Disassembly

NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.

1. Install engine on Rotunda Engine Stand 164-R3503 or equivalent, following manufacturer's instructions using Rotunda Power Floor Crane 014-00071 or equivalent.
2. Loosen four bolts retaining water pump pulley (8509) to water pump (8501). (Do not remove bolts.)
3. Release front end accessory drive belt tension by rotating drive belt tensioner (6B209) clockwise.
4. Remove drive belt (8620).
5. Disconnect ignition wires from ignition coil (12029) and spark plugs (12405).
6. Release ignition wire separators from valve cover (6582) and remove ignition wires and ignition wire separators (12297) as an assembly.
7. Remove A/C compressor mounting bolts from A/C compressor mounting bracket. Remove A/C compressor (19703).
8. Remove battery feed wire from generator (GEN) (10300).
9. Remove generator from generator mounting bracket.
10. Remove engine lifting eyes from cylinder head (60A9).
11. Remove generator mounting bracket retainers and bracket from cylinder block (6010).
12. Remove EGR valve to exhaust manifold tube (9D477) from EGR valve (9D475) and ignition cold mounting bracket.
13. Remove exhaust manifold retaining nuts, exhaust manifold (9430) and exhaust manifold gasket (9448) from cylinder head.
14. Disconnect vacuum supply hose from fuel pressure regulator vacuum connector.
15. Disconnect fuel injection supply manifold inlet and outlet tubes from retainer located on intake manifold (9424).
16. If necessary, remove fuel injection supply manifold (9D280) from intake manifold.
17. Disconnect fuel charging wiring (9D930) from engine coolant temperature sensor (ECT) (12A648).





18. Remove water thermostat housing to cylinder head retaining bolts and remove water thermostat housing.
19. Remove crankcase ventilation tube (6758) from intake manifold vacuum port and positive crankcase ventilation valve (PCV) (6A666).
20. Remove oil separator retaining bolts, crankcase vent oil separator (6A785) and oil separator to cylinder block gasket (6B752) from cylinder block.
21. If necessary, remove EGR valve retainers, EGR valve and EGR valve gasket (9D476).
22. Disconnect fuel charging wiring from throttle position sensor (TP) (9B989).
23. If necessary, remove throttle body retaining bolts throttle body (9E926) and gasket from intake manifold.
24. Disconnect fuel charging wiring from idle air control valve (IAC valve) (9F715) and camshaft position sensor (CMP) (6B288).
25. If necessary, remove idle air control valve retainer bolts, idle air control valve and gasket from intake manifold.
26. If required, remove fuel charging wiring from intake manifold.
27. Remove intake manifold retaining nuts, bolts and stud bolts in a standard-type removal sequence. Remove intake manifold and intake manifold gasket (9439) from cylinder head.
28. Loosen water pump to lower radiator hose spring clamp. Remove lower radiator hose from water pump.
29. Remove ignition cold bracket retainer bolts. Remove radio ignition interference capacitor (18801), ignition coil and ignition coil mounting bracket from cylinder head.
30. Remove power steering pump mounting bracket and support bracket from cylinder block and cylinder head.
31. Remove upper camshaft timing belt cover retaining bolts and upper camshaft timing belt cover.
32. Loosen valve cover retainer bolts in a standard-type removal sequence. Remove valve cover from cylinder head.
33. Remove spark plugs from cylinder heads.
34. Remove water pump pulley retaining bolts and water pump pulley from water pump.





35. Rotate crankshaft of top dead center (TDC) No.1 cylinder. This will position all pistons below top of cylinder block deck face.
36. Remove crankshaft pulley retainer bolt from crankshaft (6303).
37. Remove crankshaft pulley (6312) from crankshaft.
38. If necessary, remove retaining bolts and remove camshaft position sensor and crankshaft position sensor (CKP) (6C315).
39. Remove oil bypass filter (6714).
40. Remove oil pressure sensor (9278) from cylinder block.
41. Remove oil pan drain plug and drain engine oil. Reinstall oil pan drain plug. Tighten to 21-28 Nm (15-21 ft. lbs.).

CAUTION: To prevent residue in bottom of oil pan (6675) from entering engine, remove oil pan prior to turning engine upside down on engine stand.

42. In a standard-type removal sequence, remove oil pan retaining bolts.
43. Remove oil pan and oil pan gasket (6710) from cylinder block.
44. Remove center and lower camshaft timing belt covers from front of engine.
45. Loosen camshaft timing belt tensioner pulley retaining bolt and move camshaft timing belt tensioner pulley away from camshaft timing belt.
46. Mark direction of rotation of camshaft timing belt and remove camshaft timing belt.





47. Remove camshaft sprockets (6256) from camshafts (6250) by removing retaining bolt while holding the camshaft sprocket in position with Camshaft Sprocket Holding Tool T74P-6256-B.

CAUTION: Cylinder head camshaft journal caps and cylinder head should be numbered to ensure that they are assembled in their original positions. If removed, keep camshaft journal caps and cylinder head together. Do not mix with camshaft journal caps from another cylinder head.

