Section 1848 (Engine Mechanical - 3.5L): Removal: Engine

	2, 200# Floor Crane, Fold Away 300-OTC1819E
	Adjustable Grip Arm, 1735A 014-00001
	Disconnect Tool, Transmission Cooler Tube 307-569
	Eye, Engine Lift 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. Remove the engine appearance cover. For additional information, refer to ENGINE APPEARANCE COVER - EXPLODED VIEW .
3. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
4. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
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
Courtesy of FORD MOTOR CO.
5. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
6. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
7. Remove the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE .
8. Remove the LH halfshaft and intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
9. Disconnect the power steering cooler hose and drain the power steering fluid into a suitable drain pan.
   Fig 2: Locating Power Steering Cooler Hose

   Courtesy of FORD MOTOR CO.
10. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
11. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
12. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
13. Remove the 2 nuts and disconnect the power feed from the battery terminal.
    • Disconnect the wiring harness electrical connector.
      Fig 3: Locating Power Feed Nuts And Wiring Harness Electrical Connector

      Courtesy of FORD MOTOR CO.
14. Remove the nut and the ground wire.
    • Disconnect the wiring harness electrical connector.
      Fig 4: Locating Ground Wire Nut And Wiring Harness Electrical Connector

      Courtesy of FORD MOTOR CO.
15. Detach the 2 wiring harness retainers from the stud bolt and bracket.
    Fig 5: Locating Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
16. Disconnect the wiring harness electrical connector.
    Fig 6: Locating Wiring Harness Electrical Connector

    Courtesy of FORD MOTOR CO.
17. Detach the 3 wiring harness retainers from the bracket and inner fender.
    Fig 7: Locating Wiring Harness Retainers Of Bracket And Inner Fender

    Courtesy of FORD MOTOR CO.
18. Disconnect the vacuum hose from the upper intake manifold.
    Fig 8: Locating Vacuum Hose Of Upper Intake Manifold

    Courtesy of FORD MOTOR CO.
19. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
    Fig 9: Locating Upper Radiator Hose, Lower Radiator Hose And Heater Hoses Of Thermostat Housing

    Courtesy of FORD MOTOR CO.
20. Disconnect the transaxle control cable from the control lever.
    • Detach the control cable from the bracket.
      Fig 10: Locating Transaxle Control Cable And Control Lever

      Courtesy of FORD MOTOR CO.
21. If equipped, detach the engine block heater harness retainers from the radiator support and the A/C suction tube.
    Fig 11: Locating Engine Block Heater Harness, Radiator Support, A/C Suction Tube And Engine Wiring Harness

    Courtesy of FORD MOTOR CO.
22. Remove the nut and disconnect the A/C pressure tube fitting.
    • Discard the O-ring seal.
      Fig 12: Locating Nut And A/C Pressure Tube Fitting

      Courtesy of FORD MOTOR CO.
23. Remove the safety clip from the A/C fitting.
    • Disconnect the A/C suction tube fitting.
      Fig 13: Locating Safety Clip And A/C Suction Tube Fitting

      Courtesy of FORD MOTOR CO.
24. Disconnect the hose from the power steering reservoir.
    Fig 14: Locating Power Steering Reservoir Hose

    Courtesy of FORD MOTOR CO.
25. Disconnect the 2 PCM electrical connectors.
    • Detach the 2 wiring harness retainers from the stud bolts.
      Fig 15: Locating PCM Electrical Connectors And Wiring Harness Retainers

      Courtesy of FORD MOTOR CO.
26. Disconnect the wiring harness electrical connector.
    • Detach the wiring harness retainer from the RH valve cover stud bolt.
      Fig 16: Locating Wiring Harness Electrical Connector And Retainer

      Courtesy of FORD MOTOR CO.
27. Remove the oil level indicator.
    Fig 17: Identifying Oil Level Indicator

    Courtesy of FORD MOTOR CO.
28. Remove the bolt and the ground wire from the engine front cover.
    Fig 18: Locating Bolt And Ground Wire On Engine Front Cover

    Courtesy of FORD MOTOR CO.
29. Remove the nut and the radio interference capacitor wire from the engine front cover stud.
    Fig 19: Locating Nut And Radio Interference Capacitor Wire On Engine Front Cover Stud

    Courtesy of FORD MOTOR CO.
30. Remove the exhaust Y-pipe. For additional information, refer to EXHAUST SYSTEM .
31. Remove the LH inner splash shield. For additional information, refer to FRONT END BODY PANELS .
32. Remove the 2 secondary latches from the transmission fluid cooler tubes.
    Fig 20: Locating Transmission Fluid Cooler Tubes Secondary Latches

