTOR COMPANY

28. NOTE: Clean the valve cover gasket groove with soap and water or a suitable solvent.

    Remove and discard the gasket.

    Courtesy of FORD MOTOR COMPANY

29. Inspect the VCT variable force solenoid seals. Remove and discard any damaged seals using the special tools. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-142 (T80T-4000-J) Installer, Differential Bearing Cone.

    Courtesy of FORD MOTOR COMPANY

30. Inspect the spark plug seals. Remove and discard any damaged seals using the special tools. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.

    Courtesy of FORD MOTOR COMPANY

31. 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.

    Make sure that the mating faces are clean and free of foreign material. Use the General Equipment: Plastic Scraper

    Courtesy of FORD MOTOR COMPANY

32. • Remove the nuts and the RH exhaust manifold.
    • Discard the nuts.
    • Clean and inspect the exhaust manifold. Refer to: Exhaust Manifold Cleaning and Inspection .

    Courtesy of FORD MOTOR COMPANY

33. Remove and discard the gasket.

    Courtesy of FORD MOTOR COMPANY

34. Remove and discard the studs.

    Courtesy of FORD MOTOR COMPANY

35. • Remove the nuts and the LH exhaust manifold.
    • Discard the nuts.
    • Clean and inspect the exhaust manifold. Refer to: Exhaust Manifold Cleaning and Inspection .

    Courtesy of FORD MOTOR COMPANY

36. Remove and discard the gasket.

    Courtesy of FORD MOTOR COMPANY

37. Remove and discard the studs.

    Courtesy of FORD MOTOR COMPANY

38. NOTE: If further disassembly of the engine will be performed, retain the original crankshaft pulley bolt for removing the crankshaft front seal, and if necessary, turning the crankshaft while the pulley is removed.

    Remove and discard the crankshaft pulley bolt.

    Courtesy of FORD MOTOR COMPANY

39. Remove the bolts.

    Courtesy of FORD MOTOR COMPANY

40. NOTE: Use a commercially available universal puller (such as an OTC 6930, or equivalent) and a universal step plate (such as an OTC 8052, or equivalent).

    Using a Puller, a Step Plate and 2 bolts, remove the crankshaft pulley. Use the General Equipment: Puller

    Courtesy of FORD MOTOR COMPANY

41. • NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
      NOTE: If further disassembly of the engine will be performed, retain the original crankshaft pulley bolt for turning the crankshaft while the pulley is removed.

      Using the special tool and the original crankshaft bolt, remove and discard the crankshaft front oil seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.

    • Discard the crankshaft pulley bolt.

    Courtesy of FORD MOTOR COMPANY

42. 1. Remove the bolts and the coolant pump pulley.
    2. Remove the bolt and the idler pulley.
    3. Remove the bolt and the idler pulley.
    4. Remove the bolt and the belt tensioner.
    5. Remove the bolt and the belt tensioner.
    6. Remove the bolt and the idler pulley.
    7. Remove the fasteners and the generator.

    Courtesy of FORD MOTOR COMPANY

43. Remove the bolts and the coolant pump.

    Courtesy of FORD MOTOR COMPANY

44. Remove and discard the coolant pump O-ring seal.

    Courtesy of FORD MOTOR COMPANY

45. Remove the plug.

    Courtesy of FORD MOTOR COMPANY

46. Remove the fasteners, the CMP sensors and the CKP sensor.

    Courtesy of FORD MOTOR COMPANY

47. Remove the fasteners and the oil pan.

    Courtesy of FORD MOTOR COMPANY

48. Remove the fasteners and the oil pickup.

    Courtesy of FORD MOTOR COMPANY

49. Inspect the O-ring seal and replace as necessary.

    Courtesy of FORD MOTOR COMPANY

50. Remove and discard the oil pan gasket.

    Courtesy of FORD MOTOR COMPANY

51. Remove the spacer.

    Courtesy of FORD MOTOR COMPANY

52. 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.

    Make sure that the mating faces are clean and free of foreign material.

    Courtesy of FORD MOTOR COMPANY

53. 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 traces of sealant.

    Make sure that the oil pan mating faces of the cylinder block, engine front cover and real seal retaining plate are clean and free of foreign material. Use the General Equipment: Plastic Scraper

    Courtesy of FORD MOTOR COMPANY

54. NOTE: The fasteners differ in size, not the location of each fastener during removal.

    Remove the bolts, the stud bolts and the engine front cover.

