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Section 2 (Engine-4.6L 2V): Disassembly: Engine

WARNING: This page is about a different variant/trim than selected.
Fig 1: Identifying Special Tools
G01624332Courtesy of FORD MOTOR CO.
  1. Remove the flywheel.
    Fig 2: Removing Flywheel
    G01624333Courtesy of FORD MOTOR CO.
  2. Remove the separator plate.
    Fig 3: Removing Separator Plate
    G01624334Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove the crankshaft rear oil slinger.
    Fig 4: Removing Crankshaft Rear Oil Slinger
    G01624335Courtesy of FORD MOTOR CO.
  4. Using the special tools, remove the rear main seal.
    Fig 5: Removing Rear Main Seal
    G01624336Courtesy of FORD MOTOR CO.
  5. Remove the rear seal retainer plate.
    Fig 6: Removing Rear Seal Retainer Plate
    G01624337Courtesy of FORD MOTOR CO.
  6. Mount the engine on a work stand.
    Fig 7: Mounting Engine On A Work Stand
    G01624338Courtesy of FORD MOTOR CO.
    7. NOTE: RH shown, LH similar.
    Fig 8: Removing RH And LH Lifting Eyes
    G01624339Courtesy of FORD MOTOR CO.
  7. Remove the RH and LH lifting eyes.
  8. Remove the breather tube.
    Fig 9: Removing Breather Tube
    G01624340Courtesy of FORD MOTOR CO.
  9. Disconnect the differential pressure feedback EGR electrical connector.
    Fig 10: Disconnecting Differential Pressure Feedback EGR Electrical Connector
    G01624341Courtesy of FORD MOTOR CO.
  10. Disconnect the hoses from the differential pressure feedback EGR transducer (9J434).
    Fig 11: Disconnecting Hoses From Differential Pressure Feedback EGR Transducer
    G01624342Courtesy of FORD MOTOR CO.
  11. Remove the EGR vacuum regulator solenoid.
    1. Remove the vacuum hoses.
    2. Remove the electrical connector.
    3. Remove the bolts.
      Fig 12: Removing EGR Vacuum Regulator Solenoid
      G01624343Courtesy of FORD MOTOR CO.
  12. Disconnect the exhaust gas recirculation (EGR) tube from the EGR valve.
    Fig 13: Disconnecting Exhaust Gas Recirculation (EGR) Tube From EGR Valve
    G01624344Courtesy of FORD MOTOR CO.
  13. Disconnect the positive crankcase ventilation (PCV) hose from the base of the throttle body.
    Fig 14: Disconnecting Positive Crankcase Ventilation (PCV) Hose From Base Of Throttle Body
    G01624345Courtesy of FORD MOTOR CO.
  14. Disconnect the PCV valve hose.
    Fig 15: Disconnecting PCV Valve Hose
    G01624346Courtesy of FORD MOTOR CO.
  15. Remove the engine wiring harness.
    Fig 16: Removing Engine Wiring Harness
    G01624347Courtesy of FORD MOTOR CO.
  16. Disconnect the vacuum line to the fuel pressure sensor.
    Fig 17: Disconnecting Vacuum Line To Fuel Pressure Sensor
    G01624348Courtesy of FORD MOTOR CO.
  17. Remove the throttle body bolts.
    Fig 18: Removing Throttle Body Bolts
    G01624349Courtesy of FORD MOTOR CO.
    18. NOTE: The gasket is reusable if not damaged.
  18. Remove the throttle body and adapter as an assembly.
    • Inspect and clean the sealing surfaces.
      Fig 19: Removing Throttle Body And Adapter As An Assembly
      G01624350Courtesy of FORD MOTOR CO.
  19. Remove the ignition coils.
    Fig 20: Removing Ignition Coils
    G01624351Courtesy of FORD MOTOR CO.
  20. Remove the radio interference capacitors.
    Fig 21: Removing Radio Interference Capacitors
    G01624352Courtesy of FORD MOTOR CO.
  21. Rotate the belt tensioner and remove the accessory drive belt.
    Fig 22: Removing Accessory Drive Belt
    G01624353Courtesy of FORD MOTOR CO.
  22. Remove the power steering reservoir bracketet as an assembly.
    1. Disconnect the supply line from the pump.
    2. Remove the three bolts and reservoir.
      Fig 23: Removing Reservoir
      G01624354Courtesy of FORD MOTOR CO.
  23. Remove the upper generator support bracket.
    Fig 24: Removing Upper Generator Support Bracket
    G01624355Courtesy of FORD MOTOR CO.
  24. Remove the bolts and the generator.
  25. Remove the water outlet connector.
    Fig 25: Removing Water Outlet Connector
    G01624356Courtesy of FORD MOTOR CO.
  26. Remove the water thermostat and O-ring.
    Fig 26: Removing Water Thermostat And O-Ring
    G01624357Courtesy of FORD MOTOR CO.
