Engine Mechanical - 3.5L: Removal: Engine

	2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
	Adjustable Grip Arm, 1735A 014-00001 or equivalent
	Disconnect Tool, Transmission Cooler Line 307-569
	Eye, Engine Lift 303-1245
	Halfshaft Remover 205-832
	Powertrain Lift 300-OTC1585AE or equivalent
	Remover, Front Wheel Hub 205-D070 (D93P-1175-B) or equivalent
	Slide Hammer 100-001 (T50T-100-A)
	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
2. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
3. Remove the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
4. Detach the brake booster vacuum hose retainer from the strut tower brace.
   Fig 1: Locating Brake Booster Vacuum Hose Retainer Of Strut Tower Brace

   Courtesy of FORD MOTOR CO.
5. Remove the 4 nuts (2 shown in illustration) and the strut tower brace.
   Fig 2: Locating Strut Tower Brace And Nuts

   Courtesy of FORD MOTOR CO.
6. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
7. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
8. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
9. Disconnect the engine wiring harness electrical connector.
   Fig 3: Locating Engine Wiring Harness Electrical Connector

   Courtesy of FORD MOTOR CO.
10. Remove the nut and disconnect the 2 power feed wires from the positive battery terminal.
    Fig 4: Locating Battery Positive Terminal Nut

    Courtesy of FORD MOTOR CO.
11. Remove the nut and disconnect the ground cable from the negative battery terminal.
    Fig 5: Locating Negative Battery Terminal Ground Cable And Nut

    Courtesy of FORD MOTOR CO.
12. Drain the cooling system. For additional information, refer to ENGINE COOLING .
13. Remove the LF wheel and tire. For additional information, refer to WHEELS AND TIRES .
14. Remove the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE .
15. Remove the 3 pushpins, 7 screws and the front valance.
    Fig 6: Locating Pushpins, Screws And Front Valance

    Courtesy of FORD MOTOR CO.
16. Disconnect the power steering cooler tube located at the left front subframe and drain the power steering fluid into a suitable container.
    Fig 7: Locating Power Steering Cooler Tube Clamp

    Courtesy of FORD MOTOR CO.
17. Remove the nut and disconnect the A/C tube.
    • Discard the O-ring seal and gasket seal.
      Fig 8: Locating A/C Tube Nut

      Courtesy of FORD MOTOR CO.
18. Remove the nut and the A/C tube.
    • Discard the O-ring seal and gasket seal.
      Fig 9: Locating A/C Tube And Nut

      Courtesy of FORD MOTOR CO.
19. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
20. Disconnect the vacuum hose and the Evaporative Emission (EVAP) tube from the upper intake manifold.
    Fig 10: Locating Vacuum Hose And Evaporative Emission (EVAP) Tube Clamps

    Courtesy of FORD MOTOR CO.
21. Detach the EVAP tube pin-type retainer from the upper intake manifold.
    Fig 11: Locating EVAP Tube Pin-Type Retainer Of Upper Intake Manifold

    Courtesy of FORD MOTOR CO.
22. Remove the EVAP canister purge valve. For additional information, refer to EVAPORATIVE EMISSIONS .
23. Disconnect the PCM and engine harness electrical connectors.
    • Detach the wiring harness retainer.
      Fig 12: Locating PCM And Engine Harness Electrical Connectors With Wiring Harness Retainer

      Courtesy of FORD MOTOR CO.
24. Disconnect the 2 PCM electrical connectors.
    Fig 13: Locating PCM Electrical Connectors

    Courtesy of FORD MOTOR CO.
25. Remove the engine wiring harness retainer from the bulkhead.
    1. Push the wiring harness retainer tab in.
    2. Slide the wiring harness up and out of the bulkhead.
       Fig 14: Identifying Bulkhead And Wiring Harness Retainer Tab

       Courtesy of FORD MOTOR CO.
26. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
    Fig 15: Locating Upper Radiator Hose, Lower Radiator Hose And Heater Hoses

    Courtesy of FORD MOTOR CO.
27. Disconnect the transaxle control cable from the control lever.
    Fig 16: Locating Control Lever Transaxle Control Cable

