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Section 273 (Engine): Removal: Engine: Removal

WARNING: This page is about a different car, the 2003 Ford Windstar. 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 components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
CAUTION: During 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 cowl. For additional information, refer to FRONT END BODY PANELS .
  2. Recover the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  3. Disconnect the battery ground cable.
  4. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  5. Relieve the fuel pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  6. Remove the engine air cleaner and engine air cleaner outlet tube. .
  7. Disconnect the accelerator cable end and the speed control actuator cable end.
    Fig 1: Identifying Accelerator Cable End & Speed Control Actuator Cable End
    G01307866Courtesy of FORD MOTOR CO.
  8. Position the accelerator cable bracket aside.
    • Remove the bolt.
    • Remove the stud bolt.
      Fig 2: Identifying Accelerator Cable Bracket Bolt
      G01307867Courtesy of FORD MOTOR CO.
  9. Disconnect the heater hose.
    Fig 3: Identifying Heater Hose
    G01307868Courtesy of FORD MOTOR CO.
  10. Disconnect the upper radiator hose.
    Fig 4: Identifying Upper Radiator Hose
    G01307869Courtesy of FORD MOTOR CO.
  11. Position the heater hose aside.
    • Remove the nut.
      Fig 5: Identifying Heater Hose Nut
      G01307870Courtesy of FORD MOTOR CO.
  12. Disconnect the main engine wiring harness 42-pin connector.
    • Loosen the bolt.
      Fig 6: Identifying Main Engine Wiring Harness 42-Pin Connector Bolt
      G01307871Courtesy of FORD MOTOR CO.
  13. Disconnect the shift cable.
    Fig 7: Identifying Shift Cable
    G01307872Courtesy of FORD MOTOR CO.
  14. Disconnect the cable from the bracket, then position the shift cable aside.
    Fig 8: Identifying Shift Cable
    G01307873Courtesy of FORD MOTOR CO.
  15. Disconnect the EVAP emission return tube and the brake booster vacuum hose.
    Fig 9: Identifying EVAP Emission Return Tube & Brake Booster Vacuum Hose
    G01307874Courtesy of FORD MOTOR CO.
  16. Disconnect the EVAP canister purge valve.
    • Disconnect the connector.
    • Disconnect the vacuum tube.
      Fig 10: Identifying EVAP Canister Purge Valve
      G01307875Courtesy of FORD MOTOR CO.
  17. Remove the wire harness pin-type retainer.
    Fig 11: Identifying Wire Harness Pin-Type Retainer
    G01307876Courtesy of FORD MOTOR CO.
  18. Disconnect the powertrain control module (PCM).
    • Loosen the bolt.
      Fig 12: Identifying Powertrain Control Module Bolt
      G01307877Courtesy of FORD MOTOR CO.
  19. Disconnect the main engine wire harness ground.
    • Remove the bolt.
      Fig 13: Identifying Main Engine Wire Harness Ground Bolt
      G01307878Courtesy of FORD MOTOR CO.
  20. Disconnect the power steering hose.
    • Reposition the clamp.
      Fig 14: Identifying Power Steering Hose Clamp
      G01307879Courtesy of FORD MOTOR CO.
  21. Disconnect the degas bottle hose.
    • Reposition the clamp.
      Fig 15: Identifying Degas Bottle Hose Clamp
      G01307880Courtesy of FORD MOTOR CO.
  22. Disconnect the fuel line retaining clip.
    Fig 16: Identifying Fuel Line Retaining Clip
    G01307881Courtesy of FORD MOTOR CO.
  23. Disconnect the generator. For additional information, refer to GENERATOR .
  24. Position the harness aside.
    Fig 17: Positioning Harness Aside
    G01307882Courtesy of FORD MOTOR CO.
  25. Disconnect the fuel lines. For additional information, refer to ENGINE COOLING .
  26. Disconnect the ground cable.
    Fig 18: Identifying Ground Cable Bolt
    G01307883Courtesy of FORD MOTOR CO.
  27. Disconnect the heater hose.
    • Reposition the clamp.
      Fig 19: Identifying Heater Hose Clamp
      G01307884Courtesy of FORD MOTOR CO.
  28. Disconnect the vacuum hose.
    Fig 20: Identifying Vacuum Hose
    G01307885Courtesy of FORD MOTOR CO.
  29. Disconnect the positive cable.
    • Remove the nut.
      Fig 21: Identifying Positive Cable Nut
      G01307886Courtesy of FORD MOTOR CO.
  30. Remove the sight shield.
    • Remove the pin-type retainers.
      Fig 22: Identifying Sight Shield Pin-Type Retainers
      G01307887Courtesy of FORD MOTOR CO.
  31. Disconnect the ground connector.
    • Remove the bolt.
      Fig 23: Identifying Ground Connector Bolt
      G01307888Courtesy of FORD MOTOR CO.
  32. Remove the strap.
    Fig 24: Identifying Strap
    G01307889Courtesy of FORD MOTOR CO.
  33. Position the A/C suction/discharge manifold aside.
    • Remove the bolt.
      Fig 25: Identifying A/C Suction/Discharge Manifold Bolt
      G01307890Courtesy of FORD MOTOR CO.
  34. Disconnect the power steering cooler hose.
    • Reposition the clamp.
      Fig 26: Identifying Power Steering Cooler Hose Clamp
      G01307891Courtesy of FORD MOTOR CO.
  35. Disconnect the power steering cooler hose.
    • Reposition the clamp.
      Fig 27: Identifying Power Steering Cooler Hose Clamp
      G01307892Courtesy of FORD MOTOR CO.