    Courtesy of FORD MOTOR COMPANY

55. Remove and discard the engine front cover gaskets.

    Courtesy of FORD MOTOR COMPANY

56. 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.

    Make sure that the mating faces are clean and free of foreign material.

    Courtesy of FORD MOTOR COMPANY

57. Using the special tool, rotate the crankshaft clockwise until the crankshaft keyway is at the 11:00 position. Use Special Service Tool: 303-448 (T93P-6303-A) Holding Tool, Crankshaft.

    Courtesy of FORD MOTOR COMPANY

58. Verify the timing mark on the RHVCT unit is on top, if not, rotate the crankshaft clockwise one complete revolution so the crankshaft keyway is at the 11:00 position.

    Courtesy of FORD MOTOR COMPANY

59. Remove the bolts and the RH primary timing chain tensioner.

    Courtesy of FORD MOTOR COMPANY

60. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the RH timing chain tensioner arm. Return the crankshaft keyway to the 11:00 position after removing the RH timing chain tensioner arm.

    Remove the RH timing chain tensioner arm.

    Courtesy of FORD MOTOR COMPANY

61. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the RH timing chain guide. Return the crankshaft keyway to the 11:00 position after removing the RH timing chain guide.

    Remove the bolt and the RH timing chain guide.

    Courtesy of FORD MOTOR COMPANY

62. Remove the RH timing chain.

    Courtesy of FORD MOTOR COMPANY

63. Remove and discard the intake and exhaust VCT assembly bolts.

    Courtesy of FORD MOTOR COMPANY

64. 1. Depress the secondary timing chain tensioner.
    2. Turn the tensioner counterclockwise 90 degrees.

    Courtesy of FORD MOTOR COMPANY

65. NOTE: Valve spring pressure will rotate the intake camshaft after the VCT units are removed.
    1. Using a wrench on the flats of the camshaft, have an assistant hold the intake camshaft in position to prevent valve spring pressure from binding the locating pin of the VCT in the end of the camshaft.
    2. Slide the VCT units and secondary timing chain off of the camshafts as an assembly.

    Courtesy of FORD MOTOR COMPANY

66. Remove and discard the VCT system oil filters from the camshafts.

    Courtesy of FORD MOTOR COMPANY

67. NOTE: The front camshaft bearing mega cap must be removed first and then the remaining camshaft bearing caps. Failure to follow this direction may result in damage to the engine.

    Remove the bolts and the front camshaft bearing mega cap.

    Courtesy of FORD MOTOR COMPANY

68. Remove the bolts and the camshaft bearing caps.

    Courtesy of FORD MOTOR COMPANY

69. Remove the intake and exhaust camshafts.

    Courtesy of FORD MOTOR COMPANY

70. 1. Remove the camshaft roller follower and hydraulic lash adjusters.
    2. Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
    3. Inspect the hydraulic lash adjusters and roller followers for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Replace damaged components as necessary.

    Courtesy of FORD MOTOR COMPANY

71. Using the special tool, rotate the crankshaft clockwise until the keyway is at the 12:00 position. Use Special Service Tool: 303-448 (T93P-6303-A) Holding Tool, Crankshaft.

    Courtesy of FORD MOTOR COMPANY

72. Remove the bolts and the LH primary timing chain tensioner.

    Courtesy of FORD MOTOR COMPANY

73. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the LH timing chain tensioner arm. Return the crankshaft keyway to the 12:00 position after removing the LH timing chain tensioner arm.

    Remove the LH timing chain tensioner arm.

    Courtesy of FORD MOTOR COMPANY

74. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the LH timing chain guide. Return the crankshaft keyway to the 12:00 position after removing the LH timing chain guide.

    Remove the bolt and the LH timing chain guide.

    Courtesy of FORD MOTOR COMPANY

75. Remove the LH timing chain.

    Courtesy of FORD MOTOR COMPANY

76. Remove the LH timing chain. Refer to: Variable Camshaft Timing (VCT) Oil Control Solenoid .
77. Remove and discard the intake and exhaust VCT assembly bolts.

    Courtesy of FORD MOTOR COMPANY

78. 1. Depress the secondary timing chain tensioner.
    2. Turn the tensioner counterclockwise 90 degrees.

