Section 12 (Engine Mechanical - 3.5L): Removal: Engine

	2, 200# Floor Crane, Fold Away 300-OTC1819E
	Adjustable Grip Arm, 1735A 014-00001 or equivalent
	Engine Lift Eye 303-1245
	Powertrain Lift 300-OTC1585AE
	Remover, Tie-Rod End 211-105
	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
3. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
4. Remove the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE - 3.5L .
5. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
6. If equipped, remove the 6 screws and the underbody shield.
   Fig 1: Location of Underbody Cover Shield Screws

   Courtesy of FORD MOTOR CO.
7. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable drain pan.
   Fig 2: Location of Power Steering Cooler Tube

   Courtesy of FORD MOTOR CO.
8. Drain the cooling system. For additional information, refer to ENGINE COOLING .
9. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
10. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 3.5L .
11. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
12. Disconnect the 2 engine wiring harness electrical connectors.
    Fig 3: Location of Engine Wiring Harness Electrical Connectors

    Courtesy of FORD MOTOR CO.
13. Detach the 2 wiring harness retainers from the transmission mount and the battery tray bracket.
    Fig 4: Location of Wiring Harness Retainers At Transmission Mount And Battery Tray Bracket

    Courtesy of FORD MOTOR CO.
14. Remove the 2 nuts and the battery cables from the positive battery cable.
    Fig 5: Location of Battery Cables Of Positive Battery Cable With Nuts

    Courtesy of FORD MOTOR CO.
15. Remove the bolt and position aside the ground wire.
    Fig 6: Location of Battery Bolt

    Courtesy of FORD MOTOR CO.
16. Disconnect the vacuum hose and the Evaporative Emission (EVAP) tube from the upper intake manifold.
    Fig 7: Location of Vacuum Hose And Evaporative Emission (EVAP) Tube

    Courtesy of FORD MOTOR CO.
17. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
    Fig 8: Location of Upper Radiator Hose, Lower Radiator Hose And Heater Hoses At Thermostat Housing

    Courtesy of FORD MOTOR CO.
18. Disconnect the transaxle control cable from the control lever.
    Fig 9: Location of Selector Lever Cable End

    Courtesy of FORD MOTOR CO.
19. Remove the 3 nuts and position the transaxle control cable bracket aside.
    Fig 10: Location of Selector Lever Cable Bracket Bolts And Nut

    Courtesy of FORD MOTOR CO.
20. Remove the bolt and position the ground wire aside.
    Fig 11: Location of Ground Wire And Bolt

    Courtesy of FORD MOTOR CO.
21. If equipped, detach the engine block heater harness from the radiator support, power steering hose, A/C tube and the engine wiring harness.
22. Detach the coolant tube retainer clips from the A/C tube.
    Fig 12: Location of Coolant Tube Retainer Clips On A/C Tube

    Courtesy of FORD MOTOR CO.
23. Remove the nut and disconnect the A/C tube from the condenser.
    • Discard the O-ring seal.
      Fig 13: Location of O-Ring Seal

      Courtesy of FORD MOTOR CO.
24. Remove the 2 A/C tube bracket bolts.
    Fig 14: Location of A/C Tube Bracket Bolts

    Courtesy of FORD MOTOR CO.
25. Remove the A/C tube bracket bolt.
    Fig 15: Location of A/C Tube Bracket Bolt

    Courtesy of FORD MOTOR CO.
26. Remove the 2 nuts and disconnect the A/C tubes.
    • Discard the O-ring seal.
      Fig 16: Location of O-Ring seal

      Courtesy of FORD MOTOR CO.
27. Detach the 2 wiring harness retainers.
    Fig 17: Location of Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
28. Disconnect the 2 engine wiring harness electrical connectors.
    Fig 18: Location of Engine Control Wiring Harness Electrical Connectors

    Courtesy of FORD MOTOR CO.
29. Remove the 2 wiring harness retainers from the LH valve cover stud bolts and position the wiring harness aside.
    Fig 19: Location of Wiring Harness Retainers At LH Valve Cover Stud Bolts

    Courtesy of FORD MOTOR CO.
30. Remove the oil level indicator.
    Fig 20: Location of Oil Level Indicator

    Courtesy of FORD MOTOR CO.
31. Disconnect the hose from the power steering reservoir.
    • Detach the pin-type retainer from the engine mount brace.
      Fig 21: Location of Pin-Type Retainer At Engine Mount Brace