  36. Remove the hose.
    Fig 28: Identifying Hose
    G01307893Courtesy of FORD MOTOR CO.
  37. Remove the hose.
    • Remove the pin-type retainer.
      Fig 29: Identifying Hose Pin-Type Retainer
      G01307894Courtesy of FORD MOTOR CO.
  38. Disconnect the transmission oil cooler tubes.
    • Remove the clips.
    • Disconnect the oil cooler tubes.
      Fig 30: Identifying Transmission Oil Cooler Tubes Clips
      G01307895Courtesy of FORD MOTOR CO.
  39. Reposition the dust boot upward.
    Fig 31: Repositioning Dust Boot Upward
    G01307896Courtesy of FORD MOTOR CO.
  40. Disconnect the steering column.
    • Remove the bolt.
    • Slide the joint upward.
      Fig 32: Disconnecting Steering Column Joint
      G01307897Courtesy of FORD MOTOR CO.
  41. Remove the dual converter Y-pipe assembly. For additional information, refer to EXHAUST SYSTEM .
  42. Disconnect the lower radiator hose.
    • Reposition the clamp.
      Fig 33: Identifying Lower Radiator Hose Clamp
      G01307898Courtesy of FORD MOTOR CO.
  43. Remove the wheels. For additional information, refer to WHEELS & TIRES .
  44. Remove the bolts, then position the brake calipers aside.
    Fig 34: Identifying Brake Calipers Bolt
    G01307899Courtesy of FORD MOTOR CO.
  45. Remove the wiring harness retainer.
    Fig 35: Identifying Wiring Harness Retainer
    G01307900Courtesy of FORD MOTOR CO.
  46. Disconnect the ABS electrical connector.
    Fig 36: Locating ABS Electrical Connector
    G01307901Courtesy of FORD MOTOR CO.
  47. Disconnect the RH and LH front stabilizer links.
    • Remove the nut.
      Fig 37: Identifying RH & LH Front Stabilizer Links Bolt
      G01307902Courtesy of FORD MOTOR CO.
  48. Remove the RH and LH strut bolts.
    Fig 38: Identifying RH & LH Strut Bolts
    G01307903Courtesy of FORD MOTOR CO.
  49. Position the special tool under the subframe assembly.
    Fig 39: Identifying Special Tool (014-00765)
    G01307904Courtesy of FORD MOTOR CO.
  50. Remove the four bolts.
    Fig 40: Identifying Subframe Assembly Bolt
    G01307905Courtesy of FORD MOTOR CO.
  51. Lower the engine, transmission and subframe assembly.
  52. Remove the starter motor. For additional information, refer to STARTER MOTOR .
  53. Remove the inspection cover.
    • Remove the bolt.
    • Remove the cover.
      Fig 41: Identifying Inspection Cover Bolt
      G01307906Courtesy of FORD MOTOR CO.
  54. Remove the four torque converter nuts.
    Fig 42: Identifying Four Torque Converter Nuts
    G01307907Courtesy of FORD MOTOR CO.
  55. Remove the electrical connector.
    Fig 43: Identifying Electrical Connector
    G01307908Courtesy of FORD MOTOR CO.
  56. Remove the harness pin-type retainer.
    Fig 44: Identifying Harness Pin-Type Retainer
    G01307909Courtesy of FORD MOTOR CO.
  57. Disconnect the transaxle electrical connectors.
    Fig 45: Locating Transaxle Electrical Connectors
    G01307910Courtesy of FORD MOTOR CO.
  58. Remove the pin-type harness retainer.
    Fig 46: Identifying Pin-Type Harness Retainer
    G01307911Courtesy of FORD MOTOR CO.
  59. Disconnect the electrical connectors.
    Fig 47: Locating Electrical Connectors
    G01307912Courtesy of FORD MOTOR CO.
  60. Remove the electrical connector.
    Fig 48: Locating Electrical Connector
    G01307913Courtesy of FORD MOTOR CO.
  61. Disconnect the power steering pressure hose.
    Fig 49: Identifying Power Steering Pressure Hose
    G01307914Courtesy of FORD MOTOR CO.
  62. Remove the hose retainer.
    Fig 50: Identifying Hose Retainer
    G01307915Courtesy of FORD MOTOR CO.
  63. Remove the transmission oil level indicator and tube.
    • Remove the bolt.
      Fig 51: Identifying Transmission Oil Level Indicator & Tube
      G01307916Courtesy of FORD MOTOR CO.
  64. Install the special tools.
    Fig 52: Identifying Special Tools
    G01307917Courtesy of FORD MOTOR CO.
  65. Install the engine lifting equipment.
    Fig 53: Lifting Engine
    G01307918Courtesy of FORD MOTOR CO.
  66. Remove the six bellhousing bolts.
    Fig 54: Identifying Bellhousing Bolts
    G01307919Courtesy of FORD MOTOR CO.
  67. Remove the LH engine mount bolts.
    Fig 55: Identifying LH Engine Mount Bolts
    G01307920Courtesy of FORD MOTOR CO.
  68. Remove the RH engine mount nut.
    Fig 56: Identifying RH Engine Mount Nut
    G01307921Courtesy of FORD MOTOR CO.
  69. Remove the bolts.
    Fig 57: Identifying Bolts
    G01307922Courtesy of FORD MOTOR CO.
  70. Separate and lift the engine from the subframe and transmission assembly.
  71. Remove the flywheel.
    • Remove the bolts.
      Fig 58: Identifying Flywheel Bolt
      G01307923Courtesy of FORD MOTOR CO.
  72. Mount the engine on the engine stand.
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