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Section 362 (Engine - 4.2L): Disassembly: Engine: Disassembly

WARNING: This page is about a different car, the 2003 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the flywheel (6375) and engine rear plate (7007) and mount the engine (6007) on a suitable workstand.
    Fig 1: Removing Flywheel And Engine Rear Plate
    G01535994Courtesy of FORD MOTOR CO.
  2. Remove the A/C support bracket and A/C compressor mounting bracket (2882).
    Fig 2: Removing A/C Support Bracket And A/C Compressor Mounting Bracket
    G01535995Courtesy of FORD MOTOR CO.
  3. Remove the water pump pulley (8509).
    Fig 3: Removing Water Pump Pulley
    G01535996Courtesy of FORD MOTOR CO.
  4. Remove the drive belt idler pulley (8678).
    Fig 4: Removing Drive Belt Idler Pulley
    G01535997Courtesy of FORD MOTOR CO.
  5. Remove the generator mounting bracket (10153).
    Fig 5: Removing Generator Mounting Bracket
    G01535998Courtesy of FORD MOTOR CO.
  6. Remove the engine mounts.
    Fig 6: Removing Engine Mounts
    G01535999Courtesy of FORD MOTOR CO.
  7. Remove the heated oxygen sensors (HO2S) (9F472) (left side shown; right side similar).
    Fig 7: Removing Heated Oxygen Sensors
    G01536000Courtesy of FORD MOTOR CO.
  8. Remove the engine lifting eyes (left side shown; right side similar).
    Fig 8: Removing Engine Lifting Eyes
    G01536001Courtesy of FORD MOTOR CO.
  9. Remove the oil level indicator tube (6754).
    1. Remove the bolt.
    2. Remove the oil level indicator tube.
    3. Remove and discard the oil level indicator tube O-ring seal.
    Fig 9: Removing Oil Level Indicator Tube
    G01536002Courtesy of FORD MOTOR CO.
  10. Remove the exhaust manifolds (9430) (left side shown; right side similar). Discard the gaskets.
    Fig 10: Removing Exhaust Manifolds
    G01536003Courtesy of FORD MOTOR CO.
  11. Remove the valve covers (6582) (left side shown; right side similar).
    Fig 11: Removing Valve Covers
    G01536004Courtesy of FORD MOTOR CO.
    12. NOTE: The location of each rocker arm seat (6A528), rocker arm (6564) and push rod (6565) should be identified. When the engine is assembled, each component should be installed in its original position.
    Fig 12: Removing Rocker Arms, Rocker Arm Seats And Push Rods
    G01536005Courtesy of FORD MOTOR CO.
  12. Remove the rocker arms, rocker arm seats and push rods.
  13. Remove the cylinder heads (6049) and head gaskets (6051) (left side shown; right side similar). Discard the head gaskets and bolts.
    Fig 13: Removing Cylinder Heads And Head Gaskets
    G01536006Courtesy of FORD MOTOR CO.
    14. NOTE: Identify the location of each valve tappet (6500). When the engine is assembled, make sure each valve tappet is installed in its original position.
    Fig 14: Removing Tappet Guide Plates
    G01536007Courtesy of FORD MOTOR CO.
  14. Remove the tappet guide plates and retainers (6K564) and valve tappets.
  15. Remove the heater water outlet tube (18663).
    Fig 15: Removing Heater Water Outlet Tube
    G01536008Courtesy of FORD MOTOR CO.
  16. Remove the camshaft synchronizer (12A362).
    Fig 16: Removing Camshaft Synchronizer
    G01536009Courtesy of FORD MOTOR CO.
  17. Remove the crankshaft pulley bolt.
    Fig 17: Removing Crankshaft Pulley Bolt
    G01536010Courtesy of FORD MOTOR CO.
  18. Using the special tools, remove the crankshaft pulley and damper.
    Fig 18: Removing Crankshaft Pulley And Damper With Special Tools
    G01536011Courtesy of FORD MOTOR CO.
  19. Remove the oil bypass filter (6714) and the engine oil cooler (6A642) (if so equipped).
    Fig 19: Removing Oil Bypass Filter
    G01536012Courtesy of FORD MOTOR CO.
  20. Remove the oil pan (6675) and the oil pan rear seal.
    Fig 20: Removing Oil Pan
    G01536013Courtesy of FORD MOTOR CO.
  21. Remove the oil pump screen cover and tube (6622). Discard the oil pan gasket (6710).
    Fig 21: Removing Oil Pump Screen Cover And Tube
    G01536014Courtesy of FORD MOTOR CO.
  22. Remove the oil pan baffle.
    Fig 22: Removing Oil Pan Baffle
    G01536015Courtesy of FORD MOTOR CO.
  23. Remove the engine front cover (6019). Discard the engine front cover gasket (6020).
    Fig 23: Removing Engine Front Cover
    G01536016Courtesy of FORD MOTOR CO.
  24. Remove the following:
    1. Synchronizer drive gear
    2. Camshaft sprocket (6256)
    3. Crankshaft sprocket (6306)
    4. Timing chain
    5. Engine dynamic balance shaft (6A311)
    Fig 24: Removing Sprocket Assembly
    G01536017Courtesy of FORD MOTOR CO.
  25. Remove the timing chain vibration damper (6284).
    Fig 25: Removing Timing Chain Vibration Damper
    G01536018Courtesy of FORD MOTOR CO.
  26. Remove the engine dynamic balance shaft.
    Fig 26: Removing Engine Dynamic Balance Shaft
    G01536019Courtesy of FORD MOTOR CO.
  27. Remove the camshaft (6250).
    Fig 27: Removing Camshaft
    G01536020Courtesy of FORD MOTOR CO.
    28. NOTE: Ark the location of each piston, connecting rod bearing (6211) and connecting rod cap. When the engine is assembled, each component should be installed in its original position.
    Fig 28: Identifying Connecting Rod Bearing And Connecting Rod Cap
    G01536021Courtesy of FORD MOTOR CO.
  28. Inspect the top of each cylinder bore and, if necessary, remove the ridge or carbon deposits. Remove the positions.
  29. Remove the crankshaft and main bearings. Discard the crankshaft rear oil seal (6701).
    1. Remove the bolts and stud bolts.
    2. Remove the main bearing caps and lower bearings.
    3. Remove the crankshaft assembly.
    4. Remove the upper bearings from the block.
    5. Remove and discard the crankshaft rear oil seal.
    Fig 29: Removing Crankshaft Assembly
    G01536022Courtesy of FORD MOTOR CO.
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