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Section 1263 (Engine - 3.9): Removal: Engine

WARNING: This page is about a different car, the 2005 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
ENGINE SPECIAL TOOLS

G03898369
 Lifting Brackets, Engine 303-050 (T70P-6000)
G03898617
 Spreader Bar 303-D089 (D93P-6001-A3)
G03897842
 Powertrain Lift With Tilting Plate 014-00765
G03996186
 Transmission Support Bracket 014-00341
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Hold the steering wheel in the straight ahead position using a suitable holding device.
    Fig 1: Holding Steering Wheel In Straight-Ahead Position
    G03879008Courtesy of FORD MOTOR CO.
  3. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  4. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
    5. CAUTION: The engine appearance cover is equipped with a noise suppressor. If the noise suppressor becomes separated from the engine appearance cover it must be positioned on the intake manifold prior to installing the engine appearance cover.
    Fig 2: Identifying Engine Appearance Cover/Noise Suppressor
    G03996267Courtesy of FORD MOTOR CO.
  5. Remove the engine appearance cover and the noise suppressor (if detached).
  6. Remove the air cleaner assembly and outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
    7. CAUTION: The coolant drain procedure must be followed exactly or damage to the engine can occur.
  7. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
  8. Discharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  9. Remove the fresh air inlet duct. For additional information, refer to AIR DISTRIBUTION & FILTERING .
  10. Disconnect the fuel supply tube. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  11. Remove the upper radiator sight shield.
    Fig 3: Locating Upper Radiator Sight Shield
    G04007969Courtesy of FORD MOTOR CO.
    12. NOTE: RH shown, LH similar.
    Fig 4: Identifying Upper Radiator Support Bracket & Bolts
    G03995900Courtesy of FORD MOTOR CO.
  12. Remove the 6 bolts and the 2 upper radiator support brackets.
    13. CAUTION: To disconnect the quick release coupling, squeeze the tabs and pull straight out or damage to the coupling can occur.
    Fig 5: Disconnecting Evaporative Emissions Hose
    G03995908Courtesy of FORD MOTOR CO.
  13. Disconnect the evaporative emissions (EVAP) hose from the EVAP canister purge valve.
  14. Disconnect the vacuum hose.
    Fig 6: Identifying Vacuum Supply Hose/Tube
    G03996268Courtesy of FORD MOTOR CO.
  15. Disconnect the degas bottle hose.
    Fig 7: Disconnecting Degas Bottle Hose
    G03996526Courtesy of FORD MOTOR CO.
  16. Remove the 2 power steering reservoir bolts.
    Fig 8: Removing Power Steering Reservoir Bolts
    G03995902Courtesy of FORD MOTOR CO.
  17. Remove the bolt and disconnect the ground strap.
    Fig 9: Locating Ground Strap And Bolt
    G03996528Courtesy of FORD MOTOR CO.
    18. NOTE: The connectors are located on the backside of the RH strut tower.
    Fig 10: Identifying Engine Wiring Harness Electrical Connectors
    G04007484Courtesy of FORD MOTOR CO.
  18. Disconnect the engine wiring harness electrical connectors.
  19. Disconnect the bulkhead electrical connectors.
    Fig 11: Disconnecting Bulkhead Electrical Connectors
    G03996530Courtesy of FORD MOTOR CO.
  20. Disconnect the coolant valve electrical connector, unclip from the radiator support and position the harness aside.
    Fig 12: Disconnecting Coolant Valve Electrical Connector
    G03995915Courtesy of FORD MOTOR CO.
  21. Disconnect the cooling fan electrical connector.
    Fig 13: Disconnecting Cooling Fan Electrical Connector
    G03996532Courtesy of FORD MOTOR CO.
  22. Disconnect the A/C pressure switch electrical connector.
    Fig 14: Locating A/C Pressure Switch & Electrical Connector
    G03996977Courtesy of FORD MOTOR CO.
    23. NOTE: LH shown, RH similar.
    Fig 15: Locating Splash Shields
    G03995916Courtesy of FORD MOTOR CO.
  23. Remove the LH and the RH splash shields.
  24. Remove the center splash shield.
    Fig 16: Locating Air Deflector/Splash Shield Mounting Points
    G03995633Courtesy of FORD MOTOR CO.
  25. Remove the inner air deflector.
    Fig 17: Removing Inner Air Deflector
    G03995918Courtesy of FORD MOTOR CO.
  26. Remove the catalytic converters. For additional information, refer to EXHAUST SYSTEM .
    27. CAUTION: To make sure assembly will be in the exact location as when removed, index-mark the bolt, nut, washer and flex coupling to the pinion flange with paint or marker. Using a different color paint or marker, index-mark the second bolt, nut, washer and flex coupling to the pinion flange. These fasteners are balanced weights. Always assemble them in their original positions. Failure to do so can cause driveshaft noise, vibration and harshness (NVH).
    CAUTION: Do not remove the bolts retaining the flex coupling to the driveshaft.
    Fig 18: Locating Front Driveshaft Pinion Flange Bolts
    G03996537Courtesy of FORD MOTOR CO.
