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Engine - 3.8L: Removal: Engine: Removal

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.
  1. Remove the cowl. Refer to PANEL - COWL TOP VENT .
  2. Recover the air conditioning system. Refer to REFRIGERANT SYSTEM RECOVERY .
  3. Disconnect the battery ground cable.
  4. Drain the cooling system. Refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  5. Relieve the fuel pressure. Refer to FUEL SYSTEM PRESSURE RELEASE .
  6. Remove the engine air cleaner and engine air cleaner outlet tube.
  7. Disconnect the accelerator cable end and the speed control actuator cable end.
    Fig 1: Disconnecting Accelerator Cable End And Speed Control Actuator Cable End
    G03425051Courtesy of FORD MOTOR CO.
  8. Position the accelerator cable bracket aside.
    • Remove the bolt.
    • Remove the stud bolt.
      Fig 2: Removing Stud Bolt
      G03425052Courtesy of FORD MOTOR CO.
  9. Disconnect the heater hose.
    Fig 3: Disconnecting Heater Hose
    G03425053Courtesy of FORD MOTOR CO.
  10. Disconnect the upper radiator hose.
    Fig 4: Disconnecting Upper Radiator Hose
    G03425054Courtesy of FORD MOTOR CO.
  11. Position the heater hose aside.
    • Remove the nut.
      Fig 5: Positioning Heater Hose Aside
      G03425055Courtesy of FORD MOTOR CO.
  12. Disconnect the main engine wiring harness 42-pin connector.
    • Loosen the bolt.
      Fig 6: Disconnecting Main Engine Wiring Harness 42-Pin Connector
      G03425056Courtesy of FORD MOTOR CO.
  13. Disconnect the shift cable.
    Fig 7: Disconnecting Shift Cable
    G03425057Courtesy of FORD MOTOR CO.
  14. Disconnect the cable from the bracket, then position the shift cable aside.
    Fig 8: Disconnecting Cable From Bracket
    G03425058Courtesy of FORD MOTOR CO.
  15. Disconnect the EVAP emission return tube and the brake booster vacuum hose.
    Fig 9: Disconnecting EVAP Emission Return Tube
    G03425059Courtesy of FORD MOTOR CO.
  16. Disconnect the EVAP canister purge valve.
    • Disconnect the connector.
    • Disconnect the vacuum tube.
      Fig 10: Disconnecting EVAP Canister Purge Valve
      G03425060Courtesy of FORD MOTOR CO.
  17. Remove the wire harness pin-type retainer.
    Fig 11: Removing Wire Harness Pin-Type Retainer
    G03425061Courtesy of FORD MOTOR CO.
  18. Disconnect the powertrain control module (PCM).
    • Loosen the bolt.
      Fig 12: Disconnecting Powertrain Control Module (PCM)
      G03425062Courtesy of FORD MOTOR CO.
  19. Disconnect the main engine wire harness ground.
    • Remove the bolt.
      Fig 13: Disconnecting Main Engine Wire Harness Ground
      G03425063Courtesy of FORD MOTOR CO.
  20. Disconnect the power steering hose.
    • Reposition the clamp.
      Fig 14: Disconnecting Power Steering Hose
      G03425064Courtesy of FORD MOTOR CO.
  21. Disconnect the degas bottle hose.
    • Reposition the clamp.
      Fig 15: Disconnecting Degas Bottle Hose
      G03425065Courtesy of FORD MOTOR CO.
  22. Disconnect the fuel line retaining clip.
    Fig 16: Disconnecting fuel line retaining clip
    G03425066Courtesy of FORD MOTOR CO.
  23. Disconnect the generator. Refer to GENERATOR .
  24. Position the harness aside.
    Fig 17: Identifying Position Harness Aside
    G03425067Courtesy of FORD MOTOR CO.
  25. Disconnect the fuel lines. Refer to FUEL LINE CONNECTORS .
  26. Disconnect the ground cable.
    Fig 18: Disconnecting Ground Cable
    G03425068Courtesy of FORD MOTOR CO.
  27. Disconnect the heater hose.
    • Reposition the clamp.
      Fig 19: Disconnecting Heater Hose
      G03425069Courtesy of FORD MOTOR CO.
  28. Disconnect the vacuum hose.
    Fig 20: Disconnecting Vacuum Hose
    G03425070Courtesy of FORD MOTOR CO.
  29. Disconnect the positive cable.
    • Remove the nut.
      Fig 21: Disconnecting Positive Cable
      G03425071Courtesy of FORD MOTOR CO.
  30. Remove the sight shield.
    • Remove the pin-type retainers.
      Fig 22: Removing Pin-Type Retainers
      G03425072Courtesy of FORD MOTOR CO.
  31. Disconnect the ground connector.
    • Remove the bolt.
      Fig 23: Disconnecting Ground Connector
      G03425073Courtesy of FORD MOTOR CO.
  32. Remove the strap.
    Fig 24: Removing Strap
    G03425074Courtesy of FORD MOTOR CO.
  33. Position the A/C suction/discharge manifold aside.
    • Remove the bolt.
      Fig 25: Positioning A/C Suction/Discharge Manifold Aside
      G03425075Courtesy of FORD MOTOR CO.
  34. Disconnect the power steering cooler hose.
    • Reposition the clamp.
      Fig 26: Disconnecting Power Steering Cooler Hose
      G03425076Courtesy of FORD MOTOR CO.
  35. Disconnect the power steering cooler hose.
    • Reposition the clamp.
