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Engine Mechanical: Mechanical: Engine: Removal: Engine

SPECIAL TOOL(S)

G04652093Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04652094Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04652095Courtesy of FORD MOTOR CO.
 Powertrain Lift with Tilting Plate
014-00765 or equivalent
G04652096Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets
014-0001
G04652097Courtesy of FORD MOTOR CO.
 Torque Converter Holding Tool
307-346 (T97T-7902-A)
G04652098Courtesy of FORD MOTOR CO.
 Lifting Bracket, Engine
303-050 (T70P-6000)
G04652099Courtesy of FORD MOTOR CO.
 Tie-Rod End Remover
211-001 (TOOL-3290-D) or equivalent
G04652100Courtesy of FORD MOTOR CO.
 Transaxle Plugs
308-152 (T88C-7025-AH)
G04652101Courtesy of FORD MOTOR CO.
 Slide Hammer
100-001 (T50T-100-A)
G04652102Courtesy of FORD MOTOR CO.
 Front Drive Halfshaft Remover
205-241 (T86P-3514-A)

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  3. Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE .
  4. Remove the battery tray. For additional information, refer to BATTERY MOUNTING AND CABLES .
  5. Remove the power steering pump. For additional information, refer to POWER STEERING .

    6. Vehicles equipped with air conditioning 

  6. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSIS .

    7. All vehicles 

  7. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
  8. Drain the engine oil.
    • Install the drain plug and tighten to 28 Nm (21 lb-ft).
      Fig 1: Locating Drain Plug
      G04652103Courtesy of FORD MOTOR CO.
  9. Remove the 2 nuts and disconnect the catalytic converter from the muffler assembly.
    • Remove and discard the gasket.
      Fig 2: Locating Catalytic Converter Nuts
      G04652104Courtesy of FORD MOTOR CO.
  10. Remove the 4 bolts and the catalytic converter support bracket.
    Fig 3: Locating Catalytic Converter Support Bracket And Bolts
    G04652105Courtesy of FORD MOTOR CO.
    11. NOTE: All 2.3L engines and some 2.0L engines are equipped with a heat shield that must be positioned aside to access the catalytic converter-to-engine nuts.
    Fig 4: Locating Heat Shield Bolts
    G04652106Courtesy of FORD MOTOR CO.
  11. If equipped, remove the 4 heat shield bolts and position the heat shield aside.
  12. Disconnect the exhaust sensor electrical connectors.
    Fig 5: Locating Exhaust Sensor Electrical Connectors
    G04652107Courtesy of FORD MOTOR CO.
  13. If equipped, disconnect the upper exhaust sensor electrical connector and retainer.
    Fig 6: Locating Upper Exhaust Sensor Electrical Connector And Retainer
    G04652108Courtesy of FORD MOTOR CO.
  14. If equipped, disconnect the secondary air injection (AIR) hose.
    Fig 7: Locating Secondary Air Injection (AIR) Hose
    G04652109Courtesy of FORD MOTOR CO.
  15. Remove and discard the 7 catalytic converter-to-engine nuts.
    • Position aside the catalytic converter and support with mechanic's wire.
    • Remove and discard the catalytic converter gasket.
      Fig 8: Locating Catalytic Converter-To-Engine Nuts
      G04652110Courtesy of FORD MOTOR CO.
  16. Loosen the clamp and disconnect the vent tube from the air cleaner outlet pipe.
    Fig 9: Locating Vent Tube And Clamp
    G04652111Courtesy of FORD MOTOR CO.
  17. Remove the 2 bolts and detach the air intake resonator from the grommets.
    • Remove the air intake resonator and outlet pipe.
      Fig 10: Locating Air Intake Resonator Bolts And Air Intake Resonator
      G04652112Courtesy of FORD MOTOR CO.
  18. Remove the accelerator control snow shield.
    • Detach the evaporative emissions (EVAP) hose pin-type retainer.
    • Remove the screw, the pin-type retainer and the snow shield.
      Fig 11: Locating Accelerator Control Snow Shield And Pin-Type Retainers
      G04652113Courtesy of FORD MOTOR CO.
  19. Disconnect the accelerator cable and speed control cable (if equipped).
    1. Disconnect the accelerator and speed control cable (if equipped) from the throttle body.
    2. Remove the 3 bolts and position the accelerator control cables and bracket aside.
      Fig 12: Identifying Accelerator & Speed Control Cable And Bolts
      G04652114Courtesy of FORD MOTOR CO.
  20. Disconnect the fuel tube quick connect coupling from the fuel rail and position the fuel tube aside. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
    Fig 13: Locating Fuel Tube Quick Connect Coupling
    G04652115Courtesy of FORD MOTOR CO.
  21. Disconnect the evaporative emissions tube. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
    Fig 14: Locating Evaporative Emissions Tube
    G04652116Courtesy of FORD MOTOR CO.
  22. If equipped, disconnect the AIR hose.
    Fig 15: Locating Air Hose
    G04652117Courtesy of FORD MOTOR CO.
  23. If equipped, disconnect the AIR vacuum regulator electrical connector.
    Fig 16: Locating Air Vacuum Regulator Electrical Connector
    G04652118Courtesy of FORD MOTOR CO.
  24. Disconnect the power brake booster vacuum tube.
    • Depress the quick connect locking ring.
    • Pull the vacuum tube out of the quick connect fitting.
      Fig 17: Locating Power Brake Booster Vacuum Tube And Quick Connect Fitting
      G04652119Courtesy of FORD MOTOR CO.
  25. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
    Fig 18: Locating Exhaust Gas Recirculation Valve Electrical Connector
    G04652120Courtesy of FORD MOTOR CO.
  26. Disconnect the upper radiator hose, the heater hose and the coolant vent hose from the coolant bypass.
    Fig 19: Locating Upper Radiator Hose, Heater Hose And Coolant Vent Hose
    G04652121Courtesy of FORD MOTOR CO.
  27. Remove the bolt and ground eyelet.
    Fig 20: Locating Ground Eyelet Bolt
    G04652122Courtesy of FORD MOTOR CO.
  28. Disconnect the fuel charging wiring harness electrical connector and harness retainer.
    Fig 21: Locating Fuel Charging Wiring Harness Electrical Connector And Harness Retainer
    G04652123Courtesy of FORD MOTOR CO.
  29. Disconnect the fuel charging wiring harness electrical connector.
    Fig 22: Locating Fuel Charging Wiring Harness Electrical Connector
    G04652124Courtesy of FORD MOTOR CO.
  30. Disconnect the power distribution wiring harness electrical connector.
    Fig 23: Locating Power Distribution Wiring Harness Electrical Connector
    G04652125Courtesy of FORD MOTOR CO.
  31. Detach the wiring harness retainers.
    Fig 24: Locating Wiring Harness Retainers
    G04652126Courtesy of FORD MOTOR CO.
  32. Remove the nut and the power distribution wiring harness eyelet.
    Fig 25: Locating Power Distribution Wiring Harness Eyelet And Nut
    G04652127Courtesy of FORD MOTOR CO.
  33. Disconnect the 3 main engine wiring harness electrical connectors and detach the connectors from the bracket.
    Fig 26: Locating Main Engine Wiring Harness Electrical Connectors
    G04652128Courtesy of FORD MOTOR CO.

