Section 7 (Engine - 3.5L Ti-VCT): Removal: Engine

Courtesy of FORD MOTOR COMPANY	2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
Courtesy of FORD MOTOR COMPANY	Adjustable Grip Arm, 1735A 014-00001 or equivalent
Courtesy of FORD MOTOR COMPANY	Disconnect Tool, Transmission Cooler Line 307-569
Courtesy of FORD MOTOR COMPANY	Eye, Engine Lift 303-1245
Courtesy of FORD MOTOR COMPANY	Powertrain Lift 300-OTC1585AE or equivalent
Courtesy of FORD MOTOR COMPANY	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

All vehicles 

1. 1.
   
   With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting .

1. 2.
   
   Release the fuel system pressure. For additional information, refer to Fuel System General Information .

1. 3.
   
   Recover the A/C system. For additional information, refer to Climate Control System General Information and Diagnostics .

1. 4.
   
   Remove the cowl panel grille. For additional information, refer to Front End Body Panels .

1. 5.
   
   Remove the 4 nuts and the strut tower brace.

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1. 6.
   
   Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering .

1. 7.
   
   Remove the battery tray. For additional information, refer to Battery, Mounting and Cables .

1. 8.
   
   Remove the nut and disconnect the 2 battery feed cables from the positive battery terminal.

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1. 9.
   
   Remove the retainer and the ground wire cable.

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1. 10.
   
   Disconnect the engine wiring harness electrical connector.

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1. 11.
   
   If equipped, release the 4 retainers and remove the underbody shield.

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1. 12.
   
   If equipped, remove the 10 retainers and the skid plate.

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1. 13.
   
   Drain the cooling system. For additional information, refer to Engine Cooling .

1. 14.
   
   Remove the front wheels and tires. For additional information, refer to Wheels and Tires .

1. 15.
   
   Remove the 3 pin-type retainers and position aside.

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1. 16.
   
   Remove the accessory drive belt. For additional information, refer to Accessory Drive .

1. 17.
   
   Remove the nut and disconnect the A/C tube.
   • Discard the O-ring seal and gasket seal.

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1. 18.
   
   Disconnect the A/C pressure switch electrical connector.

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1. 19.
   
   Remove the nut and the A/C tube from the condenser.
   • Discard the O-ring seal and gasket seal.

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1. 20.
   
   Remove the degas bottle. For additional information, refer to Engine Cooling .

1. 21.
   
   Disconnect the degas bottle coolant hose from the engine coolant tube.

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1. 22.
   
   Disconnect the brake booster vacuum hose from the upper intake manifold.

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1. 23.
   
   Disconnect the Evaporative Emission (EVAP) tube and the fuel supply tube quick connect coupling. For additional information, refer to Fuel System General Information .

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1. 24.
   
   Disconnect the engine harness electrical connector.
   • Detach the wiring harness retainer.

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1. 25.
   
   Disconnect the PCM electrical connector.

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1. 26.
   
   Remove the engine wiring harness retainer from the bulkhead.

   1. 1.
      
      Push the wiring harness retainer tab in.

   1. 2.
      
      Slide the wiring harness up and out of the bulkhead.

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1. 27.
   
   Remove the bolt and ground wire from the RH shock tower.

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1. 28.
   
   Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.

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1. 29.
   
   Disconnect the transaxle control cable from the control lever.

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1. 30.
   
   Disconnect the transaxle control cable from the shift cable bracket and position aside.
   • Detach the wiring harness pin-type retainer from the shift cable bracket.

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1. 31.
   
   If equipped, detach the engine block heater harness from the radiator support.

1. 32.
   
   
   NOTE: Use a steering wheel holding device (such as Hunter ® 28-75-1 or equivalent).

   Using a suitable holding device, hold the steering wheel in the straight-ahead position.

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1. 33.
   
   
   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.

   Remove the bolt and disconnect the steering column shaft from the steering gear.

   • Discard the bolt.

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1. 34.
   
   Remove the exhaust Y-pipe. For additional information, refer to Exhaust System .

All-Wheel Drive (AWD) vehicles 

1. 35.
   
   
   NOTE: Index-mark the driveshaft for installation.

   Remove and discard the 4 bolts and support the driveshaft with a length of mechanic's wire.

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All vehicles 

1. 36.
   
   Remove the drain plug and drain the engine oil.
   • Install the drain plug and tighten to 27 Nm (20 lb-ft).

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1. 37.
   
   Remove and discard the engine oil filter.

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1. 38.
   
   Remove the 2 fasteners and the inspection cover.

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1. 39.
   
   Remove and discard the 3 torque converter bolts.

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1. 40.
   
   Remove the 4 oil pan-to-transaxle bolts.

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1. 41.
   
   If equipped, disconnect the 2 oil cooler coolant hoses.

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1. 42.
   
   If equipped, unlatch the cooler hose retainer latch and pry up on the oil cooler hose retainer to release the retainer and remove it from the subframe.

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1. 43.
   
   Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.

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1. 44.
   
   Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.

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1. 45.
   
   
   NOTE: LH shown, RH similar.