      Fig 27: Disconnecting Power Steering Cooler Hose
      G03425077Courtesy of FORD MOTOR CO.
  36. Remove the hose.
    Fig 28: Removing Hose
    G03425078Courtesy of FORD MOTOR CO.
  37. Remove the hose.
    • Remove the pin-type retainer.
      Fig 29: Removing Pin-Type Retainer
      G03425079Courtesy of FORD MOTOR CO.
  38. Disconnect the transmission oil cooler tubes.
    • Remove the clips.
    • Disconnect the oil cooler tubes.
      Fig 30: Disconnecting Oil Cooler Tubes
      G03425080Courtesy of FORD MOTOR CO.
  39. Reposition the dust boot upward.
    Fig 31: Repositioning Dust Boot Upward
    G03425081Courtesy of FORD MOTOR CO.
  40. Disconnect the steering column.
    • Remove the bolt.
    • Slide the joint upward.
      Fig 32: Disconnecting Steering Column
      G03425082Courtesy of FORD MOTOR CO.
  41. Remove the dual converter Y-pipe assembly.
  42. Disconnect the lower radiator hose.
    • Reposition the clamp.
      Fig 33: Disconnecting Lower Radiator Hose
      G03425083Courtesy of FORD MOTOR CO.
  43. Remove the wheels. Refer to WHEELS & TIRES .
  44. Remove the bolts, then position the brake calipers aside.
    Fig 34: Removing Caliper Bolts
    G03425084Courtesy of FORD MOTOR CO.
  45. Remove the wiring harness retainer.
    Fig 35: Removing Wiring Harness Retainer
    G03425085Courtesy of FORD MOTOR CO.
  46. Disconnect the ABS electrical connector.
    Fig 36: Disconnecting ABS Electrical Connector
    G03425086Courtesy of FORD MOTOR CO.
  47. Disconnect the RH and LH front stabilizer links.
    • Remove the nut.
      Fig 37: Disconnecting RH And LH Front Stabilizer Links
      G03425087Courtesy of FORD MOTOR CO.
  48. Remove the RH and LH strut bolts.
    Fig 38: Removing RH And LH Strut Bolts
    G03425088Courtesy of FORD MOTOR CO.
  49. Position the special tool under the subframe assembly.
    Fig 39: Positioning Special Tool Under Subframe Assembly
    G03425089Courtesy of FORD MOTOR CO.
  50. Remove the four bolts.
    Fig 40: Removing Bolts
    G03425090Courtesy of FORD MOTOR CO.
  51. Lower the engine, transmission and subframe assembly.
  52. Remove the starter motor. Refer to STARTER MOTOR .
  53. Remove the inspection cover.
    • Remove the bolt.
    • Remove the cover.
      Fig 41: Removing Starter Motor
      G03425091Courtesy of FORD MOTOR CO.
  54. Remove the four torque converter nuts.
    Fig 42: Removing Four Torque Converter Nuts
    G03425092Courtesy of FORD MOTOR CO.
  55. Remove the electrical connector.
    Fig 43: Removing Electrical Connector
    G03425093Courtesy of FORD MOTOR CO.
  56. Remove the harness pin-type retainer.
    Fig 44: Removing Harness Pin-Type Retainer
    G03425094Courtesy of FORD MOTOR CO.
  57. Disconnect the transaxle electrical connectors.
    Fig 45: Disconnecting Transaxle Electrical Connectors
    G03425095Courtesy of FORD MOTOR CO.
  58. Remove the pin-type harness retainer.
    Fig 46: Removing Pin-Type Harness Retainer
    G03425096Courtesy of FORD MOTOR CO.
  59. Disconnect the electrical connectors.
    Fig 47: Disconnecting Electrical Connectors
    G03425097Courtesy of FORD MOTOR CO.
  60. Remove the electrical connector.
    Fig 48: Removing Electrical Connector
    G03425098Courtesy of FORD MOTOR CO.
  61. Disconnect the power steering pressure hose.
    Fig 49: Disconnecting Power Steering Pressure Hose
    G03425099Courtesy of FORD MOTOR CO.
  62. Remove the hose retainer.
    Fig 50: Removing Hose Retainer
    G03425100Courtesy of FORD MOTOR CO.
  63. Remove the transmission oil level indicator and tube.
    • Remove the bolt.
      Fig 51: Removing Transmission Oil Level Indicator And Tube
      G03425101Courtesy of FORD MOTOR CO.
  64. Install the special tools.
    Fig 52: Installing Special Tools
    G03425102Courtesy of FORD MOTOR CO.
  65. Install the engine lifting equipment.
    Fig 53: Installing Engine Lifting Equipment
    G03425103Courtesy of FORD MOTOR CO.
  66. Remove the six bellhousing bolts.
    Fig 54: Removing Bellhousing Bolts
    G03425104Courtesy of FORD MOTOR CO.
  67. Remove the LH engine mount bolts.
    Fig 55: Removing LH Engine Mount Bolts
    G03425105Courtesy of FORD MOTOR CO.
  68. Remove the RH engine mount nut.
    Fig 56: Removing Rh Engine Mount Nut
    G03425106Courtesy of FORD MOTOR CO.
  69. Remove the bolts.
    Fig 57: Removing Bolts
    G03425107Courtesy of FORD MOTOR CO.
  70. Separate and lift the engine from the subframe and transmission assembly.
  71. Remove the flywheel.
    • Remove the bolts.
      Fig 58: Removing Flywheel
      G03425108Courtesy of FORD MOTOR CO.
  72. Mount the engine on the engine stand.
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