    34. Vehicles equipped with a manual transmission 

    NOTE: Press the locking tab.
  34. Detach the gearshift cables from the transaxle.
    1. Detach the shifter cable from the shift mass.
    2. Detach the selector cable from the selector lever.
      Fig 27: Identifying Shifter Cable And Selector Cable
      G04652129Courtesy of FORD MOTOR CO.
  35. Detach the gearshift cables from the bracket.
    1. Detach the shifter cable from the retaining bracket, turning the abutment sleeves counterclockwise.
    2. Detach the selector cable from the retaining bracket, turning the abutment sleeves counterclockwise.
      Fig 28: Identifying Shifter And Selector Cable
      G04652130Courtesy of FORD MOTOR CO.
    36. WARNING: Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or the eyes. If brake fluid does come into contact with the skin or eyes, rinse the affected areas with water immediately. Failure to follow these instructions may result in personal injury.
    CAUTION: If brake fluid is spilled on the paint work, the affected area must be immediately washed down with cold water.
  36. Remove the clutch slave cylinder supply tube.
    • Remove the clip.
    • Remove the supply tube and secure it to one side using cable ties.
      Fig 29: Locating Clutch Slave Cylinder Supply Tube
      G04652131Courtesy of FORD MOTOR CO.
  37. Disconnect the reversing lamp switch electrical connector.
    Fig 30: Locating Reversing Lamp Switch Electrical Connector
    G04652132Courtesy of FORD MOTOR CO.

