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Section 495 (Engine): Removal: Engine: Removal

WARNING: This page is about a different car, the 2004 Mercury Monterey and 2004 Ford Freestar. 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. 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 PRESSURE RELEASE .
  3. Disconnect the battery ground and positive cables. For additional information, refer to BATTERY & CHARGING SYSTEM
  4. Remove the windshield wiper mounting arm and pivot shaft assembly. For additional information, refer to the windshield wiper procedure in WINDSHIELD WIPER
  5. Recover the air conditioning system. For additional information, refer to AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING .
  6. Remove the engine air cleaner and engine air cleaner outlet tube. For additional information, refer to AIR CLEANER ASSEMBLY .
  7. Disconnect the fuel supply manifold spring lock coupling. For additional information, refer to FUEL SYSTEM .
  8. Remove the power steering pump. For additional information, refer to POWER STEERING PUMP .
  9. Drain the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING
  10. Remove the starter. For additional information, refer to STARTER MOTOR
  11. Remove the dual converter Y-pipe. For additional information, refer to EXHAUST SYSTEM
  12. Remove the drain plug and drain the engine oil.
    • Install the drain plug.
    Fig 1: Identifying Engine Oil Drain Plug
    G03243936Courtesy of FORD MOTOR CO.
  13. Disconnect the accelerator cable end and the speed control actuator cable end. Remove the throttle return spring.
    Fig 2: Disconnecting Accelerator Cable End And Speed Control Actuator Cable End
    G03243937Courtesy of FORD MOTOR CO.
  14. Position the accelerator cable bracket aside.
    • Disconnect the engine wiring harness retainer.
    • Remove the stud bolts.
    Fig 3: Positioning Accelerator Cable Bracket Aside
    G03243938Courtesy of FORD MOTOR CO.
  15. Disconnect the upper radiator and heater hoses.
    Fig 4: Disconnecting Upper Radiator And Heater Hoses
    G03243939Courtesy of FORD MOTOR CO.
  16. Remove the power distribution box cover.
    Fig 5: Removing Power Distribution Box Cover
    G03243940Courtesy of FORD MOTOR CO.
  17. Disconnect the B+ terminal from the power distribution box.
    Fig 6: Disconnecting B+ Terminal From Power Distribution Box
    G03243941Courtesy of FORD MOTOR CO.
  18. Remove the 68-pin electrical connector from the power distribution box.
    1. Separate the power distribution box from the bracket.
    2. Loosen the bolt.
    3. Disconnect the 68-pin connector.
      Fig 7: Disconnecting Power Distribution Box 68-Pin Connector
      G03243942Courtesy of FORD MOTOR CO.
  19. Release the engine wiring harness retainer.
    Fig 8: Removing Engine Wiring Harness Retainer
    G03243943Courtesy of FORD MOTOR CO.
  20. Release the engine wiring harness retainer.
    Fig 9: Removing Engine Wiring Harness Retainer
    G03243944Courtesy of FORD MOTOR CO.
  21. Disconnect the 16-pin electrical connector.
    Fig 10: Disconnecting 16-Pin Electrical Connector
    G03243945Courtesy of FORD MOTOR CO.
  22. Disconnect the shift cable.
    Fig 11: Disconnecting Shift Cable
    G03243946Courtesy of FORD MOTOR CO.
  23. Disconnect the cable from the bracket, then position the shift cable aside.
    Fig 12: Disconnecting Shift Cable From Bracket
    G03243947Courtesy of FORD MOTOR CO.
  24. Disconnect the evaporative (EVAP) emission return tube.
    Fig 13: Disconnecting Evaporative Emission Return Tube
    G03243948Courtesy of FORD MOTOR CO.
  25. Release the engine wiring harness retainer.
    Fig 14: Removing Engine Wiring Harness Retainer
    G03243949Courtesy of FORD MOTOR CO.
  26. Disconnect the brake booster vacuum hose.
    • Reposition the clamp.
    Fig 15: Disconnecting Brake Booster Vacuum Hose
    G03243950Courtesy of FORD MOTOR CO.
  27. Disconnect the EVAP canister purge valve electrical connector and vacuum hose.
    Fig 16: Disconnecting EVAP Canister Purge Valve Electrical Connector And Vacuum Hose
    G03243951Courtesy of FORD MOTOR CO.
  28. Remove the engine wire harness pin-type retainer.
    Fig 17: Removing Engine Wire Harness Pin-Type Retainer
    G03243952Courtesy of FORD MOTOR CO.
