Removal
Removal1. On air suspension equipped vehicles, turn air suspension switch, located in the RH kick panel area, to the OFF position.
2. Install memory saver, then disconnect battery negative cable.
3. Remove shield covering throttle body assembly.
4. Disconnect mass air flow (MAF) sensor electrical connector. Refer to Figure 1.
5. Disconnect intake air temperature (IAT) sensor electrical connector. Refer to Figure 1.
6. Remove air cleaner half and clean air tube as an assembly. See Figure 1.
7. Remove remaining half of air cleaner.
8. Disconnect accelerator cable, speed control cable and return spring from throttle body.
9. Remove accelerator cable bracket from intake manifold, then unclip cables from clip on power steering reservoir bracket. See Figure 2. Position cable assembly aside.
10. On 4.6L engines, proceed as follows:
^ Disconnect vapor management valve (VMV) vacuum line at rear of throttle body adapter. Refer to Figure 3.
^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 3.
^ Disconnect PCV hose at rear of throttle body adapter. Refer to Figure 3.
^ Remove brake booster vacuum line retainer at EGR valve. Disconnect vacuum line at throttle body adapter. See Figure 3. Position line aside.
^ Disconnect vapor management valve (VMV) vacuum line. Refer to Figure 4.
^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 4.
^ Disconnect EGR valve vacuum line. Refer to Figure 4.
^ Disconnect EVR solenoid vacuum line. See Figure 4.
^ Position vacuum harness away from engine.
11. On 5.4L engines, proceed as follows:
^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 5.
^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle.
12. Raise vehicle.
13. Disconnect EGR tube from exhaust manifold.
14. Disconnect oil pressure switch electrical connector. See Figure 6.
15. Disconnect crankshaft position (CKP) sensor electrical connector. See Figure 7.
16. On 4X2 models, disconnect A/C clutch electrical connector.
17. Drain coolant from radiator.
NOTE:
Do not remove right side cylinder block coolant drain plug.
18. Remove left side cylinder block coolant drain plug. Allow coolant to completely drain.
19. Install cylinder block coolant drain plug. Tighten plug to 16-24 Nm (12-17 lb-ft).
20. Drain engine oil. Do not final tighten drain plug at this time, as it will be removed again.
21. Lower vehicle.
NOTE:
The best access to the A/C electrical connector is through the wheel well.
22. On 4X4 models, disconnect A/C clutch electrical connector.
23. Mark and disconnect DPFE transducer hoses from EGR tube.
24. Disconnect EGR tube from EGR valve, then remove EGR tube from vehicle.
25. On 4.6L engines, proceed as follows:
^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 8.
^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle.
^ Disconnect EVR solenoid electrical connector. Refer to Figure 9.
^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 9.
^ Disconnect Idle Air Control (IAC) motor electrical connector. Refer to Figure 9.
^ Disconnect DPFE transducer electrical connector. See Figure 9.
^ Disconnect left side coil pack electrical connector. Refer to Figure 10.
^ Disconnect camshaft position (CMP) sensor electrical connector. Refer to Figure 10.
^ Disconnect left side radio interference suppressor electrical connector. See Figure 10.
^ Disconnect ignition wires from left side coil pack.
^ Remove left side coil pack from vehicle.
^ Unclip left side fuel charge harness from cam cover studs. Refer to Figure 11.
^ Unclip ignition wire separators from left cam cover studs. See Figure 11.
^ Disconnect ignition wires from left side spark plugs. Route ignition wires to front of engine.
^ Disconnect left side fuel injector electrical connectors.
26. On 5.4L engines, proceed as follows:
^ Disconnect Vapor Management Valve (VMV) vacuum line. Refer to Figure 12.
^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 12.
^ Disconnect EGR valve vacuum line. Refer to Figure 12.
^ Disconnect EVR solenoid vacuum line. See Figure 12
^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 13.
^ Position vacuum harness away from engine.
^ Disconnect VMV purge line at top of throttle body adapter. See Figure 13.
^ Disconnect brake booster vacuum line from throttle body adapter.
^ Remove brake booster vacuum line bracket from intake manifold. Position vacuum line assembly away from intake manifold.
^ Disconnect Idle Air Control (IAC) motor electrical connector. See Figure 14.
^ Disconnect left side radio interference suppressor electrical connector. Refer to Figure 15.