    38. Vehicles equipped with a 2.0L engine and automatic transmission 

  38. Disconnect the transmission shifter cable and position it aside.
    Fig 31: Locating Transmission Shifter Cable
    G04652133Courtesy of FORD MOTOR CO.
  39. Disconnect the transmission cooler hoses.
    Fig 32: Locating Transmission Cooler Hoses
    G04652134Courtesy of FORD MOTOR CO.

    40. All vehicles 

  40. Disconnect the heater hose from the "T" fitting and position it aside.
    Fig 33: Locating Heater Hose
    G04652135Courtesy of FORD MOTOR CO.
  41. Disconnect the coolant hoses from the coolant expansion tank.
    Fig 34: Locating Coolant Hoses
    G04652136Courtesy of FORD MOTOR CO.
  42. Remove the coolant expansion tank bolt.
    Fig 35: Locating Coolant Expansion Tank Bolt
    G04652137Courtesy of FORD MOTOR CO.
  43. Remove the coolant expansion tank.
    • Lift the coolant expansion tank out of the retainer.
      Fig 36: Removing Coolant Expansion Tank
      G04652138Courtesy of FORD MOTOR CO.
  44. Disconnect the cooling fan electrical connectors.
    Fig 37: Locating Cooling Fan Electrical Connectors
    G04652139Courtesy of FORD MOTOR CO.
  45. Release the top cooling fan retaining clips, lift up and remove the cooling fan.
    Fig 38: Identifying Top Cooling Fan Retaining Clips Removing Cooling Fan
    G04652140Courtesy of FORD MOTOR CO.
  46. Disconnect the lower radiator hose.
    Fig 39: Locating Lower Radiator Hose
    G04652141Courtesy of FORD MOTOR CO.
  47. Remove the bolt and the ground cable.
    Fig 40: Locating Ground Cable Bolt
    G04652142Courtesy of FORD MOTOR CO.
  48. Remove the generator cooling pipe.
    Fig 41: Locating Generator Cooling Pipe
    G04652143Courtesy of FORD MOTOR CO.
  49. Disconnect the starter motor electrical terminals.
    Fig 42: Locating Starter Motor Electrical Terminals
    G04652144Courtesy of FORD MOTOR CO.
  50. Remove the 2 nuts and detach the PSP tube brackets from the stud bolts.
    Fig 43: Locating PSP Tube Bracket Nuts
    G04652145Courtesy of FORD MOTOR CO.

    51. Vehicles equipped with air conditioning 

  51. Disconnect the A/C compressor electrical connector.
    Fig 44: Locating A/C Compressor Electrical Connector
    G04652146Courtesy of FORD MOTOR CO.
  52. Remove the 3 A/C compressor bolts.
    Fig 45: Locating A/C Compressor Bolts
    G04652147Courtesy of FORD MOTOR CO.
  53. Loosen the bolt and remove the A/C compressor.
    • Lower the A/C compressor to access the manifold bolt.
    • Discard the O-ring seals.
      Fig 46: Locating A/C Compressor Bolt
      G04652148Courtesy of FORD MOTOR CO.

