LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1154 (Engine -- 4.6L (2V)) >> Removal >> Engine

Section 1154 (Engine -- 4.6L (2V)): Removal: Engine

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL CHART

G03898617
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
G03886108
 Holding Wrench, Fan Pulley 303-239 (T84T-6312-C)
G03887732
 Wrench, Fan Clutch Nut 303-240 (T84T-6312-D)
G03930224
 Disconnect Tool, Transmission 307-441
G03948020
 Lifting Bracket Set, Engine 303-D074 (D91P-6001-A) or equivalent

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  2. Disconnect the fuel tube spring coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  3. Remove the nut and disconnect the ground wire.
    Fig 1: Disconnecting Ground Wire
    G03947803Courtesy of FORD MOTOR CO.
  4. Disconnect the electrical connector and detach the wiring harness pin-type retainers.
    Fig 2: Disconnecting Electrical Connector
    G03947804Courtesy of FORD MOTOR CO.
  5. Lift the cover, remove the nut and disconnect the wiring harness terminals.
    Fig 3: Disconnecting Wiring Harness Terminals
    G03947545Courtesy of FORD MOTOR CO.
  6. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  7. Recover the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  8. Disconnect the windshield washer hose.
    Fig 4: Disconnecting Windshield Washer Hose
    G03947806Courtesy of FORD MOTOR CO.
    9. NOTE: Mark the hinge locations for installation reference.
    Fig 5: Removing Bolts And Hood
    G03947807Courtesy of FORD MOTOR CO.
  9. Remove the 4 bolts and the hood.
  10. Remove the air cleaner outlet tube.
    1. Loosen the clamp.
    2. Disconnect the hose.
    3. Loosen the clamp.
    4. Remove the air cleaner outlet tube.
      Fig 6: Removing Air Cleaner Outlet Tube
      G03947808Courtesy of FORD MOTOR CO.
  11. Disconnect the mass air flow (MAF) electrical connector.
    Fig 7: Disconnecting Mass Air Flow (MAF) Electrical Connector
    G03947809Courtesy of FORD MOTOR CO.
  12. Remove the air cleaner assembly.
    Fig 8: Removing Air Cleaner Assembly
    G03947134Courtesy of FORD MOTOR CO.
  13. Remove the upper radiator appearance cover.
    Fig 9: Removing Upper Radiator Appearance Cover
    G03947811Courtesy of FORD MOTOR CO.
  14. Squeeze the clamps and disconnect the upper radiator and heater hoses.
    Fig 10: Disconnecting Upper Radiator And Heater Hoses
    G03947812Courtesy of FORD MOTOR CO.
  15. Squeeze the clamps and disconnect the upper radiator and degas vent hoses.
    • Remove the upper radiator hose.
      Fig 11: Removing Upper Radiator Hose
      G03947813Courtesy of FORD MOTOR CO.
  16. Squeeze the clamp and disconnect the heater hose.
    Fig 12: Disconnecting Heater Hose
    G03947814Courtesy of FORD MOTOR CO.
  17. Disconnect the A/C pressure switch electrical connector.
    Fig 13: Disconnecting A/C Pressure Switch Electrical Connector
    G03947815Courtesy of FORD MOTOR CO.
  18. Remove the nut and disconnect the manifold and tube assembly from the condenser.
    Fig 14: Disconnecting Manifold And Tube Assembly
    G03947816Courtesy of FORD MOTOR CO.
  19. Detach the A/C tube from the retainers and position the tube aside.
    Fig 15: Removing A/C Tube From Retainers
    G03948382Courtesy of FORD MOTOR CO.
    20. NOTE: Cover the accumulator with a suitable cap or tape to prevent contamination.
