Installation — Part 3 Ford Five Hundred I

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
3. Disconnect the negative and positive battery cables. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
4. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/automatic-hvac-system/#hvac-control-system-general-information) .
5. Remove the air cleaner outlet pipe and air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
6. Remove the cowl vent screen. For additional information, refer to «WIPERS AND WASHERS»(/ford/five-hundred/i-2004-2007/remont/wiperwasher-systems/#wiper-system-washer-system) .
7. Drain the cooling system. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/mechanical/#engine-system-general-information) .
8. Remove the LH and RH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
9. Remove the exhaust flex pipe and LH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/ford/five-hundred/i-2004-2007/remont/exhaust/#exhaust-system) .
10. Remove and discard the roll restrictor cross brace-to-roll restrictor bolt.
11. Remove and discard the 4 roll restrictor cross brace bolts and the cross brace.
12. Remove the bolt and detach the ground strap from the RH fender.
13. Disconnect the redundant clip, press the quick release coupling button and disconnect the fuel tube from the fuel rail.
14. Detach the fuel tube clip from the upper intake manifold.
15. Disconnect the vapor tube from the purge valve.
16. Disconnect the 2 powertrain control module (PCM) electrical connectors and detach the wiring conduit.
17. Disconnect the power steering reservoir hose and detach the retainer.
18. Remove the bolt and detach the ground wire from the LH fender.
19. Remove the nut and detach the B+ terminal from the battery cable.
20. Disconnect the shift cable.
21. Disconnect the 16-pin electrical connector and detach the wiring retainers. Detach the electrical connector from the shift cable bracket.
22. Remove the 2 bolts and position the shift cable aside.
23. Disconnect the shift cable.
24. Disconnect the 16-pin electrical connector and detach the wiring retainer. Disconnect the electrical connector from the shift cable bracket.
25. Remove the 3 shift cable bracket bolts and position the cable and bracket aside.
26. Disconnect the heater hose and the throttle body coolant hose.
27. Disconnect the brake booster vacuum hose from the upper intake manifold.
28. Disconnect the coolant hoses from the thermostat housing.
29. Detach the coolant tube retainers.
30. Disconnect the 10-pin electrical connector and detach the wiring retainers.
31. Disconnect the A/C high-pressure switch electrical connector.
32. Remove the bolt and disconnect the A/C compressor manifold tube assembly.
33. Remove the nut and position the A/C tubes aside.
34. Disconnect the transmission cooler hoses.
35. Disconnect the power steering cooler hose.
36. Remove the engine oil pan drain plug and drain the engine oil. Install the plug and tighten to 26 Nm (19 lb-ft).
37. If equipped, disconnect the block heater electrical connector and detach the wiring harness.
38. Remove the 2 pin-type retainers and the torque converter lower access plug.
39. Remove and discard the 4 torque converter nuts.
40. Remove the 3 engine-to-transaxle bolts and the LH catalytic converter bracket.
41. If equipped, remove the 2 driveshaft support bracket bolts.
42. If equipped, remove the bolts and disconnect the driveshaft. Position the driveshaft aside.
43. Using the special tool, lower the powertrain and subframe from the vehicle.
44. Remove the nuts and separate the stabilizer bar links from the struts.
45. Remove the nuts and separate the outer tie rods from the wheel knuckles. Discard the nuts.
46. Remove and discard the steering column intermediate shaft bolt. Detach the intermediate shaft from the steering gear.
47. Using the special tool, support the powertrain and the subframe.
48. Remove the 6 bolts and the 2 rear subframe brackets.
49. Remove the 2 forward subframe bolts and washers.
50. Remove the power steering pressure (PSP) tube bracket bolt and disconnect the PSP switch electrical connector.
51. Remove the bolt and disconnect the power steering fluid tubes.
52. Disconnect the RH catalyst monitor sensor electrical connector and detach the pin-type retainers from the subframe.
53. Disconnect the transaxle bulkhead electrical connector.
54. Detach the wiring harness retainer from the transaxle.
55. Detach the wiring harness retainers from the transaxle.
56. Detach the lower wiring harness retainers from the transaxle.
57. Remove the 4 bolts and the roll restrictor bracket.
58. Detach the wiring harness from the roll restrictor.
59. Remove the 2 bolts and the roll restrictor.
60. Remove the starter motor electrical connector cover.
61. Remove the nuts and disconnect the starter motor wiring.
62. Remove the 2 bolts and the starter motor.
63. Remove the bolt and disconnect the ground cable.
64. Disconnect the wire harness from the transmission control unit (TCU).
65. Remove the 4 bolts and the roll restrictor bracket.
66. Remove the 2 bolts and the roll restrictor.
67. Remove the starter motor electrical connector cover.
68. Remove the nuts and disconnect the starter motor wiring.
69. Remove the 2 bolts and the starter motor.
70. Remove the bolt and disconnect the ground cable.
71. Install the special tool to the RH cylinder head.
72. Install the special tool to the LH cylinder head.
73. Install the lower half of the special tool.
74. Install the upper half of the special tool.
75. Using the special tools and a suitable engine crane, support the powertrain.
76. Remove the front transaxle stabilizer bolt.
77. Remove the 3 bolts and the RH exhaust manifold heat shield.
78. Remove the RH engine insulator upper nut.
79. Remove the LH engine insulator upper nut.
80. If equipped, remove the upper power transfer unit (PTU) bracket bolts and the bracket.
81. Remove the 4 front transaxle insulator bracket bolts.
82. Remove the 3 front transaxle insulator bracket bolts.
83. Using the special tools and a suitable engine crane, lift the powertrain off of the subframe.
84. Lower the powertrain and support the transaxle using blocks of wood.
85. Position the knock sensor (KS) heat shield aside.
86. Disconnect the electrical connector and then remove the bolt and the KS.
87. Remove the engine-to-transaxle bolt.
88. Remove the 4 remaining transaxle-to-engine bolts. Separate the engine from the transaxle.
89. Remove the 4 remaining transaxle-to-engine bolts. Separate the engine from the transaxle.

