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Home >> Lincoln >> 2015 >> MKT Base, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine - 3.5L GTDI) >> Removal >> Engine

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

WARNING: This page is about a different variant/trim than selected.
Special Tool(s)

GFD91562Courtesy of FORD MOTOR COMPANY
 2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
GFD91563Courtesy of FORD MOTOR COMPANY
 Adjustable Grip Arm, 1735A 014-00001 or equivalent
GFD91564Courtesy of FORD MOTOR COMPANY
 Disconnect Tool, Transmission Cooler Line 307-569
GFD91565Courtesy of FORD MOTOR COMPANY
 Eye, Engine Lift 303-1245
GFD91566Courtesy of FORD MOTOR COMPANY
 Powertrain Lift 300-OTC1585AE or equivalent
GFD91567Courtesy 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.

  1. 1.

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

  1. 2.

    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.

GFD91583Courtesy of FORD MOTOR COMPANY

  1. 3.

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

  1. 4.

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

  1. 5.

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

  1. 6.

    Remove the 4 retainers and the underbody shield.
GFD91851Courtesy of FORD MOTOR COMPANY

  1. 7.

    Remove the 3 pin-type retainers, 7 bolts and the front valance.
GFD91944Courtesy of FORD MOTOR COMPANY

  1. 8.

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

  1. 9.

    Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector.
    • Detach the HO2S connector retainer from the bracket.
GFD91850Courtesy of FORD MOTOR COMPANY

  1. 10.

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

  1. 11.

    Detach the 2 brake booster vacuum hose retainers from the strut tower brace.
GFD91833Courtesy of FORD MOTOR COMPANY

  1. 12.

    Remove the 4 nuts (2 shown) and the strut tower brace.
GFD91945Courtesy of FORD MOTOR COMPANY

  1. 13.

    Disconnect the engine harness electrical connector.
GFD91946Courtesy of FORD MOTOR COMPANY

  1. 14.

    Disconnect the PCM electrical connector.
GFD91947Courtesy of FORD MOTOR COMPANY

  1. 15.

    Remove the engine wiring harness retainer from the bulkhead.

    1. 1.

      Push the tab in.

    1. 2.

      Slide the wiring harness up and out of the bulkhead.
GFD91948Courtesy of FORD MOTOR COMPANY

  1. 16.

    Remove the nut and disconnect the A/C tube.
    • Discard the O-ring seal and gasket seal.
GFD91949Courtesy of FORD MOTOR COMPANY

  1. 17.

    Remove the nut and the A/C tube.
    • Discard the O-ring seal and gasket seal.
GFD91950Courtesy of FORD MOTOR COMPANY

  1. 18.

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

  1. 19.

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

  1. 20.

    Disconnect the Turbocharger Boost Pressure (TCBP) /Charge Air Cooler Temperature (CACT) sensor electrical connector.
GFD91951Courtesy of FORD MOTOR COMPANY

  1. 21.

    Loosen the 2 clamps and remove the CAC outlet pipe.
GFD91952Courtesy of FORD MOTOR COMPANY

  1. 22.

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

  1. 23.

    Remove the bolt and the ground wire.
GFD91953Courtesy of FORD MOTOR COMPANY

  1. 24.

    Disconnect the engine wiring harness electrical connector.
GFD91954Courtesy of FORD MOTOR COMPANY

  1. 25.

    Remove the nut and disconnect the power feed wire from the positive battery terminal.
    • Disconnect the electrical connector.
GFD91568Courtesy of FORD MOTOR COMPANY

  1. 26.

    Disconnect the brake booster vacuum hose quick connect coupling from the intake manifold. For additional information, refer to Fuel System General Information .
GFD91955Courtesy of FORD MOTOR COMPANY

  1. 27.

    Disconnect the transaxle control cable from the control lever.
GFD91956Courtesy of FORD MOTOR COMPANY

  1. 28.

    Disconnect the transaxle control cable from the shift cable bracket.
    • Detach the wiring harness pin-type retainer.
GFD91957Courtesy of FORD MOTOR COMPANY

  1. 29.

    Loosen the 2 clamps and remove the RH CAC tube.
GFD91958Courtesy of FORD MOTOR COMPANY

  1. 30.

    Disconnect the 2 heater hoses from the intake manifold.
GFD91814Courtesy of FORD MOTOR COMPANY

  1. 31.

    Remove the bolt and ground wire from the engine front cover.
GFD91817Courtesy of FORD MOTOR COMPANY

  1. 32.

    Disconnect the upper radiator hose from the intake manifold coolant tube.
GFD91818Courtesy of FORD MOTOR COMPANY

  1. 33.

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

  1. 34.