  27. Index-mark the front driveshaft pinion flange. Remove the 3 nuts, washers and bolts.
  28. Slide the front shaft assembly rearward and support.
    Fig 19: Sliding Front Shaft Assembly
    G03995920Courtesy of FORD MOTOR CO.
  29. Drain the engine oil.
    • Tighten drain plug to 23 Nm (17 lb-ft).
    30. NOTE: The top heater hose has a green identifying mark to match the hose on the dual coolant flow valve. If the mark is not visible, identify the hoses for location. This will aid in the correct installation of the hose assemblies.
    NOTE: Hose assemblies shown with components removed for clarity.
    Fig 20: Identifying Heater Hose Quick Release Couplings
    G03995921Courtesy of FORD MOTOR CO.
  30. Disconnect the 3 heater hose quick release couplings. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  31. Remove the nut and disconnect the A/C high pressure hose.
    Fig 21: Removing A/C High Pressure Hose Nut
    G03996540Courtesy of FORD MOTOR CO.
  32. Disconnect the low pressure A/C hose.
    Fig 22: Identifying Low Pressure A/C Hose
    G03996234Courtesy of FORD MOTOR CO.
  33. Position the RH and LH inner splash shields aside.
    1. Remove the pin-type retainers.
    2. Position the inner splash shields aside.
    Fig 23: Removing Pin-Type Retainers
    G03996542Courtesy of FORD MOTOR CO.
  34. Disconnect the RH and LH anti-lock brake sensor electrical connectors.
    Fig 24: Locating Anti-Lock Brake Sensor Electrical Connector
    G03995926Courtesy of FORD MOTOR CO.
  35. Detach the RH and LH anti-lock brake sensor harnesses from the brake hose clips.
    Fig 25: Identifying Anti-Lock Brake Sensor Harnesses-To-Hose Clips
    G03995927Courtesy of FORD MOTOR CO.
    36. CAUTION: Do not allow the brake caliper to hang from the brake hose or damage to the brake hose can occur.
    Fig 26: Identifying Brake Caliper Mounting Bolts
    G03995928Courtesy of FORD MOTOR CO.
  36. Remove the 4 bolts and position the front brake calipers aside.
    • Support the calipers using mechanic's wire.
    37. NOTE: To remove the nut, first loosen the nut, then use the hex-holding feature to prevent the stabilizer bar link ball joint from turning while removing the nut.
    Fig 27: Identifying Stabilizer Bar Link Connection Point At Lower Control Arm
    G03995929Courtesy of FORD MOTOR CO.
  37. Remove the 2 nuts and disconnect the stabilizer bar links from the lower control arms.
    38. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut from ball joints and stabilizer bar links.
    Fig 28: Identifying Upper Ball Joint Nut At Wheel Knuckle
    G03995930Courtesy of FORD MOTOR CO.
  38. Remove the 2 nuts and disconnect the upper ball joints from the wheel knuckles.
  39. Remove the 2 strut-to-control arm bolts and nuts.
    Fig 29: Identifying Lower Strut-To-Control Arm Bolt And Nut
    G03995931Courtesy of FORD MOTOR CO.
  40. Disconnect the shift cable from the shifter.
    Fig 30: Identifying Shift Cable Connection Point At Shifter
    G03995932Courtesy of FORD MOTOR CO.
  41. Remove the 2 bolts and position the shift cable bracket aside.
    Fig 31: Locating Shift Cable Bracket-To-Body Bolts
    G03995933Courtesy of FORD MOTOR CO.
  42. Detach the shift cable pin-type retainer from the exhaust heat shield
    Fig 32: Detaching Shift Cable Pin-Type Retainer
    G04007506Courtesy of FORD MOTOR CO.
  43. Disconnect the variable assist power steering (VAPS) actuator electrical connector.
    Fig 33: Locating Variable Assist Power Steering Actuator Electrical Connector
    G03995935Courtesy of FORD MOTOR CO.
  44. Release the power steering return hose from the pressure hose clip.
    Fig 34: Releasing Power Steering Return Hose
    G03995936Courtesy of FORD MOTOR CO.
  45. Remove the retaining bolt for the high pressure power steering hose bracket.
    Fig 35: Removing Retaining Bolt
    G03995940Courtesy of FORD MOTOR CO.
  46. Disconnect the block heater electrical connector, if equipped.
    Fig 36: Locating Block Heater Electrical Connector
    G03995941Courtesy of FORD MOTOR CO.
  47. Remove the steering shaft bolt.
    Fig 37: Removing Steering Shaft Bolt
    G03996556Courtesy of FORD MOTOR CO.
    48. CAUTION: Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM .
    Fig 38: Removing Steering Coupling Bolt
    G03995938Courtesy of FORD MOTOR CO.
  48. Remove the bolt and disconnect the steering coupling.
  49. Remove the nut and starter motor ground cable.
    Fig 39: Removing Nut Starter Motor Ground Cable
    G03996954Courtesy of FORD MOTOR CO.
  50. Remove the cover.
    Fig 40: Identifying Starter Motor Terminal Cover
    G03996559Courtesy of FORD MOTOR CO.
