Section 422 (Engine - 3.9L): Removal: Engine: Removal

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. Remove the air cleaner assembly and outlet pipe. For additional information, refer to INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L for additional information.
CAUTION: The coolant drain procedure must be followed exactly or damage to the engine can occur.
4. Drain the engine coolant. For additional information, refer to ENGINE COOLING .
5. Discharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM .
6. Release the fuel pressure. For additional information, refer to FUEL SYSTEM .
7. Remove the fresh air filter panel. For additional information, refer to air distribution ducts in CLIMATE CONTROL SYSTEM .
8. Remove the front wheels and tires. .
9. Remove the three-way catalytic converter (TWC). For additional information, refer to EXHAUST SYSTEM .
10. Remove the driveshaft. For additional information, refer to DRIVELINE SYSTEM .
11. Remove the parts in the order indicated in the following illustrations and tables.
    Fig 1: Removing Order Of Fuel Hose Components

    Courtesy of FORD MOTOR CO.

Item 2: Spring lock coupling Removal Note 

1. Install the special tool.
   Fig 15: Installing Special Tool

   Courtesy of FORD MOTOR CO.
2. Press the special tool into the open end of the cage.
   Fig 16: Pressing Special Tool Into Open End Of Cage

   Courtesy of FORD MOTOR CO.
3. Separate the spring lock coupling.
   Fig 17: Separating Spring Lock Coupling

   Courtesy of FORD MOTOR CO.

Item 7: Vapor Tube Removal Note 

CAUTION: To disconnect the Norma fitting, squeeze the tabs and pull straight out or damage to the fitting can occur.
1. Remove the vapor tube from the vapor management valve (VMV).

Item 8: Power Steering Reservoir Removal Note 

1. Remove the power steering reservoir bolts.
   Fig 18: Identifying Power Steering Reservoir Bolts Removing Torque

   Courtesy of FORD MOTOR CO.

Item 14: Heater Hoses Removal Note 

NOTE: Mark the position of the heater hoses for correct installation.
1. Disconnect the three quick disconnect couplings from the coolant control valve hose at the heater tube assembly. Refer to CLIMATE CONTROL SYSTEM .

Item 15: Water Valve Electrical Connector Removal Note 

1. Disconnect the water valve electrical connector, unclip the harness from the radiator support and position the harness aside.
   Fig 19: Removing Water Valve Electrical Connector

   Courtesy of FORD MOTOR CO.

Item 32: A/C Low Pressure Hose Removal Note 

1. Disconnect the low pressure A/C hose.
   Fig 20: Disconnecting Low Pressure A/C Hose

   Courtesy of FORD MOTOR CO.

Item 33: Anti-lock Brake Sensor Electrical Connector Removal Note 

1. Position the inner splash shield aside.
   1. Remove the pin -type retainers.
   2. Position the inner splash shield aside.
   Fig 21: Positioning Inner Splash Shield Aside

   Courtesy of FORD MOTOR CO.
2. Disconnect the wheel speed sensor electrical connector.
   Fig 22: Disconnecting Wheel Speed Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.

Item 34: Anti-lock Brake Sensor Harness Removal Note 

1. Unclip the anti-lock brake harness from the brake hose.
   Fig 23: Unclipping Anti-Lock Brake Harness From Brake Hose

   Courtesy of FORD MOTOR CO.

Item 36: Brake Caliper Removal Note 

CAUTION: Do not allow the brake caliper to hang from the hose or damage to the hose may result.
1. Position the caliper aside and secure.

Item 38: Upper Ball Joint Nut Removal Note 

NOTE: Hold the external hex when removing the ball joint nuts to prevent damage to the ball joint.
Fig 24: Identifying Nut For Separating Ball Joint From Spindle
Courtesy of FORD MOTOR CO.
1. Remove the nut and separate the ball joint from the spindle.

