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Section 249 (Engine - 4.6L & 5.4L): Disassembly: Engine: Disassembly

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The crankshaft rear oil seal, the oil seal slinger and the oil seal retainer plate must be removed before mounting the engine on the engine stand.

    ALL ENGINES 

    NOTE: 5.4L engine shown, 4.6L engine similar.
    Fig 1: Removing Flexplate Bolts
    G01536711Courtesy of FORD MOTOR CO.
  1. Remove the bolts and the flexplate.
  2. Using the special tools, remove the crankshaft rear oil slinger.
    Fig 2: Removing Crankshaft Rear Oil Slinger
    G01536712Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove the crankshaft rear oil seal.
    Fig 3: Removing Crankshaft Rear Oil Seal
    G01536713Courtesy of FORD MOTOR CO.
  4. Remove the bolts, the oil pan and the oil pan gasket.
    • Clean and inspect the sealing surfaces.
    Fig 4: Inspecting Sealing Surfaces
    G01536714Courtesy of FORD MOTOR CO.
  5. Remove the bolts and the crankshaft rear oil seal retainer plate.
    • Clean and inspect the sealing surfaces.
    Fig 5: Cleaning Sealing Surfaces
    G01536715Courtesy of FORD MOTOR CO.
    6. CAUTION: Use care when lowering the engine, to prevent damage to the oil pump screen and pickup tube.
  6. Lower the engine onto wooden blocks.
  7. Remove the special tool.
    Fig 6: Removing Special Tool
    G01536716Courtesy of FORD MOTOR CO.
  8. Install the special tool.
    Fig 7: Installing Special Tool
    G01536717Courtesy of FORD MOTOR CO.
    9. NOTE: The oil level indicator and tube are removed for clarity.
    Fig 8: Installing Special Tool
    G01536718Courtesy of FORD MOTOR CO.
  9. Install the special tool.
  10. Mount the engine on a suitable work stand.
  11. Remove the special tool.
    Fig 9: Removing Special Tool
    G01536719Courtesy of FORD MOTOR CO.
    12. NOTE: The oil level indicator and tube are removed for clarity.
    Fig 10: Removing Special Tool
    G01536720Courtesy of FORD MOTOR CO.
  12. Remove the special tool.
  13. With the engine on the engine stand, remove the engine control sensor wiring.
    14. NOTE: Typical RH shown, LH similar.
    Fig 11: Removing Two Radio Interference Capacitors
    G01536721Courtesy of FORD MOTOR CO.
  14. Remove the nuts and the two radio interference capacitors.
  15. Remove the bolts and the oil pump screen and pickup tube.
    Fig 12: Removing Oil Pump Screen
    G01536722Courtesy of FORD MOTOR CO.
  16. Remove the oil pump screen and pickup tube spacer.
    Fig 13: Removing Oil Pump Screen And Pickup Tube Spacer
    G01536723Courtesy of FORD MOTOR CO.
  17. Remove the crankcase ventilation tube from the LH valve cover.
    Fig 14: Removing Crankcase Ventilation Tube From LH Valve Cover
    G01536724Courtesy of FORD MOTOR CO.
    18. 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.
    Fig 15: Removing LH Valve Cover
    G01536725Courtesy of FORD MOTOR CO.
  18. Remove the LH valve cover.
    • Fully loosen the bolts and remove the valve cover.
    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
    19. NOTE: On 4.6L engines, it is necessary to twist the positive crankcase ventilation (PCV) valve approximately 180 degrees to remove it.
    Fig 16: Removing PCV Valve And Hose From RH Valve Cover
    G01536726Courtesy of FORD MOTOR CO.
  19. Remove the PCV valve and hose from the RH valve cover.
    20. 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.
    NOTE: Windsor engine shown; Romeo engine similar.
    Fig 17: Removing RH Valve Cover
    G01536727Courtesy of FORD MOTOR CO.
  20. Remove the RH valve cover.
    • Fully loosen the bolts and remove the valve cover.
    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
  21. Remove the bolt and the belt idler pulley.
    Fig 18: Removing Belt Idler Pulley
    G01536728Courtesy of FORD MOTOR CO.
  22. Remove the coolant pump pulley.
    1. Remove the bolts.
    2. Remove the coolant pump pulley.
    Fig 19: Removing Coolant Pump Pulley
    G01536729Courtesy of FORD MOTOR CO.
  23. Remove the bolts.
    Fig 20: Removing Bolts
    G01536730Courtesy of FORD MOTOR CO.
  24. Remove the coolant pump from the cylinder block.
    Fig 21: Removing Coolant Pump From Cylinder Block
    G01536731Courtesy of FORD MOTOR CO.
  25. Remove and discard the crankshaft pulley bolt.

    Use the special tool to remove the crankshaft pulley.

