Engine 3.5L GTDI: Removal: Engine

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING

Special Tool(s)

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

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

NOTE: Whenever the turbocharger air intake system components are removed, always cover open ports from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting .
NOTE: Use a steering wheel holding device (such as Hunter ® 28-75-1 or equivalent).

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

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Release the fuel system pressure. For additional information, refer to Fuel System General Information .
Recover the A/C system. For additional information, refer to Climate Control System General Information .
Remove the front wheels and tires. For additional information, refer to Wheels and Tires .
Remove the 4 retainers and the underbody shield.

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Remove the 3 pin-type retainers, 7 bolts and the front valance.

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Drain the cooling system. For additional information, refer to Engine Cooling .
Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector.
- Detach the HO2S connector retainer from the bracket.
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Remove the cowl panel grille. For additional information, refer to Front End Body Panels .
Detach the 2 brake booster vacuum hose retainers from the strut tower brace.

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Remove the 4 nuts (2 shown) and the strut tower brace.

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Disconnect the engine harness electrical connector.

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Disconnect the PCM electrical connector.

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Remove the engine wiring harness retainer from the bulkhead.
1. Push the tab in.
2. Slide the wiring harness up and out of the bulkhead.
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Remove the nut and disconnect the A/C tube.
- Discard the O-ring seal and gasket seal.
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Remove the nut and the A/C tube.
- Discard the O-ring seal and gasket seal.
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Remove the degas bottle. For additional information, refer to Engine Cooling .
Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering .
Disconnect the Turbocharger Boost Pressure (TCBP) /Charge Air Cooler Temperature (CACT) sensor electrical connector.

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Loosen the 2 clamps and remove the CAC outlet pipe.

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Remove the battery tray. For additional information, refer to Battery, Mounting and Cables .
Remove the bolt and the ground wire.

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Disconnect the engine wiring harness electrical connector.

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Remove the nut and disconnect the power feed wire from the positive battery terminal.
- Disconnect the electrical connector.
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Disconnect the brake booster vacuum hose quick connect coupling from the intake manifold. For additional information, refer to Fuel System General Information .

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Disconnect the transaxle control cable from the control lever.

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Disconnect the transaxle control cable from the shift cable bracket.
- Detach the wiring harness pin-type retainer.
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Loosen the 2 clamps and remove the RH CAC tube.

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Disconnect the 2 heater hoses from the intake manifold.

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Remove the bolt and ground wire from the engine front cover.

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Disconnect the upper radiator hose from the intake manifold coolant tube.

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If equipped, detach the engine block heater harness from the radiator support wiring harness.
Disconnect the Evaporative Emission (EVAP) tube quick connect coupling. For additional information, refer to Fuel System General Information .

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Disconnect the EVAP valve electrical connector and detach the valve from the intake manifold.

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Disconnect the quick connect coupling from the intake manifold and remove the EVAP tube assembly. For additional information, refer to Fuel System General Information .

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Disconnect the fuel supply tube from the high pressure Fuel Pump (FP) tube. For additional information, refer to Fuel System General Information .

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Remove the 2 front suspension height sensors. For additional information, refer to Vehicle Dynamic Suspension .
Remove the 3 pin-type retainers and position aside.

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Remove the LH and RH catalytic converters. For additional information, refer to Exhaust System .
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 .

Remove the bolt and disconnect the steering column shaft from the steering gear.
- Discard the bolt.
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NOTE: Index-mark the driveshaft for installation.

Remove and discard the 4 bolts and position aside the driveshaft.

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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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Remove and discard the engine oil filter.

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Remove the A/C tube bracket bolt from the rear of the compressor.

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Remove the nut and disconnect the upper A/C tube from the compressor.
- Discard the O-ring seal and gasket seal.
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Loosen the clamp and disconnect the LH CAC tube from the LH turbocharger.

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Detach the lower radiator hose retainer from the cooling fan and shroud.

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Disconnect the lower radiator hose from the radiator.

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If equipped, disconnect the 2 PTU coolant hoses.

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

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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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Remove the 2 fasteners and the inspection cover.

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Remove and discard the 3 torque converter bolts.

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Remove the 4 oil pan-to-transaxle bolts.

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NOTE: LH shown, RH similar.

Remove the bolt and the wheel speed sensor.

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NOTE: RH shown, LH similar.

Remove and discard the upper stabilizer link nuts.

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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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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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NOTE: LH shown, RH similar.

Remove the LH and RH halfshaft nuts.
- Do not discard at this time.
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NOTE: LH shown, RH similar.

Separate the LH and RH halfshaft from the wheel hubs.

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

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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.
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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Remove the 3 nuts and the bolt from the transaxle support insulator bracket-to-transaxle.

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Remove the 4 engine mount nuts.

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Remove the 3 bolts and the engine mount.

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NOTE: RH shown, LH similar.

Remove the subframe bracket-to-body bolts.

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NOTE: RH shown, LH similar.

Remove the rear subframe bolts and the subframe brackets.

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NOTE: RH shown, LH similar.

Remove the front subframe bolts.

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Lower the subframe and powertrain assembly from the vehicle.
Disconnect the crankcase vent tube sensor electrical connector and the wire harness retainer.

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Disconnect the 2 quick connect couplings and remove the crankcase vent tube. For additional information, refer to Fuel System General Information .

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Remove the engine cover mounting stud from the LH valve cover stud bolt.
- Detach the wire harness retainers from the valve cover stud bolts.
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Remove the nut and the oil supply tube bracket from the LH valve cover stud bolt.

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Remove the 3 bolts and the LH exhaust manifold heat shield.

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Install the Engine Lift Eye on the LH cylinder head.

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Install the Heavy Duty Floor Crane and Spreader Bar.

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Install a ratchet strap from the RH knuckle to the subframe to keep the RH halfshaft from coming out of the PTU or transmission.
Remove the starter motor solenoid cover.

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Remove the 2 nuts and the starter motor wiring terminals.

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

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Remove the bolt, stud bolt and the starter.

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Remove the 5 bolts and the PTU support bracket.

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

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Detach the CMS electrical connector.

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Disconnect the A/C compressor and the pressure relief valve electrical connectors.
- Detach the wiring harness retainers.
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Remove the nut and disconnect the generator B+ cable.

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Disconnect the generator electrical connector.

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Disconnect the transaxle control electrical connector.

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

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Remove the Adjustable Grip Arm.

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Remove the ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe.
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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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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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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Remove the 2 intermediate shaft bracket nuts and the 2 studs.

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Remove the 2 bolts and the RH halfshaft support bracket.

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Remove the 2 LH bottom transaxle-to-engine bolts.

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Remove the LH transaxle-to-engine bolt.

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Remove the 3 transaxle-to-engine bolts.
- Separate the transaxle from the engine.
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Using the Floor Crane and Spreader Bar, remove the engine from the transaxle.

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