Item 40: Anti-Lock Brake Sensor Electrical Connector Removal Note 

1. Position the inner splash shield aside.
   1. Remove the pin-type retainers.
   2. Position the inner splash shield aside.
   Fig 25: Positioning Inner Splash Shield Aside

   Courtesy of FORD MOTOR CO.
2. Disconnect the anti-lock brake sensor electrical connector.
   Fig 26: Disconnecting Anti-Lock Brake Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.

Item 41: Anti-lock Brake Sensor Harness Removal Note 

1. Unclip the anti-lock brake harness from the brake hose.
   Fig 27: Unclipping Anti-Lock Brake Harness From Brake Hose

   Courtesy of FORD MOTOR CO.

Item 43: Brake Caliper Removal Note 

CAUTION: Do not allow the brake caliper to hang from the hose or damage to the hose may result.
1. Position the caliper aside and secure.

Item 45: Upper Ball Joint Nut Removal Note 

NOTE: Hold the external hex when removing the ball joint nuts to prevent damage to the ball joint.
Fig 28: Identifying Nut For Separating Ball Joint From Spindle
Courtesy of FORD MOTOR CO.
1. Remove the nut and separate the ball joint from the spindle.

Item 47: Shift Cable Removal Note 

1. Disconnect the shift cable from the shifter.
   Fig 29: Disconnecting Shift Cable From Shifter

   Courtesy of FORD MOTOR CO.

Item 48: Shift Cable Removal Note 

1. Unclip the shift cable from the bracket.
   Fig 30: Unclipping Shift Cable From Bracket

   Courtesy of FORD MOTOR CO.

Item 49: Power Steering Rack Electrical Connector Removal Note 

1. Disconnect the rack and pinion steering unit electrical connectors and remove the tie-strap.
   Fig 31: Removing Power Steering Electrical Connectors

   Courtesy of FORD MOTOR CO.

Item 62: Transmission-to-Engine Bolt Removal Note 

1. Remove the lower six transmission-to-engine bolts.

Item 64: Torque Converter Nut Removal Note 

NOTE: Make an identifying mark on the nut, stud, and adapter plate to allow for correct installation.
1. Remove the eight torque converter nuts.

Item 65: Engine and Transmission Removal Note 

1. Remove the lower air deflector pin-type retainers and remove the air dam.
2. Support the rear of the vehicle with suitable safety stands.
3. Install the special tools.
   Fig 32: Identifying Special Tools

   Courtesy of FORD MOTOR CO.

Item 70: Engine and Transmission Assembly Removal Note 

1. Carefully lower the entire assembly from the vehicle.

Item 71: Power Steering Return Hose Removal Note 

1. Drain the reservoir and disconnect the return hose at the power steering pump.
   Fig 33: Disconnecting Return Hose

   Courtesy of FORD MOTOR CO.

Item 72: Engine Block Heater Removal Note 

1. Disconnect the engine block heater electrical connector if equipped.
   Fig 34: Disconnecting Engine Block Heater Electrical Connector

   Courtesy of FORD MOTOR CO.

Item 82: Engine and Transmission Assembly Removal Note 

1. Install the special tool.
   Fig 35: Installing Special Tool (1 Of 2)

   Courtesy of FORD MOTOR CO.
2. Install the special tool.
   Fig 36: Installing Special Tool (2 Of 2)

   Courtesy of FORD MOTOR CO.
3. Using the special tool and an engine crane, support the engine and transmission in the front subframe.

Item 90: Engine and Transmission Removal Note 

1. Using the special tool and an engine crane, move the engine and transmission from the subframe to rest on the floor or on a bench.
   Fig 37: Moving Engine And Transmission From Subframe Using Special Tool And An Engine Crane

   Courtesy of FORD MOTOR CO.

Item 95 and 96: Engine Wiring Harness Removal Note 

1. Remove the nuts and position the harness aside.

Item 97: Engine-to-Transmission Bolt Removal Note 

1. Remove the bolts and separate the engine from the transmission.
   Fig 38: Removing Engine-To-Transmission Bolt

   Courtesy of FORD MOTOR CO.