Engine - 4.6L: Disassembly: Engine: Disassembly

All Engines 

1. Remove the accessory drive belt.
2. Remove the bolt and the battery ground cable from the engine.
3. Disconnect the fuel charging wiring electrical connector from the crankshaft position (CKP) sensor.
   Fig 1: Identifying Crankshaft Position (CKP) Sensor Fuel Charging Electrical Connector

   Courtesy of FORD MOTOR CO.
4. Disconnect the fuel charging wiring electrical connector from the A/C compressor.
   Fig 2: Identifying A/C Compressor Fuel Charging Electrical Connector

   Courtesy of FORD MOTOR CO.
5. Remove the oil bypass filter.
   Fig 3: Identifying Oil Bypass Filter

   Courtesy of FORD MOTOR CO.
6. Disconnect the electrical connection from the engine oil pressure (EOP) sensor, the power steering pressure (PSP) switch and the harness position retainer.
   Fig 4: Identifying Engine Oil Pressure (EOP) Sensor, Power Steering Pressure (PSP) Switch Electrical Connectors & Harness Position Retainer

   Courtesy of FORD MOTOR CO.
7. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold connector.
   Fig 5: Identifying Exhaust Gas Recirculation (EGR) Tube

   Courtesy of FORD MOTOR CO.
8. Disconnect the differential pressure feedback EGR system connector.
   Fig 6: Identifying Differential Pressure Feedback EGR System Connector

   Courtesy of FORD MOTOR CO.
9. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils.
   Fig 7: Identifying Ignition Coil Fuel Charging Electrical Connectors

   Courtesy of FORD MOTOR CO.
10. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors.
    Fig 8: Identifying Fuel Injector Fuel Charging Electrical Connectors

    Courtesy of FORD MOTOR CO.

    Gasoline Engines 

11. Remove the bolts and the EGR tube heat shield.
    Fig 9: Identifying EGR Tube Heat Shield Bolts

    Courtesy of FORD MOTOR CO.
12. Disconnect the vacuum hoses for the evaporative emission (EVAP) canister purge valve, the main chassis hose and the EGR valve.
    Fig 10: Identifying Evaporative Emission (EVAP) Canister Purge Valve, Main Chassis Hose & EGR Valve Vacuum Hoses

    Courtesy of FORD MOTOR CO.
13. Disconnect and remove the crankcase ventilation tube.
    Fig 11: Identifying Crankcase Ventilation Tube

    Courtesy of FORD MOTOR CO.
14. Disconnect the fuel charging wiring electrical connector from the EGR vacuum regulator solenoid.
    Fig 12: Identifying EGR Vacuum Regulator Solenoid Fuel Charging Electrical Connector

    Courtesy of FORD MOTOR CO.
15. Disconnect the electrical connector from the generator, generator cable and pin-type harness retainer.
    Fig 13: Identifying Generator Electrical Connector, Generator Cable & Pin-Type Harness Retainer

    Courtesy of FORD MOTOR CO.
16. Disconnect the electrical connector from the idle air control (IAC) and the throttle position (TP) sensor.
    Fig 14: Identifying Idle Air Control (IAC) & Throttle Position (TP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
17. Remove the generator mounting bracket.
    • Remove the bolts.
    • Remove the bracket.
    Fig 15: Identifying Generator Mounting Bracket Bolts

    Courtesy of FORD MOTOR CO.
18. Disconnect the fuel charging wiring from the crash bracket and the wiring support bracket and remove the harness from the engine assembly.
    Fig 16: Identifying Crash Bracket & Wiring Support Bracket

    Courtesy of FORD MOTOR CO.
19. Remove the generator.
    1. Remove the bolts.
    2. Remove the generator.
    Fig 17: Identifying Generator & Bolts

    Courtesy of FORD MOTOR CO.
20. Disconnect the EGR tube from the EGR valve.
    Fig 18: Identifying EGR Tube

    Courtesy of FORD MOTOR CO.
21. Remove the bolt and nut, and remove the transmission wiring support bracket.
    Fig 19: Identifying Transmission Wiring Support Bracket Bolt & Nut

    Courtesy of FORD MOTOR CO.
22. Remove the four bolts and the throttle body.
    Fig 20: Identifying Throttle Body Bolts

    Courtesy of FORD MOTOR CO.
23. Remove the bolt and the stud. Remove the crash bracket.
    Fig 21: Identifying Crash Bracket Bolt & Stud

    Courtesy of FORD MOTOR CO.
24. Remove the studs and the fuel injection supply manifold and fuel injectors as an assembly.
    Fig 22: Identifying Fuel Injection Supply Manifold Studs

    Courtesy of FORD MOTOR CO.
25. Remove the eight bolts and the eight ignition coils.
    Fig 23: Identifying Ignition Coil Bolts

    Courtesy of FORD MOTOR CO.
26. Remove the bolts and the water outlet adapter.
    Fig 24: Identifying Water Outlet Adapter Bolts

    Courtesy of FORD MOTOR CO.
27. Remove the water thermostat.
    Fig 25: Identifying Water Thermostat

    Courtesy of FORD MOTOR CO.
28. Remove the bolts and the intake manifold.
    Fig 26: Identifying Intake Manifold Bolts

    Courtesy of FORD MOTOR CO.

