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Special Tool(s)

WARNING: This page is about a different car, the 2010 Mercury Mariner and 2010 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL SPECIFICATION

G06390046Courtesy of FORD MOTOR CO.
 Alignment Plate, Camshaft
303-465 (T94P-6256-CH)
G06390047Courtesy of FORD MOTOR CO.
 Engine Stand
014-00232 or equivalent
G06390048Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G06390049Courtesy of FORD MOTOR CO.
 Holding Tool, Crankshaft Damper
303-1416
G06390050Courtesy of FORD MOTOR CO.
 Installer, Connecting Rod
303-462 (T94P-6136-AH)
G06390051Courtesy of FORD MOTOR CO.
 Remover, Oil Seal
303-409 (T92C-6700-CH)
G06390052Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G06390053Courtesy 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, otherwise 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 ASSEMBLY for exploded views under engine Assembly .
  1. Remove the 6 bolts and the flywheel.
    Fig 1: Locating Flywheel Bolts
    G06390054Courtesy of FORD MOTOR CO.
  2. Mount the engine on a suitable engine stand.
  3. Release the locking tab and disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
    • Detach the connector from the engine wiring harness connector bracket.
      Fig 2: Locating Locking Tab And Heated Oxygen Sensor Electrical Connector
      G06390055Courtesy of FORD MOTOR CO.
  4. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 3: Locating Catalyst Monitor Sensor Electrical Connector
    G06390056Courtesy of FORD MOTOR CO.
  5. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 4: Locating Crankshaft Position Sensor Electrical Connector
    G06390057Courtesy of FORD MOTOR CO.
  6. Remove the bolt and the engine wiring harness connector bracket.
    Fig 5: Locating Bolt And Engine Wiring Harness Connector Bracket
    G06390058Courtesy of FORD MOTOR CO.
  7. Detach the 2 engine wiring harness pin-type retainers.
    Fig 6: Locating Engine Wiring Harness Pin-Type Retainers
    G06390059Courtesy of FORD MOTOR CO.
  8. Remove the 7 nuts and the catalytic converter manifold.
    • Discard the nuts and the exhaust manifold gasket.
      Fig 7: Locating Catalytic Converter Manifold Nuts
      G06390060Courtesy of FORD MOTOR CO.
  9. Remove and discard the 7 exhaust manifold studs.
    Fig 8: Locating Exhaust Manifold Studs
    G06390061Courtesy of FORD MOTOR CO.
  10. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
    Fig 9: Rotating Accessory Drive Belt Tensioner
    G06390062Courtesy of FORD MOTOR CO.
  11. Detach the vehicle high-voltage electrical system electrical connector retainer from the accessory drive belt tensioner.
    Fig 10: Locating Vehicle High-Voltage Electrical System Electrical Connector
    G06390063Courtesy of FORD MOTOR CO.
  12. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 11: Locating Accessory Drive Belt Tensioner
    G06390064Courtesy of FORD MOTOR CO.
  13. Disconnect the electronic throttle control electrical connector.
    Fig 12: Locating Electronic Throttle Control Electrical Connector
    G06390065Courtesy of FORD MOTOR CO.
  14. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
    Fig 13: Locating Evaporative Emission Canister Purge Valve Electrical Connector
    G06390066Courtesy of FORD MOTOR CO.
  15. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
    Fig 14: Locating Engine Oil Pressure Switch Electrical Connector
    G06390067Courtesy of FORD MOTOR CO.
  16. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
    Fig 15: Locating Manifold Absolute Pressure Sensor Electrical Connector
    G06390068Courtesy of FORD MOTOR CO.
  17. Disconnect the Knock Sensor (KS) electrical connector and detach the electrical connector pin-type retainer from the intake manifold.
    Fig 16: Locating Knock Sensor Electrical Connector And Electrical Connector Pin-Type Retainer
    G06390069Courtesy of FORD MOTOR CO.
  18. Disconnect the A/C compressor electrical connector.
    Fig 17: Locating A/C Compressor Electrical Connector
    G06390070Courtesy of FORD MOTOR CO.
  19. Remove the 3 bolts and the A/C compressor.
    Fig 18: Locating A/C Compressor Bolts
    G06390071Courtesy of FORD MOTOR CO.
  20. Remove the 2 bolts and the A/C compressor bracket.
    Fig 19: Locating A/C Compressor Bracket Bolts
    G06390072Courtesy of FORD MOTOR CO.
  21. Disconnect the Variable Camshaft Timing (VCT) oil control solenoid electrical connector and detach the wiring harness retainer from the valve cover stud bolt.
