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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.
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. Remove the engine from the vehicle. For additional information, refer to ENGINE .
  2. Remove the 8 bolts and the flywheel.
    Fig 1: Locating Flywheel Bolts
    G06270101Courtesy of FORD MOTOR CO.
  3. Remove the crankshaft sensor ring.
    Fig 2: Locating Crankshaft Sensor Ring
    G06062359Courtesy of FORD MOTOR CO.
  4. Mount the engine on a suitable engine stand.
    NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.
  5. If equipped, detach the block heater wiring harness retainer from the upper intake manifold.
    Fig 3: Locating Block Heater Wiring Harness Retainer & Upper Intake Manifold
    G06270103Courtesy of FORD MOTOR CO.
  6. If equipped, remove the heat shield and disconnect the block heater electrical connector.
    Fig 4: Locating Block Heater Electrical Connector & Heat Shield
    G06062307Courtesy of FORD MOTOR CO.
  7. If equipped, detach the block heater wiring harness retainer from the power steering reservoir hose and the Power Steering Pressure (PSP) hose.
    • Remove the block heater wiring harness from the engine.
    Fig 5: Locating Block Heater Wiring Harness
    G06270105Courtesy of FORD MOTOR CO.
  8. Disconnect the PCV hose from the PCV valve.
    Fig 6: Locating PCV Hose
    G06062361Courtesy of FORD MOTOR CO.
  9. Disconnect the Throttle Body (TB) electrical connector.
    Fig 7: Locating Throttle Body (TB) Electrical Connector
    G06062242Courtesy of FORD MOTOR CO.
  10. Detach the wiring harness retainers from the upper intake manifold.
    Fig 8: Locating Wiring Harness Retainers To Upper Intake Manifold
    G06270108Courtesy of FORD MOTOR CO.
  11. Remove the upper intake manifold support bracket bolt.
    Fig 9: Locating Upper Intake Manifold Support Bracket Bolt
    G06062244Courtesy of FORD MOTOR CO.
  12. 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 10: Locating Upper Intake Manifold Bolts
    G06062246Courtesy of FORD MOTOR CO.
  13. Disconnect the PSP  switch electrical connector.
    Fig 11: Locating PSP Switch Electrical Connector
    G06269962Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

  14. Disconnect the RH Catalyst Monitor Sensor (CMS) sensor electrical connector.
    Fig 12: Locating RH Catalyst Monitor Sensor (CMS) Electrical Connector
    G06062161Courtesy of FORD MOTOR CO.

    All vehicles 

  15. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
    Fig 13: Locating RH Variable Camshaft Timing (VCT) Solenoid Electrical Connector
    G06062248Courtesy of FORD MOTOR CO.
  16. Disconnect the 3 RH coil-on-plug electrical connectors.
    Fig 14: Locating RH Coil-On-Plug Electrical Connectors
    G06062370Courtesy of FORD MOTOR CO.
  17. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
  18. Disconnect the LH CMS  sensor electrical connector.
    Fig 15: Locating LH CMS Sensor Electrical Connector
    G06270115Courtesy of FORD MOTOR CO.
  19. Disconnect the LH VCT  solenoid electrical connector.
    Fig 16: Locating LH VCT Solenoid Electrical Connector
    G06062250Courtesy of FORD MOTOR CO.
  20. Disconnect the 3 LH coil-on-plug electrical connectors.
    Fig 17: Locating LH Coil-On-Plug Electrical Connectors
    G06062251Courtesy of FORD MOTOR CO.
  21. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
  22. Remove the A/C compressor nut and stud.
    NOTE: The A/C compressor must remain bolted to the cylinder block prior to installing the oil pan.
    Fig 18: Locating A/C Compressor Nut & Stud
    G06270118Courtesy of FORD MOTOR CO.
  23. Detach the PSP  hose retainer from the engine lifting eye.
    Fig 19: Locating PSP Hose Retainer
    G06269968Courtesy of FORD MOTOR CO.
  24. Remove the PSP  hose bracket nut.
    Fig 20: Locating PSP Hose Bracket Nut
    G06269770Courtesy of FORD MOTOR CO.
  25. Remove the 3 bolts and position the power steering pump aside.
    Fig 21: Locating Power Steering Pump & Bolts
    G06269976Courtesy of FORD MOTOR CO.
  26. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 22: Locating Accessory Drive Belt Tensioner Bolts
    G06062657Courtesy of FORD MOTOR CO.
  27. Remove the 4 nuts (3 shown in illustration) and the LH catalytic converter.
    • Discard the nuts and the gasket.
    Fig 23: Locating LH Catalytic Converter & Nuts
    G06270123Courtesy of FORD MOTOR CO.