    Disconnect the Evaporative Emission (EVAP) tube quick connect coupling. For additional information, refer to Fuel System General Information .
GFD91835Courtesy of FORD MOTOR COMPANY

  1. 35.

    Disconnect the EVAP valve electrical connector and detach the valve from the intake manifold.
GFD91959Courtesy of FORD MOTOR COMPANY

  1. 36.

    Disconnect the quick connect coupling from the intake manifold and remove the EVAP tube assembly. For additional information, refer to Fuel System General Information .
GFD91804Courtesy of FORD MOTOR COMPANY

  1. 37.

    Disconnect the fuel supply tube from the high pressure Fuel Pump (FP) tube. For additional information, refer to Fuel System General Information .
GFD91960Courtesy of FORD MOTOR COMPANY

  1. 38.

    Remove the 2 front suspension height sensors. For additional information, refer to Vehicle Dynamic Suspension .

  1. 39.

    Remove the 3 pin-type retainers and position aside.
GFD91414Courtesy of FORD MOTOR COMPANY

  1. 40.

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

  1. 41.

    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.
GFD91961Courtesy of FORD MOTOR COMPANY

  1. 42.

    NOTE: Index-mark the driveshaft for installation.

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

GFD91962Courtesy of FORD MOTOR COMPANY

  1. 43.

    Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
GFD91855Courtesy of FORD MOTOR COMPANY

  1. 44.

    Remove and discard the engine oil filter.
GFD91963Courtesy of FORD MOTOR COMPANY

  1. 45.

    Remove the A/C tube bracket bolt from the rear of the compressor.
GFD91964Courtesy of FORD MOTOR COMPANY

  1. 46.

    Remove the nut and disconnect the upper A/C tube from the compressor.
    • Discard the O-ring seal and gasket seal.
GFD91965Courtesy of FORD MOTOR COMPANY

  1. 47.

    Loosen the clamp and disconnect the LH CAC tube from the LH turbocharger.
GFD91966Courtesy of FORD MOTOR COMPANY

  1. 48.

    Detach the lower radiator hose retainer from the cooling fan and shroud.
GFD91967Courtesy of FORD MOTOR COMPANY

  1. 49.

    Disconnect the lower radiator hose from the radiator.
GFD91968Courtesy of FORD MOTOR COMPANY

  1. 50.

    If equipped, disconnect the 2 PTU coolant hoses.
GFD91969Courtesy of FORD MOTOR COMPANY

  1. 51.

    Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
GFD91970Courtesy of FORD MOTOR COMPANY

  1. 52.

    Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
GFD91971Courtesy of FORD MOTOR COMPANY

  1. 53.

    Remove the 2 fasteners and the inspection cover.
GFD91972Courtesy of FORD MOTOR COMPANY

  1. 54.

    Remove and discard the 3 torque converter bolts.
GFD91973Courtesy of FORD MOTOR COMPANY

  1. 55.

    Remove the 4 oil pan-to-transaxle bolts.
GFD91974Courtesy of FORD MOTOR COMPANY

  1. 56.

    NOTE: LH shown, RH similar.

    Remove the bolt and the wheel speed sensor.

GFD91591Courtesy of FORD MOTOR COMPANY

  1. 57.

    NOTE: RH shown, LH similar.

    Remove and discard the upper stabilizer link nuts.

GFD91975Courtesy of FORD MOTOR COMPANY

  1. 58.

    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.
GFD91593Courtesy of FORD MOTOR COMPANY

  1. 59.

    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.

GFD91594Courtesy of FORD MOTOR COMPANY

  1. 60.

    NOTE: LH shown, RH similar.

    Remove the LH and RH halfshaft nuts.

    • Do not discard at this time.
GFD91595Courtesy of FORD MOTOR COMPANY

  1. 61.

    NOTE: LH shown, RH similar.

    Separate the LH and RH halfshaft from the wheel hubs.

GFD91596Courtesy of FORD MOTOR COMPANY

  1. 62.

    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.
GFD91597Courtesy of FORD MOTOR COMPANY

  1. 63.

    Install the Adjustable Grip Arm from the powertrain lift table to the LH engine-to-transmission bolt hole.
GFD91598Courtesy of FORD MOTOR COMPANY

  1. 64.

    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. 65.

    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.
GFD91599Courtesy of FORD MOTOR COMPANY

  1. 66.

    Remove the 3 nuts and the bolt from the transaxle support insulator bracket-to-transaxle.
GFD91976Courtesy of FORD MOTOR COMPANY

  1. 67.

    Remove the 4 engine mount nuts.
GFD91977Courtesy of FORD MOTOR COMPANY

  1. 68.

    Remove the 3 bolts and the engine mount.
GFD91978Courtesy of FORD MOTOR COMPANY

  1. 69.

    NOTE: RH shown, LH similar.

    Remove the subframe bracket-to-body bolts.

