Removal and Installation

All vehicles 

1. Remove the LH camshafts. For additional information, refer to Removal and Installation .
2. If equipped, remove the heat shield and disconnect the block heater electrical connector.
   • Remove the block heater wiring harness from the engine.
   Fig 1: Locating Block Heater Electrical Connector & Heat Shield

   Courtesy of FORD MOTOR CO.
3. Disconnect the A/C compressor electrical connector.
   Fig 2: Locating A/C Compressor Electrical Connector

   Courtesy of FORD MOTOR CO.
4. Remove the nut and disconnect the generator B+ cable.
   Fig 3: Locating Generator B+ Cable Nut

   Courtesy of FORD MOTOR CO.
5. Disconnect the generator electrical connector.
   Fig 4: Locating Generator Electrical Connector

   Courtesy of FORD MOTOR CO.
6. Detach the wiring harness retainer from the generator.
   Fig 5: Locating Wiring Harness Retainer

   Courtesy of FORD MOTOR CO.
7. Remove the nut, bolt and the generator.
   Fig 6: Locating Nut, Bolt & Generator

   Courtesy of FORD MOTOR CO.
8. Detach the wiring harness pin-type retainer.
   Fig 7: Locating Wiring Harness Pin-Type Retainer

   Courtesy of FORD MOTOR CO.
9. Disconnect the 6 fuel injector electrical connectors (3 shown in illustration).
   Fig 8: Locating Fuel Injector Electrical Connectors

   Courtesy of FORD MOTOR CO.
10. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
    Fig 9: Locating Cylinder Head Temperature Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
11. Disconnect the LH Camshaft Position (CMP) sensor electrical connector.
    Fig 10: Locating Camshaft Position (CMP) Sensor Electrical Connector LH Side

    Courtesy of FORD MOTOR CO.
12. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 11: Locating LH Heated Oxygen Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
13. Disconnect the LH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 12: Locating LH Catalyst Monitor Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
14. Remove the wiring harness retainer bolt from the rear of the LH cylinder head.
    Fig 13: Locating Wiring Harness Retainer Bolt

    Courtesy of FORD MOTOR CO.
15. Remove the 2 LH catalytic converter bracket bolts.
    Fig 14: Locating LH Catalytic Converter Bracket Bolts

    Courtesy of FORD MOTOR CO.
16. Remove the 4 nuts (3 shown in illustration) and the LH catalytic converter.
    • Discard the nuts and the gasket.
    Fig 15: Locating Catalytic Converter Nuts (LH)

    Courtesy of FORD MOTOR CO.
17. Remove the 3 bolts and the LH exhaust manifold heat shield.
    Fig 16: Locating Exhaust Manifold Heat Shield Bolts (LH)

    Courtesy of FORD MOTOR CO.
18. Remove the 6 nuts and the LH exhaust manifold.
    • Discard the nuts and the exhaust manifold gasket.
    Fig 17: Locating Exhaust Manifold Gasket & Nut

    Courtesy of FORD MOTOR CO.
19. Clean and inspect the LH exhaust manifold. For additional information, refer to EXHAUST MANIFOLD CLEANING AND INSPECTION .
20. Remove and discard the 6 LH exhaust manifold studs.
    Fig 18: Locating LH Exhaust Manifold Studs

    Courtesy of FORD MOTOR CO.
21. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
    Fig 19: Locating LH Cylinder Block Drain Plug

    Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

22. Remove the 2 RH catalytic converter bracket bolts.
    Fig 20: Locating RH Catalytic Converter Bracket Bolts

    Courtesy of FORD MOTOR CO.

    All vehicles 

23. Remove the 4 nuts and the RH catalytic converter.
    • Discard the nuts and the gasket.
    Fig 21: Locating RH Catalytic Converter & Nuts

    Courtesy of FORD MOTOR CO.
24. Remove the RH cylinder block drain plug or, if equipped, the block heater.
    • Allow coolant to drain from the cylinder block.
    Fig 22: Locating RH Cylinder Block Drain Plug & Block Heater

    Courtesy of FORD MOTOR CO.
25. Remove the 4 bolts and the fuel rail and injectors as an assembly.
    Fig 23: Locating Injectors Assembly Bolts & Fuel Rail

    Courtesy of FORD MOTOR CO.
26. Disconnect the coolant bypass hose from the thermostat housing.
    Fig 24: Locating Coolant Bypass Hose To Thermostat Housing

    Courtesy of FORD MOTOR CO.
27. Remove the 2 thermostat housing-to-lower intake manifold bolts.
    • Remove the thermostat housing and discard the gasket and O-ring seal.
    Fig 25: Locating Thermostat Housing-To-Lower Intake Manifold Bolts

    Courtesy of FORD MOTOR CO.
28. Remove the 10 bolts and the lower intake manifold.
    • Discard the gaskets.
    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.
    Fig 26: Locating Lower Intake Manifold Bolts

    Courtesy of FORD MOTOR CO.
29. Remove the bolt and the LH CMP  sensor.
    Fig 27: Locating CMP Sensor Bolt LH

    Courtesy of FORD MOTOR CO.
30. Remove the 2 bolts and the upper LH primary timing chain guide.
    Fig 28: Locating Upper LH Primary Timing Chain Guide & Bolts

    Courtesy of FORD MOTOR CO.
31. Remove the 2 bolts and the LH secondary timing chain tensioner.
    Fig 29: Locating LH Secondary Timing Chain Tensioner & Bolts

    Courtesy of FORD MOTOR CO.
32. Remove the valve tappets from the cylinder head.
    NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
    Fig 30: Locating Valve Tappets

    Courtesy of FORD MOTOR CO.
33. Remove and discard the M6 bolt.
    Fig 31: Locating M6 Bolt

    Courtesy of FORD MOTOR CO.
34. Remove and discard the 8 bolts from the cylinder head.
    • Remove the cylinder head.
    • Discard the cylinder head gasket.
    NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
    NOTE: Aluminum surfaces are soft and may be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
    Fig 32: Locating Cylinder Head Bolts

    Courtesy of FORD MOTOR CO.
35. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence.
    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: 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.
    NOTE: 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.
36. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to CYLINDER HEAD DISTORTION and CYLINDER BLOCK DISTORTION .