Disassembly

Special Tools:

Special Tools:

Disassembly





1. Remove the bolts and the drive belt tensioner.





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





3. Disconnect the TP sensor electrical connector.





4. Disconnect the Idle Air Control (IAC) bypass electrical connector.





5. Remove the EGR valve vacuum connector.





6. Disconnect the EGR backpressure transducer hoses.





7. Disconnect the upper EGR valve to exhaust manifold tube upper fitting.





8. If equipped with the DPFE system, disconnect the lower EGR valve to exhaust manifold tube lower fitting, and remove the EGR EGR valve to exhaust manifold tube.





9. Disconnect the following connections:
^ The Engine Vacuum Regulator (EVR) electrical connector.
^ The Engine Vacuum Regulator (EVR) vacuum connector.





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





11. Remove the screws and the intake cover plate.





12. Disconnect the Positive Crankcase Ventilation (PCV) hose, and the two PCV heater hoses.





13. Remove the bolts in sequence shown.





14. Lift the intake manifold and disconnect the two vacuum connections and the two PCV heater hoses.
^ Remove the intake manifold and discard the old gaskets.





15. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.





16. Remove the nut.





17. Disconnect the water heater tube from the lower intake manifold and remove the water heater tube nut and fitting.





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





19. Remove the water bypass hose.
1 Loosen the water bypass hose clamps.
2 Remove the water bypass hose.





20. Disconnect the eight fuel injector electrical connectors.





21. Remove the Camshaft Position Sensor (CMP sensor) and camshaft synchronizer.
22. Remove the bolts in sequence.





23. Remove the lower intake manifold and discard the lower gasket.





24. Disconnect the oil pressure sensor electrical connector.





25. Disconnect the crankshaft position sensor electrical sensor and remove the fuel charging wiring.





26. Remove the bolts and the RH valve cover.





27. Remove the bolts and the LH valve cover.





28. NOTE: Mark the rocker arms to ensure that they will be reinstalled in their original positions.

NOTE: The RH is shown; the LH is similar.

Remove the bolts from each side.





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





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





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

Remove the RH and LH push rods.





32. Remove the bolts and remove the valve tappet guide plate retainer.





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

Remove the four valve tappet guide plates and the valve tappets using a valve tappet puller.





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





35. Remove the bolt and the O-ring.





36. Remove the bolts and the wafer pump pulley.





37. Remove the bolts and the water pump from the engine front cover.





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

Remove the bolt.





39. NOTE: The jackscrew from the Vibration Damper Remover Adapter must be added to the Crankshaft Damper Remover.

Use the Crankshaft Damper Remover to remove the crankshaft pulley.
1 Install the Crankshaft Damper Remover.
2 Remove the crankshaft pulley.





40. Remove the Crankshaft Position Sensor (CKP sensor) and timing pointer.





41. Remove the bolts and remove the flywheel.





42. Remove the bolts and the oil pan.
^ Discard the old oil pan gasket.





43. Use Front Cover Seal Remover to remove the crankshaft front seal.





44. Remove the bolts and studs and the engine front cover.
^ Discard the old engine front cover gasket.





45. Remove the bolt.





46. Remove the camshaft sprocket, crankshaft sprocket and timing chain/belt at the same time.





47. Remove the bolts and the crankshaft thrust main bearing.





48. Remove the camshaft from the cylinder block.





49. NOTE: Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A and a suitable plastic or wooden scraper to clean sealing surfaces. All sealing surfaces must be clean.

Remove the oil pump screen cover and tube.
1 Remove the nut.
2 Remove the bolts.





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





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

Remove the sixteen nuts and the eight connecting rod caps.

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

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





55. Remove the bolts and the five main bearing caps.





56. Remove the crankshaft from the cylinder block.
57. Remove the crankshaft rear oil seal from the crankshaft.
58. Remove the crankshaft main bearings from the cylinder block and main bearing caps.
59. Use Camshaft Bearing Set to remove the camshaft bearings from the cylinder block.