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Section 2 (Engine - 4.6): Disassembly: Engine: Material

WARNING: This page is about a different variant/trim than selected.
MATERIAL SPECIFICATION

Item Specification
Motorcraft Silicone Gasket Remover
ZC-30		 -
Motorcraft Metal Surface Prep
ZC-31		 -
    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.
  1. Remove the engine. Refer to ENGINE .
  2. Remove the bolts and the flexplate or the flywheel.
    Fig 1: Removing Bolts And Flexplate Or Flywheel
    G03401517Courtesy of FORD MOTOR CO.
  3. Remove the separator plate.
    Fig 2: Removing Separator Plate
    G03401518Courtesy of FORD MOTOR CO.
  4. Using the special tools, remove the crankshaft rear oil slinger.
    Fig 3: Removing Crankshaft Rear Oil Slinger
    G03401519Courtesy of FORD MOTOR CO.
  5. Using the special tools, remove the rear main seal.
    Fig 4: Removing Rear Main Seal Using Special Tools
    G03401520Courtesy of FORD MOTOR CO.
  6. Remove the rear seal retainer plate.
    Fig 5: Removing Rear Seal Retainer Plate
    G03401521Courtesy of FORD MOTOR CO.
  7. Mount the engine on a suitable engine stand.
    Fig 6: Mounting Engine On A Suitable Engine Stand
    G03401522Courtesy of FORD MOTOR CO.
    8. NOTE: RH shown, LH similar.
    Fig 7: Removing RH And LH Lifting Eyes
    G03401523Courtesy of FORD MOTOR CO.
  8. Remove the RH and LH lifting eyes.
  9. Remove the breather tube.
    Fig 8: Removing Breather Tube
    G03401524Courtesy of FORD MOTOR CO.
  10. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) electrical connector.
    Fig 9: Disconnecting Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Electrical Connector
    G03401525Courtesy of FORD MOTOR CO.
  11. Disconnect the hoses from the differential pressure feedback EGR transducer.
    Fig 10: Disconnecting Hoses From Differential Pressure Feedback EGR Transducer
    G03401526Courtesy of FORD MOTOR CO.
  12. Remove the EGR vacuum regulator solenoid.
    1. Remove the vacuum hoses.
    2. Remove the electrical connector.
    3. Remove the bolts.
      Fig 11: Removing EGR Vacuum Regulator Solenoid
      G03401527Courtesy of FORD MOTOR CO.
  13. Disconnect the EGR tube from the EGR valve.
    Fig 12: Disconnecting EGR Tube From EGR Valve
    G03401528Courtesy of FORD MOTOR CO.
  14. Disconnect the positive crankcase ventilation (PCV) hose from the base of the throttle body.
    Fig 13: Disconnecting Positive Crankcase Ventilation (PCV) Hose From Base Of Throttle Body
    G03401529Courtesy of FORD MOTOR CO.
  15. Remove the PCV valve and hose as an assembly.
    Fig 14: Removing PCV Valve And Hose
    G03401530Courtesy of FORD MOTOR CO.
  16. Remove the engine wiring harness.
    Fig 15: Removing Engine Wiring Harness
    G03401531Courtesy of FORD MOTOR CO.
  17. Disconnect the vacuum line from the fuel pressure sensor.
    Fig 16: Disconnecting Vacuum Line From Fuel Pressure Sensor
    G03401532Courtesy of FORD MOTOR CO.
  18. Remove the throttle body bolts.
    Fig 17: Removing Throttle Body Bolts
    G03401533Courtesy of FORD MOTOR CO.
    19. NOTE: The gasket is reusable if not damaged.
  19. Remove the throttle body and adapter as an assembly.
    • Inspect and clean the sealing surfaces.
      Fig 18: Removing The Throttle Body And Adapter
      G03401534Courtesy of FORD MOTOR CO.
  20. Remove the ignition coils.
    Fig 19: Removing Ignition Coils
    G03401535Courtesy of FORD MOTOR CO.
  21. Remove the radio interference capacitors.
    Fig 20: Removing Radio Interference Capacitors
    G03401536Courtesy of FORD MOTOR CO.
  22. Rotate the belt tensioner and remove the accessory drive belt.
    Fig 21: Removing Accessory Drive Belt
    G03401537Courtesy of FORD MOTOR CO.
  23. Remove the power steering reservoir bracket as an assembly.
    1. Disconnect the supply line from the pump.
    2. Remove the three bolts and reservoir and bracket.
      Fig 22: Removing Power Steering Reservoir Bracket
      G03401538Courtesy of FORD MOTOR CO.
  24. Remove the upper generator support bracket.
    Fig 23: Removing Upper Generator Support Bracket
    G03401539Courtesy of FORD MOTOR CO.