    Fig 20: Locating VCT Oil Control Solenoid Electrical Connector And Wiring Harness Retainer
    G06390073Courtesy of FORD MOTOR CO.
  22. Detach the 2 wiring harness retainers from the fuel rail and the wiring harness retainer from the valve cover.
    Fig 21: Locating Wiring Harness Retainers
    G06390074Courtesy of FORD MOTOR CO.
  23. Disconnect the auxiliary coolant pump hose and the upper radiator hose.
    Fig 22: Locating Auxiliary Coolant Pump Hose And Upper Radiator Hose
    G06390075Courtesy of FORD MOTOR CO.
  24. 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 23: Locating EGR Coolant Hose And Auxiliary Coolant Pump Hose
      G06390076Courtesy of FORD MOTOR CO.
  25. Disconnect the vacuum hose from the intake manifold.
    Fig 24: Locating Vacuum Hose
    G06390077Courtesy of FORD MOTOR CO.
  26. Remove the 2 bolts, the nut and the vacuum pump assembly.
    Fig 25: Locating Bolts, Nut And Vacuum Pump Assembly
    G06390078Courtesy of FORD MOTOR CO.
  27. Detach the 3 wire harness pin-type retainers from the intake manifold.
    Fig 26: Locating Wire Harness Pin-Type Retainers
    G06390079Courtesy of FORD MOTOR CO.
    28. NOTE: The cylinder head side of the intake manifold is showing the location of the 7 bolts.
    Fig 27: Locating Intake Manifold Bolts
    G06390080Courtesy of FORD MOTOR CO.
  28. Remove the 7 bolts and position the intake manifold aside to access the PCV hose connector.
    29. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
  29. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.
    • Remove the intake manifold.
      Fig 28: Locating Crankcase Vent Oil Separator Tube
      G06390081Courtesy of FORD MOTOR CO.
  30. Remove the EGR tube.
    Fig 29: Identifying EGR Tube
    G06390082Courtesy of FORD MOTOR CO.
  31. Disconnect the 4 fuel injector electrical connectors, radio capacitor electrical connector and the Camshaft Position (CMP) sensor electrical connector.
    Fig 30: Locating Fuel Injector Electrical Connectors, Radio Capacitor Electrical Connector And CMP Sensor Electrical Connector
    G06390083Courtesy of FORD MOTOR CO.
  32. Detach the 2 wiring harness retainers from the ignition coil stud bolts.
    • Remove the high-voltage wiring harness.
      Fig 31: Locating Wiring Harness Retainers
      G06390084Courtesy of FORD MOTOR CO.
  33. Remove the fuel rail insulator.
    Fig 32: Locating Fuel Rail Insulator
    G06390085Courtesy of FORD MOTOR CO.
  34. Remove the nut and the radio capacitor.
    Fig 33: Locating Nut And Radio Capacitor
    G06390086Courtesy of FORD MOTOR CO.
  35. Remove the 2 stud bolts and the fuel rail with the fuel injectors.
    Fig 34: Locating Stud Bolts
    G06390087Courtesy of FORD MOTOR CO.
  36. Disconnect the 4 coil-on-plug electrical connectors.
    Fig 35: Locating Coil-On-Plug Electrical Connectors
    G06390088Courtesy of FORD MOTOR CO.
  37. Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
    Fig 36: Locating Rubber Boot And Cylinder Head Temperature Sensor Electrical Connector
    G06390089Courtesy 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
      G06390090Courtesy of FORD MOTOR CO.
  39. Remove the 3 bolts and the coolant pump pulley.
    Fig 38: Locating Bolts And Coolant Pump Pulley
    G06390091Courtesy of FORD MOTOR CO.
  40. Remove the 3 bolts and the coolant pump.
    Fig 39: Locating Coolant Pump Bolts
    G06390092Courtesy of FORD MOTOR CO.
  41. Remove the 3 bolts and the thermostat housing.
    Fig 40: Locating Thermostat Housing Bolts
    G06390093Courtesy of FORD MOTOR CO.
  42. Disconnect the coolant hose.
    Fig 41: Locating Coolant Hose
    G06390094Courtesy of FORD MOTOR CO.
  43. Disconnect and remove the coolant hose.
    Fig 42: Locating Coolant Hose
    G06390095Courtesy of FORD MOTOR CO.
  44. Remove the bolt and the KS  .
    Fig 43: Locating Knock Sensor Ground Bolt
    G06390096Courtesy of FORD MOTOR CO.