  27. Remove the bolts in the sequence shown, and remove the intake manifold.
    Fig 27: Identifying Removal Sequence Of Intake Manifold Bolts
    G01624358Courtesy of FORD MOTOR CO.
  28. Remove the intake manifold gaskets.
    Fig 28: Removing Intake Manifold Gaskets
    G01624359Courtesy of FORD MOTOR CO.
    29. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
  29. Remove the water bypass tube.
    1. Remove the nut.
    2. Remove the water bypass tube.
      Fig 29: Removing Water Bypass Tube
      G01624360Courtesy of FORD MOTOR CO.
    30. NOTE: RH shown, LH similar.
    Fig 30: Removing RH And LH Engine Mount
    G01624361Courtesy of FORD MOTOR CO.
  30. Remove the RH and LH engine mount.
    31. NOTE: One side shown, other side similar.
  31. Using a suitable container, drain coolant from the engine block.
    • Install the drain plugs when finished.
      Fig 31: Identifying Tightening Torque For Installing Drain Plug
      G01624362Courtesy of FORD MOTOR CO.
  32. Remove the four bolts and the power steering pump.
    Fig 32: Removing Bolts And Power Steering Pump
    G01624363Courtesy of FORD MOTOR CO.
  33. Remove the compressor.
    1. Remove the bolts.
    2. Remove the compressor.
      Fig 33: Removing Compressor
      G01624364Courtesy of FORD MOTOR CO.
  34. Remove the oil filter adapter.
    1. Remove the oil bypass filter.
    2. Remove the bolts.
    3. Remove the oil filter adapter.
    4. Clean and inspect the sealing surfaces.
      Fig 34: Removing Oil Filter Adapter
      G01624365Courtesy of FORD MOTOR CO.
  35. Remove the LH exhaust manifold.
    1. Remove the exhaust manifold nuts.
    2. Remove the exhaust manifold.
    3. Remove the exhaust manifold gasket and discard.
      Fig 35: Removing LH Exhaust Manifold
      G01624366Courtesy of FORD MOTOR CO.
  36. Disconnect the exhaust recirculation (EGR) tube (9D477) at the exhaust manifold.
    Fig 36: Disconnecting Exhaust Recirculation (EGR) Tube At Exhaust Manifold
    G01624367Courtesy of FORD MOTOR CO.
  37. Remove the RH exhaust manifold.
    1. Remove the exhaust manifold nuts.
    2. Remove the exhaust manifold.
    3. Remove the exhaust manifold gasket and discard.
      Fig 37: Removing RH Exhaust Manifold
      G01624368Courtesy of FORD MOTOR CO.
  38. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  39. Remove the oil level indicator tube bolt.
    Fig 38: Removing Oil Level Indicator Tube Bolt
    G01624369Courtesy of FORD MOTOR CO.
  40. Remove the bolt and the oil level indicator tube.
    Fig 39: Removing Bolt And Oil Level Indicator Tube
    G01624370Courtesy of FORD MOTOR CO.
  41. Remove valve cover.
    • Remove the fasteners.
    • Remove the valve cover.
      Fig 40: Removing Valve Cover
      G01624371Courtesy of FORD MOTOR CO.
  42. Remove valve cover.
    • Remove the fasteners.
    • Remove the valve cover.
      Fig 41: Removing Valve Cover
      G01624372Courtesy of FORD MOTOR CO.
    43. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs (12405).
    NOTE: One spark plug is shown; others are similar.
    Fig 42: Removing Spark Plugs
    G01624373Courtesy of FORD MOTOR CO.
  43. Remove the spark plugs.
    44. NOTE: Rotate the camshaft to the base circle of the camshaft lobe before removing followers. Keep roller followers in order when removing.
  44. Use special tool to compress the valve springs (6513) and remove the 16 camshaft roller followers.
    • Rotate the camshaft and the crankshaft as necessary.
      Fig 43: Removing Camshaft Roller Followers
      G01624374Courtesy of FORD MOTOR CO.
  45. Remove the crankshaft pulley bolt.
    Fig 44: Removing Crankshaft Pulley Bolt
    G01624375Courtesy of FORD MOTOR CO.
  46. Using the special tool, remove the crankshaft pulley.
    Fig 45: Removing Crankshaft Pulley
    G01624376Courtesy of FORD MOTOR CO.
  47. Remove the water pump pulley.
    1. Remove the water pump pulley bolts.
    2. Remove the water pump pulley.
      Fig 46: Removing Water Pump Pulley
      G01624377Courtesy of FORD MOTOR CO.
  48. Remove the bolts and belt idler pulleys.
    Fig 47: Removing Bolts And Belt Idler Pulleys
    G01624378Courtesy of FORD MOTOR CO.
    49. NOTE: The gasket can be reused if not damaged.
  49. Remove the oil pan.
    • Remove the bolts.
    • Remove the oil pan.
      Fig 48: Removing Oil Pan
      G01624379Courtesy of FORD MOTOR CO.