    Courtesy of FORD MOTOR CO.
28. Disconnect the transaxle control cable from the shift cable bracket and detach the wiring harness pin-type retainer.
    Fig 17: Locating Shift Cable Bracket And Wiring Harness Pin-Type Retainer

    Courtesy of FORD MOTOR CO.
29. If equipped, detach the engine block heater harness from the radiator support.
30. Disconnect the A/C pressure switch and remove the nut and disconnect the upper A/C tube from the condenser.
    • Discard the O-ring seal.
      Fig 18: Locating A/C Pressure Switch Electrical Connector And Nut

      Courtesy of FORD MOTOR CO.
31. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 19: Locating Fuel Supply Tube

    Courtesy of FORD MOTOR CO.
32. Detach the engine wiring harness retainer.
    Fig 20: Locating Engine Wiring Harness Retainer

    Courtesy of FORD MOTOR CO.
33. Detach the wire harness retainer from the RH valve cover stud bolt.
    Fig 21: Locating RH Valve Cover Stud Bolt Wire Harness Retainer

    Courtesy of FORD MOTOR CO.
34. Remove the bolt and the ground cable from the engine.
    Fig 22: Locating Bolt And Ground Cable

    Courtesy of FORD MOTOR CO.
35. Disconnect the hose from the power steering reservoir.
    Fig 23: Locating Power Steering Reservoir Hose Clamp

    Courtesy of FORD MOTOR CO.
NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
Fig 24: Holding Steering Wheel In Straight-Ahead Position Using Suitable Holding Device
Courtesy of FORD MOTOR CO.
36. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
NOTE: Apply the brake to keep the halfshafts from rotating.
NOTE: RH shown in illustration, LH similar.
37. Remove the RH and LH halfshaft nuts.
    • Do not discard at this time.
      Fig 25: Locating Halfshaft Nuts

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
Fig 26: Separating RH And LH Halfshaft From Wheel Hub Using Front Wheel Hub Remover
Courtesy of FORD MOTOR CO.
38. Using the Front Wheel Hub Remover, separate the RH and LH halfshaft from the wheel hubs.
39. Remove the 2 lower scrivets from the rubber shield and position the shield aside.
    Fig 27: Locating Lower Scrivets Of Rubber Shield

    Courtesy of FORD MOTOR CO.
40. Remove the bolt from the RH brake hose bracket.
    Fig 28: Locating RH Brake Hose Bracket Bolt

    Courtesy of FORD MOTOR CO.
NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM .
NOTE: Index-mark the steering column shaft position to the steering gear for reference during installation.
41. Remove the bolt and disconnect the steering column shaft from the steering gear.
    • Discard the bolt.
      Fig 29: Locating Index Mark And Steering Column Shaft Mounting Bolt

      Courtesy of FORD MOTOR CO.
42. Remove the 4 Y-pipe-to-catalytic converter nuts.
    • Discard the nuts.
      Fig 30: Locating Y-Pipe-To-Catalytic Converter Nuts

      Courtesy of FORD MOTOR CO.
43. Remove the 2 Y-pipe flange nuts.
    • Detach the exhaust hanger and remove the Y-pipe.
    • Discard the gaskets and nuts.
      Fig 31: Locating Exhaust Hanger And Y-Pipe Nuts

      Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

NOTE: Index-mark the driveshaft for installation.
Fig 32: Locating Driveshaft Bolts
Courtesy of FORD MOTOR CO.
44. Remove and discard the 4 bolts and support the driveshaft with a length of mechanic's wire.

