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Removal and Installation

WARNING: This page is about a different car, the 2010 Lincoln MKZ and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
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, may cause engine failure.
NOTE: Early build engines have 11 fastener valve covers, late built engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE .
  3. Recover the A/C system. For additional information, refer to REFRIGERANT SYSTEM RECOVERY .
  4. Remove the accessory drive belt and the power steering belt. For additional information, refer to REMOVAL .
  5. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to REMOVAL .
  6. If equipped, remove the 6 screws and the underbody shield.
    Fig 1: Locating Underbody Shield Screws
    G06269405Courtesy of FORD MOTOR CO.
  7. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable drain pan.
    Fig 2: Locating Power Steering Cooler Tube
    G06269824Courtesy of FORD MOTOR CO.
  8. Drain the cooling system. For additional information, refer to DRAINING .
  9. Remove the degas bottle. For additional information, refer to REMOVAL AND INSTALLATION .
  10. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION .
  11. Remove the battery tray. For additional information, refer to REMOVAL AND INSTALLATION .
  12. Disconnect the 2 engine wiring harness electrical connectors.
    Fig 3: Locating Engine Wiring Harness Electrical Connectors
    G06269825Courtesy of FORD MOTOR CO.
  13. Detach the 2 wiring harness retainers from transmission mount and the battery tray bracket.
    Fig 4: Locating Transmission Mount & Battery Tray Bracket
    G06269826Courtesy of FORD MOTOR CO.
  14. Remove the 2 nuts and the battery cables from the positive battery cable.
    Fig 5: Locating Battery Cables & Nuts
    G06262041Courtesy of FORD MOTOR CO.
  15. Remove the bolt and position aside the ground wire.
    Fig 6: Locating Ground Wire Bolt
    G06262414Courtesy of FORD MOTOR CO.
  16. Disconnect the vacuum hose and the Evaporative Emission (EVAP) tube from the upper intake manifold.
    Fig 7: Locating Vacuum Hose & Evaporative Emission Tube
    G06062758Courtesy of FORD MOTOR CO.
  17. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
    Fig 8: Locating Upper Radiator Hose, Lower Radiator Hose & Heater Hoses
    G06269907Courtesy of FORD MOTOR CO.
  18. Disconnect the transaxle control cable from the control lever.
    Fig 9: Locating Transaxle Control Cable
    G06269908Courtesy of FORD MOTOR CO.
  19. Remove the 3 nuts and position the transaxle control cable bracket aside.
    Fig 10: Locating Transaxle Control Cable Bracket
    G06269909Courtesy of FORD MOTOR CO.
  20. Remove the bolt and position the ground wire aside.
    Fig 11: Locating Ground Wire & Bolt
    G06269910Courtesy of FORD MOTOR CO.
  21. If equipped, detach the engine block heater harness from the radiator support, power steering hose, A/C tube and the engine wiring harness.
  22. Detach the coolant tube retainer clips from the A/C tube.
    Fig 12: Locating Coolant Tube Retainer Clips & A/C Tube
    G06269911Courtesy of FORD MOTOR CO.
  23. Remove the nut and disconnect the A/C tube from the condenser.
    • Discard the O-ring seals.
    Fig 13: Locating A/C Tube & Nut
    G06269912Courtesy of FORD MOTOR CO.
  24. Remove the 2 A/C tube retaining clamp bolts.
    Fig 14: Locating A/C Tube Retaining Clamp Bolts
    G06269836Courtesy of FORD MOTOR CO.
  25. Remove the A/C tube bracket bolt.
    Fig 15: Locating A/C Tube Bracket Bolt
    G06269837Courtesy of FORD MOTOR CO.
  26. Remove the 2 nuts and disconnect the A/C tubes.
    • Discard the O-ring seals.
    Fig 16: Locating A/C Tubes & Nuts
    G06269838Courtesy of FORD MOTOR CO.
  27. Detach the 2 wiring harness retainers.
    Fig 17: Locating Wiring Harness Retainers
    G06269756Courtesy of FORD MOTOR CO.
  28. Disconnect the 2 engine wiring harness electrical connectors.
    Fig 18: Locating Engine Control Wiring Harness Electrical Connectors
    G06269757Courtesy of FORD MOTOR CO.
  29. Remove the 2 wiring harness retainers from the LH valve cover stud bolts and position the wiring harness aside.
    Fig 19: Locating LH Valve Cover Stud Bolts & Wiring Harness
    G06269841Courtesy of FORD MOTOR CO.
  30. Remove the oil level indicator.
    Fig 20: Locating Oil Level Indicator
    G06062133Courtesy of FORD MOTOR CO.
  31. Disconnect the hose from the power steering reservoir.
    • Detach the pin-type retainer from the engine mount brace.
    Fig 21: Locating Hose
    G06269843Courtesy of FORD MOTOR CO.
  32. Using a small screwdriver, release the retaining clip and detach the power steering reservoir from the cowl.
    Fig 22: Releasing Retaining Clip
    G06271381Courtesy of FORD MOTOR CO.
  33. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 23: Locating Fuel Supply Tube From Fuel Rail
    G06269845Courtesy of FORD MOTOR CO.
  34. Remove the bolt and the ground wire from the engine mount brace.
    Fig 24: Locating Ground Wire & Bolt
    G06269846Courtesy of FORD MOTOR CO.
  35. Remove the 3 bolts and the engine mount brace.
    Fig 25: Locating Engine Mount Brace & Bolt
    G06269847Courtesy of FORD MOTOR CO.
  36. Disconnect the PCM electrical connectors and pin-type retainers.
    Fig 26: Locating PCM Electrical Connectors & Pin-Type Retainers
    G06269848Courtesy of FORD MOTOR CO.
  37. Remove the Power Steering Pressure (PSP) hose bracket bolt.
    Fig 27: Locating Power Steering Pressure Hose Bracket Bolt
    G06269849Courtesy of FORD MOTOR CO.
  38. Remove and discard the PSP  banjo bolt and the 2 seals from the steering gear.
    Fig 28: Locating PSP Hose Banjo Bolt
    G06269850Courtesy of FORD MOTOR CO.
  39. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
    NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
    Fig 29: Identifying Steering Wheel Holding Device
    G06137248Courtesy of FORD MOTOR CO.
  40. Remove the 2 nuts and the steering joint cover.
    Fig 30: Locating Steering Joint Cover & Nuts
    G06261980Courtesy of FORD MOTOR CO.
  41. Remove the bolt and disconnect the steering column shaft from the steering gear.
    • Discard the bolt.
    NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to REMOVAL .
    NOTE: Index-mark the steering column shaft position to the steering gear for reference during installation.
    Fig 31: Locating Steering Column Shaft & Bolt
    G06062138Courtesy of FORD MOTOR CO.
  42. Remove the 4 screws and position the LH fender splash shield aside.
    Fig 32: Locating LH Fender Splash Shield & Screws
    G06261987Courtesy of FORD MOTOR CO.
  43. Remove the 6 pin-type retainers (4 shown in illustration) and the LH splash shield.
    Fig 33: Locating Pin-Type Retainers & LH Splash Shield
    G06262403Courtesy of FORD MOTOR CO.
  44. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
    NOTE: The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.
    Fig 34: Locating Steering Gear Clips
    G06269856Courtesy of FORD MOTOR CO.
  45. Disconnect the transaxle cooler hoses.
    Fig 35: Locating Transaxle Cooler Hoses
    G06269934Courtesy of FORD MOTOR CO.
  46. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
    Fig 36: Locating Drain Plug
    G06061972Courtesy of FORD MOTOR CO.
  47. Remove and discard the engine oil filter.
  48. Remove the 6 nuts and the Y-pipe assembly.
    • Discard the gaskets and nuts.
      • Fig 37: Locating Y-Pipe Assembly & Nuts
      G06269936Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

