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Special Tool(s)

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS TABLE

G06094842Courtesy of FORD MOTOR CO.
 Alignment Plate, Camshaft 303-465 (T94P-6256-CH)
G06095131Courtesy of FORD MOTOR CO.
 Engine Stand 014-00232 or equivalent
G06062108Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane 014-00071 or equivalent
G06271712Courtesy of FORD MOTOR CO.
 Holding Tool, Crankshaft Damper 303-1416
G06181716Courtesy of FORD MOTOR CO.
 Installer, Connecting Rod 303-462 (T94P-6136-AH)
G06271952Courtesy of FORD MOTOR CO.
 Remover, Oil Seal 303-409 (T92C-6700-CH)
G06062110Courtesy of FORD MOTOR CO.
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
G06096788Courtesy of FORD MOTOR CO.
 Timing Peg, Crankshaft TDC  303-507
NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools or severe engine damage may occur.
NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
NOTE: Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.
NOTE: For additional information, refer to Engine  .
  1. Remove the 6 bolts and the flywheel.
    Fig 1: Locating Flywheel Bolts
    G06095136Courtesy of FORD MOTOR CO.
  2. Mount the engine on a suitable engine stand.
  3. If equipped, disconnect the engine block heater.
    Fig 2: Locating Engine Block Heater
    G06271956Courtesy of FORD MOTOR CO.
  4. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
    • Detach the connector from the engine wiring harness connector bracket.
    Fig 3: Locating Connector From Engine Wiring Harness Connector Bracket
    G06271957Courtesy of FORD MOTOR CO.
  5. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 4: Locating Catalyst Monitor Sensor (CMS) Electrical Connector
    G06271958Courtesy of FORD MOTOR CO.
  6. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 5: Locating Crankshaft Position (CKP) Sensor Electrical Connector
    G06271959Courtesy of FORD MOTOR CO.
  7. Remove the bolt and the engine wiring harness connector bracket.
    Fig 6: Locating Engine Wiring Harness Connector Bracket & Bolt
    G06271960Courtesy of FORD MOTOR CO.
  8. Detach the 2 engine wiring harness pin-type retainers.
    Fig 7: Locating Engine Wiring Harness Pin-Type Retainers
    G06271961Courtesy of FORD MOTOR CO.
  9. Remove the 6 bolts and the catalytic converter manifold heat shield.
    Fig 8: Locating Catalytic Converter Manifold Heat Shield & Bolts
    G06271962Courtesy of FORD MOTOR CO.
  10. Remove the 2 catalytic converter manifold bracket-to-engine block bolts.
    Fig 9: Locating Catalytic Converter Manifold Bracket-To-Engine Block Bolts
    G06271963Courtesy of FORD MOTOR CO.
  11. Remove the 7 nuts and the catalytic converter manifold.
    • Discard the nuts and the catalytic converter manifold gasket.
    Fig 10: Locating Catalytic Converter Manifold & Nuts
    G06271964Courtesy of FORD MOTOR CO.
  12. Remove and discard the 7 cylinder head studs.
    Fig 11: Locating Cylinder Head Studs
    G06095145Courtesy of FORD MOTOR CO.
  13. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
    Fig 12: Rotating Accessory Drive Belt Tensioner Counterclockwise
    G06271966Courtesy of FORD MOTOR CO.
  14. Detach the vehicle high voltage electrical system electrical connector retainer from the accessory drive belt tensioner.
    Fig 13: Locating Vehicle High Voltage Electrical System Electrical Connector Retainer
    G06271967Courtesy of FORD MOTOR CO.
  15. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 14: Locating Accessory Drive Belt Tensioner & Bolts
    G06271968Courtesy of FORD MOTOR CO.
  16. Disconnect the electronic throttle control electrical connector.
    Fig 15: Locating Electronic Throttle Control Electrical Connector
    G06096288Courtesy of FORD MOTOR CO.
  17. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
    Fig 16: Locating Evaporative Emission Canister Purge Valve Electrical Connector
    G06096289Courtesy of FORD MOTOR CO.