    Fig 16: Disconnecting Manifold Tube From Accumulator
    G03947818Courtesy of FORD MOTOR CO.
  20. Remove the nut and disconnect the manifold tube from the accumulator. If equipped, remove the nut and disconnect the auxiliary A/C tube.
  21. Remove the nut and disconnect the evaporator tube from the condenser.
    Fig 17: Disconnecting Evaporator Tube From Condenser
    G03948338Courtesy of FORD MOTOR CO.
    22. NOTE: RH shown, LH similar.
    NOTE: Some vehicles are equipped with only one assembly screw.
    Fig 18: Removing Bolts And Screw
    G03947820Courtesy of FORD MOTOR CO.
  22. Remove the 2 bolts and the screw(s). Discard the screws.
  23. Remove the upper fan shroud.
    Fig 19: Removing Upper Fan Shroud
    G03947821Courtesy of FORD MOTOR CO.
  24. Using the special tools, remove the cooling fan.
    Fig 20: Removing Cooling Fan
    G03947822Courtesy of FORD MOTOR CO.
  25. Remove the heater control valve bracket bolt.
    Fig 21: Removing Heater Control Valve Bracket Bolt
    G03947823Courtesy of FORD MOTOR CO.
  26. Disconnect the heater control vacuum supply hose.
    Fig 22: Disconnecting Heater Control Vacuum Supply Hose
    G03947556Courtesy of FORD MOTOR CO.
  27. Disconnect the brake booster vacuum hose.
    Fig 23: Disconnecting Brake Booster Vacuum Hose
    G03947825Courtesy of FORD MOTOR CO.
  28. Disconnect the hoses from the evaporative emissions (EVAP) canister purge valve.
    Fig 24: Disconnecting Hoses From Evaporative Emissions (EVAP) Canister Purge Valve
    G03947826Courtesy of FORD MOTOR CO.
  29. Remove the bolts and position aside the cable bracket.
    Fig 25: Removing Bolts
    G03947827Courtesy of FORD MOTOR CO.
  30. Install the special tool.
    Fig 26: Installing Special Tool
    G03947828Courtesy of FORD MOTOR CO.
  31. Drain the engine oil.
    • Install the drain plug when finished. Tighten to 14 Nm (10 lb-ft).
      Fig 27: Installing Drain Plug
      G03947615Courtesy of FORD MOTOR CO.
  32. Squeeze the clamp and disconnect the coolant hose from the radiator. Detach the hose from the retainer and position the hose aside.
    Fig 28: Disconnecting Coolant Hose From Radiator
    G03947830Courtesy of FORD MOTOR CO.
  33. Squeeze the clamp and disconnect the lower radiator hose.
    Fig 29: Disconnecting Lower Radiator Hose
    G03947831Courtesy of FORD MOTOR CO.
  34. Remove the bolts and the lower fan shroud.
    Fig 30: Removing Bolts And Lower Fan Shroud
    G03947832Courtesy of FORD MOTOR CO.
  35. Remove the lower air deflector pin-type retainers.
    Fig 31: Locating Lower Air Dam Push Pins
    G03947152Courtesy of FORD MOTOR CO.
  36. Using the special tool, disconnect the cooler tubes from the cooler.
    • Drain the fluid into a suitable container.
      Fig 32: Disconnecting Cooler Tubes From Cooler
      G03947195Courtesy of FORD MOTOR CO.
  37. Remove the 2 bolts and the LH radiator support bracket.
    Fig 33: Removing LH Radiator Support Bracket
    G03947835Courtesy of FORD MOTOR CO.
  38. Remove the 2 bolts and the RH radiator support bracket.
    Fig 34: Removing RH Radiator Support Bracket
    G03947836Courtesy of FORD MOTOR CO.
  39. Remove the radiator and A/C condenser as an assembly.
    Fig 35: Removing Radiator And A/C Condenser
    G03947209Courtesy of FORD MOTOR CO.

