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Section 170 (Engine): Removal: Engine: Removal

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
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. 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.

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  3. Disconnect the negative and positive battery cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  4. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  5. Remove the air cleaner outlet pipe and air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  6. Remove the cowl vent screen. For additional information, refer to WIPERS AND WASHERS .
  7. Drain the cooling system. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  8. Remove the LH and RH halfshafts. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  9. Remove the exhaust flex pipe and LH catalytic converter. For additional information, refer to EXHAUST SYSTEM .
  10. Remove and discard the roll restrictor cross brace-to-roll restrictor bolt.
    Fig 1: Removing Roll Restrictor Cross Brace-To-Restrictor Bolt
    G03989188Courtesy of FORD MOTOR CO.
  11. Remove and discard the 4 roll restrictor cross brace bolts and the cross brace.
    Fig 2: Removing Roll Restrictor Cross Brace Bolts & Cross Brace
    G03989189Courtesy of FORD MOTOR CO.
  12. Remove the bolt and detach the ground strap from the RH fender.
    Fig 3: Removing Bolt And Detach Ground Strap
    G03990213Courtesy of FORD MOTOR CO.
  13. Disconnect the redundant clip, press the quick release coupling button and disconnect the fuel tube from the fuel rail.
    Fig 4: Disconnecting Fuel Tube From Fuel Rail
    G03990214Courtesy of FORD MOTOR CO.
  14. Detach the fuel tube clip from the upper intake manifold.
    Fig 5: Detaching Fuel Tube Clip From Upper Intake Manifold
    G03990215Courtesy of FORD MOTOR CO.
  15. Disconnect the vapor tube from the purge valve.
    Fig 6: Disconnecting Vapor Tube From Purge Valve
    G03990216Courtesy of FORD MOTOR CO.
  16. Disconnect the 2 powertrain control module (PCM) electrical connectors and detach the wiring conduit.
    Fig 7: Disconnecting Powertrain Control Module (PCM) Electrical Connectors
    G03990217Courtesy of FORD MOTOR CO.
  17. Disconnect the power steering reservoir hose and detach the retainer.
    Fig 8: Disconnecting Power Steering Reservoir Hose And Detach Retainer
    G03990218Courtesy of FORD MOTOR CO.
  18. Remove the bolt and detach the ground wire from the LH fender.
    Fig 9: Removing Bolt And Detach Ground Wire From LH Fender
    G03990219Courtesy of FORD MOTOR CO.
  19. Remove the nut and detach the B+ terminal from the battery cable.
    Fig 10: Removing Nut And Detach B+ Terminal From Battery Cable
    G03990220Courtesy of FORD MOTOR CO.

    20. Vehicles with CVT transaxle 

  20. Disconnect the shift cable.
    Fig 11: Disconnecting Shift Cable End
    G03990221Courtesy of FORD MOTOR CO.
  21. Disconnect the 16-pin electrical connector and detach the wiring retainers.
    • Detach the electrical connector from the shift cable bracket.
      Fig 12: Detaching Electrical Connector From Shift Cable Bracket
      G03990222Courtesy of FORD MOTOR CO.
  22. Remove the 2 bolts and position the shift cable aside.
    Fig 13: Removing Bolts And Position Shift Cable Aside
    G03990223Courtesy of FORD MOTOR CO.

    23. Vehicles with 6-speed transaxle 

  23. Disconnect the shift cable.
    Fig 14: Disconnecting Shift Cable
    G03991743Courtesy of FORD MOTOR CO.
  24. Disconnect the 16-pin electrical connector and detach the wiring retainer.
    • Disconnect the electrical connector from the shift cable bracket.
      Fig 15: Disconnecting Electrical Connector From Shift Cable Bracket
      G03990225Courtesy of FORD MOTOR CO.
  25. Remove the 3 shift cable bracket bolts and position the cable and bracket aside.
    Fig 16: Removing Shift Cable Bracket Bolts
    G03990226Courtesy of FORD MOTOR CO.

