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Section 320 (Engine-2.3L): Removal: Engine: Removal

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

All Vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & HOISTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  4. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  5. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  6. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
  7. Drain the engine oil.
  8. Remove the fuel tube. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
    Fig 1: Removing Fuel Tube
    G01611520Courtesy of FORD MOTOR CO.
  9. Remove the vapor tube.
    Fig 2: Removing Vapor Tube
    G01611521Courtesy of FORD MOTOR CO.
  10. Disconnect the engine emissions hose and the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical connector.
    Fig 3: Disconnecting Engine Emissions Hose And Exhaust Gas Recirculation Vacuum Regulator Solenoid
    G01611522Courtesy of FORD MOTOR CO.
  11. Disconnect the EGR vacuum regulator (EVR) solenoid hose and position it out of the way.
    Fig 4: Disconnecting EGR Vacuum Regulator (EVR) Solenoid Hose
    G01611523Courtesy of FORD MOTOR CO.
  12. Disconnect the lower radiator hose, the heater hose and the overflow hose from the coolant bypass.
    Fig 5: Disconnecting Lower Radiator Hose
    G01611524Courtesy of FORD MOTOR CO.
  13. Disconnect the temperature manifold absolute pressure (TMAP) sensor electrical connector.
    Fig 6: Disconnecting Temperature Manifold Absolute Pressure Sensor Electrical Connector
    G01611525Courtesy of FORD MOTOR CO.
  14. Position the accelerator cable and speed control cable (if equipped) aside.
    1. Disconnect the accelerator and speed control cable (if equipped) from the throttle body.
    2. Remove the three bolts and position the accelerator cable bracket aside.
      Fig 7: Disconnecting Cable(s) & Removing Accelerator Cable Bracket Bolts
      G01611526Courtesy of FORD MOTOR CO.
  15. Disconnect the fuel injection supply manifold wiring harness electrical connector.
    Fig 8: Disconnecting Fuel Injection Supply Manifold Wiring Harness Electrical Connector
    G01611527Courtesy of FORD MOTOR CO.
  16. Disconnect the EGR valve electrical connector.
    Fig 9: Disconnecting EGR Valve Electrical Connector
    G01611528Courtesy of FORD MOTOR CO.
  17. Disconnect the heater hose from the "T" fitting and position it out of the way.
    Fig 10: Disconnecting Heater Hose From T Fitting
    G01611529Courtesy of FORD MOTOR CO.
  18. Disconnect the coil-on-plug (COP) electrical connectors.
    Fig 11: Disconnecting Coil-On-Plug (COP) Electrical Connectors
    G01611530Courtesy of FORD MOTOR CO.
  19. Remove the coolant overflow bottle. For additional information, refer to ENGINE COOLING .
  20. Disconnect the power steering pressure (PSP) switch electrical connector.
    Fig 12: Disconnecting Power Steering Pressure Switch Electrical Connector
    G01611531Courtesy of FORD MOTOR CO.
  21. Disconnect the PSP tube.
    Fig 13: Disconnecting PSP Tube
    G01611532Courtesy of FORD MOTOR CO.
  22. Remove the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
  23. Disconnect the three main engine wiring harness electrical connectors.
    Fig 14: Disconnecting Engine Wiring Harness Electrical Connectors
    G01611533Courtesy of FORD MOTOR CO.
  24. Remove the wiring harness retainers from the valve cover.
    Fig 15: Removing Wiring Harness Retainers From Valve Cover
    G01611534Courtesy of FORD MOTOR CO.
  25. Remove the bolt and the radio interference capacitor from the cylinder head.
    Fig 16: Removing Radio Interference Capacitor From Cylinder Head
    G01611535Courtesy of FORD MOTOR CO.

    26. Vehicles Equipped With An Automatic Transmission 

  26. Remove the three transmission shifter bracket bolts.
    Fig 17: Removing Transmission Shifter Bracket Bolts
    G01611536Courtesy of FORD MOTOR CO.
  27. Disconnect the transmission shifter cable and position it out of the way.
    Fig 18: Disconnecting Transmission Shifter Cable
    G01611537Courtesy of FORD MOTOR CO.

    28. All Vehicles 

  28. Disconnect the cooling fan electrical connector.
    Fig 19: Disconnecting Cooling Fan Electrical Connector
    G01611538Courtesy of FORD MOTOR CO.
  29. Disconnect the cooling fan electrical connector.
    Fig 20: Disconnecting Cooling Fan Electrical Connector
    G01611539Courtesy of FORD MOTOR CO.

