Section 81 (Engine Mechanical - 4.0L SOHC): 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
Courtesy of FORD MOTOR CO.	Adapter for 303-564	303-578 (T97T-6256-A)
Courtesy of FORD MOTOR CO.	Compressor, Valve Spring	303-581 (T97T-6565-A)
Courtesy of FORD MOTOR CO.	Holding Tool, Camshaft Sprocket	303-564 (T97T-6256-B)
Courtesy of FORD MOTOR CO.	Holding Tool, Crankshaft	303-674
Courtesy of FORD MOTOR CO.	Remover, Crankshaft Front Oil Seal	303-107 (T74P-6700-A)
Courtesy of FORD MOTOR CO.	Remover, Crankshaft Vibration Damper	303-101 (T74P-3616-A)
Courtesy of FORD MOTOR CO.	Remover, Crankshaft Vibration Damper	303-773
Courtesy of FORD MOTOR CO.	Strap Wrench	303-D055 (D85L-6000-A) or equivalent

General Equipment

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

Material

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

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

NOTE: If the fuel rail is used as a leverage device, damage may occur to the fuel rail. Care must be taken when working around the fuel rail.

NOTE: For additional information, refer to the exploded views under Engine .

Remove the 8 bolts and the flexplate or flywheel.

Fig 1: Locating Flexplate Or Flywheel Bolts

Courtesy of FORD MOTOR CO.

Remove the spacer plate and if equipped, the flexplate-to-crankshaft spacer.

Fig 2: Locating Spacer Plate Crankshaft Spacer

Courtesy of FORD MOTOR CO.

NOTE: The original crankshaft rear seal does not have a speedy sleeve. Only a new replacement crankshaft rear seal comes with a speedy sleeve.

NOTE: The crankshaft rear seal may have a metal speedy sleeve. This sleeve must be removed before engine disassembly.

If necessary, remove the speedy sleeve using 2 screwdrivers or small pry bars.

Fig 3: Removing Speedy Sleeve Using Screwdrivers

Courtesy of FORD MOTOR CO.

Mount the engine on a suitable engine stand.
Disconnect the generator and Throttle Body (TB) electrical connectors.

Fig 4: Locating Generator And Throttle Body Electrical Connectors

Courtesy of FORD MOTOR CO.

Remove the nut and detach the B+ terminal from the generator.
- Detach the wiring retainer from the coolant tube bracket.

Fig 5: Locating Wiring Retainer On Generator Nut

Courtesy of FORD MOTOR CO.

Disconnect the vacuum tube and the fuel rail pressure and temperature sensor electrical connector.

Fig 6: Locating Fuel Rail Pressure And Temperature Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the EGR system module and Throttle Position (TP) sensor electrical connectors.

Fig 7: Locating EGR System Module And Throttle Position (TP) Sensor Electrical Connectors

Courtesy of FORD MOTOR CO.

Disconnect the EGR tube fitting from the EGR system module.

Fig 8: Locating EGR Tube Fitting On EGR System Module

Courtesy of FORD MOTOR CO.

Disconnect the EGR tube fitting from the LH exhaust manifold and remove the tube.

Fig 9: Locating Exhaust Gas Recirculation (EGR) Tube

Courtesy of FORD MOTOR CO.

Disconnect the PCV tube fittings and remove the tube.

Fig 10: Locating Positive Crankcase Ventilation (PCV) Tube Fittings

Courtesy of FORD MOTOR CO.

Disconnect the Knock Sensor (KS) electrical connector and detach the wiring retainer.

Fig 11: Locating Knock Sensor (KS) Electrical Connector

Courtesy of FORD MOTOR CO.

Remove the 8 bolts and the intake manifold.

Fig 12: Locating Intake Manifold Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 fuel supply tube bracket bolts.

Fig 13: Locating Fuel Supply Tube Bracket Bolts

Courtesy of FORD MOTOR CO.

Disconnect the Camshaft Position (CMP) electrical connector.

Fig 14: Locating Camshaft Position (CMP) Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wiring retainer.