    26. All vehicles 

  26. Disconnect the heater hose and the throttle body coolant hose.
    Fig 17: Disconnecting Heater Hose And Throttle Body Coolant Hose
    G03990227Courtesy of FORD MOTOR CO.
  27. Disconnect the brake booster vacuum hose from the upper intake manifold.
    Fig 18: Disconnecting Brake Booster Vacuum Hose From Upper Intake Manifold
    G03990228Courtesy of FORD MOTOR CO.
  28. Disconnect the coolant hoses from the thermostat housing.
    Fig 19: Disconnecting Coolant Hoses From Thermostat Housing
    G03990229Courtesy of FORD MOTOR CO.
  29. Detach the coolant tube retainers.
    Fig 20: Detaching Coolant Tube Retainers
    G03990230Courtesy of FORD MOTOR CO.
  30. Disconnect the 10-pin electrical connector and detach the wiring retainers.
    Fig 21: Disconnecting Electrical Connector
    G03990231Courtesy of FORD MOTOR CO.
  31. Disconnect the A/C high-pressure switch electrical connector.
    Fig 22: Disconnecting A/C High-Pressure Switch Electrical Connector
    G03990232Courtesy of FORD MOTOR CO.
  32. Remove the bolt and disconnect the A/C compressor manifold tube assembly.
    Fig 23: Removing Bolt & Disconnecting A/C Compressor Manifold Tube Assembly
    G03990233Courtesy of FORD MOTOR CO.
  33. Remove the nut and position the A/C tubes aside.
    Fig 24: Removing Nut And Position A/C Tubes Aside
    G03990234Courtesy of FORD MOTOR CO.
  34. Disconnect the transmission cooler hoses.
    Fig 25: Disconnecting Transmission Cooler Hoses
    G03990235Courtesy of FORD MOTOR CO.
  35. Disconnect the power steering cooler hose.
    Fig 26: Disconnecting Power Steering Cooler Hose
    G03990236Courtesy of FORD MOTOR CO.
  36. Remove the engine oil pan drain plug and drain the engine oil.
    • Install the plug and tighten to 26 Nm (19 lb-ft).
      Fig 27: Locating Engine Oil Pan Drain Plug
      G03990237Courtesy of FORD MOTOR CO.
  37. If equipped, disconnect the block heater electrical connector and detach the wiring harness.
    Fig 28: Disconnecting Block Heater Electrical Connector
    G03990238Courtesy of FORD MOTOR CO.
  38. Remove the 2 pin-type retainers and the torque converter lower access plug.
    Fig 29: Removing Pin-Type Retainers And Torque Converter Lower Access Plug
    G03990239Courtesy of FORD MOTOR CO.
  39. Remove and discard the 4 torque converter nuts.
    Fig 30: Removing Torque Converter Nuts
    G03990240Courtesy of FORD MOTOR CO.
  40. Remove the 3 engine-to-transaxle bolts and the LH catalytic converter bracket.
    Fig 31: Removing Transaxle-To-Engine Bolts & LH Catalytic Converter Bracket
    G03990545Courtesy of FORD MOTOR CO.
  41. If equipped, remove the 2 driveshaft support bracket bolts.
    Fig 32: Removing Driveshaft Support Bracket Bolts
    G03990242Courtesy of FORD MOTOR CO.
  42. If equipped, remove the bolts and disconnect the driveshaft.
    • Position the driveshaft aside.
      Fig 33: Positioning Driveshaft Aside
      G03990243Courtesy of FORD MOTOR CO.
  43. Using the special tool, lower the powertrain and subframe from the vehicle.
    Fig 34: Installing Special Tool
    G03990244Courtesy of FORD MOTOR CO.
  44. Remove the nuts and separate the stabilizer bar links from the struts.
    Fig 35: Identifying Stabilizer Bar Link Nuts
    G03990245Courtesy of FORD MOTOR CO.
  45. Remove the nuts and separate the outer tie rods from the wheel knuckles.
    • Discard the nuts.
      Fig 36: Separating Outer Tie Rods From Wheel Knuckles
      G03990246Courtesy of FORD MOTOR CO.
  46. Remove and discard the steering column intermediate shaft bolt.
    • Detach the intermediate shaft from the steering gear.
      Fig 37: Removing Steering Column Intermediate Shaft Bolt
      G03990247Courtesy of FORD MOTOR CO.
  47. Using the special tool, support the powertrain and the subframe.
    Fig 38: Supporting Powertrain And Subframe
    G03990244Courtesy of FORD MOTOR CO.
  48. Remove the 6 bolts and the 2 rear subframe brackets.
    Fig 39: Removing Bolts And Rear Subframe Brackets
    G03990249Courtesy of FORD MOTOR CO.
  49. Remove the 2 forward subframe bolts and washers.
    Fig 40: Removing Forward Subframe Bolts And Washers
    G03990250Courtesy of FORD MOTOR CO.
  50. Remove the power steering pressure (PSP) tube bracket bolt and disconnect the PSP switch electrical connector.
    Fig 41: Removing Power Steering Pressure (PSP) Tube Bracket Bolt & Disconnecting PSP Switch Electrical Connector
    G03990251Courtesy of FORD MOTOR CO.
  51. Remove the bolt and disconnect the power steering fluid tubes.
    Fig 42: Removing Bolt & Disconnecting Power Steering Fluid Tubes
    G03990252Courtesy of FORD MOTOR CO.
  52. Disconnect the RH catalyst monitor sensor electrical connector and detach the pin-type retainers from the subframe.
    Fig 43: Disconnecting RH Catalyst Monitor Sensor Electrical Connector
    G03990253Courtesy of FORD MOTOR CO.