SPECIAL TOOL SPECIFICATION Slide Hammer 307-005 (T59L-100-B) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Strap Wrench 303-D055 (D85L-6000-A) Remover, Oil Seal 303-409 (T92C-6700CH) 3-Jaw Puller 303-D121

ITEM SPECIFICATION

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1. Remove the 8 bolts and the flexplate.
2. Using the special tools, remove and discard the crankshaft rear oil seal.
3. Mount the engine on a suitable stand.
4. If equipped, remove the 3 retainers and the A/C compressor pulley shield.
5. Rotate the tensioner counterclockwise and remove the accessory drive belt.
6. Disconnect the A/C compressor electrical connector.
7. Disconnect the LH catalyst monitor sensor electrical connector and detach the wiring retainer.
8. If equipped, remove the 2 nuts, the bolt and the A/C compressor shield.
9. If equipped, remove the bolt and the A/C compressor.
10. Remove the 2 bolts, 2 nuts and the A/C compressor.
11. Remove the 5 bolts and the A/C compressor bracket.
12. Disconnect the LH heated oxygen sensor (HO2S) electrical connector and detach the wiring retainer.
13. Disconnect the oil pressure sensor electrical connector.
14. Remove the 2 nuts, disconnect the camshaft position sensor (CMP) and detach the retainers.
15. Loosen the fittings and remove the exhaust gas recirculation (EGR) system module tube.
16. Disconnect the EGR system module electrical connector.
17. Disconnect the throttle body electrical connector.
18. Disconnect the throttle body coolant hose.
19. Disconnect and remove the positive crankcase ventilation (PCV) tube.
20. Disconnect the fuel rail pressure and temperature sensor vacuum tube and electrical connector.
21. Disconnect the fuel charging wiring harness electrical connector.
22. Disconnect the RH HO2S and detach the retainer.
23. Remove the bolt and detach the power steering tube bracket.
24. Remove the bolt and detach the power steering tube bracket.
25. Remove the 2 nuts and detach the power steering fluid reservoir.
26. Remove the power steering fluid reservoir bracket nut.
27. Remove the 3 nuts and the power steering pump, reservoir and tubes.
28. Remove the 8 bolts and the upper and lower intake manifold. Remove and discard the gaskets.
29. Remove the nut and position the wiring conduit aside.
30. Disconnect the RH ignition coil electrical connectors and detach the wiring retainers.
31. Remove the nut and disconnect the generator wiring. Detach the wiring retainer.
32. Remove the nut and detach the ground wire.
33. Disconnect the crankshaft position sensor (CKP) electrical connector and detach the wiring retainer.
34. Disconnect the LH ignition coil electrical connectors and detach the wiring retainers.
35. Disconnect the engine coolant temperature (ECT) sensor and the radio interference capacitor electrical connectors.
36. Disconnect the bypass and the coolant pump hoses.
37. Remove the engine wiring harness.
38. Remove the stud bolt and the oil level indicator tube. Remove and discard the O-ring seal.
39. Remove and discard the oil filter.
40. Remove the 4 bolts and the oil filter adapter. Remove and discard the O-ring seal from the M22 bolt.
41. Remove the 2 nuts, bolt and the generator.
42. Remove the 4 bolts and the RH engine insulator bracket.
43. Remove and discard the 6 RH exhaust manifold nuts.
44. Remove the RH exhaust manifold. Remove and discard the gasket.
45. Remove and discard the 6 RH exhaust manifold studs.
46. Remove and discard the 6 LH exhaust manifold nuts.