    Natural Gas Engines 

29. Disconnect the fuel charging wiring electrical connector from the fuel pressure sensor.
    Fig 27: Identifying Fuel Pressure Sensor Fuel Charging Electrical Connector

    Courtesy of FORD MOTOR CO.
30. Disconnect the fuel charging wiring electrical connector from the fuel temperature sensor.
    Fig 28: Identifying Fuel Temperature Sensor Fuel Charging Electrical Connector

    Courtesy of FORD MOTOR CO.
31. Disconnect the fuel charging wiring electrical connector from the engine coolant temperature sensor.
    Fig 29: Identifying Coolant Temperature Sensor Fuel Charging Electrical Connector

    Courtesy of FORD MOTOR CO.
32. Separate the isolation valve wiring lead from the generator support bracket and disconnect.
    Fig 30: Identifying Isolation Valve Wiring Lead & Generator Support Bracket

    Courtesy of FORD MOTOR CO.
33. Disconnect the fuel charging wiring electrical connector from the camshaft position sensor.
    Fig 31: Identifying Camshaft Position Sensor Fuel Charging Electrical Connector

    Courtesy of FORD MOTOR CO.
34. Disconnect the fuel charging wiring electrical connector from the generator.
    Fig 32: Identifying generator fuel charging electrical connector

    Courtesy of FORD MOTOR CO.
35. Disconnect the fuel charging wiring electrical connector from the throttle position sensor.
    Fig 33: Identifying Throttle Position Sensor Fuel Charging Electrical Connector

    Courtesy of FORD MOTOR CO.
36. Disconnect the fuel charging wiring from the radio ignition interference capacitor.
    Fig 34: Identifying Fuel Charging Wiring & Radio Ignition Interference Capacitor

    Courtesy of FORD MOTOR CO.
37. Disconnect the fuel charging wiring from the EGR vacuum regulator solenoid.
    Fig 35: Identifying EGR Vacuum Regulator Solenoid Fuel Charging Connector

    Courtesy of FORD MOTOR CO.
38. Disconnect the fuel charging wiring from the differential pressure feedback EGR.
    Fig 36: Identifying Differential Pressure Feedback EGR Fuel Charging Connector

    Courtesy of FORD MOTOR CO.
39. Disconnect the fuel charging wiring from the idle air control valve.
    Fig 37: Identifying Idle Air Control Valve Fuel Charging Connector

    Courtesy of FORD MOTOR CO.
40. Remove the bolts and position the fuel charging wiring out of the way.
    Fig 38: Identifying Bolt

    Courtesy of FORD MOTOR CO.
41. Disconnect the hoses from the differential pressure feedback EGR.
    Fig 39: Identifying Differential Pressure Feedback EGR Hoses

    Courtesy of FORD MOTOR CO.
42. Disconnect the vacuum hose from the exhaust gas recirculation (EGR) valve.
    Fig 40: Identifying Exhaust Gas Recirculation (EGR) Valve Vacuum Hose

    Courtesy of FORD MOTOR CO.
43. Disconnect the main chassis vacuum supply hose from the throttle body adapter.
    Fig 41: Identifying Throttle Body Adapter Main Chassis Vacuum Supply Hose

    Courtesy of FORD MOTOR CO.
44. Disconnect the crankcase ventilation tube at two locations and remove.
    Fig 42: Identifying Crankcase Ventilation Tube

    Courtesy of FORD MOTOR CO.
45. Disconnect the vacuum hose from the throttle body adapter.
    Fig 43: Identifying Throttle Body Adapter Vacuum Hose

    Courtesy of FORD MOTOR CO.
46. Disconnect the vacuum hoses from the EGR vacuum regulator solenoid.
    Fig 44: Identifying EGR Vacuum Regulator Solenoid Vacuum Hoses

    Courtesy of FORD MOTOR CO.
47. Disconnect the EGR tube from the EGR valve.
    Fig 45: Identifying EGR Tube

    Courtesy of FORD MOTOR CO.
48. Remove the bolts from the isolation valve.
    Fig 46: Identifying Isolation Valve Bolts

