Section 610 (Engine): Disassembly: Engine: Disassembly

WARNING: This page is about a different car, the 2004 Lincoln Town Car. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Servicing the bottom end of the engine (crankshaft, bearings) requires that cylinder heads be removed. Failure to do so can result in engine damage.

Remove the bolts and the flexplate.

Fig 1: Removing Flexplate
Courtesy of FORD MOTOR CO.
Remove the engine/transmission spacer plate.

Fig 2: Removing Engine/Transmission Spacer Plate
Courtesy of FORD MOTOR CO.
Using the special tools, remove the rear oil seal slinger.

Fig 3: Removing Rear Oil Seal Slinger
Courtesy of FORD MOTOR CO.
Using the special tools, remove the rear main seal.

Fig 4: Removing Rear Main Seal
Courtesy of FORD MOTOR CO.
Remove the eight bolts and the crankcase rear oil seal retainer.

Fig 5: Removing Crankcase Rear Oil Seal Retainer
Courtesy of FORD MOTOR CO.
Mount the engine on a suitable engine stand.

Fig 6: Mounting Engine On Engine Stand
Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Fig 7: Removing Engine Mounts

Courtesy of FORD MOTOR CO.

Remove the LH and the RH engine mount.

NOTE: LH shown, RH similar.

Fig 8: Identifying Drain Plugs

Courtesy of FORD MOTOR CO.

Remove the drain plugs from the engine block. Allow the coolant to completely drain.
- Install the drain plugs when finished.
Remove the bolt and the battery cables from the engine.

Fig 9: Removing Battery Cables From Engine
Courtesy of FORD MOTOR CO.
Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.

Fig 10: Disconnecting Exhaust Gas Recirculation (EGR) Tube From Exhaust Manifold
Courtesy of FORD MOTOR CO.
Disconnect the eight ignition coil electrical connectors.

Fig 11: Disconnecting Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the eight fuel injector electrical connectors.

Fig 12: Disconnecting Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Remove the bolts and the EGR tube heat shield.

Fig 13: Removing EGR Tube Heat Shield
Courtesy of FORD MOTOR CO.
Disconnect and remove the crankcase ventilation tube.

Fig 14: Removing Crankcase Ventilation Tube
Courtesy of FORD MOTOR CO.
Remove the generator mounting bracket.
- Remove the bolts.
- Remove the bracket.
Fig 15: Removing Generator Mounting Bracket
Courtesy of FORD MOTOR CO.
Disconnect the idle air control (IAC) and the throttle position (TP) sensor electrical connectors.

Fig 16: Disconnecting Idle Air Control (IAC) And Throttle Position (TP) Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the generator electrical connector.

Fig 17: Disconnecting Generator Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the cylinder head temperature (CHT) sensor electrical connector.

Fig 18: Disconnecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the generator wiring harness anchor from the LH front stud.

Fig 19: Removing Generator Wiring Harness Anchor From LH Front Stud
Courtesy of FORD MOTOR CO.
Disconnect the ground wire from the RH rear stud.

Fig 20: Disconnecting Ground Wire From RH Rear Stud
Courtesy of FORD MOTOR CO.
Disconnect the engine coolant temperature (ECT) sensor electrical connector.

Fig 21: Disconnecting Engine Coolant Temperature (ECT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the camshaft position (CMP) sensor electrical connector.

Fig 22: Disconnecting Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the radio ignition interference capacitor and remove the engine control sensor wiring.

Fig 23: Disconnecting Radio Ignition Interference Capacitor
Courtesy of FORD MOTOR CO.
Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.

Fig 24: Disconnecting Knock Sensor (KS) Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the vacuum hoses and the electrical connector.

Fig 25: Disconnecting Vacuum Hoses And Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the fuel charging wiring from the crash bracket and remove the harness from the engine assembly.

Fig 26: Disconnecting Fuel Charging Wiring From Crash Bracket
Courtesy of FORD MOTOR CO.
Disconnect the EGR tube nut from the EGR valve.

