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Home >> Mercury >> 2005 >> Monterey >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Mechanical >> Engine >> Disassembly >> Engine >> Engine Disassembly

Engine Disassembly

  1. Remove the bolts and the flywheel.
    Fig 1: Removing Bolts And Flywheel
    G04004118Courtesy of FORD MOTOR CO.
  2. Using the special tools, remove the crankshaft rear seal.
    Fig 2: Removing Crankshaft Rear Seal
    G03962078Courtesy of FORD MOTOR CO.
  3. Mount the engine on a suitable stand.
  4. Remove the bolts and the coolant pump pulley.
    Fig 3: Removing Bolts And Coolant Pump Pulley
    G03962021Courtesy of FORD MOTOR CO.
  5. Remove the accessory drive belt idler pulley.
    Fig 4: Removing Accessory Drive Belt Idler Pulley
    G04004121Courtesy of FORD MOTOR CO.
  6. Disconnect the generator.
    • Remove the B+ wire terminal.
    • Disconnect the generator electrical connector.
    Fig 5: Disconnecting Generator Electrical Connector
    G03955624Courtesy of FORD MOTOR CO.
  7. Remove the bolts and the generator.
    Fig 6: Removing Bolts And Generator
    G04004123Courtesy of FORD MOTOR CO.
  8. Remove the bolt and the coolant pump extension tube and bracket.
    Fig 7: Removing Bolt And Coolant Pump Extension Tube And Bracket
    G04004124Courtesy of FORD MOTOR CO.
  9. Remove the A/C compressor mounting bracket brace and generator mounting bracket as an assembly.
    • Remove the bolts.
    Fig 8: Removing Bracket Bolts
    G04004125Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the A/C compressor bracket.
    Fig 9: Removing Bolts And A/C Compressor Bracket
    G04004126Courtesy of FORD MOTOR CO.
    11. NOTE: Remove and discard the coolant pump outlet tube O-ring.
    Fig 10: Removing Bolts And Coolant Pump Outlet Tube
    G04004127Courtesy of FORD MOTOR CO.
  11. Remove the coolant pump outlet tube.
    • Disconnect the 3 coolant hoses.
      • Reposition the clamps.
    • Remove the 2 bolts and the coolant pump outlet tube.
  12. Remove the bolts and the accessory drive belt tensioner.
    Fig 11: Removing Bolts And Accessory Drive Belt Tensioner
    G04004128Courtesy of FORD MOTOR CO.
  13. Remove the bolts and the power steering pump bracket.
    Fig 12: Removing Bolts And Power Steering Pump Bracket
    G04004129Courtesy of FORD MOTOR CO.
  14. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 13: Disconnecting Crankshaft Position Sensor Electrical Connector
    G04004130Courtesy of FORD MOTOR CO.
  15. Remove the catalyst monitor sensor electrical connector mounting bracket.
    Fig 14: Removing Catalyst Monitor Sensor Electrical Connector Mounting Bracket
    G04003950Courtesy of FORD MOTOR CO.
  16. Remove the bolts and the RH engine mount bracket.
    Fig 15: Removing Bolts And RH Engine Mount Bracket
    G04004132Courtesy of FORD MOTOR CO.
  17. Disconnect the oil pressure sensor electrical connector and remove the engine harness pin-type retainer.
    Fig 16: Disconnecting Oil Pressure Sensor Electrical Connector
    G04004133Courtesy of FORD MOTOR CO.
  18. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 17: Disconnecting Camshaft Position Sensor Electrical Connector
    G04004134Courtesy of FORD MOTOR CO.
  19. Disconnect the intake manifold runner control (IMRC) electrical connector.
    Fig 18: Disconnecting Intake Manifold Runner Control Electrical Connector
    G04004135Courtesy of FORD MOTOR CO.
  20. Disconnect the crankcase vent hose valve electrical connector and quick-disconnect the crankcase vent hose.
    Fig 19: Disconnecting Crankcase Vent Hose Valve Electrical Connector
    G04004136Courtesy of FORD MOTOR CO.
  21. Disconnect the quick disconnect crankcase vent hose from the intake manifold and remove.
    Fig 20: Disconnecting Quick Disconnect Crankcase Vent Hose From Intake Manifold
    G04004137Courtesy of FORD MOTOR CO.
  22. Remove the bolt and the oil level indicator and tube.
    Fig 21: Removing Bolt And Oil Level Indicator And Tube
    G04004138Courtesy of FORD MOTOR CO.
    23. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire.
    NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them.