Fig 15: Locating Oil Pressure Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Remove the bolt and the accessory drive belt tensioner.

Fig 16: Locating Belt Tensioner Bolt

Courtesy of FORD MOTOR CO.

Remove the 2 bolts, the nut and the generator and bracket.

Fig 17: Locating Generator Bracket Bolt And Nut

Courtesy of FORD MOTOR CO.

Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the 2 wiring retainers.

Fig 18: Locating Crankshaft Position (CKP) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.

Fig 19: Locating Engine Coolant Temperature (ECT) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the PCV valve electrical connector.

Fig 20: Locating PCV Valve Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the 3 LH fuel injector electrical connectors and detach the wiring retainer from the valve cover stud bolt.

Fig 21: Locating Fuel Injector Electrical Connectors

Courtesy of FORD MOTOR CO.

Disconnect the 3 RH fuel injector electrical connectors and detach the wiring retainer from the valve cover stud bolt.

Fig 22: Locating Fuel Injector Electrical Connectors

Courtesy of FORD MOTOR CO.

Remove the 3 bolts, detach the wiring retainers and remove the main engine wiring harness.

Fig 23: Locating Main Engine Wiring Harness And Bolts

Courtesy of FORD MOTOR CO.

Remove the 4 bolts and then remove the fuel rail and injectors.

Fig 24: Locating Fuel Rail And Injectors Bolts

Courtesy of FORD MOTOR CO.

Remove the bolt and the KS.

Fig 25: Locating Knock Sensor Bolt

Courtesy of FORD MOTOR CO.

Remove the bolt and then disconnect the coolant bypass hose and the heater hose from the coolant pump.

Fig 26: Locating Coolant Pump Bracket Bolts

Courtesy of FORD MOTOR CO.

Remove the 3 bolts and then remove the thermostat housing, hoses and coolant tube.

Fig 27: Locating Thermostat Housing Hoses Bolts

Courtesy of FORD MOTOR CO.

Remove the 3 bolts, 3 stud bolts and the LH valve cover.

Fig 28: Locating LH Valve Cover Stud Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 bolts, 4 stud bolts and the RH valve cover.

Fig 29: Locating RH Valve Cover Stud Bolts

Courtesy of FORD MOTOR CO.

Remove the bolt and the oil level indicator tube.
- Discard the oil level indicator tube O-ring seal.

Fig 30: Locating Oil Level Indicator Tube And Bolt

Courtesy of FORD MOTOR CO.

Remove the 6 nuts and the LH exhaust manifold and gasket.
- Discard the nuts and the LH exhaust manifold gasket.

Fig 31: Locating Exhaust Manifold Nuts

Courtesy of FORD MOTOR CO.

Remove and discard the 6 LH exhaust manifold studs.

Fig 32: Locating Exhaust Manifold Studs

Courtesy of FORD MOTOR CO.

Remove the 3 bolts and the LH engine mount bracket.

Fig 33: Locating Engine Mount Bracket Bolts

Courtesy of FORD MOTOR CO.

Remove the 6 nuts and the RH exhaust manifold and gasket.
- Discard the nuts and the RH exhaust manifold gasket.

Fig 34: Locating Exhaust Manifold Nuts

Courtesy of FORD MOTOR CO.

Remove and discard the 6 RH exhaust manifold studs.

Fig 35: Locating RH Exhaust Manifold Studs

Courtesy of FORD MOTOR CO.

Clean and inspect the LH and RH exhaust manifolds. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
Remove the 4 bolts and the RH engine mount bracket.

Fig 36: Locating Engine Mount Bracket Bolts

Courtesy of FORD MOTOR CO.

Rotate the crankshaft until the cam lobe is in the upward position.

Fig 37: Locating Crankshaft Lobe

Courtesy of FORD MOTOR CO.

NOTE: Mark each camshaft roller follower to make sure it is installed in its original position during reassembly.

Using the Valve Spring Compressor, remove the camshaft roller followers.

Fig 38: Removing/Installing Camshaft Roller Followers Using Special Tool (303-581)

Courtesy of FORD MOTOR CO.