    54. All vehicles 

  54. Detach the LH brake hose from the support bracket.
    Fig 47: Locating LH Brake Hose
    G04652149Courtesy of FORD MOTOR CO.
  55. Detach the LH caliper.
    1. Remove the bolt covers.
    2. Remove the 2 bolts.
      Fig 48: Identifying Bolt Cover And Bolts
      G04652150Courtesy of FORD MOTOR CO.
    56. CAUTION: Suspend the caliper to prevent load from being placed on the brake hose.
    Fig 49: Locating Brake Caliper
    G04652151Courtesy of FORD MOTOR CO.
  56. Support the brake caliper.
  57. Loosen the LH strut and spring assembly top mount nuts by 4 turns.
    Fig 50: Locating LH Strut And Spring Assembly Top Mount Nuts
    G04652152Courtesy of FORD MOTOR CO.
  58. Remove the nut and disconnect the LH stabilizer bar at the strut.
    Fig 51: Locating LH Stabilizer Bar Nut
    G04652153Courtesy of FORD MOTOR CO.
  59. Remove the LH tie-rod end nut.
    Fig 52: Locating LH Tie-Rod End Nut
    G04652154Courtesy of FORD MOTOR CO.
  60. Remove the RH tie-rod end nut.
    Fig 53: Locating RH Tie-Rod End Nut
    G04652155Courtesy of FORD MOTOR CO.
  61. Using the special tool, disconnect both tie rods from the knuckles.
    Fig 54: Identifying Special Tool (211-001)
    G04652156Courtesy of FORD MOTOR CO.
  62. Remove the bolts and disconnect both lower control arms from the knuckles.
    Fig 55: Locating Lower Control Arms Bolts
    G04652157Courtesy of FORD MOTOR CO.
  63. Remove the 2 nuts and the intermediate shaft bearing bracket.
    Fig 56: Locating Intermediate Shaft Bearing Bracket Nuts
    G04652158Courtesy of FORD MOTOR CO.
  64. Remove the intermediate shaft and RH front drive halfshaft assembly from the transaxle. Position it aside and support with mechanic's wire.
    • Install a plug into the transaxle opening.
      Fig 57: Removing Intermediate Shaft From Transaxle
      G04652159Courtesy of FORD MOTOR CO.
  65. Using the special tools, remove the LH front drive halfshaft from the transaxle. Position it aside and support with mechanic's wire.
    • Install a plug into the transaxle opening.
      Fig 58: Identifying Special Tools (100-001, 205-241) And LH Front Drive Halfshaft
      G04652160Courtesy of FORD MOTOR CO.
  66. Remove the 2 bolts and the transaxle roll restrictor.
    Fig 59: Locating Transaxle Roll Restrictor And Bolts
    G04652161Courtesy of FORD MOTOR CO.
  67. Remove the 3 bolts and the starter.
    Fig 60: Locating Starter Bolts
    G04652162Courtesy of FORD MOTOR CO.
  68. Remove the starter isolator.
    Fig 61: Identifying Starter Motor Isolator
    G03897895Courtesy of FORD MOTOR CO.
  69. Remove the 2 lower bellhousing bolts.
    Fig 62: Locating Lower Bellhousing Bolts
    G04652164Courtesy of FORD MOTOR CO.
  70. Remove the 2 oil pan-to-bellhousing bolts.
    Fig 63: Locating Oil Pan-To-Bellhousing Bolts
    G04652165Courtesy of FORD MOTOR CO.
  71. Using the special tools, fasten the engine to the lift table.
    Fig 64: Identifying Special Tools (014-00001)
    G04652166Courtesy of FORD MOTOR CO.
  72. Remove the 2 engine mount nuts.
    Fig 65: Locating Engine Mount Nuts
    G04652167Courtesy of FORD MOTOR CO.
  73. Remove the transaxle mount center nut.
    Fig 66: Locating Transaxle Mount Center Nut
    G04652168Courtesy of FORD MOTOR CO.
  74. Lower the engine and transaxle assembly from the vehicle.

    75. Vehicles equipped with a manual transmission 

  75. Disconnect the vehicle speed sensor (VSS) electrical connector.
    Fig 67: Locating Vehicle Speed Sensor Electrical Connector
    G04652169Courtesy of FORD MOTOR CO.

    76. Vehicles equipped with a 2.0L engine and automatic transmission 

    NOTE: Mark one stud and the flexplate for assembly reference.
    Fig 68: Locating Torque Converter Nut
    G03897896Courtesy of FORD MOTOR CO.
  76. Remove the 4 torque converter nuts.
  77. Disconnect the output shaft speed (OSS) sensor electrical connector.
    Fig 69: Locating Output Shaft Speed Sensor Electrical Connector
    G04652171Courtesy of FORD MOTOR CO.
  78. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
    Fig 70: Locating Turbine Shaft Speed Sensor Electrical Connector
    G04652172Courtesy of FORD MOTOR CO.
  79. Disconnect the solenoid body and the transmission range (TR) sensor electrical connectors.
    Fig 71: Locating Transmission Range Sensor Electrical Connectors
    G04652173Courtesy of FORD MOTOR CO.

    80. All vehicles 

    NOTE: Lower the engine to within a few inches of the floor.
    Fig 72: Identifying Special Tools (303-D089, 303-050)
    G04652174Courtesy of FORD MOTOR CO.
  80. Using the engine crane, remove the engine and transaxle assembly from the lift table.
  81. Remove the remaining bellhousing bolts and separate the engine and transmission.
  82. Remove and discard the dowel pins.
    Fig 73: Locating Dowel Pins
    G04652175Courtesy of FORD MOTOR CO.

    83. Vehicles equipped with a 2.0L engine and automatic transmission 

  83. Install the special tool, to prevent damage to the torque converter.
    Fig 74: Identifying Special Tool (307-346)
    G04652176Courtesy of FORD MOTOR CO.
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