Section 170 (Engine - 4.6L): Disassembly: Engine: Disassembly

WARNING: This page is about a different car, the 2003 Lincoln Town Car. However, it is still accessible from the selected car via links, so may be relevant.

Remove the bolts and the flexplate.

Fig 1: Locating Flexplate Bolts
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Remove the eight bolts and the crankcase rear oil seal retainer.

Fig 2: Locating Rear Oil Seal Retainer Bolts
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Install the engine on a suitable engine stand.
Remove the special tool.

Fig 3: Remove Right Engine Lifting Bracket
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Remove the special tool.

Fig 4: Remove Left Engine Lifting Bracket
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Remove the oil filter.
Disconnect the exhaust gas recirculation (EGR) system module tube from the exhaust manifold connector.

Fig 5: Locating EGR System Module Tube Nut
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Disconnect the eight ignition coil electrical connectors.

Fig 6: Locating Ignition Coil Electrical Connectors
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Disconnect the eight fuel injector electrical connectors.

Fig 7: Locating Fuel Injector Connector Electrical Connectors
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Remove the bolts and the EGR system module tube heat shield.

Fig 8: Locating EGR System Module Tube Heat Shield Bolts
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Disconnect the vacuum hoses and the electrical connector.

Fig 9: Locating Vacuum Hoses & Electrical Connector
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Disconnect and remove the crankcase ventilation tube.

Fig 10: Locating Crankcase Ventilation Tube
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Disconnect the idle air control (IAC) and the throttle position (TP) sensor electrical connectors.

Fig 11: Locating IAC & TP Sensor Electrical Connectors
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Disconnect the generator electrical connector.

Fig 12: Locating Generator Connector
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Disconnect the fuel charging wiring from the crash bracket and remove the harness from the engine assembly.

Fig 13: Locating Wiring Harness Retainer
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Disconnect the EGR system module tube nut from the EGR system module.

Fig 14: Locating EGR System Module Tube Nut
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Remove the generator.
1. Remove the bolts.
2. Remove the generator.
Fig 15: Removing Generator
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Remove the four bolts and the throttle body.

Fig 16: Locating Throttle Body Bolts
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Remove the bolt, the stud, and the crash bracket.

Fig 17: Locating Crash Bracket Bolt & Stud
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Remove the four studs, and the fuel injection supply manifold and fuel injectors as an assembly.

Fig 18: Locating Fuel Injection Supply Manifold Studs
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Remove the eight bolts and the eight ignition coils.

Fig 19: Locating Ignition Coil Bolts
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Remove the bolts and the water outlet adapter.

Fig 20: Locating Water Outlet Adapter Bolts
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Remove the water thermostat.

Fig 21: Locating Water Thermostat
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Remove the bolts and the intake manifold.

Fig 22: Locating Intake Manifold Bolts
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Remove the intake manifold gaskets.

Fig 23: Locating Intake Manifold Gaskets
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Clean the sealing surfaces.

Fig 24: Locating Sealing Surfaces
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Remove the bolts and the oil pan and gasket.

Fig 25: Removing Oil Pan & Gasket
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Remove the bolts and the oil pump screen cover and tube.

Fig 26: Removing Oil Pump Screen & Tube
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Remove the oil pump screen cover and tube spacer.

Fig 27: Removing Oil Pump Screen & Tube Spacer
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Remove the studs, the bolts, and the valve cover.
- Discard the valve cover gasket and clean the mating surface of the cylinder head.
Fig 28: Locating Left Valve Cover
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Remove the studs, the bolts, and the right valve cover.
- Discard the valve cover gasket and clean the mating surface of the cylinder head.
Fig 29: Locating Right Valve Cover
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Remove the bolt and the belt idler pulley.

Fig 30: Locating Belt Idler Pulley Bolt
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Remove the bolts and the water pump pulley.

Fig 31: Locating Water Pump Pulley Bolts
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Remove the bolts and the water pump.

Fig 32: Locating Water Pump Bolts
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Remove the crankshaft pulley bolt.
Use the special tool to remove the crankshaft pulley.

Fig 33: Removing Crankshaft Pulley
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Use the special tool to remove the crankshaft front seal.

Fig 34: Removing Crankshaft Front Seal
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NOTE: Correct fastener location is essential for the assembly procedure. Record fastener location.

Fig 35: Engine Front Cover Fastener Removal Sequence

Courtesy of FORD MOTOR CO.

Remove the fasteners in the sequence shown.
Remove the engine front cover from the cylinder block.

Fig 36: Removing Engine Front Cover
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Remove the crankshaft sensor ring from the crankshaft.

Fig 37: Locating Crankshaft Sensor Ring
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Rotate the crankshaft until the timing mark on the RH camshaft sprocket is approximately at the 11 o'clock position and the timing mark on the LH camshaft sprocket is approximately at the 12 o'clock position.

Fig 38: Locating Timing Chain Timing Marks
Courtesy of FORD MOTOR CO.

CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.

Fig 39: Locating Crankshaft Correct Position

Courtesy of FORD MOTOR CO.

Install the special tool to check the correct positioning of the camshaft sprockets.
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 40: Removing Timing Chain Tensioning System
Courtesy of FORD MOTOR CO.

CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinders heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.

Fig 41: Removing Timing Chains

Courtesy of FORD MOTOR CO.

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.
- Repeat for the LH timing chain and crankshaft sprocket.
Remove both timing chain guides.
1. Remove the bolts.
2. Remove the LH timing chain guide.
3. Remove the bolts.
4. Remove the RH timing chain guide.
Fig 42: Removing Timing Chain Guides
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Remove the RH exhaust manifold.
1. Remove the nuts.
2. Remove the RH exhaust manifold.
3. Remove the RH exhaust manifold gasket.
Fig 43: Removing Right Exhaust Manifold
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Remove the LH exhaust manifold.
1. Remove the nuts.
2. Remove the LH exhaust manifold.
3. Remove the LH exhaust manifold gaskets.
Fig 44: Removing Left Exhaust Manifold
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Remove the bolt and the oil level indicator tube.

Fig 45: Locating Oil Level Tube Indicator Tube Nut
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CAUTION: New cylinder head bolts must be installed. They are tighten-to-yield designed and cannot be reused.

CAUTION: Place the cylinder head on a cardboard or wood surface to prevent damage to the joint face.

Fig 46: Locating Cylinder Head Bolts

Courtesy of FORD MOTOR CO.

Remove and discard the bolts. Remove the cylinder head.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the gasket material.

Discard the head gasket and clean the engine block surface.
Remove the bolts and the LH engine mount.

Fig 47: Locating Left Engine Mount Bolts
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Remove the bolts and the RH engine mount.

Fig 48: Locating Right Engine Mount Bolts
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Remove the bolts and the oil filter adapter and oil gasket.

Fig 49: Locating Oil Filter Adapter Bolts
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Remove the oil pump.
1. Remove the bolts.
2. Remove the oil pump.
Fig 50: Removing Oil Pump
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CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for proper orientation.

Fig 51: Locating Connecting Rod Bolts

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Remove the bolts and the connecting rod cap. Discard the bolts.

CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.

Fig 52: Removing Pistons

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Use the Connecting Rod Installer (303-442) to push the piston through the top of the cylinder block.
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 53: Removing Crankshaft Bearing Cap Bolts
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Remove the five main bearing caps and the lower crankshaft main bearings.

Fig 54: Removing Main Bearing Caps
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Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.

Fig 55: Removing Crankshaft
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