    40. 4x4 vehicles 

  40. Position a suitable jack under the transfer case.
    Fig 36: Supporting Transfer Case With Suitable Jack Stand
    G03947504Courtesy of FORD MOTOR CO.

    41. 4x2 vehicles 

    WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.
    Fig 37: Supporting Transmission With Transmission Jack
    G03947197Courtesy of FORD MOTOR CO.
  41. Support the transmission with a transmission jack.

    42. All vehicles 

  42. Remove the bolts and position the RH heat shield aside.
    Fig 38: Removing Bolts
    G03947840Courtesy of FORD MOTOR CO.
    43. NOTE: LH shown, RH similar.
    Fig 39: Locating Heated Oxygen Sensor Electrical Connector
    G03947157Courtesy of FORD MOTOR CO.
  43. Disconnect both heated oxygen sensor (HO2S) electrical connectors.
    44. NOTE: RH shown, LH similar.
    Fig 40: Identifying Catalyst Monitor Sensor Electrical Connector
    G03947158Courtesy of FORD MOTOR CO.
  44. Disconnect both catalyst monitor sensor electrical connectors.
  45. Remove the RH heat shield bolts.
    Fig 41: Removing RH Heat Shield Bolts
    G03947159Courtesy of FORD MOTOR CO.
  46. Remove the bolt and the RH heat shield.
    Fig 42: Removing RH Heat Shield
    G03947160Courtesy of FORD MOTOR CO.
  47. Remove the LH heat shield bolt.
    Fig 43: Locating LH Heat Shield Bolt
    G03947161Courtesy of FORD MOTOR CO.
  48. Remove the 2 nuts and the plastic shield on the RH side of the crossmember.
    Fig 44: Locating Plastic Shield On Right Side Of Crossmember Near Fuel Tank
    G03948762Courtesy of FORD MOTOR CO.
    49. NOTE: RH side shown, LH side similar.
    Fig 45: Removing Crossmember Upper Bolts
    G03947163Courtesy of FORD MOTOR CO.
  49. Remove the 4 crossmember upper bolts.
    50. NOTE: RH side shown, LH side similar.
    Fig 46: Locating RH Side Crossmember Bolts
    G03947164Courtesy of FORD MOTOR CO.
  50. Remove the 4 crossmember lower bolts.

    51. 4x2 vehicles 

  51. Remove the bolts and the bracket.
    Fig 47: Removing Bracket Bolts
    G03948313Courtesy of FORD MOTOR CO.

    52. All vehicles 

  52. Remove the nuts and the crossmember.
    Fig 48: Identifying Transmission Support Insulator Nuts
    G03947166Courtesy of FORD MOTOR CO.
  53. Remove the bolts, the nuts and the springs and disconnect the muffler from the dual converter Y-pipe. Remove and discard the gasket.
    Fig 49: Disconnecting Muffler From Dual Converter Y-Pipe
    G03947851Courtesy of FORD MOTOR CO.
  54. Using a suitable jack stand, support the dual converter Y-pipe.
    Fig 50: Supporting Dual Converter Y-Pipe
    G03947852Courtesy of FORD MOTOR CO.
  55. Remove the bolts and the transmission rear mount.
    Fig 51: Removing Transmission Rear Mount
    G03948303Courtesy of FORD MOTOR CO.
  56. Remove the 4 exhaust manifold-to-dual converter Y-pipe nuts. Remove the jack stand the dual converter Y-pipe and the heat shields.
    Fig 52: Locating Catalytic Converter-To-Manifold Nuts
    G03946966Courtesy of FORD MOTOR CO.
  57. Disconnect the shift cable and remove the bolts and the bracket.
    Fig 53: Identifying Shift Cable And Bracket
    G03947170Courtesy of FORD MOTOR CO.
  58. Position the manual shift lever out of the park position.
    Fig 54: Positioning Manual Shift Lever Out Of Park Position
    G03947856Courtesy of FORD MOTOR CO.

    59. 4x4 vehicles 

  59. Mark the front axle pinion flange and the front driveshaft for assembly reference.
    Fig 55: Identifying Universal Joint Retainer Ring
    G03944118Courtesy of FORD MOTOR CO.
  60. Mark the front output shaft assembly and the front driveshaft CV joint for assembly reference.
    Fig 56: Identifying Index-Mark On Front Output Shaft Assembly
    G03912439Courtesy of FORD MOTOR CO.
  61. Remove and discard the bolts and washers.
    Fig 57: Removing Bolts And Washers
    G03947173Courtesy of FORD MOTOR CO.
  62. Remove and discard the bolts and the universal joint retainers.
    Fig 58: Locating Universal Joint Retainers
    G03971114Courtesy of FORD MOTOR CO.
    63. CAUTION: Always disconnect the front driveshaft from the transfer case first. The weight of the driveshaft can pinch the boot, causing the boot to tear.
    CAUTION: Tape the bearing cups to the driveshaft to prevent them from falling off of the spider.
    Fig 59: Removing Front Driveshaft
    G03947175Courtesy of FORD MOTOR CO.
  63. Remove the front driveshaft.