NOTE: Mark each hydraulic lash adjuster to make sure it is installed in its original position.

Remove the hydraulic lash adjusters.

Fig 39: Locating Hydraulic Lash Adjusters

Courtesy of FORD MOTOR CO.

Remove the RH hydraulic chain tensioner.
- Remove and discard the washer.

Fig 40: Locating RH Hydraulic Chain Tensioner

Courtesy of FORD MOTOR CO.

Install the Camshaft Sprocket Holding Tool and Adapter on the RH cylinder head and tighten the top 2 clamp bolts to 10 Nm (89 lb-in).

Fig 41: Identifying Special Holding Tool

Courtesy of FORD MOTOR CO.

NOTE: The RH camshaft sprocket bolt is a LH-threaded bolt.

Remove the RH camshaft sprocket bolt.

Fig 42: Locating RH Camshaft Sprocket Bolt

Courtesy of FORD MOTOR CO.

Remove the RH cassette bolt.

Fig 43: Locating RH Chain Guide Bolt

Courtesy of FORD MOTOR CO.

NOTE: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.

NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.

Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.

Fig 44: Locating Cassette And Timing Chain

Courtesy of FORD MOTOR CO.

Remove the LH hydraulic chain tensioner.
- Remove and discard the washer.

Fig 45: Locating Camshaft Tensioner

Courtesy of FORD MOTOR CO.

Install the Camshaft Sprocket Holding Tool and Adapter on the LH cylinder head and tighten the top 2 clamp bolts to 10 Nm (89 lb-in).

Fig 46: Identifying Special Holding Tool

Courtesy of FORD MOTOR CO.

Remove the LH camshaft sprocket bolt.

Fig 47: Locating LH Camshaft Sprocket Bolt

Courtesy of FORD MOTOR CO.

Remove the LH cassette bolt.

Fig 48: Locating Chain Guide Bolt

Courtesy of FORD MOTOR CO.

NOTE: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.

NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.

Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.

Fig 49: Locating Cassette And Timing Chain

Courtesy of FORD MOTOR CO.

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

Remove the bolts in the sequence shown and remove the cylinder heads.
- Discard the gaskets and the bolts.

Fig 50: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

NOTE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.

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 and 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 surface 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 remove 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 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.
Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
Remove the 2 bolts and the CKP.

Fig 51: Locating Crankshaft Position (CKP) Sensor And Bolts

Courtesy of FORD MOTOR CO.

Using the Strap Wrench, hold the crankshaft pulley, remove the bolt and washer.

Fig 52: Holding Crankshaft Pulley Using Special Tool

Courtesy of FORD MOTOR CO.

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

Install the crankshaft pulley bolt 2 to 3 turns. Using the Crankshaft Vibration Damper Removers and the two 8-mm bolts, remove the crankshaft pulley.
- Discard the crankshaft pulley bolt.

Fig 53: Identifying Special Tool (303-773, 303-101)

Courtesy of FORD MOTOR CO.

Using the Crankshaft Front Oil Seal Remover, remove the crankshaft front oil seal.

Fig 54: Identifying Crankshaft Front Oil Seal & Special Tool (303-107)

Courtesy of FORD MOTOR CO.

Remove the 5 cylinder block cradle-to-engine front cover bolts.

Fig 55: Locating Cylinder Block Cradle-To-Engine Front Cover Bolts

Courtesy of FORD MOTOR CO.

Remove the 5 bolts, 5 stud bolts and the engine front cover.

Fig 56: Locating Engine Front Cover And Stud Bolts

Courtesy of FORD MOTOR CO.

Remove and discard the engine oil filter.

Fig 57: Locating Engine Oil Filter

Courtesy of FORD MOTOR CO.

Remove the bolts and the oil pan.

Fig 58: Locating Gasket, Oil Pan And Bolts

Courtesy of FORD MOTOR CO.

Remove the bolt and the oil pump screen cover and tube.

Fig 59: Locating Oil Pump Screen Cover And Bolt

Courtesy of FORD MOTOR CO.