    Fig 22: Removing Spark Plug Wires And Retainers Assembly
    G04004139Courtesy of FORD MOTOR CO.
  23. Disconnect and remove the spark plug wires and retainers as an assembly.
  24. Remove the 4 engine harness pin-type retainers.
    Fig 23: Removing Engine Harness Pin-Type Retainers
    G04003890Courtesy of FORD MOTOR CO.
  25. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 24: Disconnecting Cylinder Head Temperature Sensor Electrical Connector
    G04004141Courtesy of FORD MOTOR CO.
  26. Disconnect the following.
    1. Idle air control (IAC) electrical connector
    2. Throttle position (TP) sensor electrical connector
    3. Exhaust gas recirculation (EGR) system module electrical connector
    4. EGR system module vacuum connector
    5. EGR system module-to-exhaust manifold tube upper fitting
    Fig 25: Disconnecting Electrical Components, Vacuum Connector & EGR System Module-To-Exhaust Manifold Tube Upper Fitting
    G04004142Courtesy of FORD MOTOR CO.
  27. Loosen the nut and remove the EGR system module-to-exhaust manifold tube.
    Fig 26: Removing EGR System Module-To-Exhaust Manifold Tube
    G04004143Courtesy of FORD MOTOR CO.
  28. Disconnect the ignition coil electrical connector and remove the engine harness pin-type retainer.
    Fig 27: Disconnecting Ignition Coil Electrical Connector
    G04004144Courtesy of FORD MOTOR CO.
  29. Remove the 3 bolts and the ignition coil.
    Fig 28: Removing Bolts And Ignition Coil
    G04004287Courtesy of FORD MOTOR CO.
  30. Disconnect the 2 vacuum harness connections and remove the vacuum harness from the engine.
    Fig 29: Disconnecting Vacuum Harness Connections
    G04004146Courtesy of FORD MOTOR CO.
  31. Disconnect the engine harness-to-fuel charging harness electrical connector and remove the engine harness from the engine.
    Fig 30: Disconnecting Engine Harness-To-Fuel Charging Harness Electrical Connector
    G04004147Courtesy of FORD MOTOR CO.
  32. Remove the upper intake manifold and discard the gaskets.
    Fig 31: Removing Upper Intake Manifold
    G04004148Courtesy of FORD MOTOR CO.
  33. Remove the bolts and the fuel supply manifold, fuel injectors and fuel charging harness as an assembly.
    Fig 32: Removing Bolts And Fuel Supply Manifold, Fuel Injectors And Fuel Charging Harness Assembly
    G04004149Courtesy of FORD MOTOR CO.
  34. Remove the fuel injector clips and fuel injectors.
    Fig 33: Removing Fuel Injector Clips And Fuel Injectors
    G04004150Courtesy of FORD MOTOR CO.
  35. Remove and discard the fuel injector O-rings.
    Fig 34: Removing Fuel Injector O-Rings
    G03956375Courtesy of FORD MOTOR CO.
    36. NOTE: Record the location of the 6 long bolts and the 8 short bolts.
    Fig 35: Removing Bolts And Lower Intake Manifold Assembly
    G04004152Courtesy of FORD MOTOR CO.
  36. Remove the bolts and the lower intake manifold assembly.
  37. Remove and discard the lower intake manifold sealing components.
    Fig 36: Removing Lower Intake Manifold Sealing Components
    G04004153Courtesy of FORD MOTOR CO.
  38. Remove the nuts and the heat shield.
    Fig 37: Removing Nuts And Heat Shield
    G04004154Courtesy of FORD MOTOR CO.
  39. Remove the nuts and the RH exhaust manifold.
    Fig 38: Removing Nuts And RH Exhaust Manifold
    G04004155Courtesy of FORD MOTOR CO.
  40. Remove the nuts and the LH exhaust manifold.
    Fig 39: Removing Nuts And LH Exhaust Manifold
    G04004156Courtesy of FORD MOTOR CO.
  41. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  42. Remove the LH valve cover.
    1. Remove the bolts.
    2. Remove the stud bolts.
    3. Remove the LH valve cover.
    Fig 40: Removing LH Valve Cover
    G04004157Courtesy of FORD MOTOR CO.
  43. Remove the RH valve cover.
    1. Remove the bolts.
    2. Remove the stud bolts.
    3. Remove the RH valve cover.
    Fig 41: Removing RH Valve Cover
    G04004158Courtesy of FORD MOTOR CO.
    CAUTION: If the components are to be reinstalled, they must be installed into the same position. Mark the components for location.
    44. NOTE: If the rocker arms are to be reinstalled, they must be installed into their original locations. Mark the rocker arms for location.