    All vehicles 

45. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
      Fig 33: Locating Drain Plug

      Courtesy of FORD MOTOR CO.
46. Remove and discard the engine oil filter.
    Fig 34: Locating Engine Oil Filter

    Courtesy of FORD MOTOR CO.
47. Remove the Power Steering Pressure (PSP) tube bracket-to-steering gear bolt.
    Fig 35: Locating Power Steering Pressure (PSP) Tube Bracket-To-Steering Gear Bolt

    Courtesy of FORD MOTOR CO.
48. Remove the bolt, rotate the clamp plate clockwise and disconnect the PSP tube from the steering gear.
    • Discard the O-ring seal.
      Fig 36: Locating Clamp Plate, Bolt And PSP Tube

      Courtesy of FORD MOTOR CO.
49. Remove the engine roll restrictor-to-subframe through bolt and loosen the engine roll restrictor-to-transaxle bracket through bolt.
    Fig 37: Locating Engine Roll Restrictor Through Bolts

    Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
Fig 38: Locating Upper Stabilizer Bar Link Nut
Courtesy of FORD MOTOR CO.
50. Remove and discard the upper stabilizer link nuts.
NOTE: The hex-holding feature can be used to prevent turning of the stud while removing the nut.
NOTE: RH shown in illustration, LH similar.
51. Remove and discard the tie-rod end nuts.
    • Separate the tie-rod ends from the wheel knuckles.
      Fig 39: Locating Tie-Rod End And Nut

      Courtesy of FORD MOTOR CO.
NOTE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part number or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.
NOTE: Use care when releasing the lower arm and knuckle into the resting position or damage to the ball joint seal or Constant Velocity (CV) boot may occur.
NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut.
NOTE: RH shown in illustration, LH similar.
52. Remove and discard the lower ball joint-to-wheel knuckle nuts.
    • Separate the lower ball joints from the wheel knuckles.
      Fig 40: Locating Lower Ball Joint-To-Wheel Knuckle Nut

      Courtesy of FORD MOTOR CO.
53. Using a wax pencil, mark the relationship of the front subframe to the underbody at the mounting locations.
54. Position the Powertrain Lift under the subframe assembly.
    Fig 41: Positioning Powertrain Lift Under Subframe Assembly

    Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
Fig 42: Locating Subframe Bracket-To-Body Bolts
Courtesy of FORD MOTOR CO.
55. Remove the subframe bracket-to-body bolts.
NOTE: RH shown in illustration, LH similar.
Fig 43: Locating Rear Subframe Bolts And Subframe Brackets
Courtesy of FORD MOTOR CO.
56. Remove the rear subframe bolts and the subframe brackets.
NOTE: RH shown in illustration, LH similar.
Fig 44: Locating Front Subframe Bolt
Courtesy of FORD MOTOR CO.
57. Remove the front subframe bolts.
58. Lower the subframe assembly from the vehicle.
59. Pull the RH wheel knuckle outward and rotate it toward the rear of the vehicle.
    • Secure the RH wheel knuckle assembly.
      Fig 45: Pulling RH Wheel Knuckle Outboard

      Courtesy of FORD MOTOR CO.
60. Remove the 2 intermediate shaft bracket nuts.
    Fig 46: Locating Intermediate Shaft Bracket Nuts

    Courtesy of FORD MOTOR CO.
61. Remove the intermediate and halfshaft assembly.
NOTE: The sharp edges on the stub shaft splines can slice or puncture the oil seal. Use care when removing the stub shaft from the transmission or damage to the component may occur.
Fig 47: Removing Halfshaft From Transmission Using Slide Hammer And Halfshaft Remover
Courtesy of FORD MOTOR CO.
62. Using the Slide Hammer and Halfshaft Remover, remove the halfshaft from the transmission.
63. Remove and discard the circlip from the stub shaft.
    Fig 48: Locating Stub Shaft Circlip

    Courtesy of FORD MOTOR CO.
64. Remove the 2 RH halfshaft support bracket studs.
    Fig 49: Locating Halfshaft Support Bracket Studs

    Courtesy of FORD MOTOR CO.
65. Remove the 4 bolts and the RH halfshaft support bracket.
    Fig 50: Locating RH Halfshaft Support Bracket Bolts

    Courtesy of FORD MOTOR CO.
66. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
    Fig 51: Locating Secondary Latches

    Courtesy of FORD MOTOR CO.
67. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
    Fig 52: Disconnecting Transmission Fluid Cooler Tubes From Cooler Thermal Bypass Valve

    Courtesy of FORD MOTOR CO.
68. Remove the 2 fasteners and the inspection cover.
    Fig 53: Locating Inspection Cover And Fasteners

    Courtesy of FORD MOTOR CO.
69. Remove and discard the 3 torque converter bolts.
    Fig 54: Locating Torque Converter Bolt

    Courtesy of FORD MOTOR CO.
70. Remove the 4 oil pan-to-transaxle bolts.
    Fig 55: Locating Oil Pan-To-Transaxle Bolts

    Courtesy of FORD MOTOR CO.