NOTE: Note the location of the 2 silver-colored bolts with the washer seals. These bolts must be installed in the same position from which they were removed with new washer seals.

Remove the 8 cylinder block cradle inner bolts. Remove and discard the 2 washer seals.

Fig 60: Locating Inner Cylinder Block Cradle Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 cylinder block cradle Torx bolts.

Fig 61: Locating Rear Cylinder Block Cradle Bolts

Courtesy of FORD MOTOR CO.

Remove the 15 bolts and the 2 nuts.
- Remove the cylinder block cradle.

Fig 62: Locating Cylinder Block Cradle & Gasket

Courtesy of FORD MOTOR CO.

Remove the 2 bolts, the oil pump pickup tube and the oil pump intermediate shaft.

Fig 63: Locating Oil Pump Intermediate Shaft, Oil Pump And Bolt

Courtesy of FORD MOTOR CO.

Remove the oil filter adapter.

Fig 64: Locating Oil Filter Adapter

Courtesy of FORD MOTOR CO.

Remove the rear jackshaft plug.

Fig 65: Locating Rear Jackshaft Plug

Courtesy of FORD MOTOR CO.

Using the Crankshaft Holding Tool, hold the crankshaft.

Fig 66: Holding Crankshaft Using Special Tool (303-674)

Courtesy of FORD MOTOR CO.

Remove the rear jackshaft sprocket-retaining bolt and the spacer.

Fig 67: Locating Rear Jackshaft Sprocket Bolt

Courtesy of FORD MOTOR CO.

Remove the RH cassette bolt.

Fig 68: Locating RH Camshaft Drive Cassette Bolt & Spacer

Courtesy of FORD MOTOR CO.

Remove the RH cassette.

Fig 69: Locating Cassette And Timing Chain

Courtesy of FORD MOTOR CO.

Remove the oil pump bolt and retainer and then remove the oil pump drive.

Fig 70: Locating Oil Pump Drive

Courtesy of FORD MOTOR CO.

Using the Crankshaft Holding Tool, loosen the front sprocket retaining bolt.

Fig 71: Identifying Special Tool (303-674) & Jackshaft Sprocket Bolt

Courtesy of FORD MOTOR CO.

Remove the bolts and the chain tensioner.

Fig 72: Locating Chain Tensioner & Bolts

Courtesy of FORD MOTOR CO.

Remove the chain guide.

Fig 73: Locating Chain Guide & Bolts

Courtesy of FORD MOTOR CO.

Remove the bolt.

Fig 74: Locating Jackshaft Sprocket Bolt

Courtesy of FORD MOTOR CO.

Remove the jackshaft sprocket and chain.

Fig 75: Locating Jackshaft Chain And Sprockets

Courtesy of FORD MOTOR CO.

Remove the LH cassette bolt.

Fig 76: Locating Front Cassette & Bolt

Courtesy of FORD MOTOR CO.

Remove the LH cassette.

Fig 77: Locating Cassette And Timing Chain

Courtesy of FORD MOTOR CO.

Remove the jackshaft thrust plate.

Fig 78: Locating Jackshaft Thrust Plate & Bolts

Courtesy of FORD MOTOR CO.

Remove the jackshaft.

Fig 79: Locating Jackshaft

Courtesy of FORD MOTOR CO.

If equipped, remove the balance shaft tensioner.
1. Install a pin in the balance shaft tensioner.
2. Remove the 2 bolts.
3. Remove the balance shaft tensioner.

Fig 80: Identifying Balance Shaft Tensioner, Bolts And Pin

Courtesy of FORD MOTOR CO.

If equipped, remove the 2 bolts and the balance shaft chain guide.

NOTE: DO NOT remove the balance shaft sprocket bolt.

If equipped, remove the balance shaft chain and crankshaft sprocket.

Fig 81: Identifying Balance Shaft Chain & Crankshaft Sprocket

Courtesy of FORD MOTOR CO.

If equipped, remove the balance shaft.
1. Remove the 2 bolts.
2. Remove the balance shaft.

Fig 82: Identifying Balance Shaft

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's instructions.