    Fig 42: Removing Rocker Arms
    G04004159Courtesy of FORD MOTOR CO.
  44. Remove the rocker arms.
    1. Remove the bolts.
    2. Remove the rocker arms and pivots.
    45. NOTE: If the push rods are to be reinstalled, they must be installed into their original locations. Mark the push rods for location.
    Fig 43: Removing Push Rods
    G04004160Courtesy of FORD MOTOR CO.
  45. Remove the push rods.
  46. Remove the lower exhaust manifold studs from both cylinder heads.
    Fig 44: Identifying Exhaust Manifold Lower Studs
    G03962055Courtesy of FORD MOTOR CO.
    47. NOTE: Record the location of long and short bolts.
    Fig 45: Removing Cylinder Head Bolts
    G04004162Courtesy of FORD MOTOR CO.
  47. Remove and discard the cylinder head bolts.
    48. NOTE: RH shown, LH similar.
    Fig 46: Removing RH And LH Cylinder Heads And Gaskets
    G04004163Courtesy of FORD MOTOR CO.
  48. Remove the RH and LH cylinder heads and the gaskets. Discard the gasket.
    49. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
  49. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
  50. Inspect the cylinder heads for distortion. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  51. Remove the oil filter.
    Fig 47: Removing Oil Filter
    G04004164Courtesy of FORD MOTOR CO.
    52. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
  52. If equipped, remove the oil cooler and tube assembly and discard. For additional information, refer to OIL COOLER .
  53. Remove the oil pressure sensor.
    Fig 48: Removing Oil Pressure Sensor
    G04004165Courtesy of FORD MOTOR CO.
    54. NOTE: Discard the oil pan rear seal.
    Fig 49: Removing Bolts And Oil Pan
    G03962175Courtesy of FORD MOTOR CO.
  54. Remove the bolts and the oil pan.
    55. NOTE: In some cases the oil pump intermediate shaft may not come out with the synchronizer assembly. If so, retrieve the intermediate shaft before proceeding.
    Fig 50: Removing Bolt And Camshaft Synchronizer Assembly
    G04004167Courtesy of FORD MOTOR CO.
  55. Remove the bolt and the camshaft synchronizer assembly.
  56. Using the special tool, remove the crankshaft damper and pulley assembly.
    Fig 51: Removing Crankshaft Damper And Pulley Assembly
    G04003946Courtesy of FORD MOTOR CO.
  57. Using the special tool, remove the crankshaft front seal. Discard the seal.
    Fig 52: Removing Crankshaft Front Seal
    G04003922Courtesy of FORD MOTOR CO.
  58. Remove the coolant pump.
    • Remove the stud bolts.
    • Remove the coolant pump.
    • Discard the coolant pump housing gasket.
    Fig 53: Removing Coolant Pump
    G03962180Courtesy of FORD MOTOR CO.
  59. Remove the engine front cover and oil pump assembly and the engine front cover gasket.
    1. Remove the stud bolts.
    2. Remove the bolt.
      3. CAUTION: The capscrew is hidden; make sure to remove it or the engine front cover will be damaged.
    3. Remove the capscrew.
    4. Slide the engine front cover and engine front cover gasket from the dowels. Discard the engine front cover gasket.
    5. Remove the studs.
    Fig 54: Removing Studs
    G04004171Courtesy of FORD MOTOR CO.
  60. Remove the camshaft synchronizer drive gear.
    1. Remove the bolt.
    2. Remove the camshaft synchronizer drive gear.
    Fig 55: Removing Camshaft Synchronizer Drive Gear
    G04003964Courtesy of FORD MOTOR CO.
  61. Compress and install a retaining pin to hold the timing chain tensioner.
    Fig 56: Installing Retaining Pin To Hold Timing Chain Tensioner
    G03962183Courtesy of FORD MOTOR CO.
  62. Remove the camshaft gear, the crankshaft gear and the timing chain as an assembly.
    Fig 57: Identifying Timing Chain And Sprockets
    G03962031Courtesy of FORD MOTOR CO.
  63. Remove the bolts and the timing chain tensioner.
    Fig 58: Identifying Timing Chain Tensioner And Mounting Bolts
    G03962032Courtesy of FORD MOTOR CO.
    64. NOTE: If the valve tappets are to be reinstalled, they must be installed into their original locations. Mark the valve tappets for location.
    Fig 59: Removing Valve Tappets
    G04004176Courtesy of FORD MOTOR CO.