    53. Vehicles with CVT transaxle 

  53. Disconnect the transaxle bulkhead electrical connector.
    Fig 44: Identifying Transaxle Bulkhead Electrical Connector
    G03990860Courtesy of FORD MOTOR CO.
  54. Detach the wiring harness retainer from the transaxle.
    Fig 45: Detaching Wiring Harness Retainer From Transaxle
    G03990255Courtesy of FORD MOTOR CO.
  55. Detach the wiring harness retainers from the transaxle.
    Fig 46: Locating Wire Harness At Transaxle
    G03990911Courtesy of FORD MOTOR CO.
  56. Detach the lower wiring harness retainers from the transaxle.
    Fig 47: Detaching Lower Wiring Harness Retainers From Transaxle
    G03990257Courtesy of FORD MOTOR CO.
  57. Remove the 4 bolts and the roll restrictor bracket.
    Fig 48: Removing Bolts And Roll Restrictor Bracket
    G03990258Courtesy of FORD MOTOR CO.
  58. Detach the wiring harness from the roll restrictor.
    Fig 49: Locating Wire Harness At Roll Restrictor
    G03990915Courtesy of FORD MOTOR CO.
  59. Remove the 2 bolts and the roll restrictor.
    Fig 50: Removing Bolts And Roll Restrictor
    G03990260Courtesy of FORD MOTOR CO.
  60. Remove the starter motor electrical connector cover.
    Fig 51: Identifying Electrical Cover For Starter Motor Electrical Connectors
    G03990919Courtesy of FORD MOTOR CO.
  61. Remove the nuts and disconnect the starter motor wiring.
    Fig 52: Removing Nuts & Disconnecting Starter Motor Electrical Connectors
    G03990920Courtesy of FORD MOTOR CO.
  62. Remove the 2 bolts and the starter motor.
    Fig 53: Identifying Starter Motor Mounting Bolts
    G03990263Courtesy of FORD MOTOR CO.
  63. Remove the bolt and disconnect the ground cable.
    Fig 54: Removing Bolt & Disconnecting Ground Cable
    G03991001Courtesy of FORD MOTOR CO.

    64. Vehicles with 6-speed transaxle 

  64. Disconnect the wire harness from the transmission control unit (TCU).
    Fig 55: Disconnecting Wire Harness From Transmission Control Unit (TCU)
    G03991767Courtesy of FORD MOTOR CO.
  65. Remove the 4 bolts and the roll restrictor bracket.
    Fig 56: Removing Bolts And Roll Restrictor Bracket
    G03990266Courtesy of FORD MOTOR CO.
  66. Remove the 2 bolts and the roll restrictor.
    Fig 57: Removing Bolts And Roll Restrictor
    G03990517Courtesy of FORD MOTOR CO.
  67. Remove the starter motor electrical connector cover.
    Fig 58: Removing Starter Motor Electrical Connector Cover
    G03990268Courtesy of FORD MOTOR CO.
  68. Remove the nuts and disconnect the starter motor wiring.
    Fig 59: Removing Nuts And Disconnect Starter Motor Wiring
    G03990269Courtesy of FORD MOTOR CO.
  69. Remove the 2 bolts and the starter motor.
    Fig 60: Removing Bolts And Starter Motor
    G03990270Courtesy of FORD MOTOR CO.
  70. Remove the bolt and disconnect the ground cable.
    Fig 61: Removing Bolt And Disconnect Ground Cable
    G03991887Courtesy of FORD MOTOR CO.

