Section 1513 (Engine): Disassembly: Engine: Disassembly

WARNING: This page is about a different car, the 2005 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: Identifying Bolts And 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: Identifying Crankshaft Rear Oil Seal Retainer
Courtesy of FORD MOTOR CO.
Mount the engine on a suitable engine stand.

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

NOTE: RH shown; LH similar.

Fig 7: Removing LH And RH Engine Mount

Courtesy of FORD MOTOR CO.

Remove the LH and the RH engine mount.

NOTE: LH shown; RH similar.

Fig 8: Removing Drain Plugs From Engine Block

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 Bolt And 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 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 Bolts
Courtesy of FORD MOTOR CO.
Disconnect the throttle control and the throttle position (TP) sensor electrical connectors.

Fig 16: Locating 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 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 Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the camshaft position (CMP) sensor electrical connector.

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

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

Fig 24: Locating 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 four bolts.

Fig 29: Removing Bolts
Courtesy of FORD MOTOR CO.
Remove the bolt and the stud.
- Remove the crash bracket.
Fig 30: Removing Bolt & Stud
Courtesy of FORD MOTOR CO.
Remove the eight bolts and the eight ignition coils.

Fig 31: Removing Ignition Coil Bolts
Courtesy of FORD MOTOR CO.
Remove the bolts and the coolant outlet adapter.

Fig 32: Removing Coolant Outlet Adapter Bolts
Courtesy of FORD MOTOR CO.
Remove the thermostat.

Fig 33: Removing Thermostat
Courtesy of FORD MOTOR CO.
Remove the bolts and the intake manifold.

Fig 34: Removing Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
Remove the intake manifold gaskets.

Fig 35: 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 36: 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 coolant bypass tube.
Fig 37: Removing Coolant Bypass Tube
Courtesy of FORD MOTOR CO.
Remove the knock sensor.

Fig 38: 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 39: Removing 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 40: Removing Right 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 41: Removing Spark Plugs

Courtesy of FORD MOTOR CO.

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

Fig 42: 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 43: 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 44: 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 45: Removing Belt Idler Pulley Bolt
Courtesy of FORD MOTOR CO.
Remove the bolts and the coolant pump pulley.

Fig 46: Removing Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
Remove the bolts and the coolant pump.

Fig 47: Identifying Coolant Pump Bolts
Courtesy of FORD MOTOR CO.
Remove the crankshaft pulley bolt.

Fig 48: Removing Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
Remove the crankshaft pulley bolt.
Use the special tool to remove the crankshaft pulley.

Fig 49: Removing Crankshaft Pulley
Courtesy of FORD MOTOR CO.
Use the special tool to remove the crankshaft front seal.

Fig 50: Removing Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
Remove the bolts, and the oil pan and gasket.

Fig 51: Removing Oil Pan And Gasket
Courtesy of FORD MOTOR CO.
Remove the bolts, and the oil pump screen cover and tube.

Fig 52: Removing Oil Pump Screen Cover And Tube
Courtesy of FORD MOTOR CO.
Remove the oil pump screen cover and tube spacer.

Fig 53: 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 54: Identifying Removal Sequence Of Engine Front Cover Bolts

Courtesy of FORD MOTOR CO.

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

Fig 55: Removing Engine Front Cover From Cylinder Block
Courtesy of FORD MOTOR CO.
Remove the crankshaft sensor ring from the crankshaft.

Fig 56: Crankshaft Sensor Ring
Courtesy of FORD MOTOR CO.
Position the crankshaft with the keyway at the 12 o'clock position.

Fig 57: Positioning Crankshaft With Keyway At 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 58: Identifying Timing Chain Tensioning System Components
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 59: Removing Timing Chains

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 60: Removing Both 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 61: 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 62: Removing LH Exhaust Manifold
Courtesy of FORD MOTOR CO.
Remove the bolt and the oil level indicator tube.

Fig 63: 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 64: Installing/Removing Special Tools On 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 65: Identifying 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 66: Locating Cylinder Head Bolts

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 67: Identifying LH Cylinder Head Bolts

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 68: Removing Oil Filter Adapter Bolts
Courtesy of FORD MOTOR CO.
Remove the oil pump.
1. Remove the bolts.
2. Remove the oil pump.
Fig 69: 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 70: Inspecting Cylinder Bore
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 and rod caps for correct orientation.

Fig 71: Identifying Bolts And Connecting Rod Caps

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 72: Removing Piston

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 73: Removing Crankshaft Bearing 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 74: Removing Main Bearing Caps
Courtesy of FORD MOTOR CO.
Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.

Fig 75: Removing Crankshaft And Main Bearings From Cylinder Block

Courtesy of FORD MOTOR CO.