    64. All vehicles 

    NOTE: The axle pinion flange is shown, the transfer case output flange, if equipped, is similar.
    Fig 60: Identifying Index Mark Rear Output Flange And Driveshaft Yoke
    G03912442Courtesy of FORD MOTOR CO.
  64. Mark the driveshaft flange to the rear axle pinion flange and if equipped, the transfer case rear output flange for assembly reference.
  65. Remove the 4 pinion flange bolts.
    Fig 61: Locating Driveshaft Yoke Bolts
    G03912443Courtesy of FORD MOTOR CO.

    66. 4x4 vehicles 

  66. Remove the 4 transfer case flange bolts.
    Fig 62: Removing Transfer Case Flange Bolts
    G03947179Courtesy of FORD MOTOR CO.

    67. All vehicles 

    CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange. Damage to the driveshaft can occur.
    NOTE: Use a suitable plug to prevent transmission fluid loss on 2-wheel drive vehicles.
    Fig 63: Disconnecting Driveshaft Flange Yoke From Pinion Flange
    G03878446Courtesy of FORD MOTOR CO.
  67. Using a suitable tool as shown in Fig 63, disconnect the driveshaft flange from the rear axle pinion flange and remove the driveshaft.
  68. Disconnect the turbine shaft speed (TSS) sensor, the output shaft speed (OSS) sensor and the intermediate shaft speed (ISS) sensor electrical connectors.
    Fig 64: Locating Electrical Connectors
    G03947190Courtesy of FORD MOTOR CO.
    69. NOTE: Clean the area around the connector to prevent contamination of the solenoid body connector.
    Fig 65: Identifying Solenoid Body Electrical Connector
    G03947191Courtesy of FORD MOTOR CO.
  69. Remove the screw and disconnect the solenoid body electrical connector.
    70. NOTE: Move the rubber boot back to gain access to the connector.
    Fig 66: Locating Transmission Range (TR) Sensor Electrical Connector
    G03947189Courtesy of FORD MOTOR CO.
  70. Disconnect the transmission range sensor electrical connector.
  71. Detach the wiring harness retainers.
    Fig 67: Removing Wiring Harness Retainers
    G03948291Courtesy of FORD MOTOR CO.
    72. NOTE: RH shown, LH similar.
    Fig 68: Identifying Wire Harness Retainers
    G03948290Courtesy of FORD MOTOR CO.
  72. Detach both heated oxygen sensor (HO2S) electrical connector retainers from the transmission.
  73. Disconnect the LH catalyst monitor sensor electrical retainer from the transmission.
    Fig 69: Identifying LH Catalyst Monitor Connector Retainer At Transmission
    G03947871Courtesy of FORD MOTOR CO.
  74. Disconnect the RH catalyst monitor sensor electrical connector retainer and the fuel tubes from the bracket.
    Fig 70: Locating Fuel Lines And RH Catalyst Monitor Connector Bracket
    G03947872Courtesy of FORD MOTOR CO.

    75. 4x4 vehicles 

  75. If equipped, disconnect the shift motor electrical connector and detach the harness pin-type retainer(s).
    Fig 71: Locating Shift Motor Electrical Connector And Wiring Harness Pin-Type Retainer
    G03947184Courtesy of FORD MOTOR CO.
    76. WARNING: Secure the transmission to the jack with a safety chain. Failure to follow these instructions can result in personal injury.
    Fig 72: Supporting Transmission With Transmission Jack
    G03947197Courtesy of FORD MOTOR CO.
  76. Support the transmission with a transmission jack.
  77. Remove the jack stand from the transfer case.
    Fig 73: Supporting Transfer Case With Suitable Jack Stand
    G03947504Courtesy of FORD MOTOR CO.