  49. Remove and discard the 4 bolts (3 shown in illustration) and support the driveshaft with a length of mechanic's wire.
    NOTE: Index-mark the driveshaft for installation.
    Fig 38: Locating PTU Flange & Bolts
    G06263866Courtesy of FORD MOTOR CO.

    All vehicles 

  50. Remove the engine roll restrictor-to-subframe through bolt.
    Fig 39: Locating Engine Roll Restrictor-To-Subframe Through Bolt
    G06269864Courtesy of FORD MOTOR CO.
  51. Remove the cotter pins and nuts from the tie-rod ends.
    NOTE: LH shown in illustration, RH similar.
    Fig 40: Locating Tie-Rod Ends & Nuts
    G06261993Courtesy of FORD MOTOR CO.
  52. Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.
    NOTE: LH shown in illustration, RH similar.
    Fig 41: Separating Tie-Rod Ends
    G06269423Courtesy of FORD MOTOR CO.
  53. Remove the nuts and separate the stabilizer bar links from the struts.
    NOTE: LH shown in illustration3, RH similar.
    Fig 42: Locating Stabilizer Bar Links & Nuts
    G06261995Courtesy of FORD MOTOR CO.
  54. Position the Powertrain Lift under the subframe assembly.
    Fig 43: Positioning Powertrain Lift Under Subframe Assembly
    G06062149Courtesy of FORD MOTOR CO.
  55. Remove the 4 subframe bracket-to-body bolts.
    NOTE: LH shown in illustration, RH similar.
    Fig 44: Locating Subframe Bracket-To-Body Bolts
    G06262396Courtesy of FORD MOTOR CO.
  56. Remove the 2 subframe nuts and the 2 subframe brackets.
    NOTE: LH shown in illustration, RH similar.
    Fig 45: Locating Rear Subframe Nuts & Subframe Brackets
    G06261998Courtesy of FORD MOTOR CO.
  57. Remove the 2 front subframe nuts.
    NOTE: LH shown in illustration, RH similar.
    Fig 46: Locating Front Subframe Nuts
    G06261999Courtesy of FORD MOTOR CO.
  58. Using the Powertrain Lift, lower the subframe assembly from the vehicle.
    Fig 47: Positioning Powertrain Lift Under Subframe Assembly
    G06062149Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