  25. Remove the bolts and the generator.
    Fig 24: Removing Bolts Of Generator
    G03401540Courtesy of FORD MOTOR CO.
  26. Remove the coolant outlet adapter.
    Fig 25: Removing Coolant Outlet Adapter
    G03401541Courtesy of FORD MOTOR CO.
  27. Remove the thermostat and O-ring.
    Fig 26: Removing Thermostat And O-Ring
    G03401542Courtesy of FORD MOTOR CO.
  28. Remove the bolts in the sequence shown, and remove the intake manifold.
    Fig 27: Removing Bolts
    G03401543Courtesy of FORD MOTOR CO.
  29. Remove the intake manifold gaskets.
    Fig 28: Removing Intake Manifold Gaskets
    G03401544Courtesy of FORD MOTOR CO.
    30. 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.
  30. Clean the sealing surfaces.
  31. Remove the coolant bypass tube.
    1. Remove the nut.
    2. Remove the coolant bypass tube.
      Fig 29: Removing Coolant Bypass Tube
      G03401545Courtesy of FORD MOTOR CO.
    32. NOTE: RH shown, LH similar.
    Fig 30: Removing RH And LH Engine Mount
    G03401546Courtesy of FORD MOTOR CO.
  32. Remove the RH and the LH engine mount.
    33. NOTE: LH shown, RH similar.
  33. Using a suitable container, drain coolant from the engine block.
    • Install the drain plugs when finished.
      Fig 31: Installing Drain Plugs When Finished
      G03401547Courtesy of FORD MOTOR CO.
  34. Remove the four bolts and the power steering pump.
    Fig 32: Removing Four Bolts And Power Steering Pump
    G03401548Courtesy of FORD MOTOR CO.
  35. Remove the compressor.
    1. Remove the bolts.
    2. Remove the compressor.
      Fig 33: Removing Compressor
      G03401549Courtesy of FORD MOTOR CO.
  36. 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
      G03401550Courtesy 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 35: Removing Exhaust Manifold Nuts
      G03401551Courtesy of FORD MOTOR CO.
  38. Disconnect the LH cylinder head exhaust recirculation (EGR) tube at the exhaust manifold.
    Fig 36: Disconnecting LH Cylinder Head Exhaust Recirculation (EGR) Tube At Exhaust Manifold
    G03401552Courtesy of FORD MOTOR CO.
  39. 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 37: Removing LH Exhaust Manifold
      G03401553Courtesy of FORD MOTOR CO.
  40. Remove the oil level indicator tube bolt.
    Fig 38: Removing Oil Level Indicator Tube Bolt
    G03401554Courtesy of FORD MOTOR CO.
  41. Remove the bolt and the oil level indicator tube.
    Fig 39: Removing Bolt Of Oil Level Indicator Tube
    G03401555Courtesy of FORD MOTOR CO.
  42. Clean and inspect the exhaust manifolds. Refer to ENGINE SYSTEM-GENERAL INFORMATION .
    43. 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 old sealant.
    NOTE: The bolts are part of the valve cover and should not be removed. RH valve cover shown, LH valve cover similar.
  43. Remove the RH and LH valve covers.
    • Fully loosen the bolts and remove valve covers.
    • Clean the valve cover mating surface of the cylinder heads with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the valve cover gasket(s). If the gasket(s) is damaged, remove and discard the gasket(s). Clean the valve cover gasket groove(s) with soap and water or a suitable solvent.
      Fig 40: Inspecting Valve Cover Gasket(s)
      G03401556Courtesy of FORD MOTOR CO.
    44. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
    NOTE: One spark plug is shown; others are similar.
    Fig 41: Removing Spark Plug
    G03401557Courtesy of FORD MOTOR CO.
  44. Remove the spark plugs.
  45. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 42: Installing Special Tool Between Valve Spring Coils To Prevent Valve Stem Seal Damage
    G03401558Courtesy of FORD MOTOR CO.
    46. NOTE: Rotate the camshaft to see the base circle of the camshaft lobe before removing the followers. Keep roller followers in order when removing.
    Fig 43: Removing The Followers
    G03401559Courtesy of FORD MOTOR CO.
  46. Use the special tool to compress the valve springs and remove the 16 camshaft roller followers. Rotate the camshaft and the crankshaft as necessary.
  47. Remove the crankshaft pulley bolt.
    Fig 44: Removing Crankshaft Pulley Bolt
    G03401560Courtesy of FORD MOTOR CO.
  48. Using the special tool, remove the crankshaft pulley.
    Fig 45: Removing Crankshaft Pulley Using Special Tool
    G03401561Courtesy of FORD MOTOR CO.
  49. Remove the coolant pump pulley.
    1. Remove the coolant pump pulley bolts.
    2. Remove the coolant pump pulley.
      Fig 46: Removing Coolant Pump Pulley
      G03401562Courtesy of FORD MOTOR CO.
