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Engine 4.6L: Disassembly: Engine: Disassembly

    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.
    Fig 1: Removing Flexplate
    G02756979Courtesy of FORD MOTOR CO.
  1. Remove the flexplate.
  2. Remove the engine/transmission spacer plate.
    Fig 2: Removing Engine/Transmission Spacer Plate
    G02756980Courtesy of FORD MOTOR CO.
  3. Using the special tool, remove the rear oil slinger.
    Fig 3: Removing Rear Oil Slinger
    G02756981Courtesy of FORD MOTOR CO.
  4. Using the special tool, remove the rear main seal.
    Fig 4: Removing Rear Main Seal
    G02756982Courtesy of FORD MOTOR CO.
  5. Remove the rear seal retainer plate.
    Fig 5: Removing Rear Seal Retainer Plate
    G02756983Courtesy of FORD MOTOR CO.
  6. Mount the engine on an engine stand.
    Fig 6: Mounting Engine On Engine Stand
    G02756984Courtesy of FORD MOTOR CO.
  7. Remove the bolts and the RH engine mount.
    Fig 7: Removing Bolts And RH Engine Mount
    G02756985Courtesy of FORD MOTOR CO.
  8. Remove the bolts and the LH engine mount
    Fig 8: Removing Bolts And LH Engine Mount
    G02756986Courtesy of FORD MOTOR CO.
    9. NOTE: RH shown, LH similar.
    Fig 9: Installing Drain Plugs
    G02756987Courtesy of FORD MOTOR CO.
  9. Remove the drain plugs from the engine block. Allow the coolant to completely drain.
    • Install the drain plugs when finished.
  10. Disconnect the positive crankcase ventilation (PCV) tube.
    Fig 10: Disconnecting Positive Crankcase Ventilation (PCV) Tube
    G02756988Courtesy of FORD MOTOR CO.
  11. Disconnect the vacuum hoses and the PCV valve coolant hoses.
    Fig 11: Disconnecting Vacuum Hoses And PCV Valve Coolant Hoses
    G02756989Courtesy of FORD MOTOR CO.
  12. Remove the bolt and the bracket.
    Fig 12: Removing Bolt And Bracket
    G02756990Courtesy of FORD MOTOR CO.
  13. Disconnect the exhaust gas recirculation (EGR) system module tube from the EGR system module.
    Fig 13: Disconnecting Exhaust Gas Recirculation (EGR) System Module Tube
    G02756991Courtesy of FORD MOTOR CO.
  14. Disconnect the EGR system module tube from the exhaust manifold.
    Fig 14: Disconnecting EGR System Module Tube From Exhaust Manifold
    G02756992Courtesy of FORD MOTOR CO.
  15. Disconnect the throttle position (TP) sensor and the idle air control (IAC) sensor electrical connectors.
    Fig 15: Disconnecting Throttle Position (TP) Sensor And Idle Air Control (IAC) Sensor Electrical Connectors
    G02756993Courtesy of FORD MOTOR CO.
  16. Remove the upper intake manifold assembly bolts in the sequence shown and remove the intake manifold assembly.
    Fig 16: Removing Upper Intake Manifold Assembly Bolts In The Sequence
    G02756994Courtesy of FORD MOTOR CO.
  17. Disconnect the electrical connector, generator cable and the pin-type harness retainer.
    Fig 17: Disconnecting Electrical Connector, Generator Cable And Pin-Type Harness Retainer
    G02756995Courtesy of FORD MOTOR CO.
  18. Remove the bolts and the generator support bracket.
    Fig 18: Removing Bolts And Generator Support Bracket
    G02756996Courtesy of FORD MOTOR CO.
  19. Disconnect the engine coolant temperature (ECT) sensors.
    Fig 19: Disconnecting Engine Coolant Temperature (ECT) Sensors
    G02756997Courtesy of FORD MOTOR CO.
  20. Remove the crossover tube.
    Fig 20: Removing Crossover Tube
    G02756998Courtesy of FORD MOTOR CO.
  21. Remove the bolts and the generator.
    Fig 21: Removing Bolts And Generator
    G02756999Courtesy of FORD MOTOR CO.