^ Disconnect DPFE transducer electrical connector. Refer to Figure 15.
^ Disconnect EVR solenoid electrical connector. Refer to Figure 15.
^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 15.
^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. See Figure 15.
^ Disconnect camshaft position (CMP) sensor electrical connector. See Figure 16.
^ Disconnect ignition coil electrical connectors from left side of engine. Refer to Figure 17.
^ Disconnect fuel injector electrical connectors from left side of engine. See Figure 17.
^ Remove left side fuel charge harness from cam cover studs, then position harness away from cam cover. See Figure 18.
^ Remove left side ignition coils from vehicle.
WARNING
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
WARNING
FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING.
27. Relieve fuel system pressure as follows:
^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge.
^ Slowly open manual valve on EFI/CFI fuel pressure gauge.
^ Remove fuel pressure gauge and reinstall schrader valve cap.
28. Disconnect fuel lines from fuel manifold.
29. Remove junction block splash shield. See Figure 19.
30. Disconnect positive leads from starter relay. Refer to Figure 20.
31. Unclip two (2) mega-fuses from bracket. Refer to Figure 20.
32. Disconnect two (2) 42-pin bulkhead electrical connectors. Refer to Figure 20.
33. Remove both bulkhead electrical connector halves from bracket. See Figure 20.
34. Disconnect 16-pin electrical connector. Refer to Figure 21.
35. Disconnect single-pin electrical connector. Refer to Figure 21.
36. Remove junction block bracket. See Figure 21.
37. Remove heater supply hose from vehicle. Refer to Figure 22.
38. Disconnect heater return hose from heater core fitting. Then position hose away from right cam cover. Refer to Figure 22.
39. Remove ground strap to bulkhead retaining bolt, then unwrap ground strap from fuel manifold. See Figure 22.
40. Remove PCV valve and line from vehicle.
41. On 4.6L engines, proceed as follows:
^ Disconnect right side coil pack electrical connector. Refer to Figure 23.
^ Disconnect right side radio interference suppressor electrical connector. Refer to Figure 23.
^ Disconnect ignition wires from right side coil pack. See Figure 23.
^ Remove right side coil pack from vehicle.
^ Unclip right side fuel charge harness from cam cover studs. Refer to Figure 24.
^ Unclip ignition wire separators from right cam cover studs. See Figure 24.
^ Disconnect ignition wires from right side spark plugs. Route ignition wires to front of engine.
^ Disconnect right side fuel injector electrical connectors.
^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. Refer to Figure 25.
^ Disconnect water temperature sender electrical connector. Refer to Figure 25.
^ Remove tie strap retaining alternator wiring harness to fuel manifold. See Figure 25.
42. On 5.4L engines, proceed as follows:
^ Disconnect right side radio interference suppressor. See Figure 26.
^ Disconnect ignition coil electrical connectors from right side of engine. Refer to Figure 27.
^ Disconnect fuel injector electrical connectors from right side of engine. See Figure 27.
^ Remove right side fuel charge harness from cam cover studs, then position harness away from cam cover.
^ Remove right side ignition coils from vehicle.
^ Remove tie strap retaining alternator wiring harness to fuel manifold.
43. Disconnect upper radiator hose from thermostat housing.
44. Remove drive belt.
45. Remove alternator and mounting bracket as an assembly. The ignition wires and the alternator wiring harness will also be removed with the alternator assembly.
46. Disconnect cylinder head temperature (CHT) sensor electrical connector. Refer to Figure 28.
47. Disconnect tuning valve electrical connector. See Figure 28.
48. Remove the intake manifold retaining bolts. See Figure 29.
49. Remove intake manifold from vehicle.
50. Remove and discard intake manifold gaskets.
NOTE:
On 5.4L engine, cam cover bolts cannot be separated from cam cover.
NOTE:
Be careful not to damage cam cover gaskets, as they will be reused. Remove both camshaft covers.
51. Remove both camshaft covers.
52. Disconnect heater return hose from coolant tube, then remove heater hose from vehicle. Refer to Figure 30.
53. Remove retainers securing routing bracket to rear of right-hand cylinder head, then remove routing bracket and ground strap. Refer to Figure 30.
54. Remove coolant tube retainers securing coolant tube to rear of right hand cylinder head, then remove coolant tube. See Figure 30.
55. Remove jack handle from radiator air deflector.
56. Remove air deflector on top of radiator.
57. Disconnect coolant recovery hose from radiator.
58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, remove cooling fan and clutch assembly.
59. Remove cooling fan shroud.
60. On automatic transmission models, disconnect transmission lines from radiator.
61. Disconnect lower radiator hose from radiator.
62. Remove radiator support brackets, then the radiator.
63. Remove water pump pulley, then the water pump.
64. On 4.6L and 5.4L Windsor engines, proceed as follows:
^ Remove two (2) upper power steering pump retaining bolts. Refer to Figure 31.
^ Raise vehicle.
^ Remove one (1) lower power steering pump retaining bolt, then position power steering pump away from front engine cover. See Figure 31.
65. On Romeo engines, proceed as follows:
^ Remove two (2) upper power steering pump retaining bolts. See Figure 32.
^ Raise vehicle.
NOTE:
One of the following bolts cannot be completely removed from the power steering pump due to clearance with the power steering line.
^ Remove two (2) lower power steering pump retaining bolts, then position power steering pump away from front engine cover. See Figure 33.
66. Remove four (4) front oil pan bolts. See Figure 34.
67. Lower vehicle.
68. Using Crankshaft Damper Remover T58P-6316-D, remove crankshaft pulley.
69. Using Front Cover Seal Remover T74P-6700-A, remove engine front cover oil seal.
70. Remove idler pulley from right side of engine front cover. This pulley blocks a front cover bolt.
71. Remove engine front cover retainers. See Figure 35.
72. Remove engine front cover from engine. See Figure 36.
73. Remove crankshaft sensor ring.
74. Using Crankshaft Holding Tool T93P-6303-A, rotate crankshaft until crankshaft keyway points to the 12 o'clock position. See Figure 37.
75. Install Camshaft Holding Tool T96T-6256-B, on each camshaft. See Figure 38 for holding tool placement.
76. Remove both timing chain tensioners. See Figure 39.
77. Remove both timing chain tensioner guides. See Figure 40.
78. Lift right-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. Refer to Figure 41.
79. Lift left-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. See Figure 41.
80. Remove both timing chain guides. See Figures 42 and 43.
NOTE:
Removal of this wheel opening molding screw is necessary to access all screws for the fender splash shield.
81. On 4X4 models, remove one (1) screw shown in Figure 44, from both wheel opening moldings.
82. Remove both front fender splash shields. See Figure 45.
83. Raise vehicle.
84. Disconnect exhaust Y-pipe from exhaust manifolds.
85. Slightly lower vehicle. Exhaust manifold retainers will be accessed through the wheel well opening.
86. Remove left side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged.
87. Loosen engine oil indicator tube; then turn tube away from cylinder head. Removal of indicator tube is not necessary.
88. Remove right side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged.
89. Remove retainer securing transmission indicator tube to right cylinder head if equipped.
NOTE:
Cylinder head bolts that are under the camshaft holding tools cannot be completely removed from the head due to clearance with the holding tool. Completely loosen these bolts.
90. Remove both cylinder heads. See Figure 46. Discard all cylinder head bolts.
91. Remove and discard both cylinder head gaskets.
92. On Romeo engines, proceed as follows:
^ Remove spark plugs from right cylinder head.
^ Remove camshaft sprocket from right side camshaft.
^ Remove Camshaft Holding Tool from right side camshaft.
^ Install camshaft sprocket on new right side camshaft. Do not final tighten retaining bolt at this time.
^ Remove spark plugs from left cylinder head.
^ Remove camshaft sprocket from left side camshaft.
^ Remove Camshaft Holding Tool from left side camshaft.
^ Install camshaft sprocket on new left side camshaft. Do not final tighten retaining bolt at this time.
^ Remove power steering reservoir bracket and CHT sensor from left cylinder head.
93. On 4.6L and 5.4L Windsor engines, proceed as follows:
^ Remove Camshaft Holding Tools from both camshafts.
^ Remove power steering reservoir bracket and Cylinder Head Temperature sensor from left cylinder head.
^ Remove all eight (8) spark plugs from cylinder heads.
94. Clean the following gasket surfaces:
^ Cylinder block to cylinder head.
^ Engine front cover.
^ Water pump.
^ Intake manifold.
^ Both cam covers.