  45. Remove the 8 bolts and the crankcase vent oil separator.
    Fig 44: Locating Crankcase Vent Oil Separator Bolts
    G06390097Courtesy of FORD MOTOR CO.
  46. Remove the 4 bolts and the oil filter adapter.
    • Discard the gasket.
      Fig 45: Locating Oil Filter Adapter Bolts
      G06390098Courtesy of FORD MOTOR CO.
  47. If equipped, remove the block heater.
    Fig 46: Locating Block Heater
    G06390099Courtesy of FORD MOTOR CO.
  48. Remove the crankshaft vent tube.
    Fig 47: Locating Crankshaft Vent Tube
    G06390100Courtesy of FORD MOTOR CO.
  49. Remove the engine cover studs.
    Fig 48: Locating Engine Cover Studs
    G06390101Courtesy of FORD MOTOR CO.
  50. Remove the 4 stud bolts and the coil-on-plugs from the valve cover.
    Fig 49: Locating Coil-On-Plugs Stud Bolts
    G06390102Courtesy of FORD MOTOR CO.
  51. Remove the oil level indicator.
    Fig 50: Locating Oil Level Indicator
    G06390103Courtesy of FORD MOTOR CO.
    52. NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
  52. Remove the spark plugs and the CHT  sensor.
    • Discard the CHT  sensor.
      Fig 51: Locating Spark Plugs And CHT Sensor
      G06390104Courtesy of FORD MOTOR CO.
  53. Remove the bolts and the valve cover.
    Fig 52: Locating Retainers And Valve Cover
    G06390105Courtesy of FORD MOTOR CO.
    54. 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.
  54. 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.
      Fig 53: Turning Crankshaft Clockwise
      G06390106Courtesy of FORD MOTOR CO.
    55. 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 cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
    Fig 54: Identifying Camshaft Alignment Plate Installation Position
    G06390107Courtesy of FORD MOTOR CO.
  55. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
  56. Remove the engine plug bolt.
    Fig 55: Locating Engine Plug Bolt
    G06390108Courtesy of FORD MOTOR CO.
    57. 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 56: Installing Crankshaft TDC Timing Peg
    G06390109Courtesy of FORD MOTOR CO.
  57. Install the Crankshaft TDC  Timing Peg.
    58. 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.
  58. 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.
      Fig 57: Locating Crankshaft Pulley Bolt
      G06390110Courtesy of FORD MOTOR CO.
    59. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
    Fig 58: Removing Crankshaft Front Oil Seal
    G06390111Courtesy of FORD MOTOR CO.
  59. Using the Oil Seal Remover, remove the crankshaft front oil seal.
  60. Remove the 2 bolts and the CKP  sensor.
    Fig 59: Locating CKP Sensor Bolts
    G06390112Courtesy of FORD MOTOR CO.
  61. Remove the bolts and the engine front cover.
    Fig 60: Locating Engine Front Cover Bolts
    G06390113Courtesy of FORD MOTOR CO.
  62. Compress the timing chain tensioner.
    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 61: Compressing Timing Chain Tensioner
      G06390114Courtesy of FORD MOTOR CO.
  63. Remove the 2 bolts and the timing chain tensioner.
    Fig 62: Locating Timing Chain Tensioner Bolts
    G06390115Courtesy of FORD MOTOR CO.
  64. Remove the RH timing chain guide.
    Fig 63: Locating Timing Chain Guide
    G06390116Courtesy of FORD MOTOR CO.
  65. Remove the timing chain.
    Fig 64: Locating Timing Chain
    G06390117Courtesy of FORD MOTOR CO.
  66. Remove the bolts and the LH timing chain guide.
    Fig 65: Locating LH Timing Chain Guide Bolts
    G06390118Courtesy of FORD MOTOR CO.
    67. NOTE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
    Fig 66: Locating Flats On Camshaft, Bolt And Exhaust Camshaft Sprocket
    G06390119Courtesy of FORD MOTOR CO.
  67. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.
    68. 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 67: Locating Intake Camshaft Sprocket Bolt
    G06390120Courtesy of FORD MOTOR CO.
  68. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the intake camshaft sprocket.
  69. Remove the oil pump chain tensioner.
    1. Release the tension on the tensioner spring.
    2. Remove the tensioner and the shoulder bolts.
      Fig 68: Identifying Oil Pump Chain Drive Tensioner
      G06390121Courtesy of FORD MOTOR CO.
    70. 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.
  70. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain and sprockets.
      Fig 69: Identifying Oil Pump Chain And Sprockets
      G06390122Courtesy of FORD MOTOR CO.