  18. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
    Fig 17: Locating Engine Oil Pressure (EOP) Switch Electrical Connector
    G06271971Courtesy of FORD MOTOR CO.
  19. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
    Fig 18: Locating Manifold Absolute Pressure Sensor Electrical Connector
    G06096291Courtesy of FORD MOTOR CO.
  20. Disconnect the Knock Sensor (KS) electrical connector and detach the electrical connector pin-type retainer from the intake manifold.
    Fig 19: Locating Knock Sensor Electrical Connector & Electrical Connector Pin-Type Retainer
    G06096292Courtesy of FORD MOTOR CO.
  21. Disconnect the A/C compressor electrical connector.
    Fig 20: Locating A/C Compressor Electrical Connector
    G06271974Courtesy of FORD MOTOR CO.
  22. Remove the 3 bolts and the A/C compressor.
    Fig 21: Locating A/C Compressor & Bolts
    G06271975Courtesy of FORD MOTOR CO.
  23. Disconnect the Variable Camshaft Timing (VCT) oil control solenoid electrical connector and detach the wiring harness retainer from the valve cover stud bolt.
    Fig 22: Locating VCT Oil Control Solenoid Electrical Connector
    G06271976Courtesy of FORD MOTOR CO.
  24. Detach the 3 wire harness pin-type retainers.
    Fig 23: Locating Wire Harness Pin-Type Retainers
    G06271977Courtesy of FORD MOTOR CO.
  25. Detach the 2 auxiliary coolant pump wiring retainers and the lower radiator hose retainer.
    Fig 24: Locating Auxiliary Coolant Pump Wiring Retainers & Lower Radiator Hose Retainer
    G06271978Courtesy of FORD MOTOR CO.
  26. Disconnect the auxiliary coolant pump hose and the upper radiator hose.
    Fig 25: Locating Auxiliary Coolant Pump Hose & Upper Radiator Hose
    G06271979Courtesy of FORD MOTOR CO.
  27. Disconnect the EGR coolant hose and the auxiliary coolant pump hose.
    • Remove the upper radiator hose and the auxiliary coolant pump as an assembly.
    Fig 26: Locating Upper Radiator Hose & Auxiliary Coolant Pump Assembly
    G06271980Courtesy of FORD MOTOR CO.
  28. Remove the 2 bolts and the A/C compressor bracket.
    Fig 27: Locating A/C Compressor Bracket & Bolts
    G06271981Courtesy of FORD MOTOR CO.
  29. Disconnect the vacuum hose from the intake manifold.
    Fig 28: Locating Vacuum Hose From Intake Manifold
    G06271982Courtesy of FORD MOTOR CO.
  30. Remove the 2 bolts, the nut and the vacuum pump assembly.
    Fig 29: Locating Bolts, Nut & Vacuum Pump Assembly
    G06096314Courtesy of FORD MOTOR CO.
  31. Detach the 3 wire harness pin-type retainers from the intake manifold.
    Fig 30: Locating Wire Harness Pin-Type Retainers From Intake Manifold
    G06271984Courtesy of FORD MOTOR CO.
  32. Remove the 7 bolts and position the intake manifold aside to access the PCV hose connector.
    NOTE: The cylinder head side of the intake manifold is showing the location of the 7 bolts.
    Fig 31: Locating Position Intake Manifold Aside & Bolts
    G06271985Courtesy of FORD MOTOR CO.
  33. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.
    • Remove the intake manifold.
    Fig 32: Locating PCV Hose Connector Tabs
    G06095172Courtesy of FORD MOTOR CO.
  34. Remove the EGR tube.
    Fig 33: Locating EGR Tube
    G06095173Courtesy of FORD MOTOR CO.
  35. Disconnect the 4 fuel injector electrical connectors, radio capacitor electrical connector and the Camshaft Position (CMP) sensor electrical connector.
    Fig 34: Locating Fuel Injector Electrical Connectors, Radio Capacitor Electrical Connector & CMP Sensor Electrical Connector
    G06096297Courtesy of FORD MOTOR CO.
  36. Disconnect the 4 coil-on-plug electrical connectors.
    Fig 35: Locating Coil-On-Plug Electrical Connectors
    G06096304Courtesy of FORD MOTOR CO.