  50. Remove the coolant pump bolts.
    Fig 47: Removing Coolant Pump Bolts
    G03401563Courtesy of FORD MOTOR CO.
  51. Remove the bolts and belt idler pulleys.
    Fig 48: Removing Bolts Of Belt Idler Pulleys
    G03401564Courtesy of FORD MOTOR CO.
  52. Using the special tool, remove the front cover seal.
    Fig 49: Removing Front Cover Seal Using Special Tool
    G03401565Courtesy of FORD MOTOR CO.
    53. NOTE: The gasket can be reused if not damaged.
  53. Remove the oil pan.
    • Remove the bolts.
    • Remove the oil pan.
      Fig 50: Removing Oil Pan
      G03401566Courtesy of FORD MOTOR CO.
  54. Remove the bolts, the studs, and the engine front cover.
    • Discard the gaskets. Clean and inspect the sealing surfaces.
      Fig 51: Removing Engine Front Cover Bolts
      G03401567Courtesy 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.
  55. Remove the crankshaft sensor ring from the crankshaft.
    Fig 52: Removing Crankshaft Sensor Ring From Crankshaft
    G03401568Courtesy of FORD MOTOR CO.
  56. Position the crankshaft with the keyway at the 12 o'clock position.
    Fig 53: Positioning Crankshaft With Keyway At 12 O'Clock Position
    G03401569Courtesy of FORD MOTOR CO.
  57. Remove the RH and LH 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 54: Removing Timing Chain Tensioner Arms
      G03401570Courtesy of FORD MOTOR CO.
    58. 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.
  58. 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 55: Removing LH And RH Timing Chains And Crankshaft Sprocket
      G03401571Courtesy of FORD MOTOR CO.
    59. NOTE: The LH is shown and the RH is similar.
    Fig 56: Removing Bolts And Timing Chain Guides
    G03401572Courtesy of FORD MOTOR CO.
  59. Remove the bolts and the timing chain guides.
    60. NOTE: LH shown, RH similar.
    Fig 57: Installing Lifting Handles To RH And LH Cylinder Heads
    G03401573Courtesy of FORD MOTOR CO.
  60. Install the lifting handles to the RH and LH cylinder heads.
    61. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
    Fig 58: Removing Hydraulic Lash Adjusters
    G03401574Courtesy of FORD MOTOR CO.
  61. Remove the hydraulic lash adjusters.
    62. 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: 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.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
  62. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 59: Discarding Cylinder Head Gasket
      G03401575Courtesy of FORD MOTOR CO.
    63. 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: 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.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
  63. Remove the bolts and the LH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 60: Removing Bolts And LH Cylinder Head
      G03401576Courtesy of FORD MOTOR CO.
    64. 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    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.
  64. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head 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 direction, 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.
    65. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
  65. Support the cylinder head 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. They cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
  66. Remove the oil pump screen cover and tube, and the spacer.
    Fig 61: Removing Oil Pump Screen Cover And Tube, And Spacer
    G03401577Courtesy of FORD MOTOR CO.
  67. Remove the oil pump.
    Fig 62: Removing Oil Pump
    G03401578Courtesy of FORD MOTOR CO.
  68. 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 63: Inspecting Top Of Cylinder Bores
    G03401579Courtesy of FORD MOTOR CO.
    69. 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.
  69. Remove the connecting rod caps for piston numbers 1 and 6.
    • Discard the bolts.
      Fig 64: Removing Connecting Rod Caps For Piston Numbers 1 And 6
      G03401580Courtesy of FORD MOTOR CO.
    70. 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 65: Removing Pistons Number 1 And 6 Through Top Of Cylinder Block
    G03401581Courtesy of FORD MOTOR CO.
  70. Remove the piston removing pistons number 1 and 6 through the top of the cylinder block.
  71. 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.
  72. Remove the piston rings.
    Fig 66: Removing Piston Rings
    G03401582Courtesy of FORD MOTOR CO.
  73. Clean and inspect pistons. Refer to ENGINE SYSTEM-GENERAL INFORMATION .
  74. 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 67: Removing Crankshaft Bearing Cap Fasteners
      G03401583Courtesy of FORD MOTOR CO.
  75. Remove the main bearing cap and the crankshaft main bearings from the cylinder block.
    Fig 68: Removing Main Bearing Cap And Crankshaft Main Bearings From Cylinder Block
    G03401584Courtesy of FORD MOTOR CO.
  76. Remove the crankshaft, crankshaft main bearings and the thrust washer.
    Fig 69: Removing Crankshaft, Crankshaft Main Bearings And Thrust Washer
    G03401585Courtesy of FORD MOTOR CO.
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