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Section 1 (Engine Mechanical - 3.5L-GTDI): Removal: Engine

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOLS

G07998927
 2, 200# Floor Crane, Fold Away
300-OTC1819E or equivalent
G07998928
 Adjustable Grip Arm, 1735A
014-00001 or equivalent
G07998929
 Disconnect Tool, Transmission Cooler Line
307-569
G07998930
 Eye, Engine Lift
303-1245
G07998931
 Halfshaft Remover
205-832
G07998932
 Powertrain Lift
300-OTC1585AE or equivalent
G07998933
 Remover, Front Wheel Hub
205-D070 (D93P-1175-B) or equivalent
G07998934
 Slide Hammer
100-001 (T50T-100-A)
G07998935
 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 turbocharger air intake system components are removed, always cover open ports to protect 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.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
    2. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
    Fig 1: Holding Steering Wheel In Straight-Ahead Position Using Suitable Holding Device
    G07998936Courtesy of FORD MOTOR CO.
  2. Using a steering wheel holding device, hold the steering wheel in the straight-ahead position.
  3. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
  4. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
  5. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector.
    • Detach the HO2S connector retainer from the bracket.
      Fig 2: Locating LH Heated Oxygen Sensor (HO2S) Electrical Connector
      G07998937Courtesy of FORD MOTOR CO.
  6. Remove the 4 retainers and the underbody shield.
    Fig 3: Locating Retainers And Underbody Shield
    G07998938Courtesy of FORD MOTOR CO.
  7. Remove the 7 bolts, 3 pin-type retainers and the front splash shield.
    Fig 4: Locating Bolts And Pin-Type Retainers Of Front Splash Shield
    G07998939Courtesy of FORD MOTOR CO.
  8. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  9. Remove the front wheels and tires. For additional information, refer to WHEELS AND TIRES .
  10. Remove the 2 lower scrivets from the rubber shield and position the shield aside.
    Fig 5: Locating Engine Splash Shield RH Lower Pin-Type Retainers
    G07998940Courtesy of FORD MOTOR CO.
    11. NOTE: Apply the brake to keep the halfshafts from rotating.
    NOTE: RH shown in illustration, LH similar.
  11. Remove the RH and LH halfshaft nuts.
    • Do not discard at this time.
      Fig 6: Locating Halfshaft Nuts
      G07998941Courtesy of FORD MOTOR CO.
    12. NOTE: RH shown in illustration, LH similar.
    Fig 7: Removing RH And LH Halfshaft From Wheel Hub Using Front Wheel Hub Remover
    G07998942Courtesy of FORD MOTOR CO.
  12. Using the Front Wheel Hub Remover, separate the RH and LH halfshaft from the wheel hubs.
  13. Remove the bolt from the RH brake hose bracket.
    Fig 8: Locating Brake Hose Bracket Bolt
    G07998943Courtesy of FORD MOTOR CO.
  14. Remove the LH and RH catalytic converters. For additional information, refer to EXHAUST SYSTEM .
  15. Remove the 2 bolts and the rear roll restrictor bracket.
    Fig 9: Locating Rear Roll Restrictor Bracket And Bolts
    G07998944Courtesy of FORD MOTOR CO.
  16. Remove the 2 front engine roll restrictor-to-transaxle bolts.
    Fig 10: Locating Front Engine Roll Restrictor-To-Transaxle Bolts
    G07998945Courtesy of FORD MOTOR CO.
    17. NOTE: RH shown in illustration, LH similar.
    Fig 11: Locating Upper Stabilizer Link Nuts
    G07998946Courtesy of FORD MOTOR CO.
  17. Remove and discard the upper stabilizer link nuts.
    18. 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.
  18. Remove and discard the tie-rod end nuts.
    • Separate the tie-rod ends from the wheel knuckles.
      Fig 12: Locating Tie-Rod End And Nut
      G07998947Courtesy of FORD MOTOR CO.