    Courtesy of FORD MOTOR CO.
49. Remove the four bolts.
    Fig 47: Identifying Fuel Injection Supply Manifold Bolts

    Courtesy of FORD MOTOR CO.
50. Remove the fuel injection supply manifold and the fuel injectors as an assembly.
    Fig 48: Identifying Fuel Injection Supply Manifold

    Courtesy of FORD MOTOR CO.
51. Disconnect the heater water hose from the intake manifold.
    Fig 49: Identifying Intake Manifold Heater Water Hose

    Courtesy of FORD MOTOR CO.
52. Disconnect the upper radiator hose from the water outlet adapter.
    Fig 50: Identifying Upper Radiator Hose Clamp

    Courtesy of FORD MOTOR CO.
53. Remove the bolts and the eight ignition coils.
    Fig 51: Identifying Ignition Coil Bolts

    Courtesy of FORD MOTOR CO.
54. Remove the bolts and the generator support bracket.
    Fig 52: Identifying Generator Support Bracket & Bolts

    Courtesy of FORD MOTOR CO.
55. Remove the bolts and the water outlet adapter.
    Fig 53: Identifying Water Outlet Adapter Bolts

    Courtesy of FORD MOTOR CO.
56. Remove the water thermostat and the O-ring.
    Fig 54: Identifying Water Thermostat

    Courtesy of FORD MOTOR CO.
57. Remove the bolts.
    Fig 55: Identifying Intake Manifold Bolts

    Courtesy of FORD MOTOR CO.
58. Remove the intake manifold.
    Fig 56: Identifying Intake Manifold

    Courtesy of FORD MOTOR CO.

    All Engines 

59. Remove the intake manifold gaskets.
    Fig 57: Identifying Intake Manifold Gaskets

    Courtesy of FORD MOTOR CO.
60. Clean the sealing surfaces.
    Fig 58: Identifying Intake Manifold Sealing Surfaces

    Courtesy of FORD MOTOR CO.
61. Remove the oil pan.
    • Remove the bolts.
    • Remove the oil pan.
    • Remove the oil pan gasket.
    Fig 59: Identifying Oil Pan, Oil Pan Gasket & Bolts

    Courtesy of FORD MOTOR CO.
62. Remove the bolts and the oil pump screen cover and tube.
    Fig 60: Identifying Oil Pump Screen Cover, Tube & Bolts

    Courtesy of FORD MOTOR CO.
63. Remove the oil pump screen cover and tube spacer.
    Fig 61: Identifying Tube Spacer

    Courtesy of FORD MOTOR CO.
64. Remove the studs and bolts, and remove the valve cover.
    • Discard the valve cover gasket and clean the mating surface of the cylinder head.
    Fig 62: Identifying LH Valve Cover

    Courtesy of FORD MOTOR CO.
65. Remove the studs and bolts and remove the right valve cover.
    • Discard the valve cover gasket and clean the mating surface of the cylinder head.
    Fig 63: Identifying RH Valve Cover

    Courtesy of FORD MOTOR CO.
66. Remove the bolt and the studs and position the reservoir aside.
    Fig 64: Identifying Power Steering Reservoir Bracket Bolts

    Courtesy of FORD MOTOR CO.
67. Remove the bolts and set aside the power steering pump.
    Fig 65: Identifying Power Steering Pump Bolts

    Courtesy of FORD MOTOR CO.
68. Remove the bolt and the belt idler pulley.
    Fig 66: Identifying Belt Idler Pulley Bolt

    Courtesy of FORD MOTOR CO.
69. Remove the water pump pulley. Refer to WATER PUMP under REMOVAL AND INSTALLATION.
    Fig 67: Identifying Water Pump Pulley Bolts

    Courtesy of FORD MOTOR CO.
70. Remove the bolts and the water pump. Refer to WATER PUMP under REMOVAL AND INSTALLATION.
    Fig 68: Identifying Water Pump Bolts

    Courtesy of FORD MOTOR CO.
71. Remove the bolts and the A/C compressor.
    Fig 69: Identifying A/C Compressor Bolts

    Courtesy of FORD MOTOR CO.
72. Remove the crankshaft pulley bolt. Use the Crankshaft Damper Remover to remove the crankshaft pulley.
    Fig 70: Identifying Crankshaft Pulley & Crankshaft Damper Remover

    Courtesy of FORD MOTOR CO.
73. Use the (A) Front Cover Seal Remover to remove the (B) crankshaft front seal.
    Fig 71: Identifying Front Cover Seal Remover & Crankshaft Front Seal

    Courtesy of FORD MOTOR CO.
NOTE: Correct fastener location is essential for the assembly procedure. Record fastener location.
Fig 72: Identifying Front Cover Bolts
Courtesy of FORD MOTOR CO.
74. Remove the fasteners.
75. Remove the engine front cover from the cylinder block.
    Fig 73: Removing Engine Front Cover From Cylinder Block

