Engine Mechanical: Mechanical: Engine: Disassembly: Engine

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	Adapter for 205-126	(205-072-02)
Courtesy of FORD MOTOR CO.	Alignment Plate, Camshaft	303-465 (T94P-6256-CH)
	Engine Stand	014-00232 or equivalent
	Heavy Duty Floor Crane	014-00071 or equivalent
Courtesy of FORD MOTOR CO.	Holding Fixture, Drive Pinion Flange	205-126 (T78P-4851-A)
Courtesy of FORD MOTOR CO.	Holding Tool, Flywheel	303-103 (T74P-6375-A)
Courtesy of FORD MOTOR CO.	Remover, Oil Seal	303-409 (T92C-6700-CH)
Courtesy of FORD MOTOR CO.	Spreader Bar	303-D089 (D93P-6001-A3) or equivalent
Courtesy of FORD MOTOR CO.	Timing Peg, Crankshaft TDC	303-507

Vehicles equipped with a manual transaxle 

WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow this instruction may result in serious personal injury.
CAUTION: Loosen the bolts evenly to prevent pressure plate damage.
1. Remove the 7 bolts, clutch pressure plate and clutch disc.
Fig 1: Locating Clutch Pressure Plate Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

2. Install the Flywheel Holding Tool and remove the flywheel or flexplate.
Fig 2: Identifying Special Tool (303--103)
Courtesy of FORD MOTOR CO.
3. Mount the engine on a suitable engine stand.
4. Loosen the bolt and remove the accessory drivebelt idler pulley.
Fig 3: Locating Accessory Drivebelt Idler Pulley And Bolt
Courtesy of FORD MOTOR CO.
5. Remove the 3 bolts and the coolant pump pulley.
Fig 4: Locating Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
6. Remove the 3 bolts and the coolant pump.
Fig 5: Locating Coolant Pump Bolts
Courtesy of FORD MOTOR CO.
7. Disconnect the heater hose and lower radiator hose from the thermostat housing.
Fig 6: Identifying Radiator Hose And Lower Radiator Hose
Courtesy of FORD MOTOR CO.
8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
Fig 7: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
9. Remove the 4 bolts and the oil filter adapter.
   • Discard the gasket.
Fig 8: Locating Oil Filter Adapter And Bolts
Courtesy of FORD MOTOR CO.
10. Disconnect the 4 coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.
Fig 9: Identifying Coil-On-Plug And Camshaft Position (CMP) Connectors
Courtesy of FORD MOTOR CO.
11. Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
Fig 10: Locating Cylinder Head Temperature Sensor Electrical Connector And Rubber Boot
Courtesy of FORD MOTOR CO.
12. Disconnect the 4 fuel injector electrical connectors and detach the wiring harness retainers from valve cover stud bolts and intake manifold.
Fig 11: Identifying Fuel Injector Connectors
Courtesy of FORD MOTOR CO.
13. Remove the 2 bolts and the fuel rail with the fuel injectors.
Fig 12: Identifying Bolts
Courtesy of FORD MOTOR CO.
14. Disconnect the Knock Sensor (KS) electrical connector and pin-type retainer.
Fig 13: Locating Knock Sensor Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.
15. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
Fig 14: Locating Manifold Actual Pressure (MAP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
16. If equipped, disconnect the swirl control valve solenoid electrical connector.
Fig 15: Locating Swirl Control Valve Electrical Connector
Courtesy of FORD MOTOR CO.
17. Disconnect the EGR valve electrical connector and if equipped, disconnect the swirl control valve sensor electrical connector.
Fig 16: Identifying EGR Valve Connector And Control Valve Sensor Connector
Courtesy of FORD MOTOR CO.
18. Remove the bolt and the oil level indicator tube.
    • Discard the O-ring seal.
Fig 17: Identifying Bolt And Indicator Tube
Courtesy of FORD MOTOR CO.
19. Remove the lower intake manifold bolt.
Fig 18: Locating Lower Intake Manifold Bolt
Courtesy of FORD MOTOR CO.
NOTE: The 2 intake manifold bolts differ in length from rest of the bolts and also retain a crash bracket to the intake manifold. The 2 bolts are equipped with an attachment feature that allows them to be loosened but remain attached to the intake manifold. Do not attempt to remove the 2 bolts or the crash bracket from the intake manifold.
20. Loosen the 2 intake manifold bolts.
Fig 19: Identifying Bolts
Courtesy of FORD MOTOR CO.
21. Remove the 5 intake manifold bolts.
Fig 20: Identifying Bolts
Courtesy of FORD MOTOR CO.
22. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.
    • Remove the intake manifold.
Fig 21: Identifying PVC Hose Connector Tabs
Courtesy of FORD MOTOR CO.
23. Remove the EGR tube.
Fig 22: Locating Exhaust Gas Recirculation (EGR) Tube
Courtesy of FORD MOTOR CO.
24. Remove the radio interference capacitor bracket bolt and position the bracket aside.
Fig 23: Identifying Radio Interference Capacitor Bracket Bolt
Courtesy of FORD MOTOR CO.
25. Disconnect the EGR valve coolant hose.
Fig 24: Locating Coolant Hose
Courtesy of FORD MOTOR CO.
26. Disconnect the coolant bypass hose.
Fig 25: Locating Coolant Bypass Hose
Courtesy of FORD MOTOR CO.
27. Remove the 4 bolts and the coolant outlet.
Fig 26: Locating Coolant Bypass And Bolts
Courtesy of FORD MOTOR CO.
28. Disconnect the coolant bypass hose.
Fig 27: Locating Coolant Bypass Hose
Courtesy of FORD MOTOR CO.
29. Remove the 3 bolts, thermostat housing and thermostat.
Fig 28: Identifying Bolts, Thermostat Housing And Thermostat
Courtesy of FORD MOTOR CO.
30. Remove the 2 bolts, stud bolt and the A/C compressor.
Fig 29: Identifying Bolts, Stud Bolt And A/C Compressor
Courtesy of FORD MOTOR CO.
31. Remove the bolt and the KS.
Fig 30: Locating Knock Sensor Bolt
Courtesy of FORD MOTOR CO.
32. Remove the 8 bolts and the crankcase vent oil separator.
Fig 31: Identifying Bolts And Crankcase Vent Oil Separator
Courtesy of FORD MOTOR CO.
33. If equipped, remove the engine block heater.
Fig 32: Locating Block Heater
Courtesy of FORD MOTOR CO.
34. Remove the 4 bolts and the ignition coil-on-plugs.
Fig 33: Identifying Bolts
Courtesy of FORD MOTOR CO.
CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
35. Remove the spark plugs and the CHT sensor.
Fig 34: Locating Cylinder Head Temperature (CHT) Sensor & Spark Plugs
Courtesy of FORD MOTOR CO.
36. Remove the bolts and the valve cover.
Fig 35: Locating Valve Cover Bolts
Courtesy of FORD MOTOR CO.
CAUTION: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
37. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
    • The hole in the crankshaft pulley should be in the 6 o'clock position.
Fig 36: Identifying Hole In Crankshaft Pulley In 6 O'Clock Position
Courtesy of FORD MOTOR CO.
CAUTION: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
38. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
Fig 37: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
39. Remove the engine plug bolt.
Fig 38: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.
NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during disassembly.
Fig 39: Identifying Special Tool (303-507)
Courtesy of FORD MOTOR CO.
41. Assemble the Drive Pinion Flange Holding Fixture and Adapter using 4 hardened washers in the locations shown.
Fig 40: Assembling Special Tools (205-126 And 205-072-02) And Hardened Washers
Courtesy of FORD MOTOR CO.
CAUTION: The crankshaft must remain in the Top Dead Center (TDC) position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Drive Pinion Flange Holding Fixture and Adapter and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
CAUTION: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced, remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur.
42. Using the Drive Pinion Flange Holding Fixture and Adapter and an air impact wrench, remove the crankshaft pulley.
    • Remove and discard the crankshaft pulley bolt and washer.
    • Remove the crankshaft pulley.
    • Remove the diamond washer and discard.
Fig 41: Using Special Tools (205-126 And 205-072-02)
Courtesy of FORD MOTOR CO.
CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.
43. Using the Oil Seal Remover, remove the crankshaft front seal.
Fig 42: Identifying Special Tool (303-409) And Crankshaft Front Oil Seal
Courtesy of FORD MOTOR CO.
44. Remove the 2 bolts and the CKP sensor.
Fig 43: Locating CKP Sensor
Courtesy of FORD MOTOR CO.
45. Remove the 22 bolts and the engine front cover.
Fig 44: Locating Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
46. Remove the timing chain tensioner.
    1. Compress the timing chain tensioner, and insert a paper clip into the hole to retain the tensioner.
    2. Remove the 2 bolts and timing chain tensioner.
Fig 45: Locating Timing Chain Tensioner Bolt
Courtesy of FORD MOTOR CO.
47. Remove the RH timing chain guide.
