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Engine - 5.4L: Removal: Engine: Removal

  1. Remove the hood.
  2. Remove the radiator. For additional information, refer to ENGINE COOLING .
  3. Recover the A/C system refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  4. Remove the lower intake manifold. For additional information, refer to LOWER INTAKE MANIFOLD .
  5. Disconnect the powertrain control module (PCM) electrical connectors.
    Fig 1: Disconnecting Powertrain Control Module (PCM) Electrical Connectors
    G02782618Courtesy of FORD MOTOR CO.
  6. Remove the PCM mounting bolts and the PCM.
    Fig 2: Removing PCM Mounting Bolts And PCM
    G02782619Courtesy of FORD MOTOR CO.
  7. Remove the bolts and the PCM mounting bracket.
    Fig 3: Removing Bolts And PCM Mounting Bracket
    G02782620Courtesy of FORD MOTOR CO.
  8. Disconnect the auxiliary heater hoses at the right side valve cover.
    Fig 4: Disconnecting Auxiliary Heater Hoses At Right Side Valve Cover
    G02782621Courtesy of FORD MOTOR CO.
  9. Disconnect the heater hoses at the heater core.
    Fig 5: Disconnecting Heater Hoses At Heater Core
    G02782622Courtesy of FORD MOTOR CO.
  10. Disconnect the A/C hoses from the junction block.
    Fig 6: Disconnecting A/C Hoses From Junction Block
    G02782623Courtesy of FORD MOTOR CO.
  11. Remove the safety clips and disconnect the spring lock couplers at the evaporator core. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 7: Disconnecting Spring Lock Couplers At Evaporator Core
    G02782624Courtesy of FORD MOTOR CO.
  12. Rotate the belt tensioner counterclockwise and remove the drive belt.
    Fig 8: Removing Drive Belt
    G02782625Courtesy of FORD MOTOR CO.
    13. NOTE: Position the rubber boot aside to access the B+ cable.
    Fig 9: Disconnecting Generator Electrical Connectors
    G02782626Courtesy of FORD MOTOR CO.
  13. Disconnect the generator electrical connectors.
  14. Remove the bolts and the generator.
    Fig 10: Removing Bolts And Generator
    G02782627Courtesy of FORD MOTOR CO.
  15. Using the special tool, remove the power steering pump pulley.
    Fig 11: Removing Power Steering Pump Pulley Using Special Tool
    G02782628Courtesy of FORD MOTOR CO.
  16. Remove the nuts and disconnect the transmission cooler tube and the power steering hose brackets.
    Fig 12: Disconnecting Transmission Cooler Tube And Power Steering Hose Brackets
    G02782629Courtesy of FORD MOTOR CO.
  17. Disconnect the power steering pressure hose.
    • Drain the power steering fluid into a suitable container.
    Fig 13: Disconnecting Power Steering Pressure Hose
    G02782630Courtesy of FORD MOTOR CO.
  18. Remove the three bolts and position the power steering pump out of the way.
    Fig 14: Removing Bolts
    G02782631Courtesy of FORD MOTOR CO.
  19. Disconnect the exhaust gas recirculation (EGR) valve tube nut from the LH exhaust manifold and remove the tube.
    Fig 15: Disconnecting Exhaust Gas Recirculation (EGR) Valve Tube Nut From LH Exhaust Manifold
    G02782632Courtesy of FORD MOTOR CO.
  20. Remove the engine noise shield.
    Fig 16: Removing Engine Noise Shield
    G02782633Courtesy of FORD MOTOR CO.
  21. Squeeze the clamps and disconnect the hoses.
    • Remove the positive crankcase ventilation (PCV) valve and hose assembly from the vehicle.
    Fig 17: Removing Positive Crankcase Ventilation (PCV) Valve And Hose Assembly From Vehicle
    G02782634Courtesy of FORD MOTOR CO.
  22. Remove the bolt.
    Fig 18: Removing Bolt
    G02782635Courtesy of FORD MOTOR CO.
  23. Remove the tube.
    Fig 19: Removing Tube
    G02782636Courtesy of FORD MOTOR CO.
  24. Remove the bolt and disconnect the ground wire.
    Fig 20: Disconnecting Ground Wire
    G02782637Courtesy of FORD MOTOR CO.