    30. Vehicles Equipped With An Automatic Transmission 

  30. Disconnect the transmission cooler hoses.
    Fig 21: Disconnecting Transmission Cooler Hoses
    G01611540Courtesy of FORD MOTOR CO.

    31. All Vehicles 

  31. Remove the cooling fan.
    Fig 22: Removing Cooling Fan
    G01611541Courtesy of FORD MOTOR CO.
  32. Remove the two lower bell housing bolts.
    Fig 23: Removing Lower Bell Housing Bolts
    G01611542Courtesy of FORD MOTOR CO.
  33. Remove the two oil pan-to-bell housing bolts.
    Fig 24: Removing Oil Pan-To-Bell Housing Bolts
    G01611543Courtesy of FORD MOTOR CO.
  34. Disconnect the starter electrical terminals.
    Fig 25: Disconnecting Starter Electrical Terminals
    G01611544Courtesy of FORD MOTOR CO.
  35. Remove the PSP tube retaining bolt.
    Fig 26: Removing PSP Tube Retaining Bolt
    G01611545Courtesy of FORD MOTOR CO.
    36. CAUTION: Secure the A/C compressor out of the way with mechanic's wire. Do not let the compressor hang from the hoses.
    Fig 27: Removing A/C Compressor Bolts
    G01611546Courtesy of FORD MOTOR CO.
  36. Remove the remaining A/C compressor bolts and position the compressor out of the way.
  37. Disconnect the upper radiator hose.
    Fig 28: Disconnecting Upper Radiator Hose
    G01611547Courtesy of FORD MOTOR CO.
  38. Drain the engine oil.
  39. Remove the alternator cooling pipe.
    Fig 29: Removing Alternator Cooling Pipe
    G01611548Courtesy of FORD MOTOR CO.
  40. Disconnect the generator electrical connectors.
    Fig 30: Disconnecting Generator Electrical Connectors
    G01611549Courtesy of FORD MOTOR CO.
  41. Remove both of the halfshafts. For additional information, refer to AXLE SHAFTS .
  42. Remove the lower engine mount.
    1. Remove the bolts.
    2. Remove the mount.
      Fig 31: Removing Lower Engine Mount Bolts
      G01611550Courtesy of FORD MOTOR CO.
  43. Remove the bolt and the ground cable.
    Fig 32: Removing Ground Cable Bolts
    G01611551Courtesy of FORD MOTOR CO.
  44. Using the special tools, fasten the engine to the lift table.
    Fig 33: Fastening Engine To Lift Table
    G01611552Courtesy of FORD MOTOR CO.
  45. Remove the RH motor mount nuts.
    Fig 34: Removing RH Motor Mount Nuts
    G01611553Courtesy of FORD MOTOR CO.
  46. Remove the RH motor mount bolts and the mount.
    Fig 35: Removing RH Motor Mount
    G01611554Courtesy of FORD MOTOR CO.
  47. Remove the remaining three power steering bolts and position the power steering pump out of the way.
    Fig 36: Removing Power Steering Bolts
    G01611555Courtesy of FORD MOTOR CO.
  48. Remove the LH motor mount nut.
    Fig 37: Removing LH Motor Mount Nut
    G01611556Courtesy of FORD MOTOR CO.
  49. Remove the three bolts and the starter.
    Fig 38: Removing Starter & Bolts
    G01611557Courtesy of FORD MOTOR CO.
  50. Remove the starter isolator.
    Fig 39: Removing Starter Isolator
    G01611558Courtesy of FORD MOTOR CO.

    51. Vehicles Equipped With An Automatic Transmission 

  51. Disconnect the output shaft speed (OSS) sensor electrical connector.
    Fig 40: Disconnecting Output Shaft Speed Sensor Electrical Connector
    G01611559Courtesy of FORD MOTOR CO.
  52. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
    Fig 41: Disconnecting Turbine Shaft Speed Sensor Electrical Connector
    G01611560Courtesy of FORD MOTOR CO.
  53. Disconnect the solenoid body and the transmission range (TR) sensor electrical connectors.
    Fig 42: Disconnecting Solenoid Body And Transmission Range Sensor Electrical Connectors
    G01611561Courtesy of FORD MOTOR CO.
    54. NOTE: Mark one stud and the flexplate for assembly reference.
    Fig 43: Removing Torque Converter Nuts
    G01611562Courtesy of FORD MOTOR CO.
  54. Remove the four torque converter nuts.

    55. All Vehicles 

  55. Remove the remaining bell housing bolts and separate the engine and transmission.
  56. Lower the engine and transaxle assembly from the vehicle.
    57. NOTE: Lower the engine to within a few inches of the floor.
  57. Using the engine crane, remove the engine from the lift table.
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