Fig 46: Locating RH Timing Chain Guide
Courtesy of FORD MOTOR CO.
48. Remove the timing chain.
Fig 47: View Of Timing Chain
Courtesy of FORD MOTOR CO.
49. Remove the 2 bolts and the LH timing chain guide.
Fig 48: Identifying Bolts And LH Timing Chain Guide
Courtesy of FORD MOTOR CO.
CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
50. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
Fig 49: Locating Cam Holding Area And Sprocket Bolt
Courtesy of FORD MOTOR CO.
51. Remove the oil pump drive chain tensioner.
    1. Release the tension on the tensioner spring.
    2. Remove the tensioner and the 2 shoulder bolts.
Fig 50: Locating Shoulder Bolts & Tensioner
Courtesy of FORD MOTOR CO.
NOTE: Remove and discard the crankshaft sprocket diamond washer located behind the crankshaft sprocket.
NOTE: The oil pump chain sprocket must be held in place.
52. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain and sprockets.
Fig 51: Identifying Chain & Sprockets
Courtesy of FORD MOTOR CO.
53. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
Fig 52: Locating Camshaft Lobe
Courtesy of FORD MOTOR CO.
CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
NOTE: Mark the location and orientation of each camshaft bearing cap.
54. Remove the camshafts from the engine.
    • Loosen the camshaft bearing bolts in the sequence shown, one turn at a time. Repeat until all the tension is released.
    • Remove the camshaft bearing caps.
    • Remove the camshafts.
Fig 53: Identifying Loosening/Tightening Sequence Of Camshaft Bearing Bolts
Courtesy of FORD MOTOR CO.
NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.
55. Remove the valve tappets.
NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
56. Inspect the valve tappets. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
57. Remove the cylinder head.
    • Remove and discard the 10 cylinder head bolts.
    • Remove the cylinder head.
    • Remove and discard the cylinder head gasket.
Fig 54: Locating Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
58. Remove the cylinder head alignment dowels.
Fig 55: Identifying Cylinder Head Alignment Dowels
Courtesy of FORD MOTOR CO.
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.
59. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
    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 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.
60. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.
61. Remove the 13 bolts and the oil pan.
Fig 56: Locating Oil Pan Bolts
Courtesy of FORD MOTOR CO.
62. Remove the 6 bolts and the crankshaft rear seal with retainer plate.
Fig 57: Locating Rear Crankshaft Seal Bolts
Courtesy of FORD MOTOR CO.
63. Remove the 2 bolts, oil pump pickup tube and gasket.
    • Discard the gasket.
Fig 58: Locating Oil Pump Pickup Tube Bolts
Courtesy of FORD MOTOR CO.
64. Remove the 4 bolts and the oil pump.
    Fig 59: Locating Oil Pump Assembly & Bolts

    Courtesy of FORD MOTOR CO.
65. Remove the Crankshaft TDC Timing Peg.

    Courtesy of FORD MOTOR CO.

66. 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 manufacturer's instructions.
NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
67. Remove the connecting rod cap bolts and cap.

    Courtesy of FORD MOTOR CO.

NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
68. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
    • Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.

    Courtesy of FORD MOTOR CO.

69. Remove the bolts in the sequence shown.
    • Remove the main bearing beam.
    • Discard the bolts.

    Courtesy of FORD MOTOR CO.

70. Remove the crankshaft from the engine block.

    Courtesy of FORD MOTOR CO.

NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
71. Remove the main bearings from the main bearing beam.

    Courtesy of FORD MOTOR CO.

NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
NOTE: The center bulkhead has the thrust bearing.
72. Remove the main bearings from the cylinder block.

    Courtesy of FORD MOTOR CO.

NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly.
NOTE: The front bulkhead does not have an oil squirter.
73. Remove the 4 oil squirters.

    Courtesy of FORD MOTOR CO.

74. Inspect the cylinder block, main bearing beam, pistons and connecting rods.