  22. Disconnect the electrical connector and the vacuum hose from the fuel pressure sensor.
    Fig 22: Disconnecting Electrical Connector And Vacuum Hose
    G02757000Courtesy of FORD MOTOR CO.
  23. Separate the fuel charging wiring from the fuel injection supply manifold studs in three places.
    Fig 23: Separating Fuel Charging Wiring From Fuel Injection Supply Manifold
    G02757001Courtesy of FORD MOTOR CO.
  24. Disconnect the eight fuel injector electrical connectors.
    Fig 24: Disconnecting Eight Fuel Injector Electrical Connectors
    G02757002Courtesy of FORD MOTOR CO.
  25. Remove the eight bolts and two studs in the sequence shown, and raise the lower intake manifold slightly.
    Fig 25: Lower Intake Manifold Bolts And Studs Removal Sequence
    G02757003Courtesy of FORD MOTOR CO.
  26. Disconnect the fuel charging wiring harness from the rear of the lower intake manifold and remove the manifold.
  27. Remove the intake manifold gaskets.
    Fig 26: Removing Intake Manifold Gaskets
    G02757004Courtesy of FORD MOTOR CO.
    28. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools will cause scratches and gouges which make leak paths.
  28. Clean the sealing surfaces.
  29. Remove the LH coil cover.
    Fig 27: Removing LH Coil Cover
    G02757005Courtesy of FORD MOTOR CO.
  30. Remove the RH coil cover.
    Fig 28: Removing RH Coil Cover
    G02757006Courtesy of FORD MOTOR CO.
  31. Disconnect the LH ignition coil electrical connectors.
    Fig 29: Disconnecting LH Ignition Coil Electrical Connectors
    G02757007Courtesy of FORD MOTOR CO.
  32. Disconnect the RH ignition coil electrical connectors.
    Fig 30: Disconnecting RH Ignition Coil Electrical Connectors
    G02757008Courtesy of FORD MOTOR CO.
  33. Remove the eight ignition coils.
    Fig 31: Removing Eight Ignition Coils
    G02757009Courtesy of FORD MOTOR CO.
  34. Disconnect the knock sensor (KS) jumper harness from the fuel charging harness.
    Fig 32: Disconnecting Knock Sensor (KS) Jumper Harness
    G02757010Courtesy of FORD MOTOR CO.
  35. Remove the coolant pump pulley.
    1. Remove the bolts.
    2. Remove the coolant pump pulley.
    Fig 33: Removing Coolant Pump Pulley
    G02757011Courtesy of FORD MOTOR CO.
  36. Remove the coolant pump from the cylinder block.
    • Inspect and clean the sealing surfaces.
    Fig 34: Inspecting And Cleaning Sealing Surfaces
    G02757012Courtesy of FORD MOTOR CO.
  37. Remove the bolt.
    Fig 35: Removing Bolt
    G02757013Courtesy of FORD MOTOR CO.
  38. Using the special tool, remove the crankshaft pulley.
    Fig 36: Removing Crankshaft Pulley
    G02757014Courtesy of FORD MOTOR CO.
  39. Using the special tool, remove the crankshaft front seal.
    Fig 37: Removing Crankshaft Front Seal
    G02757015Courtesy of FORD MOTOR CO.
  40. Remove the belt idler pulleys.
    Fig 38: Removing Belt Idler Pulleys
    G02757016Courtesy of FORD MOTOR CO.
  41. Disconnect the camshaft position (CMP) sensors and the engine wiring harness retainers.
    Fig 39: Disconnecting Camshaft Position (CMP) Sensors And Engine Wiring Harness Retainers
    G02757017Courtesy of FORD MOTOR CO.
  42. Disconnect the oil pressure sensor electrical connector.
    Fig 40: Disconnecting Oil Pressure Sensor Electrical Connector
    G02757018Courtesy of FORD MOTOR CO.
    43. NOTE: LH shown, RH similar.
    Fig 41: Removing Nuts And Capacitors
    G02757019Courtesy of FORD MOTOR CO.
  43. Disconnect and remove the LH and RH radio capacitors.
    • Disconnect the electrical connectors.