  25. Disconnect the vacuum hose and remove the vacuum harness.
    Fig 21: Removing Vacuum Harness
    G02782638Courtesy of FORD MOTOR CO.
  26. Disconnect the main engine harness electrical connector.
    Fig 22: Disconnecting Main Engine Harness Electrical Connector
    G02782639Courtesy of FORD MOTOR CO.
  27. Raise the vehicle. For additional information, refer to JACKING & LIFTING .
  28. Remove the bolts and the skid plate, if equipped.
    29. NOTE: The bolt is accessed through the RH fender well.
    Fig 23: Removing Transmission Filler Tube-To-Engine Block Bolt
    G02782640Courtesy of FORD MOTOR CO.
  29. Remove the transmission filler tube-to-engine block bolt.
    30. NOTE: Right side shown, left side similar.
    Fig 24: Disconnecting Heated Oxygen Sensor (HO2S) Electrical Connectors
    G02782641Courtesy of FORD MOTOR CO.
  30. Disconnect the heated oxygen sensor (HO2S) electrical connectors.
    31. NOTE: Left side shown, right side similar.
    Fig 25: Removing Nuts
    G02782642Courtesy of FORD MOTOR CO.
  31. Remove the nuts and detach the dual converter Y-pipe.
  32. Remove the bolt and detach the wire harness bracket.
    Fig 26: Removing Bolt
    G02782643Courtesy of FORD MOTOR CO.
  33. Remove the starter. For additional information, refer to STARTERS .
  34. Disconnect the A/C clutch electrical connector.
  35. Remove the bolts and position the A/C compressor aside.
    Fig 27: Removing Bolts And Positioning A/C Compressor
    G02782644Courtesy of FORD MOTOR CO.
  36. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 28: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector
    G02782645Courtesy of FORD MOTOR CO.
  37. Remove the oil filter.
    Fig 29: Removing Oil Filter
    G02782646Courtesy of FORD MOTOR CO.
  38. Remove the drain plug and drain the engine oil.
    • Install the drain plug when finished.
    Fig 30: Removing Drain Plug
    G02782647Courtesy of FORD MOTOR CO.
  39. Squeeze the clamps and disconnect the hoses.
    • Remove the lower radiator hose.
    Fig 31: Removing Lower Radiator Hose
    G02782648Courtesy of FORD MOTOR CO.
  40. Remove the inspection plate bolts and the inspection plate.
    Fig 32: Removing Inspection Plate Bolts And Inspection Plate
    G02782649Courtesy of FORD MOTOR CO.
  41. Remove the flexplate-to-torque converter nut access plug.
    Fig 33: Removing Flexplate-To-Torque Converter Nut Access Plug
    G02782650Courtesy of FORD MOTOR CO.
    42. NOTE: Mark one stud and the flexplate for assembly reference.
    Fig 34: Removing Torque Converter Nuts
    G02782651Courtesy of FORD MOTOR CO.
  42. Remove the four torque converter nuts.
    • Rotate the crankshaft, using the crankshaft pulley bolt.
  43. Remove the six lower transmission-to-engine bolts.
    Fig 35: Removing Lower Transmission-To-Engine Bolts
    G02782652Courtesy of FORD MOTOR CO.
    44. NOTE: The caged nut on the frame may break during bolt removal. If necessary, install a new nut.
    Fig 36: Removing Bolt From LH Motor Mount
    G02782653Courtesy of FORD MOTOR CO.
  44. Remove the bolt from the LH motor mount.
  45. Remove the nut from the RH motor mount.
    Fig 37: Removing Nut From RH Motor Mount
    G02782654Courtesy of FORD MOTOR CO.
  46. Lower the vehicle.
  47. Support the transmission, using a block of wood and a floor jack.
    48. NOTE: On 4x4 vehicles, disconnect the transfer case vent hose from the bracket and position aside to gain access to the upper transmission-to-engine bolts.
  48. Remove the two upper transmission-to-engine bolts.
    49. NOTE: The alternator bolts may be used to attach the special tool to the front of the engine. The two bolts used to attach the special tool to the rear of the engine must be shorter than the transmission-to-engine mounting bolts.
    Fig 38: Installing Special Tool
    G02782655Courtesy of FORD MOTOR CO.
  49. Install the special tool.
  50. Using a floor crane, remove the engine from the vehicle.
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