48. If removed, mark cylinder head camshaft journal cap number on outside edge of camshaft journal cap and cylinder head.

NOTE: Loosen cylinder head camshaft journal thrust cap last to ensure proper camshaft position in cylinder head.

49. Loosen cylinder head camshaft journal cap bolts in sequence shown. Loosen camshaft journal thrust cap last.

CAUTION: If camshafts and valve tappets (6500) are to be reused, mark position of valve tappets to make sure that they are assembled in their original positions.

50. Remove cylinder head camshaft journal caps, camshafts and camshaft front oil seals from cylinder head.
51. Remove valve tappets from cylinder head.
52. Remove camshaft timing belt tensioner pulley retaining bolt and camshaft timing belt tensioner pulley from front of engine. Discard pulley retaining bolt.
53. Remove crankshaft sprocket (6306) and camshaft timing belt guide from crankshaft.
54. Remove camshaft timing belt routing pulley retaining bolts and camshaft timing belt routing pulleys from front of engine.
55. Remove engine front cover (6019) from cylinder head.

Fig. 11 Cylinder head bolt removal sequence:

56. Remove cylinder head retaining bolts in sequence shown.

NOTE: Cylinder heads should not be set on cylinder head face. Protect cylinder head face surface to avoid scratches and dents on cylinder head face sealing surfaces.

57. Remove cylinder head from cylinder block.





58. Remove cylinder head gasket (6051) from cylinder block.
59. If required, disassemble cylinder head.
60. Remove water pump retaining bolts, water pump and water pump housing gasket (8507) from front of cylinder block.
61. Turn engine over on engine stand.
62. Remove oil pump screen cover and tube support self-locking retaining nut and discard nut.





63. Remove oil pump screen cover and tube retaining bolts, oil pump screen cover and tube (6622) and gasket from oil pump (6600).
64. Remove oil pan baffle retaining nuts and oil pan baffle (6687) from cylinder block main bearing cap retaining stud bolts.

CAUTION: Avoid scratching or damaging the oil seal sealing surfaces on the crankshaft and camshaft rear oil seal retainer or possible oil leakage may occur.

65. Using a sharp awl, punch a hole in the crankshaft rear oil seal metal surface, between the crankshaft rear oil seal lip and the crankshaft rear oil seal retainer (6335).





66. Screw in the threaded end of the Jet Plug Remover T77L-9533-B into the crankshaft rear oil seal (6701) and remove crankshaft rear oil seal from the crankshaft rear oil seal retainer.





67. Remove retaining bolts for the crankshaft rear oil seal retainer to the cylinder block and remove the crankshaft rear oil seal retainer and crankshaft rear oil seal retainer gasket (6344).





68. Remove oil pump retaining bolts. Remove oil pump from cylinder block. Inspect oil pump.

CAUTION: Pistons (6108), connecting rods (6200) and connecting rod bearings (6211) should be numbered to make sure they are assembled in their original positions.

NOTE: Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the ridge and/or carbon deposits from each cylinder using Cylinder Ridge Reamer T64L-6011-EA.

69. Turn crankshaft until piston to be removed is at the high point of its travel.
70. If more than one piston is being removed, identify the pistons connecting rods and connecting rod caps for cylinder position.





71. Remove the connecting rod cap and lower connecting rod bearing. Keep connecting rod cap and lower connecting rod bearing together. Using Piston and Rod Guide Tool T93P-6136-A inserted into the bottom of connecting rod bolt holes, push the piston, connecting rod and upper connecting rod bearing through the top of the cylinder bore. Use care to prevent damage to the crankshaft bearing journals and cylinder bore surfaces. Keep upper connecting rod bearing and connecting rod together.

CAUTION: Care should be taken not to damage the connecting rod and cap joint face surfaces.

NOTE: Connecting rod bolts are retained in the bolt hole with a light press fit. The bolts have been torqued to yield at least twice and must be discarded. Use a hammer and punch to drive bolt from bolt hole.





72. Using a new connecting rod bolt, attach connecting rod cap and lower connecting rod bearing to connecting rod and upper connecting rod bearing to prevent mixing parts and damaging the connecting rod joint face surfaces.
73. If piston ring replacement is required, replace piston rings.
74. If required, remove pistons from connecting rods.
75. Remove retaining bolts for crankshaft main bearing caps to cylinder block.
76. If bearings are to be reused, mark position of lower main bearings.
77. Remove lower main bearings from crankshaft main bearing caps.

CAUTION: When removing crankshaft, use care not to damage any crankshaft journal bearing surfaces.

78. Remove crankshaft.
79. If bearings are to be reused, mark position of upper crankshaft main bearings (6333) and upper crankshaft thrust main bearing (6337).





80. Remove upper crankshaft main bearings and crankshaft thrust main bearing from cylinder block.
81. If necessary, remove crankshaft key from crankshaft keyway.
82. Remove pipe plugs and alignment dowels from cylinder block as necessary to clean cylinder block and debris from oil passages.