  29. Remove the bolt from the engine wire harness ground.
    Fig 18: Removing Bolt From Engine Wire Harness Ground
    G03243953Courtesy of FORD MOTOR CO.
  30. Loosen the bolt and disconnect the powertrain control module (PCM).
    Fig 19: Disconnecting Powertrain Control Module
    G03243954Courtesy of FORD MOTOR CO.
  31. Disconnect the degas bottle hose.
    • Reposition the clamp.
    Fig 20: Disconnecting Degas Bottle Hose
    G03243955Courtesy of FORD MOTOR CO.
  32. Remove the upper radiator sight shield.
    Fig 21: Removing Upper Radiator Sight Shield
    G03243956Courtesy of FORD MOTOR CO.
  33. Release the two engine wiring harness retainers.
    Fig 22: Removing Engine Wiring Harness Retainers
    G03243957Courtesy of FORD MOTOR CO.
  34. Remove the engine roll restrictor.
    • Remove the bolts.
    • Remove the engine roll restrictor.
    Fig 23: Removing Engine Roll Restrictor
    G03243958Courtesy of FORD MOTOR CO.
  35. Remove the bolt from the ground cable.
    Fig 24: Removing Bolt From Ground Cable
    G03243959Courtesy of FORD MOTOR CO.
  36. Remove the bolt from the ground cable.
    Fig 25: Removing Bolt From Ground Cable
    G03243960Courtesy of FORD MOTOR CO.
  37. Disconnect the heater hose.
    Fig 26: Disconnecting Heater Hose
    G03243961Courtesy of FORD MOTOR CO.
  38. Disconnect the A/C electrical connector.
    Fig 27: Disconnecting A/C Electrical Connector
    G03243962Courtesy of FORD MOTOR CO.
  39. Remove the bolt and position the A/C compressor manifold aside.
    Fig 28: Removing Bolt And Positioning A/C Compressor Manifold
    G03243963Courtesy of FORD MOTOR CO.
  40. Disconnect the power steering cooler hose.
    • Reposition the clamp.
    Fig 29: Disconnecting Power Steering Cooler Hose
    G03243964Courtesy of FORD MOTOR CO.
  41. Remove the power steering cooler hose from the retaining clip.
    Fig 30: Removing Power Steering Cooler Hose From Retaining Clip
    G03243965Courtesy of FORD MOTOR CO.
  42. Disconnect the transaxle cooler tubes.
    • Remove the clips.
    • Disconnect the oil cooler tubes.
    Fig 31: Disconnecting Transaxle Oil Cooler Tubes
    G03243966Courtesy of FORD MOTOR CO.
  43. Disconnect the steering column.
    • Remove the bolt.
    • Slide the joint upward.
    Fig 32: Disconnecting Steering Column
    G03243967Courtesy of FORD MOTOR CO.
  44. Disconnect the lower radiator hose.
    • Reposition the clamp.
    Fig 33: Disconnecting Lower Radiator Hose
    G03243968Courtesy of FORD MOTOR CO.
  45. Remove the oil pan-to-transaxle bolts.
    Fig 34: Removing Oil Pan-To-Transaxle Bolts
    G03243969Courtesy of FORD MOTOR CO.
    46. NOTE: RH shown; LH similar.
    Fig 35: Removing RH And LH Lower Engine Mount Nuts
    G03243970Courtesy of FORD MOTOR CO.
  46. Remove the RH and LH lower engine mount nuts.
  47. Remove the inspection cover.
    • Remove the bolt.
    • Remove the cover.
    Fig 36: Removing Inspection Cover
    G03243971Courtesy of FORD MOTOR CO.
  48. Remove the four torque converter nuts.
    Fig 37: Removing Torque Converter Nuts
    G03243972Courtesy of FORD MOTOR CO.
  49. Remove the RH and LH wiring harness retainers.
    Fig 38: Removing RH And LH Wiring Harness Retainers
    G03243973Courtesy of FORD MOTOR CO.
  50. Remove the nuts and the RH and LH anti-lock brake sensor (ABS) electrical connectors.
    Fig 39: Removing RH And LH ABS Sensor
    G03243974Courtesy of FORD MOTOR CO.
    51. CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose. Provide a suitable support.
    Fig 40: Removing Bolts & Positioning Calipers Aside
    G03243975Courtesy of FORD MOTOR CO.
  51. Remove the bolts, then position the RH and LH brake calipers aside.
  52. Remove the nuts and disconnect the RH and LH front stabilizer links.
    Fig 41: Disconnecting RH And LH Front Stabilizer Links
    G03243976Courtesy of FORD MOTOR CO.