    Courtesy of FORD MOTOR CO.
76. Remove the crankshaft sensor ring from the crankshaft (6303).
    Fig 74: Identifying Crankshaft Sensor Ring

    Courtesy of FORD MOTOR CO.
CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
Fig 75: Identifying Crankshaft Holding Tool
Courtesy of FORD MOTOR CO.
77. Position the crankshaft with the Crankshaft Holding Tool as shown.
78. Remove the timing chain tensioning system from both timing chains.
    1. Remove the bolts.
    2. Remove the timing chain tensioners.
    3. Remove the timing chain tensioner arms.
    Fig 76: Identifying Timing Chain Tensioners, Tensioner Arms & Bolts

    Courtesy of FORD MOTOR CO.
CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinders heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
Fig 77: Identifying Timing Chain & Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
79. Remove the LH and RH timing chains and the crankshaft sprockets.
    • Remove the Crankshaft Holding Tool.
    • Remove the RH timing chain from the camshaft sprocket.
    • Remove the RH timing chain and outer crankshaft sprocket from the crankshaft.
    • Repeat for the LH timing chain and crankshaft sprocket.
80. Remove both timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
    Fig 78: Identifying Timing Chain Guides & Bolts

    Courtesy of FORD MOTOR CO.
81. Remove the RH exhaust manifold.
    1. Remove the nuts.
    2. Remove the RH exhaust manifold.
    3. Remove the RH exhaust manifold gasket.
    Fig 79: Identifying RH Exhaust Manifold, Gasket & Nuts

    Courtesy of FORD MOTOR CO.
82. Remove the LH exhaust manifold.
    1. Remove the nuts.
    2. Remove the LH exhaust manifold.
    3. Remove the LH exhaust manifold gaskets.
    Fig 80: Identifying LH Exhaust Manifold, Gasket & Nuts

    Courtesy of FORD MOTOR CO.
83. Remove the bolt and the oil level indicator tube.
    Fig 81: Identifying Oil Level Indicator Tube Bolt

    Courtesy of FORD MOTOR CO.
CAUTION: Install new cylinder head bolts. They are tighten-to-yield designed and cannot be reused.
CAUTION: Place cylinder head on a cardboard or wood surface to prevent damage to the joint face.
NOTE: RH shown; LH similar.
Fig 82: Identifying Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
84. Remove the bolts and discard.
    • Remove the cylinder head.
85. Discard the head gasket and clean the engine block surface.
86. Remove the bolts, and remove the LH engine mount.
    Fig 83: Identifying LH Engine Mount Bolts

    Courtesy of FORD MOTOR CO.
87. Remove the bolts, and remove the engine mount.
    Fig 84: Identifying RH Engine Mount Bolts

    Courtesy of FORD MOTOR CO.
88. Remove the bolts retaining the oil filter adapter and oil filter adapter gasket to the cylinder block.
    Fig 85: Identifying Oil Filter Adapter Bolts

    Courtesy of FORD MOTOR CO.
CAUTION: Inspect the oil pump housing and gears for wear, scoring or grooves. Inspect gears for nicks, burrs or score marks. Remove minor imperfections with an oil stone. If necessary, install a new oil pump. If metal contamination is found in the oil pump, install a new oil cooler, if equipped.
Fig 86: Identifying Oil Pump Bolts
Courtesy of FORD MOTOR CO.
89. Remove the oil pump.
    1. Remove the bolts.
    2. Remove the oil pump.
CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for correct orientation.
Fig 87: Identifying Connecting Rod Caps
Courtesy of FORD MOTOR CO.
90. Remove the bolts and the connecting rod caps. Discard the bolts.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Fig 88: Removing Piston & Connecting Rod
Courtesy of FORD MOTOR CO.
91. Use the Connecting Rod Guide Tool to push the piston through the top of the cylinder block.
92. Remove the crankshaft bearing cap fasteners.
    1. Remove and discard the cross-mounted main cap bolts.
    2. Loosen the jack screws.
    3. Remove and discard the main cap bolts.
    Fig 89: Identifying Cross-Mounted Main Cap Bolts, Jack Screws & Main Cap Bolts

    Courtesy of FORD MOTOR CO.
93. Remove the five main bearing caps and the lower crankshaft main bearings.
    Fig 90: Identifying Main Bearing Caps & Lower Crankshaft Main Bearings

    Courtesy of FORD MOTOR CO.
94. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.
    Fig 91: Identifying Crankshaft & Upper Crankshaft Main Bearings

    Courtesy of FORD MOTOR CO.