    FWD vehicles 

  28. Remove the 4 nuts and the RH catalytic converter.
    • Discard the nuts and the gasket.
    Fig 24: Locating RH Catalytic Converter & Nuts
    G06269875Courtesy of FORD MOTOR CO.

    All vehicles 

  29. Remove the RH cylinder block drain plug or, if equipped, the block heater.
    • Allow coolant to drain from the cylinder block.
    Fig 25: Locating RH Cylinder Block Drain Plug & Block Heater
    G06062308Courtesy of FORD MOTOR CO.
  30. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
    Fig 26: Locating LH Cylinder Block Drain Plug
    G06062305Courtesy of FORD MOTOR CO.
  31. Remove the 6 bolts and the 6 coil-on-plugs.
    NOTE: LH shown in illustration, RH similar.
    Fig 27: Locating Bolts And Coil-On-Plug Assemblies
    G06062252Courtesy of FORD MOTOR CO.
  32. Remove the 2 nuts and the wiring harness retaining bracket.
    Fig 28: Locating Wiring Harness Retaining Bracket & Nuts
    G06269758Courtesy of FORD MOTOR CO.

    Early build vehicles 

  33. Loosen the 11 stud bolts and remove the LH valve cover.
    • Discard the gasket.
    Fig 29: Locating Stud Bolts & Valve Cover
    G06269972Courtesy of FORD MOTOR CO.
  34. Loosen the bolt, the 10 stud bolts and remove the RH valve cover.
    • Discard the gasket.
    Fig 30: Locating Stud Bolts & Valve Cover
    G06269972Courtesy of FORD MOTOR CO.

    Late build vehicles 

  35. Loosen the 9 stud bolts and remove the LH valve cover.
    • Discard the gasket.
    Fig 31: Locating Stud Bolts & Valve Cover
    G06251726Courtesy of FORD MOTOR CO.
  36. Loosen the 9 stud bolts and remove the RH valve cover.
    • Discard the gasket.
    Fig 32: Locating Stud Bolts & RH Valve Cover
    G06251727Courtesy of FORD MOTOR CO.

    All vehicles 

  37. Inspect the VCT  solenoid seals and the spark plug tube seals. Remove any damaged seals.
    • 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 33: Identifying VCT Spark Plug Tube Seal Remover And Handle
    G06270133Courtesy of FORD MOTOR CO.
  38. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
    • Discard the bolt.
    Fig 34: Locating Crankshaft Pulley Bolt & Washer
    G06061937Courtesy of FORD MOTOR CO.
  39. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 35: Identifying Jaw Puller
    G06061968Courtesy of FORD MOTOR CO.
  40. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 36: Identifying Oil Seal Remover
    G06061944Courtesy of FORD MOTOR CO.
  41. Remove the 2 bolts and the engine mount bracket.
    Fig 37: Locating Engine Mount Bracket & Bolts
    G06061983Courtesy of FORD MOTOR CO.
  42. Remove the 2 engine mount studs.
    NOTE: Only use hand tools to remove the studs.
    Fig 38: Locating Engine Mount Studs
    G06061984Courtesy of FORD MOTOR CO.
  43. Remove the 3 bolts and the engine mount bracket.
    Fig 39: Locating Engine Mount Bracket & Bolts
    G06074073Courtesy of FORD MOTOR CO.
  44. Remove the 22 engine front cover bolts.
    Fig 40: Locating Engine Front Cover Bolts
    G06061990Courtesy of FORD MOTOR CO.
  45. 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 41: Identifying Engine Front Cover Bolt
    G06061991Courtesy of FORD MOTOR CO.
  46. Remove the 16 oil pan bolts.
    Fig 42: Locating Oil Pan Bolts
    G06062396Courtesy of FORD MOTOR CO.
  47. Install 2 of the oil pan bolts (finger-tight) into the 2 threaded holes in the oil pan.
    • Alternately tighten the 2 bolts one turn at a time until the oil pan-to-cylinder block seal is released.
      • Remove the oil pan.
    48. Fig 43: Locating Oil Pan Bolts
    G06062397Courtesy of FORD MOTOR CO.
  48. Clean the engine front cover and oil pan 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 and oil pan 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 and oil pan. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.
  49. Clean all engine sealing surfaces of the 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, can 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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