  71. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
    Fig 70: Identifying Camshaft Lobe Position
    G06390123Courtesy of FORD MOTOR CO.
  72. Remove the bolt and the Variable Camshaft Timing (VCT) solenoid.
    Fig 71: Locating Bolt And Variable Camshaft Timing Solenoid
    G06390124Courtesy of FORD MOTOR CO.
  73. Remove the plug and the VCT  system oil filter from the intake camshaft thrust cap.
    Fig 72: Locating Plug And VCT System Oil Filter
    G06390125Courtesy of FORD MOTOR CO.
    74. 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.
  74. Remove the camshafts from the engine.
    • Loosen the camshaft bearing bolts in the sequence shown, one turn at a time. Repeat until all the tension is released.
    • Remove the camshaft bearing caps.
    • Remove the camshafts.
      Fig 73: Identifying Camshaft Bearing Cap Bolts Loosening Sequence
      G06390126Courtesy of FORD MOTOR CO.
    75. 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.
  75. Remove and inspect the valve tappets. For additional information, refer to VALVE TAPPET INSPECTION .
  76. Remove the cylinder head.
    • Remove and discard the cylinder head bolts.
    • Remove the cylinder head.
    • Remove and discard the cylinder head gasket.
      Fig 74: Locating Cylinder Head Bolts
      G06390127Courtesy of FORD MOTOR CO.
  77. 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 .
  78. Remove the cylinder head alignment dowels.
    Fig 75: Locating Cylinder Head Alignment Dowels
    G06390128Courtesy of FORD MOTOR CO.
  79. Remove the bolts and the oil pan.
    Fig 76: Locating Oil Pan Bolts
    G06390129Courtesy of FORD MOTOR CO.
  80. Remove the bolts and the rear crankshaft seal.
    Fig 77: Locating Bolts And Rear Crankshaft Seal
    G06390130Courtesy of FORD MOTOR CO.
  81. Remove the bolts, oil pump pickup tube and gasket.
    Fig 78: Locating Bolts, Oil Pump Pickup Tube And Gasket
    G06390131Courtesy of FORD MOTOR CO.
  82. Remove the bolts and the oil pump.
    Fig 79: Locating Oil Pump Assembly Bolts
    G06390132Courtesy of FORD MOTOR CO.
  83. Remove the bolts and the block-off plate.
    Fig 80: Locating Block-Off Plate Bolts
    G06390133Courtesy of FORD MOTOR CO.
  84. Make sure the Crankshaft TDC  Timing Peg is still installed and the engine is still at TDC  .
    • Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC  Timing Peg.
      Fig 81: Installing Crankshaft TDC Timing Peg
      G06390134Courtesy of FORD MOTOR CO.
  85. Mark the balancer unit front shafts on the top for reference that the balancer unit is at TDC  .
    Fig 82: Locating Balancer Unit And Shafts Reference Mark
    G06390135Courtesy of FORD MOTOR CO.
    86. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
    Fig 83: Locating Balancer Unit Bolts
    G06390136Courtesy of FORD MOTOR CO.
  86. Remove the 4 bolts and the balancer unit.
  87. Remove the Crankshaft TDC  Timing Peg.
    Fig 84: Installing Crankshaft TDC Timing Peg
    G06390137Courtesy of FORD MOTOR CO.
  88. 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.
    89. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
    Fig 85: Locating Connecting Rod Cap Bolts
    G06390138Courtesy of FORD MOTOR CO.
  89. Remove the connecting rod cap bolts and cap.
    90. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
  90. 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.
      Fig 86: Identifying Connecting Rod Installer
      G06390139Courtesy of FORD MOTOR CO.
  91. Remove the bolts in the sequence shown.
    • Remove the main bearing beam.
    • Discard the bolts.
      Fig 87: Identifying Main Bearing Bolts Tightening Sequence
      G06390140Courtesy of FORD MOTOR CO.
  92. Remove the crankshaft from the engine block.
    Fig 88: Locating Crankshaft Gear
    G06390141Courtesy of FORD MOTOR CO.
    93. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
    Fig 89: Locating Main Bearings
    G06390142Courtesy of FORD MOTOR CO.
  93. Remove the main bearings from the main bearing beam.
    94. 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 90: Locating Main Bearings
    G06390143Courtesy of FORD MOTOR CO.
  94. Remove the main bearings from the cylinder block.
    95. 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 91: Locating Oil Squirters
    G06390144Courtesy of FORD MOTOR CO.
  95. Remove the 4 oil squirters.
  96. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to GENERAL PROCEDURES .
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