GFD91979Courtesy of FORD MOTOR COMPANY

  1. 70.

    NOTE: RH shown, LH similar.

    Remove the rear subframe bolts and the subframe brackets.

GFD91980Courtesy of FORD MOTOR COMPANY

  1. 71.

    NOTE: RH shown, LH similar.

    Remove the front subframe bolts.

GFD91981Courtesy of FORD MOTOR COMPANY

  1. 72.

    Lower the subframe and powertrain assembly from the vehicle.

  1. 73.

    Remove the engine cover mounting stud from the LH valve cover stud bolt.
GFD91982Courtesy of FORD MOTOR COMPANY

  1. 74.

    Detach the 4 wiring harness retainer from the valve cover stud bolt.
GFD91983Courtesy of FORD MOTOR COMPANY

  1. 75.

    Remove the nut and the oil supply tube bracket from the LH valve cover stud bolt.
GFD91984Courtesy of FORD MOTOR COMPANY

  1. 76.

    Remove the 3 bolts and the LH exhaust manifold heat shield.
GFD91985Courtesy of FORD MOTOR COMPANY

  1. 77.

    Install the Engine Lift Eye on the LH cylinder head.
GFD91986Courtesy of FORD MOTOR COMPANY

  1. 78.

    Disconnect the 2 quick connect couplings and remove the crankcase vent tube. For additional information, refer to Fuel System General Information .
GFD91987Courtesy of FORD MOTOR COMPANY

  1. 79.

    Install the Heavy Duty Floor Crane and Spreader Bar.
GFD91988Courtesy of FORD MOTOR COMPANY

  1. 80.

    Install a ratchet strap from the RH knuckle to the subframe to keep the RH halfshaft from coming out of the PTU or transmission.

  1. 81.

    Remove the starter motor solenoid cover.
GFD91989Courtesy of FORD MOTOR COMPANY

  1. 82.

    Remove the 2 nuts and the starter motor wiring terminals.
GFD91990Courtesy of FORD MOTOR COMPANY

  1. 83.

    Disconnect the wiring harness retainer from the starter motor stud bolt.
GFD91991Courtesy of FORD MOTOR COMPANY

  1. 84.

    Remove the bolt, stud bolt and the starter.
GFD91992Courtesy of FORD MOTOR COMPANY

  1. 85.

    Remove the 3 bolts and the RH turbocharger lower bracket.
GFD91993Courtesy of FORD MOTOR COMPANY

  1. 86.

    Remove the 3 bolts and the PTU support bracket.
GFD91994Courtesy of FORD MOTOR COMPANY

  1. 87.

    Remove the bolt and the ground wire from the RH cylinder head.
GFD91995Courtesy of FORD MOTOR COMPANY

  1. 88.

    Disconnect the A/C electrical connector and detach the wiring harness retainer.
GFD91996Courtesy of FORD MOTOR COMPANY

  1. 89.

    Remove the nut and disconnect the generator B+ cable.
GFD91997Courtesy of FORD MOTOR COMPANY

  1. 90.

    Disconnect the generator electrical connector.
GFD91998Courtesy of FORD MOTOR COMPANY

  1. 91.

    Disconnect the transaxle control electrical connector.
GFD91999Courtesy of FORD MOTOR COMPANY

  1. 92.

    Detach the transaxle control wire harness retainer from the transaxle stud bolt.
GFD92000Courtesy of FORD MOTOR COMPANY

  1. 93.

    Remove the Adjustable Grip Arm.
GFD91623Courtesy of FORD MOTOR COMPANY

  1. 94.

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

  1. 95.

    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.

GFD91624Courtesy of FORD MOTOR COMPANY

  1. 96.

    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.
GFD91988Courtesy of FORD MOTOR COMPANY

  1. 97.

    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.

GFD91624Courtesy of FORD MOTOR COMPANY

  1. 98.

    Remove the 2 intermediate shaft bracket nuts and the 2 studs.
GFD92001Courtesy of FORD MOTOR COMPANY

  1. 99.

    Remove the 2 bolts and the RH halfshaft support bracket.
GFD92002Courtesy of FORD MOTOR COMPANY

  1. 100.

    Remove the 2 LH bottom transaxle-to-engine bolts.
GFD92003Courtesy of FORD MOTOR COMPANY

  1. 101.

    Remove the LH transaxle-to-engine bolt.
GFD92004Courtesy of FORD MOTOR COMPANY

  1. 102.

    Remove the 3 transaxle-to-engine bolts.
    • Separate the transaxle from the engine.
GFD92005Courtesy of FORD MOTOR COMPANY

  1. 103.

    Using the Floor Crane and Spreader Bar, remove the engine from the transaxle.
GFD91988Courtesy of FORD MOTOR COMPANY
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