47. Remove the LH exhaust manifold. Remove and discard the gasket.
48. Remove and discard the 6 LH exhaust manifold studs.
49. Remove the 6 bolts and the RH and LH ignition coils.
50. Remove the 6 bolts, 8 stud bolts and the LH valve cover. Remove and discard the gasket.
51. Remove the 9 bolts, 5 stud bolts and the RH valve cover. Remove and discard the gasket.
52. Remove the 2 bolts and the thermostat housing. Remove and discard the O-ring seal.
53. Remove the 4 bolts and the coolant pump.
54. Remove the 2 bolts and the coolant bypass tube.
55. Remove the bolt and the radio interference capacitor.
56. Remove the 15 bolts and the oil pan. Remove and discard the gasket.
57. Remove the 2 bolts and the oil pump screen and pickup tube. Remove and discard the O-ring seal.
58. Remove the 8 nuts and the oil pan baffle.
59. Remove the oil pressure sender.
60. If equipped, remove the block heater.
61. Use the special tool to hold the crankshaft damper and remove the bolt.
62. Using the special tool, remove the crankshaft damper.
63. Using the special tool, remove and discard the crankshaft front seal from the engine front cover.
64. Remove the bolt and the belt tensioner.
65. Remove the stud bolt, 14 bolts and the front cover. Remove and discard the gaskets.
66. Remove the ignition pulse wheel.
67. Install the damper bolt.
68. Remove the LH and RH spark plugs.
69. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the No. 1 cylinder at top dead center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
70. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.
71. Verify that the RH camshafts are in the neutral position.
72. Remove the RH timing chain tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
73. Remove the 2 bolts, RH timing chain guide and the timing chain.
74. Rotate the crankcase clockwise 600 degrees (1-2/3 turns) to position the crankcase keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
75. Verify the LH camshafts are in the neutral position.
76. Remove the LH timing chain and tensioner arm. Remove the 2 bolts. Remove the tensioner. Remove the tensioner arm.
77. Remove the LH timing chain and timing chain guide.
78. Remove the damper bolt and the crankshaft sprockets.
79. Remove the 3 bolts and camshaft oil seal retainer. Remove and discard the press-in-place gasket.
80. Using a suitable press, remove the camshaft oil seal.
81. Loosen the LH and RH camshaft cap bolts in the indicated sequence and remove the camshaft caps. Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.
82. Remove the LH and RH camshafts.
83. Remove the LH and RH camshaft roller followers. Mark the location of the roller followers using a permanent-type marker.
84. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads. Remove and discard the gaskets and the bolts.
85. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. 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. Apply metal surface prep, following package directions, to remove any 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.
86. Support the cylinder head on a bench with the head gasket side up.
87. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
88. Remove the 3 bolts and the power steering pump bracket.
89. Remove the 2 bolts and the oil separator cover. Remove and discard the gasket.
90. Remove the crankshaft key.

SPECIAL TOOL SPECIFICATION Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

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ITEM SPECIFICATION

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