    19. 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.
  19. Remove and discard the lower ball joint-to-wheel knuckle nuts.
    • Separate the lower ball joints from the wheel knuckles.
      Fig 13: Locating Ball Joint Nut
      G07998948Courtesy of FORD MOTOR CO.
    20. 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 .
  20. Remove the bolt and disconnect the steering column shaft from the steering gear.
    • Discard the bolt.
      Fig 14: Locating Steering Column Intermediate Shaft Bolt
      G07998949Courtesy of FORD MOTOR CO.
  21. Remove the bolt and disconnect the 2 Electronic Power Assist Steering (EPAS) electrical connectors (1 shown in illustration) and the wiring retainer (not shown).
    Fig 15: Locating Bolt And Electronic Power Assist Steering Electrical Connectors
    G07998950Courtesy of FORD MOTOR CO.
  22. Using a wax pencil, mark the relationship of the front subframe to the underbody at the mounting locations.
  23. Position the Powertrain Lift under the subframe assembly.
    Fig 16: Identifying Powertrain Lift Under Subframe
    G07998951Courtesy of FORD MOTOR CO.
    24. NOTE: RH shown in illustration, LH similar.
    Fig 17: Locating Subframe Bracket-To-Body Bolts
    G07998952Courtesy of FORD MOTOR CO.
  24. Remove the subframe bracket-to-body bolts.
    25. NOTE: RH shown in illustration, LH similar.
    Fig 18: Locating Rear Subframe Bolts And Subframe Bracket
    G07998953Courtesy of FORD MOTOR CO.
  25. Remove the rear subframe bolts and the subframe brackets.
    26. NOTE: RH shown in illustration, LH similar.
    Fig 19: Locating Front Subframe Bolts
    G07998954Courtesy of FORD MOTOR CO.
  26. Remove the front subframe bolts.
  27. Lower the subframe assembly from the vehicle.
  28. Pull the RH wheel knuckle outboard and rotate it toward the rear of the vehicle.
    • Secure the RH wheel knuckle assembly.
      Fig 20: Pulling RH Wheel Knuckle Outboard
      G07998955Courtesy of FORD MOTOR CO.
  29. Remove the 2 halfshaft bracket bolts.
    Fig 21: Locating Halfshaft Bracket Bolts
    G07998956Courtesy of FORD MOTOR CO.
  30. Remove the intermediate and halfshaft assembly.
    • Inspect the intermediate shaft for pitting or damage in the seal contact area. Replace if necessary.
    31. 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 22: Removing Halfshaft From Transmission Using Slide Hammer And Halfshaft Remover
    G07998957Courtesy of FORD MOTOR CO.
  31. Using the Slide Hammer and Halfshaft Remover, remove the halfshaft from the transmission.
  32. Remove and discard the circlip from the stub shaft.
    Fig 23: Identifying Circlip Over Stub Shaft
    G07998958Courtesy of FORD MOTOR CO.
  33. Remove the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
  34. Detach the 2 brake booster vacuum hose retainers (1 shown in illustration) from the strut tower brace.
    Fig 24: Locating Brake Booster Vacuum Hose Retainer And Strut Tower Brace
    G07998959Courtesy of FORD MOTOR CO.
  35. Remove the 4 nuts (2 shown in illustration) and the strut tower brace.
    Fig 25: Locating Strut Tower Brace And Nuts
    G07998960Courtesy of FORD MOTOR CO.
  36. Disconnect the PCM and engine harness electrical connectors.
    • Detach the wiring harness retainer.
      Fig 26: Locating PCM And Engine Harness Electrical Connectors
      G07998961Courtesy of FORD MOTOR CO.
  37. Disconnect the 2 PCM electrical connectors.
    Fig 27: Locating PCM Electrical Connectors
    G07998962Courtesy of FORD MOTOR CO.
  38. 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.
      Fig 28: Identifying Bulkhead And Engine Wiring Harness Retainer
      G07998963Courtesy of FORD MOTOR CO.