      Courtesy of FORD MOTOR CO.
32. Using a small screwdriver, release the retaining clip and detach the power steering reservoir from the cowl.
    Fig 22: Releasing Retaining Clip

    Courtesy of FORD MOTOR CO.
33. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 23: Location of Fuel Supply Tube

    Courtesy of FORD MOTOR CO.
34. Remove the bolt and the ground wire from the engine mount brace.
    Fig 24: Location of Bolt And Ground Wire On Engine Mount Brace

    Courtesy of FORD MOTOR CO.
35. Remove the 3 bolts and the engine mount brace.
    Fig 25: Location of Bolts And Engine Mount Brace

    Courtesy of FORD MOTOR CO.
36. Disconnect the PCM electrical connectors and pin-type retainers.
    Fig 26: Location of PCM Electrical Connectors And Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
37. Remove the Power Steering Pressure (PSP) hose bracket bolt.
    Fig 27: Location of Power Steering Pressure Hose Bracket Bolt

    Courtesy of FORD MOTOR CO.
38. Remove and discard the PSP hose banjo bolt and the 2 seals from the steering gear.
    Fig 28: Location of PSP Hose Banjo Bolt

    Courtesy of FORD MOTOR CO.
NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
Fig 29: Holding Steering Wheel In Straight-Ahead Position Using Suitable Holding Device
Courtesy of FORD MOTOR CO.
39. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
40. Remove the 2 nuts and the steering joint cover.
    Fig 30: Location of Nuts And Steering Joint Cover

    Courtesy of FORD MOTOR CO.
NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can 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 .
NOTE: Index-mark the steering column shaft position to the steering gear for reference during installation.
41. Remove the bolt and disconnect the steering column shaft from the steering gear.
    • Discard the bolt.
      Fig 31: Location of Index Mark, Steering Column Shaft And Mounting Bolt

      Courtesy of FORD MOTOR CO.
42. Remove the 4 screws and position the LH fender splash shield aside.
    Fig 32: Location of Fender Splash Shield Mounting Screws

    Courtesy of FORD MOTOR CO.
43. Remove the 6 pin-type retainers (4 shown in illustration) and the LH splash shield.
    Fig 33: Location of LH Splash Shield And 6 Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
NOTE: The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.
Fig 34: Location of Clips And Steering Gear-To-Dash Seal
Courtesy of FORD MOTOR CO.
44. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
45. Disconnect the transaxle cooler hoses.
    Fig 35: Location of Transaxle Cooler Hoses

    Courtesy of FORD MOTOR CO.
46. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
      Fig 36: Location of Drain Plug Mounting Bolt

      Courtesy of FORD MOTOR CO.
47. Remove and discard the engine oil filter.
48. Remove the 6 nuts and the Y-pipe assembly.
    • Discard the gaskets and nuts.
      Fig 37: Location of Nuts And Y-Pipe Assembly

      Courtesy of FORD MOTOR CO.
49. Remove the 4 oil pan-to-transaxle bolts.
    Fig 38: Location of Oil Pan-To-Transaxle Bolts

    Courtesy of FORD MOTOR CO.
50. Remove the 2 fasteners and the inspection cover.
    Fig 39: Location of Inspection Cover And Fasteners

    Courtesy of FORD MOTOR CO.
51. Remove and discard the 4 torque converter nuts.
    Fig 40: Location of Torque Converter Nut

    Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

NOTE: Index-mark the driveshaft for installation.
Fig 41: Location of Driveshaft Bolts
Courtesy of FORD MOTOR CO.
52. Remove and discard the 4 bolts (3 shown in illustration) and support the driveshaft with a length of mechanic's wire.

    All vehicles 

53. Remove the engine roll restrictor-to-subframe through bolt.
    Fig 42: Location of Engine Roll Restrictor-To-Subframe Bolt

    Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
Fig 43: Location of Cotter Pin And Nut On Tie-Rod Ends
Courtesy of FORD MOTOR CO.
54. Remove the cotter pins and nuts from the tie-rod ends.
NOTE: LH shown in illustration, RH similar.
Fig 44: Separating Tie-Rod Ends From Wheel Knuckles Using Tie-Rod End Remover
Courtesy of FORD MOTOR CO.
55. Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.
NOTE: LH shown in illustration, RH similar.
Fig 45: Location of Stabilizer Bar Link Nut
Courtesy of FORD MOTOR CO.
56. Remove the nuts and separate the stabilizer bar links from the struts.
57. Using a wax pencil, mark the relationship of the front subframe to the underbody at the mounting locations.
58. Position the Powertrain Lift under the subframe assembly.
    Fig 46: Identifying Powertrain Lift Under Subframe

    Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
Fig 47: Location of Front Subframe Nut
Courtesy of FORD MOTOR CO.
59. Remove the 4 subframe bracket-to-body bolts.
NOTE: LH shown in illustration, RH similar.
Fig 48: Location of Rear Subframe Nut And Subframe Bracket
Courtesy of FORD MOTOR CO.
60. Remove the 2 rear subframe nuts and the 2 subframe brackets.
NOTE: LH shown in illustration, RH similar.
Fig 49: Location of Front Subframe Nut
Courtesy of FORD MOTOR CO.
61. Remove the 2 front subframe nuts.
62. Lower the subframe assembly from the vehicle.
63. Remove the 2 RH catalytic converter bracket bolts.
    Fig 50: Location of Catalytic Converter-To-Bracket Bolts

    Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

64. Remove the 2 nuts and remove the RH catalytic converter bracket.
    Fig 51: Location of Catalytic Converter Support Bracket Nuts

    Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

65. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 52: Location of RH Catalyst Monitor Electrical Connector

    Courtesy of FORD MOTOR CO.
66. Remove the 4 nuts and the RH catalytic converter.
    • Discard the gasket.
      Fig 53: Location of RH Catalytic Converter And Nuts

      Courtesy of FORD MOTOR CO.
67. Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket.
    Fig 54: Location of Power Transfer Unit Support Bracket Bolts

    Courtesy of FORD MOTOR CO.
68. Remove the 5 bolts and the PTU.
    Fig 55: Location of Bolts And PTU

    Courtesy of FORD MOTOR CO.

    All vehicles 

NOTE: Position a block of wood under the transaxle.
Fig 56: Installing Powertrain Lift And Adjustable Grip Arms
Courtesy of FORD MOTOR CO.
69. Install the Powertrain Lift and Adjustable Grip Arms.
70. Remove the transaxle support insulator through bolt and nut.
    Fig 57: Location of Transaxle Support Insulator Through Bolt And Nut

    Courtesy of FORD MOTOR CO.
71. Remove the transaxle support insulator bracket bolt and the 2 nuts.
    Fig 58: Location of Transaxle Support Insulator Bracket Bolt And Nuts

    Courtesy of FORD MOTOR CO.
72. Remove the 4 engine mount nuts.
    • Remove the 2 engine mount spacers.
      Fig 59: Location of Engine Mount Nuts

      Courtesy of FORD MOTOR CO.
73. Remove the nut, 2 bolts and the engine mount.
    Fig 60: Location of Engine Mount Nut And Bolts

    Courtesy of FORD MOTOR CO.
74. Lower the engine and transaxle assembly from the vehicle.
75. Disconnect the wiring harness fasteners from the transaxle-to-engine stud bolt and the starter.
    Fig 61: Location of Wiring Harness Fasteners And Torque Converter Housing Stud Bolt

    Courtesy of FORD MOTOR CO.
76. Remove the bolt and ground wire.
    Fig 62: Location of Bolt And Ground Wire

    Courtesy of FORD MOTOR CO.
77. Disconnect the Transmission Control Module (TCM) electrical connector.
    Fig 63: Location of Transmission Control Module Electrical Connector

    Courtesy of FORD MOTOR CO.
78. Remove the 2 nuts and the starter motor wiring.
    Fig 64: Location of Nuts And Starter Motor Wiring

    Courtesy of FORD MOTOR CO.
79. Remove the 2 bolts and the starter.
    Fig 65: Location of Starter Bolts

    Courtesy of FORD MOTOR CO.
80. Install the Engine Lift Eye on the LH cylinder head.
    Fig 66: Identifying Engine Lift Eye On LH Cylinder Head

    Courtesy of FORD MOTOR CO.
81. Using the Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table.
    Fig 67: Removing Engine And Transaxle From Lift Table Using Floor Crane And Spreader Bar

    Courtesy of FORD MOTOR CO.
82. Remove the 2 engine-to-transaxle bolts.
    Fig 68: Location of Engine-To-Transaxle Bolts

    Courtesy of FORD MOTOR CO.
83. Remove the transaxle-to-engine stud bolt and the 4 transaxle-to-engine bolts.
    • Separate the transaxle from the engine.
      Fig 69: Location of Transaxle-To-Engine Stud Bolt And Bolts

      Courtesy of FORD MOTOR CO.