  53. Remove the RH and LH strut bolts.
    Fig 42: Removing RH And LH Strut Bolts
    G03243977Courtesy of FORD MOTOR CO.
  54. Position the special tool under the subframe assembly.
    Fig 43: Installing Special Tool Under Subframe Assembly
    G03243978Courtesy of FORD MOTOR CO.
  55. Remove the four bolts.
    Fig 44: Removing Four Subframe Bolts
    G03243979Courtesy of FORD MOTOR CO.
  56. Lower the engine, transaxle and subframe assembly.
  57. Remove the generator brace bolt.
    Fig 45: Removing Generator Brace Bolt
    G03243980Courtesy of FORD MOTOR CO.
  58. Disconnect the A/C compressor electrical connector.
    Fig 46: Disconnecting A/C Compressor Electrical Connector
    G03243981Courtesy of FORD MOTOR CO.
  59. Remove the bolts and the A/C compressor.
    Fig 47: Removing A/C Compressor
    G03243982Courtesy of FORD MOTOR CO.
  60. Release the engine wiring harness retainer.
    Fig 48: Removing Engine Wiring Harness Retainer
    G03243983Courtesy of FORD MOTOR CO.
  61. Detach the electrical connector from the subframe.
    Fig 49: Disconnecting Electrical Connector From Subframe
    G03243984Courtesy of FORD MOTOR CO.
  62. Release the engine wiring harness retainers.
    Fig 50: Removing Engine Wiring Harness Retainers
    G03243985Courtesy of FORD MOTOR CO.
  63. Remove the engine roll restrictor bracket.
    • Remove the bolts.
    • Remove the engine roll restrictor bracket.
    Fig 51: Removing Engine Roll Restrictor Bracket
    G03243986Courtesy of FORD MOTOR CO.
  64. Remove the engine wiring harness pin-type retainer.
    Fig 52: Removing Engine Wiring Harness Pin-Type Retainer
    G03243987Courtesy of FORD MOTOR CO.
  65. Disconnect the transaxle electrical connectors.
    Fig 53: Disconnecting Transaxle Electrical Connectors
    G03243988Courtesy of FORD MOTOR CO.
  66. Disconnect the turbine shaft speed (TSS) sensor connector.
    Fig 54: Disconnecting Turbine Shaft Speed Sensor Connector
    G03243989Courtesy of FORD MOTOR CO.
  67. Remove the pin-type harness retainer.
    Fig 55: Removing Pin-Type Harness Retainer
    G03243990Courtesy of FORD MOTOR CO.
  68. Disconnect the electrical connectors.
    Fig 56: Disconnecting Electrical Connectors
    G03243991Courtesy of FORD MOTOR CO.
  69. Detach the two electrical connectors from the wiring harness bracket.
    Fig 57: Removing Electrical Connectors From Wiring Harness Bracket
    G03243992Courtesy of FORD MOTOR CO.
  70. Detach the electrical connector from the subframe.
    Fig 58: Removing Electrical Connector From Subframe
    G03243993Courtesy of FORD MOTOR CO.
  71. Remove the bolt and the transaxle fluid level indicator and tube.
    Fig 59: Removing Transaxle Fluid Level Indicator And Tube
    G03243994Courtesy of FORD MOTOR CO.
  72. Install the special tools.
    Fig 60: Installing Special Tools
    G03243995Courtesy of FORD MOTOR CO.
  73. Install the engine lifting equipment.
    Fig 61: Installing Lifting Equipment
    G03243996Courtesy of FORD MOTOR CO.
  74. Remove the four bellhousing bolts.
    Fig 62: Removing Bellhousing Bolts
    G03243997Courtesy of FORD MOTOR CO.
  75. Remove the bolt and the LH engine mount.
    Fig 63: Removing Bolt And LH Engine Mount
    G03243998Courtesy of FORD MOTOR CO.
  76. Remove the bolt and the RH engine mount.
    Fig 64: Removing Bolt And RH Engine Mount
    G03243999Courtesy of FORD MOTOR CO.
  77. Remove the oil pan-to-transaxle bolt.
    Fig 65: Removing Oil Pan-To-Transaxle Bolt
    G03244000Courtesy of FORD MOTOR CO.
  78. Remove the engine mount bracket-to-transaxle bolts.
    Fig 66: Removing Engine Mount Bracket-To-Transaxle Bolts
    G03244001Courtesy of FORD MOTOR CO.
  79. Using the engine lifting equipment, separate and lift the engine from the subframe and transaxle assembly.
    Fig 67: Removing And Lifting Engine From Subframe And Transaxle Assembly
    G03244002Courtesy of FORD MOTOR CO.
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