    71. All vehicles 

  71. Install the special tool to the RH cylinder head.
    Fig 62: Installing Special Tool To RH Cylinder Head
    G03990013Courtesy of FORD MOTOR CO.
  72. Install the special tool to the LH cylinder head.
    Fig 63: Installing Special Tool To LH Cylinder Head
    G03990012Courtesy of FORD MOTOR CO.
    73. NOTE: When installing the lower half of the lifting bracket it will be easier to loosely install the upper bolt first then install the lower bolt.
    Fig 64: Identifying Lower Half Of Lifting Hook
    G03990010Courtesy of FORD MOTOR CO.
  73. Install the lower half of the special tool.
  74. Install the upper half of the special tool.
    Fig 65: Identifying Upper Half Of Lifting Hook
    G03990011Courtesy of FORD MOTOR CO.
  75. Using the special tools and a suitable engine crane, support the powertrain.
    Fig 66: Supporting Powertrain
    G03990276Courtesy of FORD MOTOR CO.
  76. Remove the front transaxle stabilizer bolt.
    Fig 67: Removing Front Transaxle Stabilizer Bolt
    G03990277Courtesy of FORD MOTOR CO.
  77. Remove the 3 bolts and the RH exhaust manifold heat shield.
    Fig 68: Removing Bolts And RH Exhaust Manifold Heat Shield
    G03990278Courtesy of FORD MOTOR CO.
  78. Remove the RH engine insulator upper nut.
    Fig 69: Removing RH Engine Insulator Upper Nut
    G03990279Courtesy of FORD MOTOR CO.
  79. Remove the LH engine insulator upper nut.
    Fig 70: Removing LH Engine Insulator Upper Nut
    G03990280Courtesy of FORD MOTOR CO.
  80. If equipped, remove the upper power transfer unit (PTU) bracket bolts and the bracket.
    Fig 71: Identifying Upper PTU Bracket Bolts And Bracket
    G03990281Courtesy of FORD MOTOR CO.

    81. Vehicles with CVT transaxle 

  81. Remove the 4 front transaxle insulator bracket bolts.
    Fig 72: Removing Front Transaxle Insulator Bracket Bolts
    G03990282Courtesy of FORD MOTOR CO.

    82. Vehicles with 6-speed transaxle 

  82. Remove the 3 front transaxle insulator bracket bolts.
    Fig 73: Removing Front Transaxle Insulator Bracket Bolts
    G03990283Courtesy of FORD MOTOR CO.

    83. All vehicles 

  83. Using the special tools and a suitable engine crane, lift the powertrain off of the subframe.
    Fig 74: Lifting Powertrain Off Of Subframe
    G03990284Courtesy of FORD MOTOR CO.
  84. Lower the powertrain and support the transaxle using blocks of wood.
  85. Position the knock sensor (KS) heat shield aside.
    Fig 75: Identifying Heat Shield Over Knock Sensor
    G03990937Courtesy of FORD MOTOR CO.
  86. Disconnect the electrical connector and then remove the bolt and the KS.
    Fig 76: Disconnecting Electrical Connector
    G03990286Courtesy of FORD MOTOR CO.
  87. Remove the engine-to-transaxle bolt.
    Fig 77: Removing Engine-To-Transaxle Bolt
    G03991790Courtesy of FORD MOTOR CO.

    88. Vehicles with CVT transaxle 

  88. Remove the 4 remaining transaxle-to-engine bolts.
    • Separate the engine from the transaxle.
      Fig 78: Separating Engine From Transaxle
      G03990288Courtesy of FORD MOTOR CO.

    89. Vehicles with 6-speed transaxle 

  89. Remove the 4 remaining transaxle-to-engine bolts.
    • Separate the engine from the transaxle.
      Fig 79: Removing Remaining Transaxle-To-Engine Bolts
      G03990289Courtesy of FORD MOTOR CO.
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