Fig 27: Disconnecting EGR Tube Nut From EGR Valve
Courtesy of FORD MOTOR CO.
Remove the generator.
1. Remove the bolts.
2. Remove the generator.
Fig 28: Removing Generator
Courtesy of FORD MOTOR CO.
Remove the throttle return spring.

Fig 29: Removing Throttle Return Spring
Courtesy of FORD MOTOR CO.
Remove the four bolts and the throttle body.

Fig 30: Removing Bolts And Throttle Body
Courtesy of FORD MOTOR CO.
Remove the bolt and the stud.
- Remove the crash bracket.
Fig 31: Removing Crash Bracket Bolt And Stud
Courtesy of FORD MOTOR CO.
Remove the eight bolts and the eight ignition coils.

Fig 32: Removing Ignition Coils
Courtesy of FORD MOTOR CO.
Remove the bolts and the water outlet adapter.

Fig 33: Removing Water Outlet Adapter
Courtesy of FORD MOTOR CO.
Remove the thermostat.

Fig 34: Removing Thermostat
Courtesy of FORD MOTOR CO.
Remove the bolts and the intake manifold.

Fig 35: Removing Intake Manifold
Courtesy of FORD MOTOR CO.
Remove the intake manifold gaskets.

Fig 36: Removing Intake Manifold Gaskets
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.

Fig 37: Cleaning Sealing Surfaces

Courtesy of FORD MOTOR CO.

Clean the sealing surfaces.
Remove the coolant bypass tube.
1. Remove the retaining nut.
2. Remove the ground strap.
3. Remove the water bypass tube.
Fig 38: Removing Coolant Bypass Tube
Courtesy of FORD MOTOR CO.
Remove the knock sensor.

Fig 39: Removing Knock Sensor
Courtesy of FORD MOTOR CO.
Remove the studs and bolts, and remove the valve cover.
- Clean the mating surface and, if necessary, install new gaskets.
Fig 40: Removing LH Valve Cover
Courtesy of FORD MOTOR CO.
Remove the studs and bolts, and remove the right valve cover.
- Clean the mating surface and, if necessary, install new gaskets.
Fig 41: Removing RH Valve Cover
Courtesy of FORD MOTOR CO.

NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.

Fig 42: Removing Spark Plug

Courtesy of FORD MOTOR CO.

Remove the spark plugs.
Position the lobe of the camshaft up.

Fig 43: Positioning Lobe Of Camshaft Up
Courtesy of FORD MOTOR CO.
Install the special tool between the valve spring coils to prevent valve stem seal damage.

Fig 44: Installing Special Tool Between Valve Spring Coils
Courtesy of FORD MOTOR CO.

NOTE: The roller followers are positional. Mark the followers for installation in their original locations.

Fig 45: Removing Camshaft Roller Followers

Courtesy of FORD MOTOR CO.

Use the special tool to compress the valve springs and remove the camshaft roller followers.
Remove the bolt and the belt idler pulley.

Fig 46: Removing Belt Idler Pulley
Courtesy of FORD MOTOR CO.
Remove the bolts and the coolant pump pulley.

Fig 47: Removing Coolant Pump Pulley
Courtesy of FORD MOTOR CO.
Remove the bolts and the coolant pump.

Fig 48: Removing Coolant Pump
Courtesy of FORD MOTOR CO.
Remove the crankshaft pulley bolt.

Fig 49: Removing Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
Remove the crankshaft pulley bolt.
Use the special tool to remove the crankshaft pulley.

Fig 50: Removing Crankshaft Pulley
Courtesy of FORD MOTOR CO.
Use the special tool to remove the crankshaft front seal.

Fig 51: Removing Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
Remove the bolts, and the oil pan and gasket.

Fig 52: Removing Bolts, And Oil Pan And Gasket
Courtesy of FORD MOTOR CO.
Remove the bolts, and the oil pump screen cover and tube.

Fig 53: Removing Bolts, And Oil Pump Screen Cover And Tube
Courtesy of FORD MOTOR CO.
Remove the oil pump screen cover and tube spacer.

Fig 54: Removing Oil Pump Screen Cover And Tube Spacer
Courtesy of FORD MOTOR CO.