    Courtesy of FORD MOTOR CO.
33. Using the Transmission Cooler Tube Disconnect Tool, disconnect the transmission cooling tubes.
    Fig 21: Disconnecting Transmission Cooling Tubes Using Transmission Cooler Tube Disconnect Tool

    Courtesy of FORD MOTOR CO.
34. Remove the 4 oil pan-to-transaxle bolts.
    Fig 22: Locating Oil Pan-To-Transaxle Bolts

    Courtesy of FORD MOTOR CO.
35. Remove the 2 fasteners and the inspection cover.
    Fig 23: Locating Fasteners And Inspection Cover

    Courtesy of FORD MOTOR CO.
36. Remove and discard the 3 torque converter bolts.
    Fig 24: Locating Torque Converter Bolts

    Courtesy of FORD MOTOR CO.
37. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
      Fig 25: Locating Drain Plug

      Courtesy of FORD MOTOR CO.
38. Remove and discard the engine oil filter.
    Fig 26: Locating Engine Oil Filter

    Courtesy of FORD MOTOR CO.
39. Remove the power steering cooler bracket bolt from the RH side of the subframe.
    Fig 27: Locating Power Steering Cooler Bracket Bolt

    Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

NOTE: Index-mark the driveshaft for installation.
Fig 28: Locating Driveshaft Bolts
Courtesy of FORD MOTOR CO.
40. Remove the 4 bolts and support the driveshaft with a length of mechanic's wire.

    All vehicles 

41. Remove the 2 nuts and the roll restrictor heat shield.
    Fig 29: Locating Roll Restrictor Heat Shield And Nuts

    Courtesy of FORD MOTOR CO.
42. Remove the engine roll restrictor-to-subframe through bolt.
    Fig 30: Locating Engine Roll Restrictor-To-Subframe Through Bolt

    Courtesy of FORD MOTOR CO.
43. Remove and discard the Power Steering Pressure (PSP) tube-to-steering gear banjo bolt and the 2 seals.
    Fig 31: Locating Power Steering Pressure Tube-To-Steering Gear Banjo Bolt And Seals

    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 .
44. Remove and discard the steering intermediate shaft bolt.
    • Separate the steering intermediate shaft from the steering gear.
      Fig 32: Locating Steering Intermediate Shaft And Bolt

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
45. Remove and discard the cotter pins and tie-rod end nuts.
    • Using the Tie-Rod End Remover, separate the tie-rod ends from the wheel knuckles.
      Fig 33: Separating Tie-Rod Ends From Wheel Knuckles Using Tie-Rod End Remover

      Courtesy of FORD MOTOR CO.
46. Remove the 3 RH subframe-to-lower bumper nuts.
    Fig 34: Locating RH Subframe-To-Lower Bumper Nuts

    Courtesy of FORD MOTOR CO.
47. Remove the 3 LH subframe-to-lower bumper nuts and separate the lower bumper from the subframe.
    Fig 35: Locating LH Subframe-To-Lower Bumper Nuts

    Courtesy of FORD MOTOR CO.
48. Mark the relationship of the front subframe to the underbody at the mounting locations.
    Fig 36: Locating Marks On Front Subframe To Underbody At Mounting Locations

    Courtesy of FORD MOTOR CO.
49. Position the Powertrain Lift under the subframe assembly.
    Fig 37: Positioning Powertrain Lift Under Subframe Assembly

    Courtesy of FORD MOTOR CO.
50. Remove the 2 bolts and the subframe brace.
    Fig 38: Locating Bolts And Subframe Brace

    Courtesy of FORD MOTOR CO.
51. Remove the 2 nuts, 2 bolts and the 2 subframe support brackets.
    Fig 39: Locating Nuts, Bolts And Subframe Support Brackets

    Courtesy of FORD MOTOR CO.
52. Remove the 2 front subframe nuts.
    Fig 40: Locating Front Subframe Nuts

    Courtesy of FORD MOTOR CO.
53. Remove the 2 middle subframe nuts.
    Fig 41: Locating Middle Subframe Nuts

    Courtesy of FORD MOTOR CO.
54. Using the Powertrain Lift, lower the subframe assembly from the vehicle.
    Fig 42: Positioning Powertrain Lift Under Subframe Assembly

    Courtesy of FORD MOTOR CO.

