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WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using the special tool, remove the bolts and the flexplate.
    Fig 1: Identifying Special Tool (303-103)
    GF0008972Courtesy of FORD MOTOR CO.
  2. Mount the engine on a suitable engine stand.
  3. Remove the drive belt.
    Fig 2: Locating Drive Belt
    GF0009025Courtesy of FORD MOTOR CO.
  4. Remove the engine oil level indicator, 2 bolts and the engine oil level indicator tube.
    Fig 3: Locating Engine Oil Level Indicator Tube & Bolt
    GF0009026Courtesy of FORD MOTOR CO.
  5. Remove the 2 bolts and the front coolant outlet pipe.
    Fig 4: Locating Bolts & Front Coolant Outlet Pipe
    GF0009027Courtesy of FORD MOTOR CO.
  6. Remove the 4 bolts and the A/C compressor.
    Fig 5: Locating A/C Compressor Bolts
    GF0009028Courtesy of FORD MOTOR CO.
    7. NOTE: The generator will be removed with the accessory bracket.
    Fig 6: Locating Accessory Bracket Bolts
    GF0009029Courtesy of FORD MOTOR CO.
  7. Remove the bolts and the accessory bracket and generator as an assembly.
  8. Remove the 4 bolts and the RH engine mount bracket.
    Fig 7: Locating Bolts & RH Engine Mount Bracket
    GF0009030Courtesy of FORD MOTOR CO.
  9. Disconnect the coolant hose assembly from the thermostat housing and the PCV fitting on the intake manifold.
    Fig 8: Locating Positive Crankcase Ventilation (PCV) Fitting On Intake Manifold
    GF0009031Courtesy of FORD MOTOR CO.
  10. Remove the 2 nuts and the coolant tube assembly.
    Fig 9: Locating Coolant Tube Assembly & Nuts
    GF0009032Courtesy of FORD MOTOR CO.
  11. Remove the 7 nuts, the exhaust manifold and gasket.
    Fig 10: Locating Exhaust Manifold Nuts & Gasket
    GF0009033Courtesy of FORD MOTOR CO.
    • Discard the 7 nuts and the exhaust manifold gasket.
  12. Remove and discard the exhaust manifold-to-cylinder head studs.
  13. Clean and inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
  14. If equipped, remove the block heater.
    Fig 11: Locating Block Heater
    GF0009034Courtesy of FORD MOTOR CO.
  15. Remove the rear coolant outlet pipe.
    • Disconnect the coolant hose.
    • Remove the 4 bolts, the rear coolant outlet pipe and discard the gasket.
      Fig 12: Locating Bolts & Rear Coolant Outlet Pipe
      GF0009035Courtesy of FORD MOTOR CO.
  16. Remove the EGR valve.
    • Disconnect the electrical connector.
    • Disconnect the coolant hose.
      Fig 13: Identifying Coolant Hose & Bolts
      GF0009036Courtesy of FORD MOTOR CO.
    • Remove the 2 bolts, the EGR valve and discard the gasket.
  17. Remove the 4 bolts and the power steering pump.
    Fig 14: Locating Power Steering Pump Bolts
    GF0009037Courtesy of FORD MOTOR CO.
  18. Disconnect the idle air control (IAC) valve, the throttle position (TP) sensor and the manifold absolute pressure (MAP) sensor electrical connectors.
    Fig 15: Disconnecting Electrical Connectors (IAC, TP And MAP)
    GF0009038Courtesy of FORD MOTOR CO.
  19. Disconnect the crankshaft position (CKP) sensor and the wiring harness pin-type retainers.
    Fig 16: Locating Crankshaft Position Sensor And Wiring Harness Pin-Type Retainers
    GF0009039Courtesy of FORD MOTOR CO.
  20. Disconnect the knock sensor (KS) electrical connector, remove the 3 bolts and position the engine wiring harness and bracket aside.
    Fig 17: Locating Bolts & Engine Wiring Harness
    GF0009040Courtesy of FORD MOTOR CO.
  21. Disconnect the camshaft position (CMP) sensor electrical connector and the PCV hose.
    Fig 18: Locating CMP Sensor Electrical Connector & PCV Hose
    GF0009041Courtesy of FORD MOTOR CO.
  22. Disconnect the engine wiring harness pin-type retainers from the intake manifold.
  23. Remove the 2 bolts and the EGR tube from the intake manifold.
    Fig 19: Locating Intake Manifold EGR Tube Bolt
    GF0009042Courtesy of FORD MOTOR CO.