    Fig 22: Removing Crankshaft Pulley
    G01536732Courtesy of FORD MOTOR CO.
  26. Use the special tool to remove the crankshaft front seal.
    Fig 23: Removing Crankshaft Front Seal
    G01536733Courtesy of FORD MOTOR CO.
  27. Remove the power steering pump.
    Fig 24: Removing Power Steering Pump
    G01536734Courtesy of FORD MOTOR CO.
    28. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 25: Removing Fasteners
    G01536735Courtesy of FORD MOTOR CO.
  28. Remove the fasteners.
  29. Remove the engine front cover from the cylinder block.
    Fig 26: Removing Engine Front Cover From Cylinder Block
    G01536736Courtesy of FORD MOTOR CO.
  30. Remove the crankshaft sensor ring from the crankshaft.
    Fig 27: Removing Crankshaft Sensor Ring From Crankshaft
    G01536737Courtesy of FORD MOTOR CO.
  31. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 28: Installing Special Tool Between Valve Spring Coils
    G01536738Courtesy of FORD MOTOR CO.
    32. NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.
    Fig 29: Compressing Valve Springs
    G01536739Courtesy of FORD MOTOR CO.
  32. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
  33. Remove the special tool.
    Fig 30: Removing Special Tool
    G01536740Courtesy of FORD MOTOR CO.
  34. Position the crankshaft with the keyway at the 12 o'clock position.
    Fig 31: Positioning Crankshaft With Keyway
    G01536741Courtesy of FORD MOTOR CO.
  35. 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 32: Removing Timing Chain Tensioner Arms
    G01536742Courtesy of FORD MOTOR CO.
  36. Remove the LH and RH timing chains and the crankshaft sprocket.
    • Remove the Crankshaft Holding Tool.
    • 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 and crankshaft sprocket.
    Fig 33: Removing LH Timing Chain
    G01536743Courtesy of FORD MOTOR CO.
  37. Remove both timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
    Fig 34: Removing Timing Chain Guides
    G01536744Courtesy of FORD MOTOR CO.
  38. Remove the RH exhaust manifold.
    1. Remove the nuts.
    2. Remove the RH exhaust manifold.
    3. Remove the RH exhaust manifold gasket.
    Fig 35: Removing RH Exhaust Manifold
    G01536745Courtesy of FORD MOTOR CO.
  39. Remove the LH exhaust manifold.
    1. Remove the nuts.
    2. Remove the LH exhaust manifold.
    3. Remove the LH exhaust manifold gasket.
    Fig 36: Removing LH Exhaust Manifold
    G01536746Courtesy of FORD MOTOR CO.
  40. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  41. Remove the bolt and the oil level indicator tube.
    Fig 37: Removing Oil Level Indicator Tube
    G01536747Courtesy of FORD MOTOR CO.
  42. Install the special tools on both ends of the cylinder head.
    Fig 38: Installing Special Tools On Both Ends Of Cylinder Head
    G01536748Courtesy of FORD MOTOR CO.
    43. CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
    CAUTION: Place cylinder head on a cardboard or wood surface to prevent damage to the joint face.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    NOTE: The cylinder heads are cleaned as part of the cylinder head disassembly process.
    Fig 39: Identifying Cylinder Heads Bolts
    G01536749Courtesy of FORD MOTOR CO.
  43. Remove the bolts and discard.
    • RH is shown; LH is similar.
    • Remove the cylinder heads.
    44. 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 scraper to remove all traces of the head gasket.
  44. Discard the cylinder head gaskets. Clean the engine block sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  45. If required, remove the bolts, and remove the LH engine mount.
    Fig 40: Removing LH Engine Mount
    G01536750Courtesy of FORD MOTOR CO.
  46. If required, remove the bolts, and remove the RH engine mount.
    Fig 41: Removing RH Engine Mount
    G01536751Courtesy of FORD MOTOR CO.
    47. NOTE: 5.4L is shown; 4.6L is similar.
    Fig 42: Removing Mounting Hardware
    G01536752Courtesy of FORD MOTOR CO.
  47. If required, remove the mounting hardware, the oil filter adapter and the oil filter adapter gasket.
  48. Clean the oil filter adapter gasket surface at the cylinder block.
    Fig 43: Cleaning Oil Filter Adapter Gasket Surface
    G01536753Courtesy of FORD MOTOR CO.
  49. Remove the oil pump.
    1. Remove the bolts.
    2. Remove the oil pump.
    Fig 44: Removing Oil Pump
    G01536754Courtesy of FORD MOTOR CO.
  50. 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 45: Removing Ridge Or Carbon Deposits From Cylinder
    G01536755Courtesy of FORD MOTOR CO.
    51. CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods (6200) and rod caps for correct orientation.
    Fig 46: Removing Connecting Rod Cap Bolts
    G01536756Courtesy of FORD MOTOR CO.
  51. Remove the bolts and the connecting rod cap. Discard the bolts.
    52. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 47: Removing Piston With Special Tool
    G01536757Courtesy of FORD MOTOR CO.
  52. Use the special tool to push the piston through the top of the cylinder block.

    53. ROMEO ENGINES (4.6L) 

  53. 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.
    Fig 48: Removing Main Cap Bolts (Romeo Engines 4.6L)
    G01536758Courtesy of FORD MOTOR CO.

    54. WINDSOR ENGINES (5.4L) 

  54. Remove the fasteners.
    1. Remove and discard the cross-mounted main cap bolts.
    2. Remove the dowels.
    3. Remove and discard the main bearing cap bolts.
    Fig 49: Removing Main Bearing Cap Bolts (Windsor Engines 5.4L)
    G01536759Courtesy of FORD MOTOR CO.

    55. ALL ENGINES 

  55. Remove the five main bearing caps and the lower crankshaft main bearings.
    Fig 50: Removing Main Bearing Caps And Lower Crankshaft Main Bearings
    G01536760Courtesy of FORD MOTOR CO.
  56. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.
    Fig 51: Removing Crankshaft And Upper Crankshaft Main Bearings
    G01536761Courtesy of FORD MOTOR CO.
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