  39. Remove the nut and disconnect the A/C tube.
    • Discard the O-ring seal and gasket seal.
      Fig 29: Locating A/C Tube And A/C Tube Nut
      G07998964Courtesy of FORD MOTOR CO.
  40. Remove the nut and the A/C tube.
    • Discard the O-ring seal and gasket seal.
      Fig 30: Locating A/C Tube And Nut
      G07998965Courtesy of FORD MOTOR CO.
  41. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
  42. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  43. Remove the noise generator. For additional information, refer to REMOVAL AND INSTALLATION Intake Air System Components - Exploded View .
  44. Disconnect the Turbocharger Boost Pressure (TCBP) /Charge Air Cooler Temperature (CACT) sensor electrical connector.
    Fig 31: Locating Turbocharger Boost Pressure/Charge Air Cooler Temperature Sensor Electrical Connector
    G07998966Courtesy of FORD MOTOR CO.
  45. Loosen the 2 clamps and remove the CAC outlet pipe.
    Fig 32: Locating CAC Outlet Pipe And Clamps
    G07998967Courtesy of FORD MOTOR CO.
  46. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  47. Disconnect the engine wiring harness electrical connector.
    Fig 33: Locating Engine Wiring Harness Electrical Connector
    G07998968Courtesy of FORD MOTOR CO.
  48. Remove the nut and disconnect the ground cable from the negative battery terminal.
    Fig 34: Locating Negative Battery Terminal Ground Cable And Nut
    G07998969Courtesy of FORD MOTOR CO.
  49. Remove the nut and disconnect the power feed wires from the positive battery terminal.
    Fig 35: Locating Positive Battery Terminal Nut
    G07998970Courtesy of FORD MOTOR CO.
  50. Disconnect the brake booster vacuum hose quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 36: Locating Brake Booster Quick Connect Coupling
    G07998971Courtesy of FORD MOTOR CO.
  51. Disconnect the transaxle control cable from the control lever.
    Fig 37: Locating Control Lever Transaxle Control Cable
    G07998972Courtesy of FORD MOTOR CO.
  52. Disconnect the transaxle control cable from the shift cable bracket.
    • Detach the wiring harness pin-type retainer.
      Fig 38: Locating Shift Cable Bracket And Wiring Harness Pin-Type Retainer
      G07998973Courtesy of FORD MOTOR CO.
  53. Loosen the 2 clamps and remove the RH CAC tube.
    Fig 39: Locating RH CAC Tube And Clamps
    G07998974Courtesy of FORD MOTOR CO.
  54. Disconnect the 2 heater hoses from the intake manifold.
    Fig 40: Locating Heater Hoses Clamps
    G07998975Courtesy of FORD MOTOR CO.
  55. Remove the bolt and ground wire from the engine front cover.
    Fig 41: Locating Engine Front Cover Bolt And Ground Wire
    G07998976Courtesy of FORD MOTOR CO.
  56. Disconnect the upper radiator hose from the intake manifold coolant tube.
    Fig 42: Locating Upper Radiator Hose Clamp
    G07998977Courtesy of FORD MOTOR CO.
  57. If equipped, detach the engine block heater harness from the radiator support wiring harness.
  58. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 43: Locating Evaporative Emission Tube Quick Connect Coupling
    G07998978Courtesy of FORD MOTOR CO.
  59. Disconnect the EVAP valve electrical connector and detach the valve from the intake manifold.
    Fig 44: Locating EVAP Valve Electrical Connector And Intake Manifold Valve
    G07998979Courtesy of FORD MOTOR CO.
  60. Disconnect the quick connect coupling from the intake manifold and remove the EVAP tube assembly. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 45: Locating EVAP Tube Assembly And Intake Manifold Quick Connect Coupling
    G07998980Courtesy of FORD MOTOR CO.