  59. Remove the 2 RH catalytic converter bracket bolts.
    Fig 48: Locating RH Catalytic Converter Bracket Bolts
    G06269947Courtesy of FORD MOTOR CO.
  60. Remove the 2 nuts and remove the RH catalytic converter bracket.
    Fig 49: Locating RH Catalytic Converter Bracket & Nuts
    G06269582Courtesy of FORD MOTOR CO.

    All vehicles 

  61. Install the Powertrain Lift and Universal Adapter Brackets.
    NOTE: Position a block of wood under the transaxle.
    Fig 50: Identifying Powertrain Lift & Universal Adapter Brackets
    G06251620Courtesy of FORD MOTOR CO.
  62. Remove the transaxle support insulator through bolt.
    Fig 51: Locating Transaxle Support Insulator Through Bolt & Nut
    G06269950Courtesy of FORD MOTOR CO.
  63. Remove the transaxle support insulator bracket bolt and the 2 nuts.
    Fig 52: Locating Transaxle Support Insulator Bracket Bolt & Nuts
    G06269880Courtesy of FORD MOTOR CO.
  64. Remove the 4 engine mount nuts.
    • Remove the 2 engine mount spacers.
      • Fig 53: Locating Engine Mount Nuts
      G06269952Courtesy of FORD MOTOR CO.
  65. Remove the nut, 2 bolts and the engine mount.
    Fig 54: Locating Engine Mount Bolts & Nut
    G06269882Courtesy of FORD MOTOR CO.
  66. Lower the engine and transaxle assembly from the vehicle.
  67. If equipped, detach the block heater wiring harness retainer from the upper intake manifold.
    Fig 55: Locating Block Heater Wiring Harness Retainer From Upper Intake Manifold
    G06269954Courtesy of FORD MOTOR CO.
  68. If equipped, detach the block heater wiring harness retainers from the PSP  hose and the power steering reservoir hose.
    Fig 56: Locating Block Heater Wiring Harness Retainers
    G06269955Courtesy of FORD MOTOR CO.
  69. Disconnect the PCV hose from the PCV valve.
    Fig 57: Locating PCV Hose
    G06062361Courtesy of FORD MOTOR CO.
  70. Disconnect the Throttle Body (TB) electrical connector.
    Fig 58: Locating Instrument Panel Bolts LH
    G06062690Courtesy of FORD MOTOR CO.
  71. Detach the wiring harness retainers from the upper intake manifold.
    Fig 59: Locating Wiring Harness Retainers
    G06269958Courtesy of FORD MOTOR CO.
  72. Remove the upper intake manifold support bracket bolt.
    Fig 60: Locating Upper Intake Manifold Support Bracket Bolt
    G06062244Courtesy of FORD MOTOR CO.
  73. Remove the 6 bolts and the upper 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 61: Locating Upper Intake Manifold Bolts
    G06062246Courtesy of FORD MOTOR CO.
  74. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 62: Locating RH Catalyst Monitor Sensor (CMS) Electrical Connector
    G06062161Courtesy of FORD MOTOR CO.
  75. Disconnect the PSP  switch electrical connector.
    Fig 63: Locating PSP Switch Electrical Connector
    G06269962Courtesy of FORD MOTOR CO.
  76. Disconnect the RH VCT  solenoid electrical connector.
    Fig 64: Locating RH Variable Camshaft Timing (VCT) Solenoid Electrical Connector
    G06062248Courtesy of FORD MOTOR CO.
  77. Disconnect the 3 RH coil-on-plug electrical connectors.
    Fig 65: Locating RH Coil-On-Plug Electrical Connectors
    G06062370Courtesy of FORD MOTOR CO.
  78. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
  79. Disconnect the LH VCT  solenoid electrical connector.
    Fig 66: Locating LH VCT Solenoid Electrical Connector
    G06062250Courtesy of FORD MOTOR CO.
  80. Disconnect the 3 LH coil-on-plug electrical connectors.
    Fig 67: Locating LH Coil-On-Plug Electrical Connectors
    G06062251Courtesy of FORD MOTOR CO.
  81. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
  82. Remove the 6 bolts and the 6 coil-on-plugs.
    NOTE: LH shown in illustration, RH similar.
    Fig 68: Locating Coil-On-Plugs & Bolts
    G06269967Courtesy of FORD MOTOR CO.
  83. Detach the PSP  hose retainer from the engine lifting eye.
    Fig 69: Locating PSP Hose Retainer
    G06269968Courtesy of FORD MOTOR CO.
  84. Remove the PSP  hose bracket nut and position the PSP  hose aside.
    Fig 70: Locating PSP Hose Bracket Nut
    G06269770Courtesy of FORD MOTOR CO.
  85. Remove the 2 nuts and the wiring harness retaining bracket.
    Fig 71: Locating Wiring Harness Retaining Bracket & Nuts
    G06269758Courtesy of FORD MOTOR CO.