  37. Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
    Fig 36: Locating CHT Sensor Electrical Connector
    G06262317Courtesy of FORD MOTOR CO.
  38. Disconnect the EGR valve electrical connector and detach the 2 wiring harness retainers from the valve cover and stud bolt.
    • Remove the engine control wiring harness from the engine.
    Fig 37: Locating EGR Valve Electrical Connector & Wiring Harness Retainers From Valve Cover & Stud Bolt
    G06271991Courtesy of FORD MOTOR CO.
  39. Remove the fuel rail insulator.
    Fig 38: Locating Fuel Rail Insulator
    G06271992Courtesy of FORD MOTOR CO.
  40. Remove the nut and the radio capacitor.
    Fig 39: Locating Nut & Radio Capacitor
    G06096302Courtesy of FORD MOTOR CO.
  41. Remove the 2 stud bolts and the fuel rail with the fuel injectors.
    Fig 40: Locating Stud Bolts
    G06096303Courtesy of FORD MOTOR CO.
  42. Remove the 3 bolts and the coolant pump pulley.
    Fig 41: Locating Bolts & Coolant Pump Pulley
    G06095149Courtesy of FORD MOTOR CO.
  43. Remove the 3 bolts and the coolant pump.
    Fig 42: Locating Bolts & Coolant Pump
    G06095150Courtesy of FORD MOTOR CO.
  44. Remove the 3 bolts and the thermostat housing.
    Fig 43: Locating Bolts & Thermostat Housing
    G06271997Courtesy of FORD MOTOR CO.
  45. Disconnect the bypass hose.
    Fig 44: Locating Bypass Hose
    G06262309Courtesy of FORD MOTOR CO.
  46. Remove the bolt and the KS  .
    Fig 45: Locating Knock Sensor & Bolt
    G06262307Courtesy of FORD MOTOR CO.
  47. Remove the 8 bolts and the crankcase vent oil separator.
    Fig 46: Locating Bolts & Crankcase Vent Oil Separator
    G06095178Courtesy of FORD MOTOR CO.
  48. Remove the 4 bolts and the oil filter adapter.
    • Discard the gasket.
    Fig 47: Locating Bolts & Oil Filter Adapter
    G06095154Courtesy of FORD MOTOR CO.
  49. If equipped, remove the block heater.
    Fig 48: Identifying Block Heater
    G06095179Courtesy of FORD MOTOR CO.
  50. Remove the crankshaft vent tube.
    Fig 49: Locating Crankshaft Vent Tube
    G06096319Courtesy of FORD MOTOR CO.
  51. Remove the 2 engine cover studs (one shown).
    Fig 50: Locating Engine Cover Studs
    G06272004Courtesy of FORD MOTOR CO.
  52. Remove the 4 stud bolts and the coil-on-plugs from the valve cover.
    Fig 51: Locating Coil-On-Plugs Stud Bolts
    G06096321Courtesy of FORD MOTOR CO.
  53. Remove the oil level indicator.
    Fig 52: Locating Oil Level Indicator
    G06095180Courtesy of FORD MOTOR CO.
  54. Remove the CHT  sensor.
    Fig 53: Locating CHT Sensor
    G06272007Courtesy of FORD MOTOR CO.
  55. Remove the bolts and the valve cover.
    Fig 54: Locating Bolts & Valve Cover
    G06272008Courtesy of FORD MOTOR CO.
  56. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
    • The hole in the crankshaft pulley should be in the 6 o'clock position.
    NOTE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
    Fig 55: Locating Crankshaft Pulley Bolt
    G06271778Courtesy of FORD MOTOR CO.
  57. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
    NOTE: The Camshaft Alignment Plate 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate 303-465 cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
    Fig 56: Removing Camshaft Alignment Plate
    G06271853Courtesy of FORD MOTOR CO.
  58. Remove the engine plug bolt.
    Fig 57: Locating Engine Plug Bolt
    G06094848Courtesy of FORD MOTOR CO.
