Part 1 of 2

1. Disconnect the exhaust gas recirculation (EGR) tube from the EGR valve.
1 Disconnect the hoses from the EGR tube to the differential pressure feedback EGR (DPFE).
2 Unscrew the tube fitting.





2. Remove the RH exhaust manifold.
- Remove the nuts in the indicated sequence.
- Remove the gasket.





3. Remove the bolts and the connecting shaft bracket from the cylinder block.





4. Disconnect the generator electrical connections.
1 Remove the battery positive voltage retaining nut.
2 Disconnect the voltage regulator electrical connector.
3 Disconnect the stator circuit electrical connector.





5. Disconnect the differential pressure feedback EGR (DPFE) electrical connector.





6. Disconnect the electronic vacuum regulator (EVR) electrical connector.





7. Disconnect the engine coolant temperature (ECT) sensor and remove the wiring harness.





8. Disconnect the intake manifold runner control (IMRC) cable.
1 Disconnect the IMRC cable from the retainer.
2 Disconnect the IMRC cable end.





9. Remove the bolts and remove the IMRC.
1 Disconnect the IMRC electrical connector.
2 Remove the IMRC retaining bolts and remove the IMRC.





10. Disconnect the 6 spark plug wires.





11. Remove the coil and ignition wires.
1 Disconnect the coil electrical connector.
2 Remove the coil retaining bolts and remove the coil.





12. Remove the vacuum harness.
1 Disconnect the vacuum supply hoses from the upper intake manifold.
2 Disconnect the electronic vacuum regulator (EVR) vacuum hoses.
3 Disconnect the fuel pressure regulator vacuum hoses.
4 Disconnect the DPFE vacuum hose.
5 Disconnect the EGR valve vacuum hose and remove the vacuum harness.





13. Disconnect the PCV hose from the throttle body.





14. Disconnect the throttle position sensor (TPS) electrical connector.





15. Disconnect the idle air control (IAC) valve electrical connector.





16. Remove the bolts in the indicated sequence and remove the upper intake manifold.
- Remove the gaskets.





17. Disconnect the heated oxygen sensor (H02S) electrical connector.





18. Disconnect the oil pressure switch electrical connector.





19. Disconnect the crankshaft position (CKP) sensor electrical connector.
1 Unclip the harness from the stud.
2 Disconnect the electrical connector.





20. Disconnect the camshaft position (CMP) sensor electrical connector.
1 Unclip the harness from the stud.
2 Disconnect the electrical connector.





21. Disconnect the engine coolant temperature warning light electrical connector.





22. Disconnect the fuel injector electrical connectors and remove the wiring harness.





23. Remove the bolts in the indicated sequence and remove the lower intake manifold.
- Remove the gaskets.





24. Disconnect the coolant hoses and remove the thermostat housing.





25. Disconnect the coolant distribution tube.
- Remove the nuts.





26. Remove the LH engine lifting eye.
1 Remove the nut.
2 Remove the engine lifting eye.





27. Remove the dipstick tube.
- Remove the nut.





28. Remove the water pump drive belt.
- Rotate the belt tensioner clockwise to relieve tension on the drive belt.





29. Remove the PCV valve and hoses.
1 Remove the PCV valve bracket nut.
2 Remove the PCV valve and hoses.





30. Remove the coolant crossover tube.
1 Remove the bolts.
2 Remove the crossover tube.





31. Remove the water pump.
l Disconnect the coolant hose.
2 Disconnect the oil cooler hose.
3 Remove the bolts.
4 Remove the pump.





32. Remove the flywheel.
1 Remove the flywheel bolts.
2 Remove the backing plate.





33. Install rear crankshaft seal remover.





34. Remove the crankshaft oil seal.
1 Install impact slide hammer.
2 Remove the seal.





35. Remove the generator.
1 Remove the bracket bolt.
2 Remove the generator bolts and remove the generator.





36. Remove the bolts and the generator bracket.





37. Remove the oil filter.





38. Remove the bolts and the LH exhaust manifold.
- Remove the gasket.





39. Remove the oil cooler.
1 Remove the oil cooler bolt and the oil cooler.
2 Remove the oil pressure switch.





40. Remove the studs and the oil pan heat shields.





41. Remove the oil pan.
- Remove the bolts and studs in the indicated sequence.
- Remove the gasket.
- Clean and inspect oil pan and cylinder block using metal surface cleaner F4AZ-1 9A536-RA or equivalent meeting Ford specification WSE-M5B392-A.





42. Remove the inline connector bracket.
1 Remove the nuts.
2 Remove the bracket.