    Early build vehicles 

  86. Loosen the 11 stud bolts and remove the LH valve cover.
    • Discard the gasket.
    Fig 72: Locating Stud Bolts & Valve Cover
    G06251724Courtesy of FORD MOTOR CO.
  87. Loosen the bolt, the 10 stud bolts and remove the RH valve cover.
    • Discard the gasket.
    Fig 73: Locating Stud Bolts & Valve Cover
    G06269972Courtesy of FORD MOTOR CO.

    Late build vehicles 

  88. Loosen the 9 stud bolts and remove the LH valve cover.
    • Discard the gasket.
    Fig 74: Locating Stud Bolts & Valve Cover
    G06251726Courtesy of FORD MOTOR CO.
  89. Loosen the 9 stud bolts and remove the RH valve cover.
    • Discard the gasket.
    Fig 75: Locating Stud Bolts & Valve Cover
    G06269974Courtesy of FORD MOTOR CO.

    All vehicles 

  90. Inspect the VCT  solenoid seals and the spark plug tube seals. Install new seals if damaged.
    • Using the VCT  Spark Plug Tube Seal Remover and Handle, remove the seal(s).
    NOTE: VCT  solenoid seal removal shown in illustration, spark plug tube seal removal similar.
    Fig 76: Identifying VCT Spark Plug Tube Seal Remover And Handle
    G06061919Courtesy of FORD MOTOR CO.
  91. Remove the 3 bolts and position the power steering pump aside.
    Fig 77: Locating Power Steering Pump & Bolts
    G06269976Courtesy of FORD MOTOR CO.
  92. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 78: Locating Accessory Drive Belt Tensioner Bolts
    G06062657Courtesy of FORD MOTOR CO.
  93. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
    • Discard the bolt.
    Fig 79: Locating Crankshaft Pulley Bolt & Washer
    G06061937Courtesy of FORD MOTOR CO.
  94. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 80: Removing Crankshaft Pulley
    G06251959Courtesy of FORD MOTOR CO.
  95. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 81: Locating Crankshaft Front Seal Using Oil Seal Remover
    G06269980Courtesy of FORD MOTOR CO.
  96. Remove the 2 bolts and the engine mount bracket.
    Fig 82: Locating Engine Mount Bracket & Bolts
    G06061983Courtesy of FORD MOTOR CO.
  97. Remove the 2 engine mount studs.
    NOTE: Only use hand tools to remove the studs.
    Fig 83: Locating Engine Mount Studs
    G06061984Courtesy of FORD MOTOR CO.
  98. Remove the 3 bolts and the engine mount bracket.
    Fig 84: Locating Engine Mount Bracket & Bolts
    G06074073Courtesy of FORD MOTOR CO.
  99. Remove the 22 engine front cover bolts.
    Fig 85: Locating Engine Front Cover Bolts
    G06061990Courtesy of FORD MOTOR CO.
  100. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover in the following sequence.
    1. Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.
    2. Remove the engine front cover.
    Fig 86: Identifying Engine Front Cover Bolt
    G06061991Courtesy of FORD MOTOR CO.
  101. Clean the engine front cover using a 3M Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
    • Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
    NOTE: Only use a 3M Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover. These tools cause scratches and gouges that make leak paths.
  102. Clean all engine sealing surfaces, including the cylinder heads, the oil pan and cylinder block in the following sequence.
    1. Remove any large deposits of silicone or gasket material.
    2. Apply silicone gasket remover and allow to set for several minutes.
    3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
    5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
    NOTE: Place clean, lint-free 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: Do not use wire brushes, power abrasive discs or 3M Roloc® Bristle Disk (2-in white part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.
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