    Courtesy of FORD MOTOR COMPANY

79. NOTE: Valve spring pressure will rotate the intake camshaft after the VCT units are removed.
    1. Using a wrench on the flats of the camshaft, have an assistant hold the intake camshaft in position to prevent valve spring pressure from binding the locating pin of the VCT in the end of the camshaft.
    2. Slide the VCT units and secondary timing chain off of the camshafts as an assembly.

    Courtesy of FORD MOTOR COMPANY

80. Remove and discard the VCT system oil filters.

    Courtesy of FORD MOTOR COMPANY

81. NOTE: The front camshaft bearing mega cap must be removed first and then the remaining camshaft bearing caps. Failure to follow this direction may result in damage to the engine.

    Remove the bolts and the front camshaft bearing mega cap.

    Courtesy of FORD MOTOR COMPANY

82. Remove the bolts and the camshaft bearing caps.

    Courtesy of FORD MOTOR COMPANY

83. Remove the intake and exhaust camshafts.

    Courtesy of FORD MOTOR COMPANY

84. 1. Remove the camshaft roller follower and hydraulic lash adjusters.
    2. Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
    3. Inspect the hydraulic lash adjusters and roller followers for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Replace damaged components as necessary.

    Courtesy of FORD MOTOR COMPANY

85. 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: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    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.
    • Remove and discard the bolts.
    • Remove the cylinder head.

    Courtesy of FORD MOTOR COMPANY

86. Remove and discard the cylinder head gasket.

    Courtesy of FORD MOTOR COMPANY

87. Remove the dowels.

    Courtesy of FORD MOTOR COMPANY

88. 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.
    NOTE: Clean the cylinder head bolt holes in the cylinder block using compressed air. Make sure all coolant, oil or other foreign material is removed.
    • Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
    • Refer to: Cylinder Head Distortion .
    • Refer to: Cylinder Block Distortion .

    Courtesy of FORD MOTOR COMPANY

89. 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: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    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.
    • Remove and discard the bolts.
    • Remove the cylinder head.

    Courtesy of FORD MOTOR COMPANY

90. Discard the cylinder head gasket.

    Courtesy of FORD MOTOR COMPANY

91. Remove the dowels.

    Courtesy of FORD MOTOR COMPANY

92. 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.
    NOTE: Clean the cylinder head bolt holes in the cylinder block using compressed air. Make sure all coolant, oil or other foreign material is removed.
    • Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
    • Refer to: Cylinder Head Distortion .
    • Refer to: Cylinder Block Distortion .

    Courtesy of FORD MOTOR COMPANY

93. Remove the bolts and the KSs.

    Courtesy of FORD MOTOR COMPANY

94. Remove the bolts and the oil filter adapter.

    Courtesy of FORD MOTOR COMPANY

95. Remove and discard the gasket.

    Courtesy of FORD MOTOR COMPANY

96. Remove the bolts and the crankshaft rear seal retainer plate.

    Courtesy of FORD MOTOR COMPANY

97. Clean and prepare the RTV sealing surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation .

    Courtesy of FORD MOTOR COMPANY

98. Clean and prepare the RTV sealing surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation .

    Courtesy of FORD MOTOR COMPANY

99. Remove the crankshaft sprocket.

    Courtesy of FORD MOTOR COMPANY

100. Remove the bolts, stud bolts and the oil pump.

     Courtesy of FORD MOTOR COMPANY

101. • 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.

     Courtesy of FORD MOTOR COMPANY

102. NOTE: Verify that the connecting rod and rod cap have orientation numbers cast into them. If not, number the connecting rod and rod cap for correct orientation. Failure to do so can result in engine damage.

     Remove the bolts and the connecting rod cap.

     Courtesy of FORD MOTOR COMPANY

103. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

     Remove the piston through the top of the cylinder block.

     Courtesy of FORD MOTOR COMPANY

104. Repeat the previous 2 steps for each of the remaining pistons.
105. Disassemble the 8 pistons. Refer to: Piston .
106. 1. Remove and discard the cross-mounted main cap bolts.
     2. Remove and discard the main bearing cap bolts and stud bolt.

     Courtesy of FORD MOTOR COMPANY

107. Remove the main bearing caps (1), the lower crankshaft main bearings (2) and the lower thrust bearing (3).

     Courtesy of FORD MOTOR COMPANY

108. Remove the crankshaft (1), the upper crankshaft main bearings (2) and the upper thrust washer (3) from the cylinder block.

     Courtesy of FORD MOTOR COMPANY

109. Remove the bolts and the piston oil coolers.

Courtesy of FORD MOTOR COMPANY