  59. Install the Crankshaft TDC  Timing Peg.
    NOTE: The Crankshaft TDC  Timing Peg will contact the crankshaft and prevent it from turning past TDC  . However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC  position during the crankshaft pulley removal and installation.
    Fig 58: Installing Crankshaft Timing Peg
    G06096793Courtesy of FORD MOTOR CO.
  60. Using the Crankshaft Damper Holding Tool and an air impact wrench, remove the crankshaft pulley.
    • Remove and discard the crankshaft pulley bolt and washer.
    • Remove the crankshaft pulley.
    • Remove the diamond washer and discard.
    NOTE: The crankshaft must remain in the Top Dead Center (TDC) position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
    NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced; remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur.
    Fig 59: Locating Crankshaft Pulley Bolt
    G06181755Courtesy of FORD MOTOR CO.
  61. Using the Oil Seal Remover, remove the crankshaft front oil seal.
    NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
    Fig 60: Removing Crankshaft Front Oil Seal
    G06181756Courtesy of FORD MOTOR CO.
  62. Remove the 2 bolts and the CKP  sensor.
    Fig 61: Locating CKP Sensor & Bolts
    G06272015Courtesy of FORD MOTOR CO.
  63. Remove the bolts and the engine front cover.
    Fig 62: Identifying Engine Front Cover Bolts
    G06094884Courtesy of FORD MOTOR CO.
  64. Compress the timing chain tensioner in the following sequence.
    1. Using a small pick, release and hold the ratchet mechanism.
    2. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.
    3. Insert a paper clip into the hole to retain the tensioner.
    Fig 63: Compressing Timing Chain Tensioner
    G06181585Courtesy of FORD MOTOR CO.
  65. Remove the 2 bolts and timing chain tensioner.
    Fig 64: Locating Timing Chain Tensioner Bolts
    G06181586Courtesy of FORD MOTOR CO.
  66. Remove the RH timing chain guide.
    Fig 65: Locating RH Timing Chain Guide & Bolts
    G06094894Courtesy of FORD MOTOR CO.
  67. Remove the timing chain.
    Fig 66: Locating Timing Chain
    G06271761Courtesy of FORD MOTOR CO.
  68. Remove the bolts and the LH timing chain guide.
    Fig 67: Identifying Bolts & LH Timing Chain Guide
    G06094896Courtesy of FORD MOTOR CO.
  69. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.
    NOTE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
    Fig 68: Locating Flats On Camshaft, Bolt & Exhaust Camshaft Sprocket
    G06094897Courtesy of FORD MOTOR CO.
  70. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the intake camshaft phaser and sprocket.
    NOTE: The Camshaft Alignment Plate 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    Fig 69: Locating Flats On Camshaft, Bolt & Camshaft Phaser & Sprocket
    G06094898Courtesy of FORD MOTOR CO.
  71. Remove the oil pump chain tensioner.
    1. Release the tension on the tensioner spring.
    2. Remove the tensioner and the shoulder bolts.
    Fig 70: Identifying Oil Pump Chain Drive Tensioner
    G06095011Courtesy of FORD MOTOR CO.
  72. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain and sprockets.
    NOTE: Remove and discard the crankshaft sprocket diamond washer located behind the crankshaft sprocket.
    NOTE: The oil pump chain sprocket must be held in place.
    Fig 71: Identifying Oil Pump Chain & Sprockets With Bolt
    G06095200Courtesy of FORD MOTOR CO.
  73. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
    Fig 72: Identifying Camshaft Lobe Position
    G06094924Courtesy of FORD MOTOR CO.
  74. Remove the bolt and the Variable Camshaft Timing (VCT) solenoid.
    Fig 73: Locating Bolt & Variable Camshaft Timing Solenoid
    G06095202Courtesy of FORD MOTOR CO.
  75. Remove the plug and the VCT  system oil filter from the intake camshaft thrust cap.
    Fig 74: Locating Plug & VCT System Oil Filter From Intake Camshaft Thrust Cap
    G06272028Courtesy of FORD MOTOR CO.
  76. Remove the camshafts from the engine.
    • Loosen the camshaft bearing bolts in the sequence shown below, one turn at a time. Repeat until all the tension is released.