  61. Disconnect the fuel supply tube from the High-Pressure Fuel Pump (FP) tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 46: Locating High-Pressure Fuel Pump (FP) Tube
    G07998981Courtesy of FORD MOTOR CO.
    62. NOTE: Index-mark the driveshaft for installation.
    Fig 47: Locating Driveshaft Bolts
    G07998982Courtesy of FORD MOTOR CO.
  62. Remove and discard the 4 bolts and position aside the driveshaft.
  63. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
      Fig 48: Locating Drain Plug Mounting Bolt
      G07998983Courtesy of FORD MOTOR CO.
  64. Remove and discard the engine oil filter.
    Fig 49: Locating Engine Oil Filter
    G07998984Courtesy of FORD MOTOR CO.
  65. Remove the A/C tube bracket bolt from the rear of the compressor.
    Fig 50: Locating A/C Tube Bracket Bolt
    G07998985Courtesy of FORD MOTOR CO.
  66. Remove the nut and disconnect the upper A/C tube from the compressor.
    • Discard the O-ring seal and gasket seal.
      Fig 51: Locating Compressor Upper A/C Tube And Nut
      G07998986Courtesy of FORD MOTOR CO.
  67. Loosen the clamp and disconnect the LH CAC tube from the LH turbocharger.
    Fig 52: Locating LH CAC Tube Clamp
    G07998987Courtesy of FORD MOTOR CO.
  68. Detach the lower radiator hose retainer from the cooling fan and shroud.
    Fig 53: Locating Lower Radiator Hose Retainer
    G07998988Courtesy of FORD MOTOR CO.
  69. Disconnect the lower radiator hose from the radiator.
    Fig 54: Locating Lower Radiator Hose Clamp
    G07998989Courtesy of FORD MOTOR CO.
  70. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
    Fig 55: Locating Secondary Latches
    G07998990Courtesy of FORD MOTOR CO.
  71. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
    Fig 56: Disconnecting Transmission Fluid Cooler Tubes From Transmission Fluid Cooler Thermal Bypass Valve
    G07998991Courtesy of FORD MOTOR CO.
  72. Remove the 2 fasteners and the inspection cover.
    Fig 57: Locating Inspection Cover And Fasteners
    G07998992Courtesy of FORD MOTOR CO.
  73. Remove and discard the 3 torque converter bolts.
    Fig 58: Locating Torque Converter Bolt
    G07998993Courtesy of FORD MOTOR CO.
  74. Remove the 4 oil pan-to-transaxle bolts.
    Fig 59: Locating Oil Pan-To-Transaxle Bolts
    G07998994Courtesy of FORD MOTOR CO.
  75. Remove the 2 LH bottom transaxle-to-engine bolts.
    Fig 60: Locating LH Bottom Transaxle-To-Engine Bolts
    G07998995Courtesy of FORD MOTOR CO.
  76. Remove the 3 bolts and the RH turbocharger lower bracket.
    Fig 61: Locating RH Turbocharger Lower Bracket And Bolts
    G07998996Courtesy of FORD MOTOR CO.
  77. Remove the 2 bolts and the RH halfshaft support bracket.
    Fig 62: Locating RH Halfshaft Support Bracket And Bolts
    G07998997Courtesy of FORD MOTOR CO.
  78. Remove the 3 bolts and the Power Transfer Unit (PTU) support bracket.
    Fig 63: Locating Power Transfer Unit Support Bracket And Bolts
    G07998998Courtesy of FORD MOTOR CO.
  79. Remove the 5 bolts and the PTU.
    Fig 64: Locating PTU Bolts
    G07998999Courtesy of FORD MOTOR CO.
    80. NOTE: Position a block of wood under the transaxle.
    Fig 65: Installing Powertrain Lift And Adjustable Grip Arms
    G07999000Courtesy of FORD MOTOR CO.