    78. All vehicles 

    NOTE: RH shown, LH similar.
    Fig 74: Removing Front Crossmember Bolts
    G03947876Courtesy of FORD MOTOR CO.
  78. Remove the 4 bolts and the front crossmember.
  79. Remove the cover.
    Fig 75: Removing Cover
    G03947877Courtesy of FORD MOTOR CO.
  80. Disconnect the starter wiring.
    1. Remove the nut and disconnect the battery positive cable.
    2. Remove the nut and disconnect the starter solenoid wire.
      Fig 76: Disconnecting Starter Solenoid Wire
      G03947878Courtesy of FORD MOTOR CO.
  81. Remove the 3 bolts and the starter.
    Fig 77: Removing Starter Bolts
    G03947879Courtesy of FORD MOTOR CO.
  82. Remove the bolts and the cover.
    Fig 78: Removing Cover Bolts
    G03948778Courtesy of FORD MOTOR CO.
  83. Remove the access cover.
    Fig 79: Removing Access Cover
    G03947881Courtesy of FORD MOTOR CO.
    84. NOTE: Mark one stud and the flexplate for assembly reference.
  84. Remove the 4 torque converter nuts.
    • Rotate the crankshaft using the crankshaft pulley bolt.
      Fig 80: Removing Torque Converter Nuts
      G03947882Courtesy of FORD MOTOR CO.
    85. CAUTION: Use a wrench to hold the transmission case fitting, to prevent damage to the cooler tubes.
    Fig 81: Locating Transmission Cooler Tubes
    G03947193Courtesy of FORD MOTOR CO.
  85. Disconnect the cooler tubes.
  86. Remove the 7 engine-to-transmission bolts.
    Fig 82: Locating Engine-To-Transmission Retaining Bolts
    G03947199Courtesy of FORD MOTOR CO.
  87. Using a suitable wooden block, support the front of the engine against the front crossmember.
    • Position the wooden block as shown in Fig 83.
      Fig 83: Supporting Front Of Engine Against Front Crossmember
      G03947885Courtesy of FORD MOTOR CO.
  88. Lower the transmission and, if equipped, the transfer case.
  89. Disconnect the LH HO2S wiring harness from the retainer.
    Fig 84: Disconnecting LH HO2S Wiring Harness
    G03947886Courtesy of FORD MOTOR CO.
  90. Remove the nut and the cooler tube bracket.
    Fig 85: Removing Cooler Tube Bracket
    G03947623Courtesy of FORD MOTOR CO.
  91. Disconnect the power steering return hose.
    • Drain the fluid into a suitable container.
      Fig 86: Disconnecting Power Steering Return Hose
      G03947888Courtesy of FORD MOTOR CO.
  92. Disconnect the power steering pressure (PSP) hose.
    Fig 87: Disconnecting Power Steering Pressure (PSP) Hose
    G03947889Courtesy of FORD MOTOR CO.
  93. Remove the nut and washer from the RH motor mount.
    Fig 88: Removing Nut And Washer From RH Motor Mount
    G03947890Courtesy of FORD MOTOR CO.
  94. Remove the bolt from the LH motor mount.
    Fig 89: Removing Bolt From LH Motor Mount
    G03947891Courtesy of FORD MOTOR CO.
  95. Disconnect the fuel charging wiring harness electrical connectors.
    Fig 90: Disconnecting Fuel Charging Wiring Harness Electrical Connectors
    G03947135Courtesy of FORD MOTOR CO.
    96. NOTE: If necessary, separate the tape from the transmission harness.
    Fig 91: Disconnecting Fuel Charging Wiring Harness Pin-Type Retainer
    G03947893Courtesy of FORD MOTOR CO.
  96. Disconnect the fuel charging wiring harness pin-type retainer.
  97. Remove the harness retaining clip from the ground stud bolt.
    Fig 92: Removing Harness Retaining Clip
    G03947894Courtesy of FORD MOTOR CO.
  98. Remove the stud bolt and disconnect the ground strap.
    Fig 93: Disconnecting Ground Strap
    G03947895Courtesy of FORD MOTOR CO.
  99. Install the special tool.
    Fig 94: Installing Special Tool
    G03947896Courtesy of FORD MOTOR CO.
  100. Support the fuel hose with a wire tie or mechanic's wire.
    Fig 95: Supporting Fuel Hose With Wire
    G03947897Courtesy of FORD MOTOR CO.
  101. Attach the special tool to a floor crane and the engine and remove the engine from the vehicle.
    Fig 96: Attaching Special Tool To Floor Crane
    G03947898Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals