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Contents Section: Engine All sections

Removal Ford Five Hundred I

Engine 12 illustrations ~1161 words

Removal

  1. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
  2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  3. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
  4. Remove the 4 transaxle roll restrictor cross brace bolts.
  5. Remove the bolt and the transaxle roll restrictor cross brace.
  6. Disconnect the evaporative emissions (EVAP) canister purge valve tube from the upper intake manifold and detach the retainer.
  7. Disconnect the positive crankcase ventilation (PCV), brake booster and vacuum harness tubes from the upper intake manifold.
  8. Detach the fuel tube retainer from the upper intake manifold.
  9. Disconnect the exhaust gas recirculation (EGR) system module electrical connector and vacuum tube.
  10. Detach the vacuum tube from the upper intake manifold vacuum tube retainer.
  11. Disconnect the EGR system module tube from the EGR system module.
  12. Disconnect and plug the throttle body and PCV coolant hoses.
  13. Disconnect the throttle body electrical connector.
  14. If equipped, remove and discard the 4 upper-to-lower intake manifold screws.
  15. Remove the 8 bolts and the upper intake manifold. Remove and discard the gaskets.

Scheme 4

Scheme 4: Installation
Scheme 4: Installation
  1. Position the upper intake manifold and install the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  2. Connect the throttle body electrical connector.
  3. Connect the throttle body and PCV coolant hoses.
  4. Connect the EGR system module tube to the EGR system module. Tighten to 40 Nm (30 lb-ft).
  5. Attach the vacuum tube to the upper intake manifold vacuum tube retainer.
  6. Connect the EGR system module electrical connector and vacuum tube.
  7. Attach the fuel tube retainer to the upper intake manifold.
  8. Connect the PCV, brake booster and vacuum harness tubes to the upper intake manifold.
  9. Connect the EVAP canister purge valve tube to the upper intake manifold and attach the retainer.
  10. Clean the 4 transaxle roll restrictor cross brace bolts using a wire brush and apply new threadlock to the threads.
  11. Position the transaxle roll restrictor cross brace and install the 4 new bolts. Tighten to 55 Nm (41 lb-ft).
  12. Clean the transaxle roll restrictor cross brace-to-roll restrictor bolt using a wire brush and apply new threadlock to the threads.
  13. Install a new transaxle roll restrictor cross brace-to-roll restrictor bolt. Tighten to 48 Nm (35 lb-ft).
  14. Install the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
  15. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  16. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

ITEM SPECIFICATION

Scheme 5

Scheme 5
Scheme 5
WARNINGDo 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.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7
  1. 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) .
  2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  3. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(/ford/five-hundred/i-2004-2007/remont/mechanical/#engine) .
  4. Disconnect the fuel tube redundant clip.
  5. Press the fuel tube quick release coupling button and disconnect the fuel tube from the fuel rail.
  6. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
  7. Disconnect the fuel charging wiring harness electrical connector.
  8. Remove the lower intake manifold. Remove and discard the gaskets.

Scheme 8

Scheme 8: Installation
Scheme 8: Installation
  1. Position the lower intake manifold.
  2. Connect the fuel charging wiring harness electrical connector.
  3. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
  4. Connect the fuel tube to the fuel rail.
  5. Connect the fuel tube redundant clip.
  6. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(/ford/five-hundred/i-2004-2007/remont/mechanical/#engine) .
  7. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
ItemSpecification
Silicone Gasket and Sealant TA-30WSE-M4G323-A4

ITEM SPECIFICATION

Scheme 9

Scheme 9
Scheme 9
CAUTIONDuring 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, can cause engine failure.
  1. Remove the LH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION»(/ford/five-hundred/i-2004-2007/remont/ignition-system/#engine-ignition-system) .
  2. Disconnect the crankcase ventilation tube from the valve cover.
  3. Remove the 3 nuts and position the wiring conduit aside.
  4. Detach the 3 wiring retainers from the valve cover stud bolts.
  5. Remove the oil level indicator.
  6. Remove the 6 bolts, 8 stud bolts and the valve cover. Remove and discard the gasket.

Scheme 10

Scheme 10: Installation
Scheme 10: Installation
  1. Clean the valve cover, cylinder head and front cover sealing surfaces.
  2. Apply a 5 mm (0.19 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
  3. Position the valve cover and install the 6 bolts and 8 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  4. Install the oil level indicator.
  5. Attach the wiring retainers to the valve cover stud bolts.
  6. Position the wiring conduit and install the 3 nuts. Tighten to 6 Nm (53 lb-in).
  7. Attach the crankcase ventilation tube to the valve cover.
  8. Install the LH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION»(/ford/five-hundred/i-2004-2007/remont/ignition-system/#engine-ignition-system) .
ItemSpecification
Silicone Gasket and Sealant TA-30WSE-M4G323-A4

ITEM SPECIFICATION

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12
CAUTIONDuring 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, can cause engine failure.
  1. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(/ford/five-hundred/i-2004-2007/remont/mechanical/#engine) .
  2. Remove the RH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION»(/ford/five-hundred/i-2004-2007/remont/ignition-system/#engine-ignition-system) .
  3. If equipped, disconnect the positive crankcase ventilation (PCV) valve electrical connector.
  4. Remove the PCV tube.
  5. Remove the 2 nuts and position the power steering fluid reservoir aside.
  6. Remove the bolt and detach the power steering pressure (PSP) tube bracket from the fluid reservoir bracket.
  7. Remove the nut and the power steering fluid reservoir bracket.
  8. Remove the 3 power steering fluid reservoir bracket stud bolts from the valve cover.
  9. Remove the bolt and detach the PSP tube bracket from the backside of the RH cylinder head.
  10. Remove the 3 nuts and detach the wiring conduit from the valve cover stud bolts.
  11. Detach the 2 wiring retainers from the valve cover stud bolts.
  12. Remove the 9 bolts, 5 stud bolts and the RH valve cover. Remove and discard the gasket.

Scheme 13

Scheme 13: Installation
Scheme 13: Installation
  1. Clean the valve cover, cylinder head and front cover sealing surfaces.
  2. Apply a 5 mm (0.19 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
  3. Position the valve cover and install the 9 bolts and 5 stud bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
  4. Attach the 2 wiring retainers to the valve cover stud bolts.
  5. Attach the wiring conduit to the valve cover stud bolts and install the 3 nuts. Tighten to 6 Nm (53 lb-in).
  6. Position the PSP tube bracket to the backside of the RH cylinder head and install the bolt. Tighten to 7 Nm (62 lb-in).
  7. Install the 3 power steering fluid reservoir bracket stud bolts into the valve cover. Tighten to 7 Nm (62 lb-in).
  8. Position the power steering fluid reservoir bracket and install the nut. Tighten to 9 Nm (80 lb-in).
  9. Position the PSP tube bracket and install the bolt. Tighten to 7 Nm (62 lb-in).
  10. Position the power steering fluid reservoir and install the 2 nuts. Tighten to 9 Nm (80 lb-in).
  11. Install the PCV tube.
  12. If equipped, connect the PCV valve electrical connector.
  13. Install the RH ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION»(/ford/five-hundred/i-2004-2007/remont/ignition-system/#engine-ignition-system) .
  14. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(/ford/five-hundred/i-2004-2007/remont/mechanical/#engine) .

Scheme 14

Scheme 14: Lower End Components - Exploded View
Scheme 14: Lower End Components - Exploded View

Scheme 15

Scheme 15
Scheme 15
  1. For additional information, refer to the procedures below.