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 the engine on the Engine Stand or equivalent using the Heavy Duty Floor Crane.
2. Loosen the bolts retaining the water pump pulley.
3. Remove the drive belt.
4. Remove the water pump pulley.
5. Disconnect the fuel charging wiring from the oil control solenoid.
^ On early production vehicles, remove the connector cover from the engine appearance cover.
^ Disconnect the oil control solenoid.





6. On early production vehicles, remove the engine appearance cover.





7. Remove the ignition wires.
8. Remove the A/C compressor.
9. Remove the battery ground cable.
10. Remove the Generator (GEN).
11. Remove the generator mounting bracket.
12. Disconnect the fuel charging wiring from the fuel temperature sensor and fuel pressure sensor.





13. Remove the exhaust manifold heat shield.





14. Remove the exhaust manifold.
^ Remove the nine nuts in the sequence shown.
^ Remove the exhaust manifold.
^ Remove the exhaust manifold gasket.
15. Remove the throttle body.
16. Remove the fuel injection supply manifold.





17. Remove the intake manifold.
^ Remove the two nuts and seven bolts in the sequence shown.
^ Remove the intake manifold.
18. Remove the water thermostat housing.
19. Remove the crankcase ventilation tube.





20. Remove the water bypass tube.





21. Remove the oil separator.
^ Remove the bolts.
^ Remove the oil separator.
^ Remove the oil separator to cylinder block gasket and discard.





22. Remove the oil level dipstick, tube.
23. Remove the fuel charging wiring.
24. Remove the lower radiator hose.
25. Remove the ignition coil, the radio ignition interference capacitor and the bracket.





26. Remove the steering pump and brackets.





27. Remove the upper timing belt cover.





28. Remove the valve cover.
^ Remove the bolts and grommets.
^ Remove the spacers.
^ Remove the O-Rings.
^ Remove the valve cover.
^ Remove the valve cover gasket.





29. Note: Identify spark plug location if new spark plugs are not going to be installed.
Original spark plugs must be installed in their original locations.

Remove the spark plugs.





30. Remove the Camshaft position sensor (CMP sensor).





31. Remove the knock sensor.





32. Remove the center timing belt cover.





33. Note: Hold the camshaft with a wrench to prevent camshaft rotation.

Remove the oil plug on the variable camshaft timing assembly.





34. Remove the bolt then remove the crankshaft pulley.





35. Remove the lower timing belt cover.





36. Remove the timing belt tensioner.
37. Remove the timing belt.








38. Note: Hold the camshafts with a wrench to prevent camshaft rotation.

Remove the camshaft sprockets.





39. Remove the idler pulley.





40. Remove the crankshaft sprocket and timing belt guide.
41. Remove the camshaft timing belt guide pulleys.





42. Remove the timing cover back plate.





43. Remove the water pump housing.





44. Remove the bolts.





45. Rotate the oil control solenoid assembly 90 degrees.





46. Remove the camshaft journal caps.
^ Loosen the bolts in several two-turn steps in the sequence shown.
^ Remove the bolts.
47. Remove camshaft front oil seals.





48. Note: The oil control solenoid assembly and exhaust camshafts are removed as an assembly.

Remove the camshafts.





49. Note: If valve tappets are being reused the valve tappet must be installed in its original position or engine damage may occur.

Remove valve tappets.





50. CAUTION: The bolts are torque-to-yield and must be replaced or possible engine damage may occur.

Remove the cylinder head and the head gasket.
51. If the cylinder head is to be repaired.
52. Turn the engine upside down on the engine stand.





53. Remove the Crankshaft Position Sensor (CKP sensor) and the bushing.





54. Remove the oil pan.
^ Remove the bolts.
^ Remove the oil pan.
^ Clean sealing surfaces with a non-abrasive cleaner.





55. Remove the oil pump cover and screen.
^ Remove the bolts.
^ Remove the oil pump cover and screen.
^ Remove and discard the oil pump inlet tube gasket).
56. Remove the lower cylinder block shims, if equipped.





57. Remove the lower cylinder block and the gasket.
58. If required, remove the crankshaft front seal.





59. Remove the oil pump.
^ Remove the bolts.
^ Remove the oil pump.
^ Remove the oil pump to cylinder block gasket.





60. Remove the rear main oil seal retainer assembly and discard the gasket.





61. CAUTION: The connecting rods and connecting rod caps must be properly oriented, the interlocking tangs on the same side of the connecting rod or possible engine damage may occur.

CAUTION: The connecting rod bolts are torque-to-yield. Discard the connecting rod bolts.

Remove the four connecting rod caps.





62. If the connecting rod bearings are to be revised, each one must be identified so that it can be installed in its original location. Remove the four upper and four lower connecting rod bearings.





63. Remove the four piston and connecting rod assemblies.





64. CAUTION: Make sure the main bearing caps are installed in their original position or possible engine damage may occur.

^ Remove the bolts.
^ Remove the crankshaft main bearing caps.
^ Remove the lower crankshaft main bearings.





65. Remove the crankshaft.





66. Remove the upper crankshaft main bearing.
67. Remove the upper crankshaft main bearing and the upper crankshaft thrust main bearing.





68. Remove the crankshaft key.
69. If required, remove all the pipe plugs and alignment dowels.