    • Remove the camshaft bearing caps.
    • Remove the camshafts.
    NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
    NOTE: Mark the location and orientation of each camshaft bearing cap.
    Fig 75: Identifying Camshaft Bearing Cap Bolt Loosening Sequence
    G06094925Courtesy of FORD MOTOR CO.
  77. Remove and inspect the valve tappets. For additional information, refer to VALVE TAPPET INSPECTION .
    NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.
    NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
  78. Remove the cylinder head.
    • Remove and discard the cylinder head bolts.
    • Remove the cylinder head.
    • Remove and discard the cylinder head gasket.
    Fig 76: Locating Cylinder Head Bolts
    G06095205Courtesy of FORD MOTOR CO.
  79. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to GENERAL PROCEDURES .
  80. Remove the cylinder head alignment dowels.
    Fig 77: Identifying Cylinder Head Alignment Dowels
    G06095206Courtesy of FORD MOTOR CO.
  81. Remove the bolts and the oil pan.
    Fig 78: Locating Oil Pan & Bolts
    G06272032Courtesy of FORD MOTOR CO.
  82. Remove the bolts and the crankshaft rear oil seal with retainer.
    Fig 79: Locating Bolts & Rear Crankshaft Seal
    G06095208Courtesy of FORD MOTOR CO.
  83. Remove the bolts, oil pump pickup tube and gasket.
    Fig 80: Locating Oil Pump Pickup Tube & Gasket
    G06095209Courtesy of FORD MOTOR CO.
  84. Remove the bolts and the oil pump.
    Fig 81: Locating Oil Pump Assembly Bolts
    G06095210Courtesy of FORD MOTOR CO.
  85. Remove the bolts and the block-off plate.
    Fig 82: Locating Bolts & Block-Off Plate
    G06272036Courtesy of FORD MOTOR CO.
  86. Make sure the Crankshaft TDC  Timing Peg is still installed and the engine is still at Top Dead Center (TDC).
    • Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC  Timing Peg.
    Fig 83: Locating Crankshaft Timing Peg
    G06181552Courtesy of FORD MOTOR CO.
  87. Mark the balancer unit front shafts on the top for reference that the balancer unit is at TDC  .
    Fig 84: Locating Balancer Unit & Shafts Reference Mark
    G06261755Courtesy of FORD MOTOR CO.
  88. Remove the 4 bolts and the balancer unit.
    NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
    Fig 85: Locating Bolts & Balancer Unit
    G06261756Courtesy of FORD MOTOR CO.
  89. Remove the Crankshaft TDC  Timing Peg.
    Fig 86: Locating Crankshaft Timing Peg
    G06181552Courtesy of FORD MOTOR CO.
  90. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
  91. Remove the connecting rod cap bolts and cap.
    NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
    Fig 87: Locating Connecting Rod Cap Bolts
    G06095215Courtesy of FORD MOTOR CO.
  92. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
    • Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
    NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 88: Identifying Connecting Rod Installer
    G06095216Courtesy of FORD MOTOR CO.
  93. Remove the bolts in the sequence shown.
    • Remove the main bearing beam.
    • Discard the bolts.
    Fig 89: Identifying Crankshaft Cap Bolt Removing Sequence
    G06095217Courtesy of FORD MOTOR CO.
  94. Remove the crankshaft from the engine block.
    Fig 90: Locating Crankshaft
    G06095218Courtesy of FORD MOTOR CO.
  95. Remove the main bearings from the main bearing beam.
    NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
    Fig 91: Locating Main Bearings
    G06095219Courtesy of FORD MOTOR CO.
  96. Remove the main bearings from the cylinder block.
    NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
    NOTE: The center bulkhead has the thrust bearing.
    Fig 92: Locating Main Bearings
    G06095220Courtesy of FORD MOTOR CO.
  97. Remove the 4 oil squirters.
    NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly.
    NOTE: The front bulkhead does not have an oil squirter.
    Fig 93: Locating Oil Squirters
    G06272047Courtesy of FORD MOTOR CO.
  98. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to GENERAL PROCEDURES .
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