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Engine - Manual Transaxle

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G04618080Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04618081Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04618082Courtesy of FORD MOTOR CO.
 Powertrain Lift
014-00765
G04618083Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets
014-0001
Lifting Bracket Set, Engine
303-D095 (D94L-6001-A) or equivalent
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

    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 PRESSURE RELEASE .
  3. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION - AIR CLEANER and REMOVAL AND INSTALLATION - AIR CLEANER OUTLET PIPE .
  4. Remove the battery tray. For additional information, refer to REMOVAL AND INSTALLATION .
  5. Drain the engine oil.
  6. Drain the cooling system. For additional information, refer to DRAINING .
  7. Remove the starter. For additional information, refer to STARTING SYSTEM .
  8. Remove the exhaust flex pipe. For additional information, refer to REMOVAL AND INSTALLATION .
  9. Disconnect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
    Fig 1: Locating Heated Oxygen Sensor (HO2S) & Catalyst Monitor Sensor Electrical Connectors
    G04618084Courtesy of FORD MOTOR CO.
  10. Remove the accessory drive belt tensioner. For additional information, refer to REMOVAL AND INSTALLATION .
  11. Remove the bolt and press the locking tab to release the lower air duct from the upper air duct.
    Fig 2: Locating Bolt & Lower Air Duct
    G04618085Courtesy of FORD MOTOR CO.
  12. Detach the wire retainers from the generator shield and remove the nut and pin-type retainer and remove the generator shield.
    Fig 3: Locating Nut & Pin-Type Retainer
    G04618086Courtesy of FORD MOTOR CO.
  13. Remove the bolts and the lateral support crossmember.
    Fig 4: Identifying Lateral Support Crossmember And Bolts
    G03897847Courtesy of FORD MOTOR CO.
  14. Remove the LH front drive halfshaft. For additional information, refer to REMOVAL .
  15. Remove the front drive intermediate halfshaft. For additional information, refer to REMOVAL .

    16. All wheel drive (AWD) vehicles 

  16. Remove the 6 bolts holding the driveshaft to the transfer case.
    Fig 5: Locating Driveshaft Bolts
    G04618088Courtesy of FORD MOTOR CO.
  17. Position the driveshaft aside.
    Fig 6: Locating Driveshaft Aside
    G04618089Courtesy of FORD MOTOR CO.