    AWD vehicles 

71. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 56: Locating RH Catalyst Monitor Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
72. Remove the 4 nuts and the RH catalytic converter.
    • Discard the nuts and gasket.
      Fig 57: Locating RH Catalytic Converter Nuts

      Courtesy of FORD MOTOR CO.
73. Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket.
    Fig 58: Locating Power Transfer Unit (PTU) Support Bracket Bolts

    Courtesy of FORD MOTOR CO.
74. Remove the 5 bolts and the PTU.
    Fig 59: Locating Bolts And PTU

    Courtesy of FORD MOTOR CO.

    All vehicles 

NOTE: Position a block of wood under the transaxle.
Fig 60: Installing Powertrain Lift And Adjustable Grip Arms
Courtesy of FORD MOTOR CO.
75. Install the Powertrain Lift and Adjustable Grip Arms.
76. Remove the transaxle support insulator through bolt and nut.
    Fig 61: Locating Transaxle Support Insulator Through Bolt And Nut

    Courtesy of FORD MOTOR CO.
77. Remove the bolt, 3 nuts and the transaxle support insulator bracket.
    Fig 62: Locating Nuts, Bolt And Transaxle Support Insulator Bracket

    Courtesy of FORD MOTOR CO.
78. Remove the nut, bolt and engine mount brace.
    Fig 63: Locating Engine Mount Brace, Nut And Bolt

    Courtesy of FORD MOTOR CO.
79. Remove the 4 engine mount nuts.
    Fig 64: Locating Engine Mount Nuts

    Courtesy of FORD MOTOR CO.
80. Remove the 3 bolts and the engine mount.
    Fig 65: Locating Engine Mount And Bolts

    Courtesy of FORD MOTOR CO.
81. Lower the engine and transaxle assembly from the vehicle.
82. Remove the starter motor solenoid cover.
    Fig 66: Locating Starter Motor Solenoid Cover

    Courtesy of FORD MOTOR CO.
83. Remove the 2 nuts and the starter motor wiring terminals.
    Fig 67: Locating Starter Motor Wiring Terminals Nuts

    Courtesy of FORD MOTOR CO.
84. Disconnect the wiring harness retainer from the starter motor stud bolt.
    Fig 68: Locating Wiring Harness Retainer Of Starter Motor Stud Bolt

    Courtesy of FORD MOTOR CO.
85. Remove the bolt, stud bolt and the starter.
    Fig 69: Locating Starter Bolt And Studbolt

    Courtesy of FORD MOTOR CO.
86. Install the Engine Lift Eye on the LH cylinder head.
    Fig 70: Installing Engine Lift Eye On LH Cylinder Head

    Courtesy of FORD MOTOR CO.
87. Disconnect the transaxle control electrical connector.
    Fig 71: Locating Transaxle Control Electrical Connector

    Courtesy of FORD MOTOR CO.
88. Detach the transaxle control wire harness retainer from the transaxle stud bolt.
    Fig 72: Locating Transaxle Control Wire Harness Retainer Of Transaxle Stud Bolt

    Courtesy of FORD MOTOR CO.
89. Using the Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table.
    Fig 73: Removing Engine And Transaxle From Lift Table

    Courtesy of FORD MOTOR CO.
90. Remove the 2 engine-to-transaxle bolts.
    Fig 74: Locating Engine-To-Transaxle Bolts

    Courtesy of FORD MOTOR CO.
91. Remove the 5 transaxle-to-engine bolts.
    • Separate the transaxle from the engine.
      Fig 75: Locating Transaxle-To-Engine Bolts

      Courtesy of FORD MOTOR CO.