  50. Using the special tool, remove the front cover seal.
    Fig 49: Removing Front Cover Seal
    G01624380Courtesy of FORD MOTOR CO.
  51. Remove the bolts, the studs, and the engine front cover.
    • Discard the gaskets. Clean and inspect the sealing surfaces.
      Fig 50: Removing Bolts, Studs, And Engine Front Cover
      G01624381Courtesy of FORD MOTOR CO.
    CAUTION: Since the engine is not free-wheeling, if the crankshaft or the camshafts are moved in any manner during removal and installation, the crankshaft and the camshafts must be re-synchronized.
  52. Remove the crankshaft sensor ring from the crankshaft.
    Fig 51: Removing Crankshaft Sensor Ring From Crankshaft
    G01624382Courtesy of FORD MOTOR CO.
  53. Remove the RH and LH timing chain tensioner (RH shown, LH similar).
    1. Remove the bolts.
    2. Remove the timing chain tensioners.
    3. Remove the timing chain tensioner arms.
      Fig 52: Removing RH And LH Timing Chain Tensioner
      G01624383Courtesy of FORD MOTOR CO.
    54. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated. Severe piston and valve damage can occur.
    CAUTION: Do not remove the special tool from the camshafts.
  54. 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.
    • Remove the LH timing chain from the camshaft sprocket.
    • Remove the LH timing chain from the crankshaft sprocket.
      Fig 53: Removing RH Timing Chain From Camshaft Sprocket
      G01624384Courtesy of FORD MOTOR CO.
    55. NOTE: The LH is shown and the RH is similar.
    Fig 54: Removing Bolts And Timing Chain Guides
    G01624385Courtesy of FORD MOTOR CO.
  55. Remove the bolts and the timing chain guides.
    56. NOTE: One side shown, other side similar.
    Fig 55: Installing Lifting Handles To RH And LH Cylinder Heads
    G01624386Courtesy of FORD MOTOR CO.
  56. Install the lifting handles to the RH and LH cylinder heads.
    57. CAUTION: New cylinder head bolts must be installed. They are tighten-to-yield designed and cannot be reused.
    CAUTION: Place cylinder head on cardboard or wood surface to prevent damage to the joint face.
  57. Remove the RH and LH cylinder heads.
    1. Remove the bolts.
    2. Remove the cylinder heads.
      Fig 56: Removing RH And LH Cylinder Heads
      G01624387Courtesy of FORD MOTOR CO.
    58. CAUTION: Do not use metal scrappers, wire brushes, power abrasive discs or other abrasive means to clean gasket surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scrapping tool to remove all traces of the head gasket (6051).
  58. Clean and inspect all of the sealing surfaces. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  59. Remove the oil pump screen cover and tube, and the spacer.
    Fig 57: Removing Oil Pump Screen Cover And Tube, And Spacer
    G01624388Courtesy of FORD MOTOR CO.
  60. Remove the oil pump.
    Fig 58: Removing Oil Pump
    G01624389Courtesy of FORD MOTOR CO.
    61. CAUTION: Do not stamp the top of pistons, as ring land damage can occur.
    NOTE: Connecting rods and rod caps should be numbered to retain correct orientation.
  61. Remove the connecting rod caps for piston numbers 1 and 6.
    • Discard the bolts.
      Fig 59: Removing Connecting Rod Caps For Piston Numbers 1 And 6
      G01624390Courtesy of FORD MOTOR CO.
    62. CAUTION: Do not scratch cylinder walls or crankshaft journals with the connecting rod.
    NOTE: Before removing 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 60: Using Ridge Reamer
    G01624391Courtesy of FORD MOTOR CO.
    Fig 61: Removing Piston
    G01624392Courtesy of FORD MOTOR CO.
  62. Remove the piston removing pistons number 1 and 6 through the top of the cylinder block.
  63. Repeat the previous two steps to remove the remaining pistons, rotating the crankshaft 90 degrees between piston pairs 3 and 5, 4 and 7, 2 and 8.
  64. Remove the piston rings.
    Fig 62: Removing Piston Rings
    G01624393Courtesy of FORD MOTOR CO.
  65. Clean and inspect pistons. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  66. Remove the crankshaft bearing cap fasteners.
    1. Remove and discard the cross-mounted main cap bolts.
    2. Loosen the jackscrews.
    3. Remove and discard the main cap bolts.
      Fig 63: Removing Crankshaft Bearing Cap Fasteners
      G01624394Courtesy of FORD MOTOR CO.
  67. Remove the main bearing cap and the crankshaft main bearings from the cylinder block.
    Fig 64: Removing Main Bearing Cap And The Crankshaft Main Bearings From The Cylinder Block
    G01624395Courtesy of FORD MOTOR CO.
  68. Remove the crankshaft, crankshaft main bearings and the thrust washer.
    Fig 65: Removing Crankshaft, Crankshaft Main Bearings And Thrust Washer
    G01624396Courtesy of FORD MOTOR CO.
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