    • Remove the nuts and capacitors.
  44. Disconnect the retainers and remove the fuel charging wiring harness.
    Fig 42: Disconnecting Retainers And Removing Fuel Charging Wiring Harness
    G02757020Courtesy of FORD MOTOR CO.
    45. 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.
    Fig 43: Removing LH Valve Cover
    G02757021Courtesy of FORD MOTOR CO.
  45. Remove the LH valve cover.
    • Remove and discard the gasket, clean and inspect the sealing surfaces.
    46. 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 oil sealant.
    Fig 44: Removing RH Valve Cover
    G02757022Courtesy of FORD MOTOR CO.
  46. Remove the RH valve cover.
    • Remove and discard the gasket, clean and inspect the sealing surfaces.
  47. Remove the LH exhaust manifold.
    1. Remove the 16 nuts.
    2. Remove the exhaust manifold.
    3. Remove the exhaust manifold gasket.
    Fig 45: Removing Exhaust Manifold And Gasket
    G02757023Courtesy of FORD MOTOR CO.
  48. Remove the oil level indicator tube.
    Fig 46: Removing Oil Level Indicator Tube
    G02757024Courtesy of FORD MOTOR CO.
  49. Remove the RH exhaust manifold.
    1. Remove the RH exhaust manifold nuts.
    2. Remove the RH exhaust manifold.
    3. Remove the RH exhaust manifold gasket and discard.
    Fig 47: Removing RH Exhaust Manifold Gasket
    G02757025Courtesy of FORD MOTOR CO.
  50. Remove the coolant bypass tube.
    1. Remove the retaining nut.
    2. Remove the ground strap.
    3. Remove the coolant bypass tube.
    Fig 48: Removing Coolant Bypass Tube
    G02757026Courtesy of FORD MOTOR CO.
  51. Remove the nut and position the wiring harness bracket aside.
    Fig 49: Removing Nut And Positioning Wiring Harness Bracket Aside
    G02757027Courtesy of FORD MOTOR CO.
  52. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  53. Remove the four bolts.
    Fig 50: Removing Four Bolts
    G02757028Courtesy of FORD MOTOR CO.
    54. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools will cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: Clean and inspect the mating surfaces.
    NOTE: Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    Fig 51: Removing Bolts And Engine Front Cover
    G02757029Courtesy of FORD MOTOR CO.
  54. Remove the bolts and the engine front cover.
  55. Remove the crankshaft position sensor pulse wheel.
    Fig 52: Removing Crankshaft Position Sensor Pulse Wheel
    G02757030Courtesy of FORD MOTOR CO.
    56. CAUTION: Mark the roller follower positions. Reused followers must be installed in their original locations.
  56. Position the piston of the cylinder being repaired at the bottom of the stroke and the camshaft lobe at the base circle.
    57. NOTE: LH shown, RH similar.
    Fig 53: Removing Spark Plugs
    G02757031Courtesy of FORD MOTOR CO.
  57. Remove the eight spark plugs.
  58. Using the special tool, compress the intake valve spring and remove the roller follower.
    Fig 54: Compressing Intake Valve Spring And Removing Roller Follower
    G02757032Courtesy of FORD MOTOR CO.
  59. Using the special tool, compress the exhaust valve spring and remove the roller follower.
    Fig 55: Compressing Exhaust Valve Spring And Removing Roller Follower
    G02757033Courtesy of FORD MOTOR CO.
  60. Repeat the above three steps to remove all the necessary roller followers. Inspect the roller followers and camshafts. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  61. Remove the bolts and the RH and LH timing chain tensioners.
    Fig 56: Removing Bolts And RH And LH Timing Chain Tensioners
    G02757034Courtesy of FORD MOTOR CO.
  62. Remove the RH and LH timing chain tensioner arms.
    Fig 57: Removing RH And LH Timing Chain Tensioner Arms
    G02757035Courtesy of FORD MOTOR CO.
  63. Remove the RH and the LH timing chains and the crankshaft sprocket
    Fig 58: Removing RH And LH Timing Chains And Crankshaft Sprocket
    G02757036Courtesy of FORD MOTOR CO.