    AWD vehicles 

55. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 43: Locating RH Catalyst Monitor Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
56. Remove the 4 nuts (3 shown in illustration) and the RH catalytic converter.
    • Discard the gasket and the nuts.
      Fig 44: Locating Nuts And RH Catalytic Converter

      Courtesy of FORD MOTOR CO.
57. Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket.
    Fig 45: Locating Bolts And Power Transfer Unit Support Bracket

    Courtesy of FORD MOTOR CO.
58. Remove the 5 bolts and the PTU.
    Fig 46: Locating PTU Bolts

    Courtesy of FORD MOTOR CO.

    All vehicles 

NOTE: The fuel and vapor tube assembly clip must remain attached to the transaxle case stud during engine removal. Failure to follow these instructions can result in damage to the fuel and vapor tube assembly.
Fig 47: Locating Fuel Supply Tube And Evaporative Emission Tube Quick Connect Couplings
Courtesy of FORD MOTOR CO.
59. Disconnect the fuel supply tube and Evaporative Emission (EVAP) tube quick connect couplings. For additional information, refer to the quick connect coupling procedure in FUEL SYSTEM - GENERAL INFORMATION .
NOTE: Position a block of wood under the transaxle.
Fig 48: Identifying Powertrain Lift And Adjustable Grip Arms
Courtesy of FORD MOTOR CO.
60. Install the Powertrain Lift and Adjustable Grip Arms.
61. Remove the transaxle support insulator through bolt and nut.
    Fig 49: Locating Transaxle Support Insulator Through Bolt And Nut

    Courtesy of FORD MOTOR CO.
62. Remove the 3 nuts, the bolt and the transaxle support insulator bracket.
    Fig 50: Locating Nuts, Bolt And Transaxle Support Insulator Bracket

    Courtesy of FORD MOTOR CO.
63. Remove the nut, bolt and engine mount brace.
    Fig 51: Locating Nut, Bolt And Engine Mount Brace

    Courtesy of FORD MOTOR CO.
64. Remove the 4 engine mount nuts.
    Fig 52: Locating Engine Mount Nuts

    Courtesy of FORD MOTOR CO.
65. Remove the 3 bolts and the engine mount.
    Fig 53: Locating Engine Mount Bolts

    Courtesy of FORD MOTOR CO.
66. Lower the engine and transaxle assembly from the vehicle.
67. Disconnect the EVAP tube quick connect coupling from the purge valve. For additional information, refer to the quick connect coupling procedure in FUEL SYSTEM - GENERAL INFORMATION .
    • Detach the EVAP tube retainer.
      Fig 54: Locating EVAP Tube Retainer

      Courtesy of FORD MOTOR CO.
NOTE: Do not separate the fuel and vapor tube assembly clip from the transaxle case stud. Failure to follow these instructions can result in damage to the fuel and vapor tube assembly.
Fig 55: Locating Fuel Supply Tube
Courtesy of FORD MOTOR CO.
68. Disconnect the fuel supply tube. For additional information, refer to the quick connect coupling procedure in FUEL SYSTEM - GENERAL INFORMATION .
69. Disconnect the transmission control electrical connector.
    • Detach the wiring harness retainer.
      Fig 56: Locating Transmission Control Electrical Connector And Retainer

      Courtesy of FORD MOTOR CO.
70. Position the starter cable boot back and remove the 2 nuts.
    • Detach the 2 wire terminals from the starter.
      Fig 57: Locating Starter Wire Terminals And Nuts

      Courtesy of FORD MOTOR CO.
71. Disconnect the wiring harness retainer from the starter motor stud bolt.
    Fig 58: Locating Wiring Harness Retainer At Starter Motor Stud Bolt

    Courtesy of FORD MOTOR CO.
72. Remove the bolt, stud bolt and the starter.
    Fig 59: Locating Bolt, Stud Bolt And Starter

    Courtesy of FORD MOTOR CO.
73. Install the Engine Lift Eye on the LH cylinder head.
    Fig 60: Identifying Engine Lift Eye On LH Cylinder Head

    Courtesy of FORD MOTOR CO.
74. Using the Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table.
    Fig 61: Removing Engine And Transaxle From Lift Table Using Floor Crane And Spreader Bar

    Courtesy of FORD MOTOR CO.
75. Remove the 2 engine-to-transaxle bolts.
    Fig 62: Locating Engine-To-Transaxle Bolts

    Courtesy of FORD MOTOR CO.
76. Remove the 5 transaxle-to-engine bolts.
    • Separate the transaxle from the engine.
      Fig 63: Locating Transaxle-To-Engine Bolts

      Courtesy of FORD MOTOR CO.