  24. Remove the EGR tube.
    Fig 20: Locating EGR Tube To Cylinder Head
    GF0009043Courtesy of FORD MOTOR CO.
    • Remove the EGR tube bracket from the intake manifold.
    • Disconnect the EGR tube from the cylinder head.
    • Remove the EGR tube.
    25. CAUTION: 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    Fig 21: Locating Intake Manifold Assembly Bolts
    GF0009044Courtesy of FORD MOTOR CO.
  25. Remove the 5 bolts and the intake manifold.
    • Clean and inspect the sealing surfaces with metal surface prep and silicone gasket remover. Follow the directions on the packaging.
  26. Disconnect the 4 fuel injector electrical connectors and the 2 wiring harness pin-type retainers.
    Fig 22: Locating Fuel Injector Electrical Connectors
    GF0009045Courtesy of FORD MOTOR CO.
  27. Disconnect the ignition coil and the cylinder head temperature (CHT) sensor electrical connectors.
    Fig 23: Locating Ignition Coil & Cylinder Head Temperature (CHT) Sensor Electrical Connectors
    GF0009046Courtesy of FORD MOTOR CO.
  28. Detach the engine wiring harness anchors from the valve cover studs. Remove the engine wiring harness.
    Fig 24: Detaching Engine Wiring Harness Anchors From Valve Cover Studs
    GF0009047Courtesy of FORD MOTOR CO.
    29. CAUTION: Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. Failure to follow this instruction may result in poor engine performance.
    CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.
  29. With a twisting motion, disconnect the spark plug wires from the spark plugs.
  30. Remove the 4 bolts and the ignition coil.
    Fig 25: Locating Ignition Coil Bolts
    GF0009048Courtesy of FORD MOTOR CO.
  31. Remove the 3 bolts and the thermostat housing.
    Fig 26: Locating Thermostat Housing Bolts
    GF0009049Courtesy of FORD MOTOR CO.
  32. Remove the bolts, the KS and the engine vent cover.
    Fig 27: Locating Engine Vent Cover & KS Bolts
    GF0009050Courtesy of FORD MOTOR CO.
  33. Remove the 4 bolts and the LH engine mount bracket.
    Fig 28: Locating LH Engine Mount Bracket Bolts
    GF0009051Courtesy of FORD MOTOR CO.
  34. Remove the bolts, fuel rail with the injectors and the ground strap.
    Fig 29: Locating Fuel Rail Bolts
    GF0009052Courtesy of FORD MOTOR CO.
    • Discard the fuel injector O-ring seals.
  35. Remove the 3 bolts and the water pump pulley.
    Fig 30: Locating Coolant Pump Pulley Bolts
    G03897969Courtesy of FORD MOTOR CO.
  36. Remove the 3 bolts and the water pump.
    Fig 31: Locating Coolant Pump Bolts
    G03897970Courtesy of FORD MOTOR CO.
    • Discard the O-ring seal.
  37. Remove the CMP sensor, CHT sensor and the spark plugs.
    Fig 32: Locating CMP Sensor, CHT Sensor & Spark Plugs
    GF0009053Courtesy of FORD MOTOR CO.
  38. Remove the fasteners and the valve cover.
    Fig 33: Locating Valve Cover Fasteners
    GF0009054Courtesy of FORD MOTOR CO.
  39. Remove the 2 bolts and discard the CKP sensor.
    Fig 34: Locating CKP Sensor Bolts
    GF0009055Courtesy of FORD MOTOR CO.
    40. CAUTION: 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 you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage may occur.
    CAUTION: Failure to position the No. 1 piston at top dead center (TDC) may result in damage to the engine.
    CAUTION: Turn the crankshaft in the normal direction of rotation only, or the engine may be damaged.
    Fig 35: Turning Crankshaft Clockwise
    GF0008921Courtesy of FORD MOTOR CO.
  40. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
    41. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation may result in engine damage.
    Fig 36: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
    NOTE: The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
  41. Install the special tool in the slots on the rear of both camshafts.
  42. Assemble the special tools using 4 hardened washers in the locations shown.
    Fig 37: Assembling Special Tools (205-072-02 And 205-126)
    GF0008922Courtesy of FORD MOTOR CO.