   Remove the bolt and the wheel speed sensor.

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1. 46.
   
   
   NOTE: LH shown, RH similar.

   Remove and discard the upper stabilizer link nut.

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1. 47.
   
   
   NOTE: Do not allow the brake caliper to hang from the brake flexible hose or damage to the hose may occur.
   NOTE: LH shown, RH similar.

   Remove the brake caliper guide pin bolts and calipers.

   • Support the calipers.

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1. 48.
   
   
   NOTE: RH shown, LH similar.

   Using a wax pencil, mark the relationship of the front and rear subframe to the underbody at the mounting locations on both side.

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1. 49.
   
   
   NOTE: LH shown, RH similar.

   Remove the LH and RH halfshaft nuts.

   • Do not discard at this time.

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1. 50.
   
   
   NOTE: LH shown, RH similar.

   Separate the LH and RH halfshaft from the wheel hubs.

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1. 51.
   
   Position a 2 x 6 board, 36 in (914.4 mm) in length and two 2 x 6 boards 24 in (609.6 mm) in length onto the powertrain lift.
   • Position the powertrain lift table with:
     • the long board towards the rear of the subframe.
     • the short boards under the engine and transmission.

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1. 52.
   
   Install the Adjustable Grip Arm from the powertrain lift table to the LH engine-to-transmission bolt hole.

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1. 53.
   
   Install a ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe, to secure the subframe to the powertrain lift table.

1. 54.
   
   
   NOTE: LH shown, RH similar.
   NOTE: The halfshafts are not being remove from the transmission.

   Remove the strut-to-wheel knuckle nuts and bolts.

   • Remove the strut from the wheel knuckle and the halfshafts from the wheel knuckle.

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1. 55.
   
   Remove the transaxle support insulator through bolt and nut.

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1. 56.
   
   Remove the bolt, 3 nuts and the transaxle support insulator bracket.

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1. 57.
   
   Remove the 4 engine mount nuts.

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1. 58.
   
   Remove the 3 bolts and the engine mount.

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1. 59.
   
   
   NOTE: RH shown, LH similar.

   Remove the subframe bracket-to-body bolts.

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1. 60.
   
   
   NOTE: RH shown, LH similar.

   Remove the rear subframe bolts and the subframe brackets.

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1. 61.
   
   
   NOTE: RH shown, LH similar.

   Remove the front subframe bolts.

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1. 62.
   
   Lower the subframe and powertrain assembly from the vehicle.

1. 63.
   
   Install 303-1245 on the LH cylinder head.

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1. 64.
   
   Install the Heavy Duty Floor Crane and Spreader Bar.

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1. 65.
   
   Remove the starter motor solenoid cover.

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1. 66.
   
   Remove the 2 nuts and the starter motor wiring terminals.

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1. 67.
   
   Disconnect the wiring harness retainer from the starter motor stud bolt.

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1. 68.
   
   Remove the bolt, stud bolt and the starter.

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1. 69.
   
   Remove the bolt and the ground wire from the RH cylinder head.

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1. 70.
   
   Disconnect the 2 A/C compressor electrical connectors.
   • Detach the A/C wiring harness retainer.

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1. 71.
   
   Disconnect the generator electrical connector and position the generator B+ cable cover aside.

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1. 72.
   
   Remove the nut and disconnect the generator B+ cable.

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1. 73.
   
   Detach the 3 wiring harness retainer from the valve cover stud bolt and position the harness on transmission.

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1. 74.
   
   Disconnect the transaxle control electrical connector.

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1. 75.
   
   Detach the transaxle control wire harness retainer from the transaxle stud bolt.

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1. 76.
   
   Disconnect the RH catalyst monitor electrical connector.

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1. 77.
   
   Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.

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1. 78.
   
   Remove the 4 nuts and the RH catalytic converter heat shield.

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1. 79.
   
   Remove the 6 nuts and the RH catalytic converter manifold.
   • Discard the nuts and RH catalytic converter manifold gasket.

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1. 80.
   
   Remove and discard the 6 RH catalytic converter manifold studs.

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AWD vehicles 

1. 81.
   
   Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket.

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All vehicles 

1. 82.
   
   Remove the Adjustable Grip Arm.

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1. 83.
   
   Remove the ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe.

1. 84.
   
   
   NOTE: LH shown, RH similar.

   Install the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

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1. 85.
   
   Using the Floor Crane and Spreader Bar, remove the powertrain and subframe as an assembly from the powertrain lift table and set on the ground.
   • Position wood blocks under the engine and transmission.

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1. 86.
   
   
   NOTE: LH shown, RH similar.

   Remove the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

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1. 87.
   
   Remove the 2 intermediate shaft bracket nuts and the 2 studs.

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1. 88.
   
   Remove the 2 bolts and the RH halfshaft support bracket.

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1. 89.
   
   Remove the 2 engine-to-transaxle bolts.

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1. 90.
   
   Remove the 5 transaxle-to-engine bolts.
   • Separate the transaxle from the engine.

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1. 91.
   
   Using the Floor Crane and Spreader Bar, remove the engine from the transaxle.

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