  64. Remove the RH and LH timing chain guides.
    Fig 59: Removing RH And LH Timing Chain Guides
    G02757037Courtesy of FORD MOTOR CO.
    65. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
    Fig 60: Removing Hydraulic Lash Adjusters
    G02757038Courtesy of FORD MOTOR CO.
  65. Remove the hydraulic lash adjusters.
    66. 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 sealing surfaces. These tools will cause scratches and gouges which 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.
    Fig 61: Removing Cylinder Head Bolts
    G02757039Courtesy of FORD MOTOR CO.
  66. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
    67. 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 sealing surfaces. These tools will cause scratches and gouges which 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.
    NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
    Fig 62: Removing Cylinder Head Bolts
    G02757040Courtesy of FORD MOTOR CO.
  67. Remove the bolts and the LH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
    68. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools will cause scratches and gouges which 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 surfaces.
  68. 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 directions, 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 surface is normal.
    69. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
  69. 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. The 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).
  70. Remove the knock sensors.
    Fig 63: Removing Knock Sensors
    G02757041Courtesy of FORD MOTOR CO.
  71. Remove the oil pan and the gasket.
    Fig 64: Removing Oil Pan And Gasket
    G02757042Courtesy of FORD MOTOR CO.
  72. Remove the bolts, the oil filter adapter, and the oil gasket.
    Fig 65: Removing Bolts Oil Filter Adapter, And Oil Gasket
    G02757043Courtesy of FORD MOTOR CO.
  73. Clean and inspect the oil filter adapter and the oil cooler.
    • Plug the oil cooler coolant lines.
    • Flush the adapter and cooler with parts cleaner. If metal particles are present, install a new oil filter adapter and oil cooler.
  74. Remove the bolts and the oil pump screen and pickup tube.
    Fig 66: Removing Bolts And Oil Pump Screen And Pickup Tube
    G02757044Courtesy of FORD MOTOR CO.
  75. Remove the oil pump screen and pickup tube spacer.
    Fig 67: Removing Oil Pump Screen And Pickup Tube Spacer
    G02757045Courtesy of FORD MOTOR CO.
  76. Remove the spacers and the windage tray.
    Fig 68: Removing Spacers And Windage Tray
    G02757046Courtesy of FORD MOTOR CO.
  77. Remove the bolts and the oil pump.
    Fig 69: Removing Bolts And Oil Pump
    G02757047Courtesy of FORD MOTOR CO.
    78. CAUTION: Do not stamp the top of pistons, as ring land damage can occur.
    NOTE: Connecting rods and rod caps should be numbered to keep the correct orientation in the following sequence.
    Fig 70: Identifying Connecting Rod Cap Bolts
    G02757048Courtesy of FORD MOTOR CO.
  78. Remove the connecting rod caps for piston numbers 1 and 6.
    • Discard the bolts.
    79. CAUTION: Do not scratch the 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 manufacturer's instructions.
    Fig 71: Removing Piston
    G02757049Courtesy of FORD MOTOR CO.
  79. Using the special tool, push piston numbers 1 and 6 through the top of the cylinder block.
  80. To remove pistons 3 and 5, 4 and 7, 2 and 8, turn crankshaft 90 degrees and repeat the previous two steps.
  81. Remove the side bolts.
    Fig 72: Removing Side Bolts
    G02757050Courtesy of FORD MOTOR CO.
  82. Remove and discard the bolts.
    Fig 73: Removing Bolts
    G02757051Courtesy of FORD MOTOR CO.
  83. Remove the main bearing cap and the crankshaft lower main bearings from the cylinder block.
    Fig 74: Removing Main Bearing Cap And Crankshaft Lower Main Bearings From Cylinder Block
    G02757052Courtesy of FORD MOTOR CO.
  84. Remove the crankshaft, the crankshaft thrust washer, and the crankshaft upper main bearings from the cylinder block.
    Fig 75: Removing Crankshaft, Crankshaft Thrust Washer, And Crankshaft Upper Main Bearings
    G02757053Courtesy of FORD MOTOR CO.
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