Disassembly

1. Remove the two drive belt tensioner bolts and the drive belt tensioner.





2. Remove the four generator bracket bolts and remove the generator mounting bracket.





3. On early models disconnect the throttle position (TP) sensor electrical connector.





4. On late models disconnect the TP sensor electrical connector.





5. Disconnect the idle air control (IAC) bypass electrical connector.





6. On early models disconnect the EGR electrical connector.





7. On early models disconnect the EGR vacuum connector.





8. On late models equipped with the differential pressure feedback EGR (DPFE) system, remove the EGR vacuum connector.





9. On late models equipped with the DPFE system, disconnect the EGR backpressure transducer hoses.





10. On late models equipped with the DPFE system, disconnect the upper EGR tube fitting.





11. If equipped with the DPFE system, disconnect the lower EGR tube fitting, and remove the EGR tube.





12. Disconnect the following connections:
^ The engine vacuum regulator (EVR) electrical connector.
^ The engine vacuum regulator (EVR) vacuum connector.





13. If equipped with the differential pressure feedback EGR (DPFE) system, disconnect the EGR backpressure transducer electrical connector.





14. Remove the two intake cover plate screws and the intake cover plate.





15. Remove the six upper intake manifold bolts in sequence shown.





16. Lift the intake manifold and disconnect the two vacuum connections.
^ Remove the intake manifold and discard the old gaskets.





17. Disconnect the engine coolant temperature (ECT) sensor electrical connector.





18. Remove the water heater tube nut.





19. Disconnect the water heater tube from the lower intake manifold and remove the water heater tube.





20. Remove the upper radiator hose from the intake manifold.





21. Remove the water bypass hose.
a. Loosen the water bypass hose clamps.
b. Remove the water bypass hose.





22. Disconnect the eight fuel injector electrical connectors.
23. Remove the camshaft position sensor and camshaft synchronizer.





24. Remove the twelve lower intake manifold bolts in sequence.





25. Remove the lower intake manifold and discard the lower intake manifold gaskets.





26. Disconnect the oil pressure sensor electrical connector.





27. Disconnect the crankshaft position sensor electrical sensor and remove the engine control sensor wiring.





28. Remove the six RH valve cover bolts and the RH valve cover.





29. Remove the six LH valve cover bolts and the LH valve cover.





30. Remove the eight rocker arm bolts from each side.

NOTE: Mark the rocker arms to ensure that they will be reinstalled in their original positions. The RH is shown; the LH is similar.





31. Remove the eight rocker arm fulcrums from each side.





32. Remove the rocker arms and rocker arm fulcrum guides from each side.





33. Remove the RH and LH push rods.

NOTE: Mark the RH and LH push rods to ensure that they will be reinstalled in their original positions.





34. On early models, remove the valve tappet guide plate retainer bolts and the valve tappet guide plate retainer.





35. On early models, remove the valve tappet guide plates and the valve tappets using a valve tappet puller.

NOTE: Mark the RH and LH tappet guides and tappets to ensure that they will be reinstalled in their original positions.





36. On late models, remove the valve tappet guide plate retainer bolts and remove the valve tappet guide plate retainer.





37. On late models, remove the four valve tappet guide plates and the valve tappets using a valve tappet puller.

NOTE: Mark the valve tappets so they can be reinstalled in their original positions.





38. Remove the ten cylinder head bolts in the indicated sequence and remove the cylinder head from each side.
^ Discard the old cylinder head bolts.





39. Remove the oil cooler bolt and the oil cooler bolt O-ring.





40. Disconnect the water inlet hose from the oil cooler and remove the oil cooler.





41. Remove the four water pump pulley bolts and the water pump pulley.





42. Remove the nine water pump bolts and the water pump from the engine front cover.





43. Remove the crankshaft vibration damper bolt.

NOTE: Use a suitable strap wrench to hold the crankshaft pulley.





44. Use Crankshaft Damper Remover to remove the crankshaft pulley.
a. Install Crankshaft Damper Remover.
b. Remove the crankshaft pulley.

NOTE: The jackscrew from T82L-6316-B must be added to T58P-6316-D crankshaft damper remover.





45. Remove the crankshaft position sensor (CKP sensor) and timing pointer.





46. Remove the six flywheel bolts and remove the flywheel.





47. Remove the 22 engine oil pan bolts and the oil pan.
^ Discard the old gasket.





48. Use Front Cover Seal Remover to remove the front cover seal.





49. Remove the four engine front cover bolts and the engine front cover.
^ Discard the old gasket.





50. Remove the camshaft sprocket bolt.





51. Remove the camshaft sprocket, crankshaft sprocket and timing chain at the same time.





52. Remove the two camshaft thrust plate bolts and the crankshaft thrust main bearing.





53. Remove the camshaft from the cylinder block.





54. Remove the oil pump screen cover and tube.
a. Remove the oil pump screen cover and tube nut.
b. Remove the oil pump screen cover and tube bolts.

NOTE: Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A and a suitable plastic or wooden scraper to clean sealing surfaces. All sealing surfaces must be clean.





55. Remove the two oil pump bolts and the oil pump.
56. Use Cylinder Ridge Reamer to remove the ridge off the top of the eight cylinder bores.
57. Turn the crankshaft until the connecting rod cap being removed is in the down position.





58. Remove the sixteen connecting rod nuts and the eight connecting rod caps.

NOTE: Mark the connecting rod caps so they can be reinstalled in their original positions.

59. Push the piston and connecting rod assembly out of the top of the cylinder.

CAUTION: Place rubber hose over the connecting rod studs to protect the crankshaft journals and cylinder walls from being damaged.





60. Remove the ten main bearing cap bolts and the five main bearing caps.





61. Remove the crankshaft from the cylinder block.
62. Remove the crankshaft rear oil seal from the crankshaft.
63. Remove the crankshaft main bearings from the cylinder block and main bearing caps.
64. Use Camshaft Bearing Set to remove the camshaft bearings from the cylinder block.