  51. Remove the nuts and disconnect the starter motor wiring.
    Fig 41: Disconnecting Starter Motor Wiring
    G03996560Courtesy of FORD MOTOR CO.
  52. Disconnect the generator electrical connector and pin-type retainer.
    Fig 42: Disconnecting Generator Electrical Connector
    G03996561Courtesy of FORD MOTOR CO.
  53. Remove the 6 lower transmission to ENGINE  bolts.
    Fig 43: Identifying Lower Transmission-To-Engine Bolts
    G03996562Courtesy of FORD MOTOR CO.
  54. Remove the cover.
    Fig 44: Locating Torque Converter Cover
    G03996563Courtesy of FORD MOTOR CO.
    55. NOTE: Make an identifying mark on the nut, the stud and adapter plate to allow for correct installation.
    Fig 45: Locating Torque Converter Nuts
    G03996211Courtesy of FORD MOTOR CO.
  55. Remove the 4 torque converter nuts.
  56. Support the rear of the vehicle with suitable safety stands.
  57. Support the engine, transmission, front and center crossmembers, and the cooling system with a powertrain lift and a transmission support bracket.
    Fig 46: Supporting Engine
    G03996565Courtesy of FORD MOTOR CO.
  58. Remove the 4 transmission support bolts.
    Fig 47: Locating Transmission Crossmember Support Bolts
    G03995952Courtesy of FORD MOTOR CO.
    59. NOTE: RH shown, LH similar.
    Fig 48: Removing RH And LH Center Crossmember I-Brace Bolts
    G03996567Courtesy of FORD MOTOR CO.
  59. Remove the 4 RH and LH center crossmember I-brace bolts.
    60. NOTE: LH shown, RH similar.
    Fig 49: Identifying Front Crossmember And Center Crossmember Bolts
    G03995953Courtesy of FORD MOTOR CO.
  60. Remove the 4 front crossmember and the 4 center crossmember bolts.
  61. Carefully lower the entire assembly from the vehicle.
    Fig 50: Lowering Entire Assembly
    G03996565Courtesy of FORD MOTOR CO.
  62. Remove the lower radiator hose bracket nut.
    Fig 51: Identifying Lower Radiator Hose Bracket Nut
    G03996321Courtesy of FORD MOTOR CO.
  63. Disconnect the lower radiator, upper radiator and heater hose.
    Fig 52: Locating Lower Radiator, Upper Radiator And Heater Hoses
    G03996322Courtesy of FORD MOTOR CO.
  64. Disconnect the 2 oil cooler hoses, if equipped.
    Fig 53: Disconnecting Oil Cooler Hoses
    G03996572Courtesy of FORD MOTOR CO.
  65. Rotate the tensioner and remove the accessory drive belt.
    Fig 54: Rotating The Tensioner
    G03996573Courtesy of FORD MOTOR CO.
  66. Disconnect the A/C compressor and power steering pressure (PSP) switch electrical connectors.
    Fig 55: Disconnecting A/C Compressor And Power Steering Pressure Switch Electrical Connectors
    G03996574Courtesy of FORD MOTOR CO.
  67. Remove the 4 bolts and position the A/C compressor aside.
    Fig 56: Removing A/C Compressor Bolts
    G03995959Courtesy of FORD MOTOR CO.
  68. Remove the power steering tube bracket nut.
    Fig 57: Removing Power Steering Tube Bracket Nut
    G03996425Courtesy of FORD MOTOR CO.
  69. Remove the 4 bolts and position aside the power steering pump and reservoir.
    Fig 58: Removing Power Steering Pump Bolts
    G03996577Courtesy of FORD MOTOR CO.
  70. Remove the transmission cooler tube bracket nut.
    Fig 59: Locating Transmission Cooler Tube Bracket Nut
    G03996578Courtesy of FORD MOTOR CO.
  71. Disconnect the transmission cooler tubes.
    Fig 60: Identifying Transmission Cooler Tubes
    G03996579Courtesy of FORD MOTOR CO.
  72. Install the special tool.
    Fig 61: Installing Special Tool RH
    G03996580Courtesy of FORD MOTOR CO.
  73. Install the special tool.
    Fig 62: Installing Special Tool LH
    G03996820Courtesy of FORD MOTOR CO.
  74. Using an engine crane, support the engine and transmission.
    75. NOTE: LH shown, RH similar.
    Fig 63: Locating Upper Engine Mount Nuts
    G03996582Courtesy of FORD MOTOR CO.
  75. Remove the LH and the RH upper engine mount nuts.
  76. Using the special tool and an engine crane, move the engine and transmission from the crossmember and cooling system assembly to rest on the floor or on a bench.
    Fig 64: Moving Engine And Transmission From Crossmember
    G03996191Courtesy of FORD MOTOR CO.
  77. Remove the nuts and position the wiring harness aside.
    Fig 65: Identifying Engine Wiring Harness Retainer And Nuts
    G03996270Courtesy of FORD MOTOR CO.
  78. Remove the bolts and separate the engine from the transmission.
    Fig 66: Locating Engine-To-Transmission Bolts
    G03996585Courtesy of FORD MOTOR CO.
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