NOTE: Correct fastener location is essential for the assembly procedure. Record fastener location.

Fig 55: Identifying Engine Front Cover Fasteners Removal Sequence

Courtesy of FORD MOTOR CO.

Remove the fasteners in the sequence shown.
Remove the engine front cover from the cylinder block.

Fig 56: Removing Engine Front Cover From Cylinder Block
Courtesy of FORD MOTOR CO.
Remove the crankshaft sensor ring from the crankshaft.

Fig 57: Removing Crankshaft Sensor Ring From Crankshaft
Courtesy of FORD MOTOR CO.
Position the crankshaft with the keyway at the 12 o'clock position.

Fig 58: Positioning Crankshaft Keyway To 12 O'Clock Position
Courtesy of FORD MOTOR CO.
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 59: Removing Timing Chain Tensioning System
Courtesy of FORD MOTOR CO.

CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinders heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.

Fig 60: Removing LH And RH Timing Chains And Crankshaft Sprocket

Courtesy of FORD MOTOR CO.

Remove the LH and RH timing chains and the crankshaft sprocket.
- Remove the RH timing chain from the camshaft sprocket.
- Remove the RH timing chain from the crankshaft sprocket.
- Repeat for the LH timing chain and crankshaft sprocket.
Remove both timing chain guides.
1. Remove the bolts.
2. Remove the LH timing chain guide.
3. Remove the bolts.
4. Remove the RH timing chain guide.
Fig 61: Removing Timing Chain Guides
Courtesy of FORD MOTOR CO.
Remove the RH exhaust manifold.
1. Remove the nuts.
2. Remove the RH exhaust manifold.
3. Remove the RH exhaust manifold gasket.
Fig 62: Removing RH Exhaust Manifold
Courtesy of FORD MOTOR CO.
Remove the LH exhaust manifold.
1. Remove the nuts.
2. Remove the LH exhaust manifold.
3. Remove the LH exhaust manifold gaskets.
Fig 63: Removing LH Exhaust Manifold
Courtesy of FORD MOTOR CO.
Remove the bolt and the oil level indicator tube.

Fig 64: Removing Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
Install the special tool on both ends of the cylinder head.

Fig 65: Installing Special Tool To Both Ends Of Cylinder Head
Courtesy of FORD MOTOR CO.

NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.

Fig 66: Removing Hydraulic Lash Adjusters

Courtesy of FORD MOTOR CO.

Remove the hydraulic lash adjusters.

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 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 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, which 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.

Fig 67: Removing RH Cylinder Head

Courtesy of FORD MOTOR CO.

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

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 installed. They are tighten-to-yield designed and cannot be reused.

CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

Fig 68: Removing LH Cylinder Head

Courtesy of FORD MOTOR CO.

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

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 cylinder heads 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 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.

NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.

Support the cylinder heads 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 heads must not have depressions deeper than 0.0254 mm (0.001 in) across at 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
Remove the bolts and the oil filter adapter and oil gasket.

Fig 69: Removing Oil Filter Adapter
Courtesy of FORD MOTOR CO.
Remove the oil pump.
1. Remove the bolts.
2. Remove the oil pump.
Fig 70: Removing Oil Pump
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 a cylinder ridge reamer, following the manufacturer's instructions.

Fig 71: Removing Ridge Or Carbon From Cylinder Bores
Courtesy of FORD MOTOR CO.

CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods (6200) and rod caps for correct orientation.

Fig 72: Removing Connecting Rod Cap

Courtesy of FORD MOTOR CO.

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

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

Fig 73: Pushing Piston Through Top Of Cylinder Block

Courtesy of FORD MOTOR CO.

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

CAUTION: Servicing the bottom end of the engine (crankshaft, bearings) requires that cylinder heads be removed. Failure to do so can result in engine damage.

Fig 74: Removing Main Cap Fasteners

Courtesy of FORD MOTOR CO.

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.
Remove the five main bearing caps and the lower crankshaft main bearings.

Fig 75: Removing Main Bearing Caps And Lower Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.

Fig 76: Removing Crankshaft And Upper Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.