    43. CAUTION: The crankshaft must remain in the top dead center (TDC) position during removal of the pulley bolt or damage to the engine may occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
    CAUTION: If the crankshaft sprocket diamond washer comes off with the crankshaft pulley, it must be installed back onto the crankshaft. Failure to follow this instruction may cause engine damage.
    Fig 38: Identifying Special Tools (205-072-02, 205-126) And Crankshaft Pulley Bolt
    GF0008923Courtesy of FORD MOTOR CO.
  43. Using the special tools and an air impact wrench, remove the crankshaft pulley.
    • Remove and discard the crankshaft pulley bolt and washer.
    • Remove the crankshaft pulley.
    44. NOTE: There is one front cover bolt behind the cooling fan drive pulley. To remove this bolt, align one of the cooling fan drive pulley access holes with the bolt head.
    Fig 39: Locating Front Cover Bolts
    GF0009056Courtesy of FORD MOTOR CO.
  44. Remove the front cover.
  45. Compress the timing chain tensioner, and insert a paper clip into the hole. Remove the 2 bolts and the timing chain tensioner.
    Fig 40: Locating Timing Chain Tensioner & Bolts
    GF0008938Courtesy of FORD MOTOR CO.
  46. Remove the RH timing chain guide.
    Fig 41: Locating RH Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
  47. Remove the timing chain.
    Fig 42: View Of Timing Chain
    G03897779Courtesy of FORD MOTOR CO.
  48. Remove the 2 bolts and the LH timing chain guide.
    Fig 43: Identifying Bolts And LH Timing Chain Guide
    G03897780Courtesy of FORD MOTOR CO.
    49. CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft may occur.
    NOTE: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshaft in place.
    Fig 44: Locating Camshaft Sprockets & Bolts
    GF0009057Courtesy of FORD MOTOR CO.
  49. Remove the bolts, washers and camshaft drive sprockets.
  50. Remove the oil pump chain drive tensioner.
    1. Release the tension on the tensioner spring.
    • Remove the 2 shoulder bolts and the tensioner.
      Fig 45: Locating Shoulder Bolts & Tensioner
      GF0009058Courtesy of FORD MOTOR CO.
    51. NOTE: The oil pump chain sprocket must be held in place.
    Fig 46: Locating Bolt, Chain, Sprockets & Diamond Washers
    GF0009059Courtesy of FORD MOTOR CO.
  51. Remove the bolt, the chain, sprockets and diamond washers.
  52. Remove the special tool.
    Fig 47: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
    53. CAUTION: Failure to follow the camshaft loosening procedure may result in damage to the camshafts.
    NOTE: Note the position of the lobes on the No. 1 cylinder before removing the camshafts for assembly reference.
  53. Remove the camshaft bearing caps.
    • Loosen the camshaft bearing cap bolts in sequence shown, one turn at a time.
      Fig 48: Identifying Sequence Of Camshaft Bearing Caps
      GF0009060Courtesy of FORD MOTOR CO.
    • Repeat the first step until all tension is released from the camshaft bearing caps.
    • Remove the camshaft bearing caps.
  54. Remove the camshafts.
    55. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage may result if a warm or hot cylinder head is removed.
    CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Foreign material, including any material created while cleaning gasket surfaces, may enter the cylinders, oil passages, coolant passages or the oil pan, and cause engine failure.
    CAUTION: 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.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface, or the cylinder head may be damaged.
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
    Fig 49: Locating Cylinder Head Bolts
    GF0009061Courtesy of FORD MOTOR CO.
  55. Remove the bolts and the cylinder head.
    • Discard the cylinder head bolts.
  56. Remove and discard the cylinder head gasket.
  57. Remove the cylinder head alignment dowels.
    Fig 50: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
  58. Remove the bolts and the oil pan.
    Fig 51: Locating Oil Pan Bolts
    GF0009062Courtesy of FORD MOTOR CO.
  59. Remove the bolts and the rear crankshaft seal and retainer plate.
    Fig 52: Locating Rear Crankshaft Seal Bolts
    GF0009063Courtesy of FORD MOTOR CO.
    • Discard the crankshaft rear seal and retainer plate assembly.
  60. Remove the bolts, the oil pump pickup tube and discard the gasket.
    Fig 53: Locating Oil Pump Screen & Pickup Tube Bolts
    GF0009064Courtesy of FORD MOTOR CO.
  61. Remove the 4 bolts and the oil pump assembly.
    Fig 54: Locating Oil Pump Assembly & Bolts
    GF0009065Courtesy of FORD MOTOR CO.
    • Discard the gasket.
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