Removal And Installation

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
3. Remove the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION article.
4. Remove the cooling fan stator. For additional information, refer to ENGINE COOLING article.

Vehicles with dual generator 

5. Remove the accessory drive belt.
Fig 1: Rotating Drive Belt Tensioner Clockwise
Courtesy of FORD MOTOR CO.
6. Remove the bolt and the accessory drive belt tensioner.
   • To install, tighten to 25 Nm (18 lb-ft).
Fig 2: Locating Accessory Drive Belt Tensioner Bolt
Courtesy of FORD MOTOR CO.
7. Remove the accessory drive belt.
Fig 3: Rotating Accessory Drive Belt Tensioner
Courtesy of FORD MOTOR CO.
8. Remove the 3 bolts, bracket and accessory drive belt idler pulley.
   • To install, tighten to 25 Nm (18 lb-ft).
Fig 4: Locating Bracket And Accessory Drive Belt Idler Pulley Bolts
Courtesy of FORD MOTOR CO.
9. Remove the 2 bolts and the accessory drive belt tensioner.
   • To install, tighten to 25 Nm (18 lb-ft).
Fig 5: Locating Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
10. Disconnect the generator electrical connector and the B+ wire.
    • To install, tighten to 8 Nm (71 lb-in).
Fig 6: Generator Electrical Connector & B+ Wire
Courtesy of FORD MOTOR CO.
11. Remove the 4 bolts and the generator with mounting bracket.
    • To install, tighten to 47 Nm (35 lb-ft).
Fig 7: Identifying Generator Mounting Bracket Bolts
Courtesy of FORD MOTOR CO.

Vehicles with single generator 

12. Remove the accessory drive belt.
Fig 8: Rotating Accessory Drive Belt Tensioner Clockwise
Courtesy of FORD MOTOR CO.

All vehicles 

13. Remove the LH fan stator stand-off.
    • To install, tighten to 47 Nm (35 lb-ft).
Fig 9: Identifying LH Fan Stator Stand-Off
Courtesy of FORD MOTOR CO.
NOTE: Lower bolts shown, upper bolts similar.
14. Remove the 4 bolts and position the power steering pump aside.
    • To install, tighten to 25 Nm (18 lb-ft).
Fig 10: Identifying Power Steering Pump Bolts
Courtesy of FORD MOTOR CO.
15. Install the Adapter.
Fig 11: Special Tool (303-D043-01)
Courtesy of FORD MOTOR CO.
16. Remove the turbocharger-to-exhaust downpipe clamp.
    • To install, tighten to 9 Nm (80 lb-in).
Fig 12: Turbocharger-To-Exhaust Downpipe Clamp
Courtesy of FORD MOTOR CO.
17. Remove the 2 exhaust downpipe-to-catalytic converter nuts and position the exhaust downpipe aside. Discard the nuts.
    • To install, tighten the new nuts to 40 Nm (30 lb-ft).
Fig 13: Locating Nuts On Exhaust Downpipe
Courtesy of FORD MOTOR CO.
18. Loosen the 2 RH motor mount nuts.
    • To install, tighten to 90 Nm (66 lb-ft).
Fig 14: RH Motor Mount Nuts
Courtesy of FORD MOTOR CO.
19. Loosen the 4 LH motor mount-to-cylinder block bolts.
    • To install, tighten to 80 Nm (59 lb-ft).
Fig 15: Identifying LH Motor Mount Bolts
Courtesy of FORD MOTOR CO.
20. Remove the 2 LH motor mount nuts.
    • To install, tighten to 90 Nm (66 lb-ft).
Fig 16: Identifying Engine Mount Nuts
Courtesy of FORD MOTOR CO.
21. Remove the removable stud.
    • To install, tighten to 55 Nm (41 lb-ft).
Fig 17: Removable Stud
Courtesy of FORD MOTOR CO.
NOTE: The lifting crane and lifting chain must be rated at a minimum 4,000-pound capacity by the manufacturer. Failure to follow this instruction may result in engine damage.
22. Connect a Heavy Duty Floor Crane and lifting chain to the Adapter and raise the engine as needed to remove the motor mount.
Fig 18: Lifting Crane And Lifting Chain To Engine Lifting Bracket
Courtesy of FORD MOTOR CO.
23. Remove the 4 bolts and the LH motor mount. Carefully lower the engine.
Fig 19: Identifying LH Motor Mount Bolts
Courtesy of FORD MOTOR CO.
24. Remove the bolt and position the Manifold Absolute Pressure (MAP) sensor aside.
Fig 20: Manifold Absolute Pressure (MAP) Sensor & Bolt
Courtesy of FORD MOTOR CO.
25. Remove the 3 bolts for the Charge Air Cooler (CAC) pipe and oil fill tube.
Fig 21: Locating CAC Tube And Oil Fill Tube Bolts
Courtesy of FORD MOTOR CO.
26. Remove the nut and disconnect the pushpin retainer for the transmission fluid indicator and tube.
    • To install, tighten to 13 Nm (115 lb-in).
Fig 22: Pushpin & Transmission Fluid Indicator Tube Nut
Courtesy of FORD MOTOR CO.
27. Remove the retaining nut for the transmission fluid level indicator and tube. Position the tube aside.
    • To install, tighten to 8 Nm (71 lb-in).
Fig 23: Transmission Fluid Indicator Tube Nut
Courtesy of FORD MOTOR CO.
28. Loosen the clamp at the turbocharger outlet hose. Disconnect the CAC pipe from the turbocharger.
Fig 24: Turbocharger Outlet Hose & Clamp
Courtesy of FORD MOTOR CO.
29. Disconnect the oil fill tube at the valve cover.
Fig 25: Identifying Oil Fill Tube At Valve Cover
Courtesy of FORD MOTOR CO.
30. Disconnect the Injection Control Pressure (ICP) sensor electrical connector and wire retainers.
Fig 26: Injection Control Pressure (ICP) Sensor
Courtesy of FORD MOTOR CO.
31. Remove the ICP sensor.
    • Plug or cap the opening as needed.
    • To install, tighten to 12 Nm (106 lb-in).
32. Position the wiring away from the valve cover as needed.
Fig 27: Wiring Retainers
Courtesy of FORD MOTOR CO.
NOTE: To prevent engine damage, do not use air-powered tools when installing the valve cover.
NOTE: Mark the position of the valve cover bolts for the valve cover bolt installation.
33. Remove the 6 stud bolts, the 5 bolts and the valve cover.
    • Clean and inspect the valve cover gasket.
    • To install, tighten to 9 Nm (80 lb-in).
34. Remove the high-pressure oil rail-to-valve cover gasket.
Fig 28: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
Courtesy of FORD MOTOR CO.
35. To install, reverse the removal procedure.
    • Tighten the top retaining nuts on the motor mount first.