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Section 362 (Engine - 4.2L): Removal: Engine: Removal

WARNING: This page is about a different car, the 2003 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the battery ground cable (14301). For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  3. Discharge the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  4. Remove the air cleaner assembly and the throttle body inlet tube.
  5. Remove the radiator air deflector (8326). For additional information, refer to FRONT END BODY PANELS .
  6. Remove the radiator (8005), the fan shroud and the fan. For additional information, refer to ENGINE COOLING .
  7. Remove the radiator inner grille (8150). For additional information, refer to FRONT END BODY PANELS .
  8. Remove the headlamps. For additional information, refer to EXTERIOR LIGHTING .
  9. Remove the side marker lamps. For additional information, refer to EXTERIOR LIGHTING .
  10. Remove the radiator grille opening panel reinforcement (8A284). For additional information, refer to FRONT END BODY PANELS .
  11. Remove the front end stone deflector. For additional information, refer to FRONT END BODY PANELS .
  12. Remove the power steering cooler. For additional information, refer to POWER STEERING .
  13. Remove the auxiliary transmission cooler. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING .
  14. Remove the bolts and the transmission/power steering cooler mounting brackets.
    Fig 1: Removing Transmission/Power Steering Cooler Mounting Brackets
    G01535978Courtesy of FORD MOTOR CO.
  15. Remove the A/C condenser core (19712). For additional information, refer AIR CONDITIONING .
  16. Set aside the hood latch (16700).
    1. Remove the hood latch retaining bolts.
    2. Disengage the cable routing clip.
    Fig 2: Removing Hood Latch Retaining Bolts
    G01535979Courtesy of FORD MOTOR CO.
  17. Set aside the battery feed wire wiring harness to the power distribution box.
    • Remove the cover at the power distribution box.
    • Remove the nut and cable.
    • Disengage the routing clips.
    Fig 3: Removing Nut And Cable
    G01535980Courtesy of FORD MOTOR CO.
  18. Remove the bolts and set the power steering reservoir aside.
  19. Remove the bolts and the upper core support.
    Fig 4: Removing Upper Core Support Bolts
    G01535981Courtesy of FORD MOTOR CO.
  20. Set aside the headlamp dash panel junction wiring harness.
    • Remove the screw.
    • Disconnect the wiring at the front air bag sensor.
    • Disconnect the wiring at the horn.
    • Disconnect the wiring at the daytime running lamp module, if so equipped.
    • Disengage the wiring harness routing clips and set the harness aside.
    Fig 5: Disconnecting Wiring Harness Routing Clips
    G01535982Courtesy of FORD MOTOR CO.
  21. Remove the bolt and the lower core support.
  22. Remove the engine oil level indicator. Remove the bolt and the engine oil level indicator extension tube.
    Fig 6: Removing Engine Oil Level Indicator
    G01535983Courtesy of FORD MOTOR CO.
  23. Remove the bolt and the engine oil level indicator tube.
  24. Remove the lower intake manifold. For additional information, refer to LOWER INTAKE MANIFOLD .
  25. Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE .
  26. Set the power steering pump (3A674) aside.
    1. Disconnect the low-pressure line at the power steering pump.
    2. Remove the bolts.
    Fig 7: Removing Bolts
    G01535984Courtesy of FORD MOTOR CO.
  27. Disconnect the degas bottle supply hose.
    Fig 8: Disconnecting Degas Bottle Supply Hose
    G01535985Courtesy of FORD MOTOR CO.
  28. Disconnect the oil cooler coolant hoses.
    Fig 9: Disconnecting Oil Cooler Coolant Hoses
    G01535986Courtesy of FORD MOTOR CO.
  29. Remove the lower radiator hose.
  30. Set the A/C manifold and tube (19D734) aside.
    • Remove the bolt.
    • Remove and discard the O-rings.
    • Cap the lines.
    Fig 10: Removing Bolt
    G01535987Courtesy of FORD MOTOR CO.
  31. Disconnect the A/C high-pressure line at the A/C evaporator core (19860). Discard the O-ring.
  32. Raise the vehicle.
  33. Drain the engine oil.
  34. Remove the starter motor (11002). For additional information, refer to STARTERS - EXCEPT DIESEL .
  35. Remove the torque converter access cover and the nuts. Rotate the crankshaft to access the nuts.
    Fig 11: Removing Torque Converter Access Cover And Nuts
    G01535988Courtesy of FORD MOTOR CO.
  36. Remove the bolts on the left side.
    Fig 12: Removing Bolts
    G01535989Courtesy of FORD MOTOR CO.
  37. Remove the bolt on the right side.
    Fig 13: Removing Bolts
    G01535990Courtesy of FORD MOTOR CO.
  38. Remove the nuts retaining the exhaust pipe at the exhaust manifolds (9430).
  39. Remove the bolt retaining the shift cable routing bracket.
  40. Remove the nuts retaining the engine mount (Left side shown).
    Fig 14: Removing Nuts Retaining Engine Mount
    G01535991Courtesy of FORD MOTOR CO.
  41. Lower the vehicle.
  42. Install the engine lifting equipment.
  43. Remove the transmission dipstick tube.
    • Position the drain pan.
    • Remove the transmission-to-engine retaining bolt at the dipstick tube bracket.
    • Remove the tube.
    • Discard the O-ring.
  44. Remove the bolts retaining the transmission to the engine.
    Fig 15: Removing Bolts Retaining Transmission To Engine
    G01535992Courtesy of FORD MOTOR CO.
  45. Remove the engine.
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