Removal Procedure

1. Remove the engine. For additional information, refer to ENGINE  under REMOVAL in this section.
2. Mount the engine on a suitable engine stand.
3. To remove individual components, carry out only the listed steps.
   INDIVIDUAL COMPONENTS REMOVING STEPS
   
   

   Component	Step
   RH cylinder head	1-76, 83-133, 142-144
   LH cylinder head	1-82, 89-125, 134-141, 145-147

4. Illustration 1 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 1.
   Fig 1: Removing Order Of Cylinder Head Components (1 Of 20)

   Courtesy of FORD MOTOR CO.
5. Illustration 2 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 2.
   Fig 2: Removing Order Of Cylinder Head Components (2 Of 20)

   Courtesy of FORD MOTOR CO.
6. Illustration 3 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 3.
   Fig 3: Removing Order Of Cylinder Head Components (3 Of 20)

   Courtesy of FORD MOTOR CO.
7. Illustration 4 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 4.
   Fig 4: Removing Order Of Cylinder Head Components (4 Of 20)

   Courtesy of FORD MOTOR CO.
8. Illustration 5 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 5.
   Fig 5: Removing Order Of Cylinder Head Components (5 Of 20)

   Courtesy of FORD MOTOR CO.
9. Illustration 6 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 6.
   Fig 6: Removing Order Of Cylinder Head Components (6 Of 20)

   Courtesy of FORD MOTOR CO.
10. Illustration 7 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 7.
    Fig 7: Removing Order Of Cylinder Head Components (7 Of 20)

    Courtesy of FORD MOTOR CO.
11. Illustration 8 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 8.
    Fig 8: Removing Order Of Cylinder Head Components (8 Of 20)

    Courtesy of FORD MOTOR CO.
12. Illustration 9 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 9.
    Fig 9: Removing Order Of Cylinder Head Components (9 Of 20)

    Courtesy of FORD MOTOR CO.
13. Illustration 10 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 10.
    Fig 10: Removing Order Of Cylinder Head Components (10 Of 20)

    Courtesy of FORD MOTOR CO.
14. Illustration 11 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 11.
    Fig 11: Removing Order Of Cylinder Head Components (11 Of 20)

    Courtesy of FORD MOTOR CO.
15. Illustration 12 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 12.
    Fig 12: Removing Order Of Cylinder Head Components (12 Of 20)

    Courtesy of FORD MOTOR CO.
16. Illustration 13 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 13.
    Fig 13: Removing Order Of Cylinder Head Components (13 Of 20)

    Courtesy of FORD MOTOR CO.
17. Illustration 14 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 14.
    Fig 14: Removing Order Of Cylinder Head Components (14 Of 20)

    Courtesy of FORD MOTOR CO.
18. Illustration 15 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 15.
    Fig 15: Removing Order Of Cylinder Head Components (15 Of 20)

    Courtesy of FORD MOTOR CO.
NOTE: The following illustration is for reference only. Removal notes must be followed for removing timing drive components.
Fig 16: Removing Order Of Cylinder Head Components (16 Of 20)
Courtesy of FORD MOTOR CO.
19. Illustration 16 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 16.
NOTE: The following illustration is for reference only. Removal notes must be followed for removing drive components.
Fig 17: Removing Order Of Cylinder Head Components (17 Of 20)
Courtesy of FORD MOTOR CO.
20. Illustration 17 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 17.
NOTE: The following illustration is for reference only. Removal notes must be followed for removing drive components.
Fig 18: Removing Order Of Cylinder Head Components (18 Of 20)
Courtesy of FORD MOTOR CO.
21. Illustration 18 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 18.
22. Illustration 19 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 19.
    Fig 19: Removing Order Of Cylinder Head Components (19 Of 20)

    Courtesy of FORD MOTOR CO.
23. Illustration 20 of 20. Remove the components in the order indicated in the following illustration and table. See Fig 20.
    Fig 20: Removing Order Of Cylinder Head Components (20 Of 20)

    Courtesy of FORD MOTOR CO.

Items 1 and 2: Flanged Plug Removal Note 

1. Drain the coolant from the engine block.

Item 9: Coolant Pump Pulley Bolts Removal Note 

1. Loosen the coolant pump pulley bolts prior to removing the accessory drive bolt.

Item 15: Coolant Pump Pulley Removal Note 

1. Remove the coolant pump pulley bolts and the coolant pump pulley.

Items 16-18: Crankshaft Pulley Removal Note 

NOTE: Hold the crankshaft pulley with the special tool while removing the bolt and washer.
Fig 21: Removing Crankshaft Pulley Bolt And Washer
Courtesy of FORD MOTOR CO.
1. Remove the bolt and washer.
   • Discard the bolt and washer.
2. Using the special tool, remove the crankshaft damper.
   Fig 22: Removing Crankshaft Damper Using Special Tool

   Courtesy of FORD MOTOR CO.

Item 19: Crankshaft Front Seal Removal Note 

1. Using the special tool, remove the crankshaft front seal.
   • Discard the seal.
   Fig 23: Removing Crankshaft Front Seal Using Special Tool

   Courtesy of FORD MOTOR CO.

Items 27-30: RH and LH Coil Cover Removal Note 

1. Remove all silicone sealer and residue from the coil covers.
   Fig 24: Removing All Silicone Sealer And Residue From Coil Covers

   Courtesy of FORD MOTOR CO.
2. Remove all silicone sealer and residue from the valve cover surface and ignition coil wiring harness.
   Fig 25: Removing All Silicone Sealer And Residue From Valve Cover Surface And Ignition Coil Wiring Harness

   Courtesy of FORD MOTOR CO.

Items 41 and 42: Engine Cover Support Bracket Removal Note 

1. Disconnect the engine wiring harness retainers from the engine cover support bracket.
   Fig 26: Disconnecting Engine Wiring Harness Retainers From Engine Cover Support Bracket

   Courtesy of FORD MOTOR CO.

Item 43: Engine Wiring Harness Removal Note 

NOTE: LH is shown, RH is similar.
Fig 27: Disconnecting Engine Wiring Harness Retainers From RH Engine Appearance Cover Support Bracket
Courtesy of FORD MOTOR CO.
1. Disconnect the engine wiring harness retainers from the RH engine appearance cover support bracket.
NOTE: LH is shown, RH is similar.
Fig 28: Disconnecting Fuel Injector And Radio Interference Capacitor Electrical Connectors
Courtesy of FORD MOTOR CO.
2. Disconnect the fuel injector and radio interference capacitor electrical connectors
NOTE: LH shown, RH similar.
Fig 29: Disconnecting Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
3. Disconnect the ignition coil electrical connectors.
4. Disconnect the EGR system module electrical connector.
5. Remove the nuts and the engine wiring harness retainer and position aside.
   Fig 30: Removing Engine Wiring Harness Retainer Nuts

   Courtesy of FORD MOTOR CO.
NOTE: RH is shown, LH is similar.
Fig 31: Disconnecting Variable Cam Timing (VCT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
6. Disconnect the variable cam timing (VCT) sensor electrical connector.
7. Disconnect the wiring harness retainers from the LH valve cover.
   Fig 32: Disconnecting Wiring Harness Retainers From LH Valve Cover

   Courtesy of FORD MOTOR CO.
8. Disconnect the three wiring harness retainers from the RH valve cover.
   Fig 33: Disconnecting Wiring Harness Retainers From RH Valve Cover

   Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
Fig 34: Disconnecting Pin-Type Retainers
Courtesy of FORD MOTOR CO.
9. Disconnect the pin-type retainers.
10. Disconnect the generator electrical connector.
    Fig 35: Disconnecting Generator Electrical Connector

    Courtesy of FORD MOTOR CO.
11. Remove the wiring harness from the front cover.
    Fig 36: Removing Wiring Harness From Front Cover

    Courtesy of FORD MOTOR CO.
12. Remove the wiring harness from the front cover.
    Fig 37: Removing Wiring Harness From Front Cover

    Courtesy of FORD MOTOR CO.
13. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 38: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
14. Remove the heated oxygen sensor (HO2S) connectors from the brackets.
    Fig 39: Removing Heated Oxygen Sensor (HO2S) Connectors From Brackets

    Courtesy of FORD MOTOR CO.
15. Remove the engine wiring harness from the engine.

Item 52: EGR System Module Removal Note 

1. Disconnect the EGR system module-to-exhaust manifold tube from the EGR system module.
   Fig 40: Disconnecting EGR System Module-To-Exhaust Manifold Tube From EGR System Module

   Courtesy of FORD MOTOR CO.

Items 65-67 Intake Manifold Removal Note 

NOTE: RH is shown, LH is similar.
Fig 41: Removing Radio Interference Capacitor Nut
Courtesy of FORD MOTOR CO.
1. Remove the nut and the radio interference capacitor.
2. Remove the bolts and studs in the sequence shown. See Fig 42.
   Fig 42: Removing Sequence Of Intake Manifold Bolts And Studs

   Courtesy of FORD MOTOR CO.
3. Remove the intake manifold.
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, which make leak paths. Use a plastic scraping tool to clean the surfaces.
Fig 43: Cleaning Sealing Surfaces
Courtesy of FORD MOTOR CO.
4. Clean the sealing surfaces.

Items 69-71: RH Valve Cover Removal Note 

1. Remove the bolts in the sequence shown and remove the RH valve cover. See Fig 44.
   Fig 44: Identifying RH Valve Cover Bolt Removing Sequence

   Courtesy of FORD MOTOR CO.
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, which make leak paths. Use a plastic scraping tool to clean the surfaces.
Fig 45: Identifying Mating Surfaces Cleaning Area (RH)
Courtesy of FORD MOTOR CO.
2. Remove the gaskets and all silicone sealer. Clean the mating surfaces with silicone gasket remover.

Items 73-75: LH Valve Cover Removal Note 

1. Remove the bolts in the sequence shown and remove the LH valve cover.
   Fig 46: Identifying LH Valve Cover Bolts Removing Sequence

   Courtesy of FORD MOTOR CO.
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, which make leak paths. Use a plastic scraping tool to clean the surfaces.
Fig 47: Identifying Mating Surfaces Cleaning Area (LH)
Courtesy of FORD MOTOR CO.
2. Remove the gaskets and all silicone sealer. Clean the mating surfaces with silicone gasket remover.

Item 86: RH Exhaust Manifold Removal Note 

1. Remove the EGR tube.
   • Remove the nuts.
   • Remove the EGR tube.
   • Remove and discard the EGR tube gasket.
Fig 48: Removing EGR Tube
Courtesy of FORD MOTOR CO.

Items 89 and 90: Engine Front Cover Removal Note 

1. Remove the engine front cover.
   • Remove the bolts in the sequence shown.
   • Remove the engine front cover.
   Fig 49: Identifying Engine Front Cover Bolts Removing Sequence

   Courtesy of FORD MOTOR CO.
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, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
Fig 50: Cleaning Sealing Surfaces
Courtesy of FORD MOTOR CO.
2. Clean the sealing surfaces.

Items 97-115, 112-122, 124: Timing Drive Components Removal Note 

1. Remove the crankshaft position (CKP) sensor.
   Fig 51: Removing Crankshaft Position (CKP) Sensor

   Courtesy of FORD MOTOR CO.
NOTE: There is one window on the ignition pulse wheel that is unique to accept the special tool.
Fig 52: Installing Special Tool
Courtesy of FORD MOTOR CO.
2. Install the special tool.
   • Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position.
   • Install the special tool.
3. Make sure the flats of the camshaft are facing upward. If not, repeat Step  1.
   Fig 53: Identifying Flats Of Camshaft Are Facing Upward

   Courtesy of FORD MOTOR CO.
CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
Fig 54: Installing Special Tool On RH Cylinder Head
Courtesy of FORD MOTOR CO.
4. Install the special tool on the RH cylinder head.
CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.
Fig 55: Removing Exhaust Camshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
5. Remove and discard the exhaust camshaft sprocket bolt.
CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.
Fig 56: Removing Variable Camshaft Timing (VCT) Unit Bolt
Courtesy of FORD MOTOR CO.
6. Remove and discard the variable camshaft timing (VCT) unit bolt.
7. Remove the RH timing chain tensioner.
   1. Push the lever down and install a drill rod to lock the piston.
   2. Remove the bolts and the tensioner.
   Fig 57: Removing RH Timing Chain Tensioner

   Courtesy of FORD MOTOR CO.
8. Remove the tensioner arm.
   Fig 58: Removing Tensioner Arm

   Courtesy of FORD MOTOR CO.
9. Remove the timing chain guide.
   Fig 59: Removing Timing Chain Guide

   Courtesy of FORD MOTOR CO.
10. Remove the RH primary timing chain.
    Fig 60: Removing RH Primary Timing Chain

    Courtesy of FORD MOTOR CO.
11. Remove the special tool from the RH head.
    Fig 61: Removing Special Tool From RH Head

    Courtesy of FORD MOTOR CO.
CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
Fig 62: Installing Special Tool On LH Head
Courtesy of FORD MOTOR CO.
12. Install the special tool on the LH head.
CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the cylinder head will occur.
Fig 63: Removing LH VCT Unit Bolt And Exhaust Camshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
13. Remove and discard the LH VCT unit bolt and the exhaust camshaft sprocket bolt.
14. Remove the LH timing chain tensioner.
    1. Push the lever down and install a drill rod to lock the piston.
    2. Remove the bolts and the tensioner.
    Fig 64: Removing LH Timing Chain Tensioner

    Courtesy of FORD MOTOR CO.
15. Remove the tensioner arm.
    Fig 65: Removing Tensioner Arm

    Courtesy of FORD MOTOR CO.
16. Remove the timing chain guide.
    Fig 66: Removing Timing Chain Guide

    Courtesy of FORD MOTOR CO.
17. Remove the LH primary timing chain.
    Fig 67: Removing LH Primary Timing Chain

    Courtesy of FORD MOTOR CO.
18. Collapse the LH secondary timing chain tensioner and install a pin to lock the piston.
    Fig 68: Installing Pin To Lock Piston (LH Secondary Timing Chain Tensioner)

    Courtesy of FORD MOTOR CO.
19. Remove the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
    Fig 69: Removing LH VCT Unit

    Courtesy of FORD MOTOR CO.
20. Collapse the RH secondary timing chain tensioner and install a pin to lock the piston.
    Fig 70: Installing Pin To Lock Piston (RH Secondary Timing Chain Tensioner)

    Courtesy of FORD MOTOR CO.
21. Remove the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
    Fig 71: Removing RH VCT Unit

    Courtesy of FORD MOTOR CO.
22. Remove the special tool from the LH head.
    Fig 72: Removing Special Tool From LH Head

    Courtesy of FORD MOTOR CO.

Items 126-141: RH and LH Camshaft Removal Note 

CAUTION: Record the camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
CAUTION: Do not use any means of marking the shims other than a permanent-type marker. Any scratches or paint on the shims can result in incorrect lash adjustments and severe engine damage.
CAUTION: Record the shim and bucket tappet location. The shim and bucket tappet are positional and if installed in the incorrect location, engine damage can occur.
1. Record the camshaft component locations prior to removal.

Items 142-147: RH and LH Cylinder Head Removal Note 

CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
NOTE: RH cylinder head shown, LH cylinder similar.
Fig 73: Removing Cylinder Head Bolt (RH)
Courtesy of FORD MOTOR CO.
1. Remove and discard the bolts.
NOTE: RH cylinder head shown, LH cylinder similar.
Fig 74: Identifying Cylinder Head Bolt Removing Sequence
Courtesy of FORD MOTOR CO.
2. Remove and discard the head bolts in the sequence shown.
NOTE: RH cylinder head shown, LH cylinder similar.
Fig 75: Removing Head Gasket
Courtesy of FORD MOTOR CO.
3. Remove and discard the head gasket(s).
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, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
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.
4. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head 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 remaining 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.
NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
5. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).