    18. All vehicles 

  18. If equipped, remove the bolt and ground eyelet.
    Fig 7: Locating Bolt & Ground Eyelet
    G04618090Courtesy of FORD MOTOR CO.
  19. Remove the power distribution box cover.
    Fig 8: Locating Power Distribution Box Cover
    G03897849Courtesy of FORD MOTOR CO.
  20. Remove the nuts and disconnect the cables.
    Fig 9: Locating Cables & Nuts
    G03897850Courtesy of FORD MOTOR CO.
  21. Disconnect the electrical connector from the power distribution box.
    Fig 10: Locating Electrical Connector
    G04618093Courtesy of FORD MOTOR CO.
  22. Remove the bolt and disconnect the ground strap. Loosen the bolt and disconnect the 42-pin electrical connector.
    Fig 11: Locating Ground Strap & Electrical Connector
    G03897852Courtesy of FORD MOTOR CO.
  23. Detach the wiring harness retainers from the battery tray bracket and position the wiring harness aside.
    Fig 12: Locating Wiring Harness Retainers
    G04618095Courtesy of FORD MOTOR CO.
  24. Disconnect the clutch hydraulic tube fitting. Remove the clutch hydraulic tube mounting bolt, detach the spring clip and position the tube aside.
    Fig 13: Locating Clutch Hydraulic Tube Fitting
    G04618096Courtesy of FORD MOTOR CO.
  25. Remove the retaining clips and disconnect the transaxle control cable.
    Fig 14: Locating Transaxle Control Cable (1 Of 2)
    G04618097Courtesy of FORD MOTOR CO.
  26. Remove the retaining clips and disconnect the transaxle control cable.
    Fig 15: Locating Transaxle Control Cable (2 Of 2)
    G04618098Courtesy of FORD MOTOR CO.
  27. Disconnect the vehicle speed sensor (VSS) electrical connector and pin-type retainer.
    Fig 16: Locating Vehicle Speed Sensor (VSS) Electrical Connector
    G04618099Courtesy of FORD MOTOR CO.
  28. Disconnect the reversing lamp indicator switch and detach the wiring harness retainers.
    Fig 17: Locating Reversing Lamp Indicator Switch
    G04618100Courtesy of FORD MOTOR CO.
  29. If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.
    Fig 18: Locating Block Heater Electrical Connector
    G04618101Courtesy of FORD MOTOR CO.
  30. Disconnect the upper radiator and coolant vent hoses.
    Fig 19: Locating Upper Radiator & Coolant Vent Hoses
    G04618102Courtesy of FORD MOTOR CO.
  31. Remove the nuts and the coolant vent hose brackets. Position the coolant vent hose aside.
    Fig 20: Locating Nuts & Coolant Vent Hose Brackets
    G04618103Courtesy of FORD MOTOR CO.
  32. Detach the heater hose support strap from the stud.
    Fig 21: Locating Heater Hose Support Strap From Stud
    G04618104Courtesy of FORD MOTOR CO.
  33. Disconnect the heater hoses from the heater core.
    Fig 22: Locating Heater Hoses
    G03897868Courtesy of FORD MOTOR CO.
  34. Remove the retainers and the accelerator cable snow shield.
    Fig 23: Locating Retainers & Accelerator Cable Snow Shield
    G04618106Courtesy of FORD MOTOR CO.
  35. Disconnect the accelerator cable and speed control cable (if equipped).
    1. Disconnect the accelerator and speed control cable (if equipped) from the throttle body.
    2. Remove the bolts from the accelerator cable bracket.
      Fig 24: Identifying Accelerator Cable Bracket Bolts
      G04618107Courtesy of FORD MOTOR CO.
  36. Remove the nut from the accelerator control cable bracket.
    Fig 25: Locating Accelerator Control Cable Bracket Nut (1 Of 2)
    G04618108Courtesy of FORD MOTOR CO.
  37. Remove the nut from the accelerator control cable bracket and position the accelerator control cable and bracket assembly aside.
    Fig 26: Locating Accelerator Control Cable Bracket Nut (2 Of 2)
    G04618109Courtesy of FORD MOTOR CO.
  38. Remove the nut and position the power steering tube and bracket aside.
    Fig 27: Locating Power Steering Tube & Bracket Aside
    G04618110Courtesy of FORD MOTOR CO.
  39. Disconnect the vacuum supply tube and position aside.
    Fig 28: Locating Vacuum Supply Tube
    G04618111Courtesy of FORD MOTOR CO.
  40. Disconnect the fuel vapor return tube and position aside.
    Fig 29: Locating Fuel Vapor Return Tube
    G04618112Courtesy of FORD MOTOR CO.
  41. Disconnect the vacuum reservoir tube and position aside.
    Fig 30: Locating Vacuum Reservoir Tube
    G04618113Courtesy of FORD MOTOR CO.
  42. Disconnect the fuel supply tube and retainer and position aside.
    Fig 31: Locating Fuel Supply Tube & Retainer
    G04618114Courtesy of FORD MOTOR CO.
  43. Detach the electrical connector retainers.
    Fig 32: Locating Electrical Connector Retainers
    G04618115Courtesy of FORD MOTOR CO.
  44. Disconnect the powertrain control module (PCM) electrical connectors. Remove the nut and position the harness aside.
    Fig 33: Locating Powertrain Control Module (PCM) Electrical Connectors
    G03897879Courtesy of FORD MOTOR CO.
  45. Remove the bolt and detach the ground wire.
    Fig 34: Locating Ground Wire & Bolt
    G03897880Courtesy of FORD MOTOR CO.
  46. Remove the 2 power steering pump bolts.
    Fig 35: Locating Power Steering Pump Bolts
    G03897741Courtesy of FORD MOTOR CO.
  47. Disconnect the lower radiator hose from the radiator.
    Fig 36: Locating Lower Radiator Hose
    G03897882Courtesy of FORD MOTOR CO.
  48. Disconnect the A/C compressor electrical connector and remove the 3 bolts. Position the A/C compressor aside and support the compressor with a length of mechanic's wire.
    Fig 37: Locating A/C Compressor Bolts
    G04618120Courtesy of FORD MOTOR CO.
  49. Disconnect the power steering pressure (PSP) sensor electrical connector.
    Fig 38: Locating Power Steering Pressure (PSP) Sensor Electrical Connector
    G04618121Courtesy of FORD MOTOR CO.
    50. NOTE: The bolt under the power steering pressure tube will remain with the power steering pump.
    Fig 39: Identifying Power Steering Pump Bolts
    G03897742Courtesy of FORD MOTOR CO.
  50. Remove the bolts and position the power steering pump aside.
  51. Remove the front roll restrictor bolt and the 2 bolts for the engine support crossmember.
    Fig 40: Identifying Front Roll Restrictor Bolt & Bolts For Engine Support Crossmember
    G04619986Courtesy of FORD MOTOR CO.
  52. Remove the rear nut and the engine support crossmember.
    • Discard the nut.
      Fig 41: Identifying Cross Brace And Rear Nut
      G03897887Courtesy of FORD MOTOR CO.
    53. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
    Fig 42: Locating Transaxle-To-Engine Bolts
    G04618125Courtesy of FORD MOTOR CO.
  53. Remove the 2 transaxle-to-engine bolts.
    54. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
    Fig 43: Locating Transaxle-To-Engine Bolts
    G04618126Courtesy of FORD MOTOR CO.
  54. Remove the 2 transaxle-to-engine bolts.
  55. Using the special tools, secure the engine to the lift table.
    Fig 44: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
    G03897890Courtesy of FORD MOTOR CO.
  56. Remove the engine mount bracket bolt.
    Fig 45: Locating Engine Mount Bracket Bolt
    G04618128Courtesy of FORD MOTOR CO.
  57. Remove the nuts and the engine mount bracket.
    Fig 46: Locating Nuts & Engine Mount Bracket
    G04618129Courtesy of FORD MOTOR CO.
  58. Remove the bolt from the transaxle rear mount.
    Fig 47: Locating Transaxle Rear Mount Bolt
    G04618130Courtesy of FORD MOTOR CO.
  59. Remove bolt from the LH transaxle mount.
    Fig 48: Locating Transaxle Mount Bolt
    G03897894Courtesy of FORD MOTOR CO.
  60. Lower the engine and transaxle from the vehicle.
  61. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
    62. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
  62. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.
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