  64. Remove the valve tappets.
    1. Remove the bolts.
    2. Remove the tappet guide plate and retainer.
    3. Remove the valve tappets.
  65. Remove the engine balance shaft drive gear and camshaft key.
    Fig 60: Removing Engine Balance Shaft Drive Gear And Camshaft Key
    G04004177Courtesy of FORD MOTOR CO.
  66. Remove the engine dynamic balance shaft.
    • Remove the bolts.
    • Remove the balance shaft driven gear, thrust plate and engine dynamic balance shaft as an assembly.
    Fig 61: Removing Engine Dynamic Balance Shaft
    G04004178Courtesy of FORD MOTOR CO.
  67. Remove the camshaft.
    1. Remove the bolts.
    2. Remove the camshaft thrust plate.
    3. Remove the spacer.
    4. Remove the camshaft.
    Fig 62: Removing Camshaft
    G04004179Courtesy of FORD MOTOR CO.
  68. Remove the bearing covers.
    1. Remove the engine dynamic balance shaft bearing cover.
    2. Remove the camshaft bearing cover.
    Fig 63: Removing Bearing Covers
    G04004180Courtesy of FORD MOTOR CO.
  69. Remove the oil pump screen cover and tube.
    • Remove the nut.
    • Remove the bolts.
    Fig 64: Removing Oil Pump Screen Cover And Tube
    G03962191Courtesy of FORD MOTOR CO.
  70. Remove the nuts and the oil pan baffle.
    Fig 65: Removing Nuts And Oil Pan Baffle
    G03962192Courtesy of FORD MOTOR CO.
  71. If necessary, remove the ridge at the top of the cylinder.
    72. CAUTION: The connecting rods and bearings are matched to the crankshaft journals. Make sure the components are marked and installed in the correct location.
    CAUTION: Each connecting rod and connecting rod cap are matched sets. They will fit together only one way. Mark them before removing.
    CAUTION: Do not damage the connecting rod and the connecting rod cap fractured joint face surface or engine damage can occur.
    Fig 66: Removing Connecting Rod Cap And Lower Connecting Rod Bearing
    G04004183Courtesy of FORD MOTOR CO.
  72. Remove the piston.
    1. Make sure the piston being removed is at the bottom of the cylinder bore.
    2. Remove the bolts.
    3. Remove the connecting rod cap and the lower connecting rod bearing.
      4. CAUTION: Do not damage the cylinder wall when removing the piston.
    4. Push the piston and the connecting rod out of the cylinder.
  73. Repeat the piston removal steps for the remaining pistons.
    74. CAUTION: The crankshaft main bearings and the main bearing caps are matched to the crankshaft journals. Make sure the components are marked for position.
    NOTE: The crankshaft main bearing located at the main bearing cap is the thrust bearing.
    Fig 67: Removing Main Bearing Cap And Lower Crankshaft Main Bearing
    G04004184Courtesy of FORD MOTOR CO.
  74. Remove the 4 main bearing caps and lower crankshaft main bearings.
    1. Remove the stud bolts.
    2. Remove the main bearing cap and lower crankshaft main bearing.
  75. Repeat the main bearing cap and the lower bearing removal steps for the remaining main bearing caps and the lower crankshaft main bearings.
    76. CAUTION: The crankshaft journals must be protected from damage when the crankshaft is removed.
    Fig 68: Removing Crankshaft
    G03962195Courtesy of FORD MOTOR CO.
  76. Remove the crankshaft.
    77. NOTE: For ease in reassembly, record the location of the crankshaft upper thrust bearing.
    Fig 69: Removing Upper Crankshaft Main Bearings And Crankshaft Upper Thrust Bearing
    G03962196Courtesy of FORD MOTOR CO.
  77. Remove the upper crankshaft main bearings and the crankshaft upper thrust bearing.
  78. Remove the camshaft bearings.
    Fig 70: Removing Camshaft Bearings
    G03962197Courtesy of FORD MOTOR CO.
  79. Remove the engine dynamic balance shaft bearings.
    Fig 71: Removing Engine Dynamic Balance Shaft Bearings
    G03962198Courtesy of FORD MOTOR CO.
  80. If equipped, remove the engine block heater.
    Fig 72: Removing Engine Block Heater
    G03962199Courtesy of FORD MOTOR CO.
    81. NOTE: For cleaning purposes, the plugs should be removed.
    Fig 73: Removing Cylinder Block Dowels
    G04004190Courtesy of FORD MOTOR CO.
  81. If necessary, remove the following:
    1. Cylinder block dowels
    2. Oil gallery plugs
    3. Water jacket plugs
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