  80. Install the Powertrain Lift and Adjustable Grip Arms.
  81. Remove the 3 nuts and the bolt from the transaxle support insulator bracket-to-transaxle.
    Fig 66: Locating Transaxle Support Insulator Bracket Bolts And Nuts
    G07999001Courtesy of FORD MOTOR CO.
  82. Remove the 4 engine mount nuts.
    Fig 67: Locating Engine Mount Nuts
    G07999002Courtesy of FORD MOTOR CO.
  83. Remove the 3 bolts and the engine mount.
    Fig 68: Locating Engine Mount Bolts
    G07999003Courtesy of FORD MOTOR CO.
  84. Lower the engine and transaxle assembly from the vehicle.
  85. Remove the starter motor solenoid cover.
    Fig 69: Locating Starter Motor Solenoid Cover
    G07999004Courtesy of FORD MOTOR CO.
  86. Remove the 2 nuts and the starter motor wiring terminals.
    Fig 70: Locating Starter Motor Wiring Terminals Nuts
    G07999005Courtesy of FORD MOTOR CO.
  87. Disconnect the wiring harness retainer from the starter motor stud bolt.
    Fig 71: Locating Starter Motor Stud Bolt
    G07999006Courtesy of FORD MOTOR CO.
  88. Remove the bolt, stud bolt and the starter.
    Fig 72: Locating Bolt, Studbolt And Starter
    G07999007Courtesy of FORD MOTOR CO.
  89. Remove the engine cover mounting stud from the LH valve cover stud bolt.
    Fig 73: Locating Engine Cover Mounting Stud
    G07999008Courtesy of FORD MOTOR CO.
  90. Detach the wiring harness retainer from the valve cover stud bolt.
    Fig 74: Locating Valve Cover Stud Bolt Wiring Harness Retainer
    G07999009Courtesy of FORD MOTOR CO.
  91. Remove the nut and the oil supply tube bracket from the LH valve cover stud bolt.
    Fig 75: Locating LH Valve Cover Stud Bolt
    G07999010Courtesy of FORD MOTOR CO.
  92. Remove the 3 bolts and the LH exhaust manifold heat shield.
    Fig 76: Locating LH Exhaust Manifold Heat Shield And Bolts
    G07999011Courtesy of FORD MOTOR CO.
  93. Install the Engine Lift Eye on the LH cylinder head.
    Fig 77: Identifying Engine Lift Eye On LH Cylinder Head
    G07999012Courtesy of FORD MOTOR CO.
  94. Disconnect the 2 quick connect couplings and remove the crankcase vent tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 78: Locating Crankcase Vent Tube And Quick Connect Couplings
    G07999013Courtesy of FORD MOTOR CO.
  95. Disconnect the transaxle control electrical connector.
    Fig 79: Locating Transaxle Control Electrical Connector
    G07999014Courtesy of FORD MOTOR CO.
  96. Detach the transaxle control wire harness retainer from the transaxle stud bolt.
    Fig 80: Locating Transaxle Control Wire Harness Retainer
    G07999015Courtesy of FORD MOTOR CO.
  97. Detach the 2 wiring harness retainers from the transaxle stud bolts.
    Fig 81: Locating Transaxle Stud Bolt Wiring Harness Retainers
    G07999016Courtesy of FORD MOTOR CO.
  98. Remove the bolt and the ground wire from the RH cylinder head.
    Fig 82: Locating Ground Wire Bolt
    G07999017Courtesy of FORD MOTOR CO.
  99. Using the Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table.
    Fig 83: Removing Engine And Transaxle From Lift Table
    G07999018Courtesy of FORD MOTOR CO.
  100. Remove the LH transaxle-to-engine bolt.
    Fig 84: Locating LH Engine-To-Transaxle Bolt
    G07999019Courtesy of FORD MOTOR CO.
  101. Remove the 3 transaxle-to-engine bolts.
    • Separate the transaxle from the engine.
      Fig 85: Locating Engine-To-Transaxle Bolts
      G07999020Courtesy of FORD MOTOR CO.
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