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Section 589 (Engine 4.6 & 5.4L): Removal: Engine

WARNING: This page is about a different car, the 2004 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S) 

Fig 1: Identifying Special Tool
G02763051Courtesy of FORD MOTOR CO.

    VEHICLES EQUIPPED WITH A/C 

  1. Recover the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .

    2. ALL VEHICLES 

  2. With the vehicle in NEUTRAL, position it on a hoist, For additional information, refer to JACKING & LIFTING .
  3. Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD - 4.6L  or INTAKE MANIFOLD - 5.4L .
  4. Remove the front bumper. For additional information, refer to BUMPERS .
  5. Disconnect the lower radiator hose from the radiator.
    • Disconnect the hose hanger.
    • Disconnect the hose.
    Fig 2: Disconnecting Lower Radiator Hose From Radiator
    G02763052Courtesy of FORD MOTOR CO.
  6. Remove the pushpin retainers and the splash shield.
    Fig 3: Removing Pushpin Retainers And Splash Shield
    G02763053Courtesy of FORD MOTOR CO.
  7. Disconnect the transmission cooler hoses and drain the fluid into a suitable container.
    Fig 4: Disconnecting Transmission Cooler Hoses
    G02763054Courtesy of FORD MOTOR CO.
  8. Disconnect the exhaust system from the LH and RH exhaust manifolds.
    Fig 5: Disconnecting Exhaust System From LH And RH Exhaust Manifolds
    G02763055Courtesy of FORD MOTOR CO.
  9. Drain the engine oil.
    Fig 6: Draining Engine Oil
    G02763056Courtesy of FORD MOTOR CO.
  10. Disconnect the oil cooler hoses and set aside.
    Fig 7: Disconnecting Oil Cooler Hoses
    G02763057Courtesy of FORD MOTOR CO.
  11. Remove the oil filter.
    Fig 8: Removing Oil Filter
    G02763058Courtesy of FORD MOTOR CO.
  12. Loosen the threaded insert and remove the oil cooler from the oil filter adapter.
    Fig 9: Removing Oil Cooler From Oil Filter Adapter
    G02763059Courtesy of FORD MOTOR CO.
  13. Remove the starter motor solenoid terminal cover.
    Fig 10: Removing Starter Motor Solenoid Terminal Cover
    G02763060Courtesy of FORD MOTOR CO.
  14. Disconnect the starter motor electrical connections.
    Fig 11: Disconnecting Starter Motor Electrical Connections
    G02763061Courtesy of FORD MOTOR CO.
  15. Remove the starter motor.
    1. Remove the stud bolt.
    2. Remove the two bolts.
    3. Remove the starter.
    Fig 12: Removing Starter Motor
    G02763062Courtesy of FORD MOTOR CO.
  16. Remove the flexplate inspection cover.
    Fig 13: Removing Flexplate Inspection Cover
    G02763063Courtesy of FORD MOTOR CO.
  17. Remove the cylinder block opening cover.
    Fig 14: Removing Cylinder Block Opening Cover
    G02763064Courtesy of FORD MOTOR CO.
  18. Remove the four nuts retaining the torque converter to the flexplate.
    • Rotate the crankshaft to access all of the torque converter nuts.
    • Discard the torque converter nuts.
    Fig 15: Removing Nuts Retaining Torque Converter To Flexplate
    G02763065Courtesy of FORD MOTOR CO.

    19. VEHICLES EQUIPPED WITH 4R70E TRANSMISSION 

  19. Disconnect the shift cables and the mounting bracket.
    1. Disconnect the clip.
    2. Remove the bolts.
    Fig 16: Disconnecting Shift Cables And Mounting Bracket
    G02763066Courtesy of FORD MOTOR CO.

    20. ALL VEHICLES 

  20. Remove the two transmission-to-engine bolts and position the shifter cable support bracket, mounting bracket and cable aside.
    Fig 17: Removing Transmission-To-Engine Bolts
    G02763067Courtesy of FORD MOTOR CO.
  21. Remove the RH lower transmission-to-engine bolt.
    Fig 18: Removing RH Lower Transmission-To-Engine Bolt
    G02763068Courtesy of FORD MOTOR CO.
    22. NOTE: RH shown, LH similar.
    Fig 19: Removing Engine Mount Nuts
    G02763069Courtesy of FORD MOTOR CO.
  22. Remove the four engine mount nuts.
  23. Disconnect the power steering reservoir hose and the power steering pressure tube at the power steering pump.
    • Allow the fluid to drain into a drain pan.
    Fig 20: Disconnecting Power Steering Reservoir Hose And Power Steering Pressure Tube At Power Steering Pump
    G02763070Courtesy of FORD MOTOR CO.
  24. Remove the nut and position the transmission fluid cooler support bracket aside.
    Fig 21: Removing Nut
    G02763071Courtesy of FORD MOTOR CO.
  25. Remove the valance panel. For additional information, refer to FRONT END BODY PANELS .
  26. Disconnect the upper radiator hose and the degas hose from the radiator.
    Fig 22: Disconnecting Upper Radiator Hose And Degas Hose From Radiator
    G02763072Courtesy of FORD MOTOR CO.
    27. CAUTION: The large clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it.
    Fig 23: Removing Fan Blade And Fan Clutch Using Special Tool
    G02763073Courtesy of FORD MOTOR CO.
  27. Remove the fan blade assembly and fan clutch.
    1. Use the special tool to hold the coolant pump pulley.
    2. Using the special tool, remove the fan blade and the fan clutch.
  28. Disconnect the degas hose retainer from the fan shroud.
    Fig 24: Disconnecting Degas Hose Retainer From Fan Shroud
    G02763074Courtesy of FORD MOTOR CO.
  29. Remove the fan shroud, the fan, and the fan clutch.
    1. Remove the bolts.
    2. Lift the fan shroud, the fan, and the fan clutch from the vehicle.
    Fig 25: Removing Fan Shroud, Fan, And Fan Clutch
    G02763075Courtesy of FORD MOTOR CO.
    30. NOTE: LH shown, RH similar.
    Fig 26: Removing Bolts And Radiator Support Brackets
    G02763076Courtesy of FORD MOTOR CO.
  30. Remove the bolts and the radiator support brackets.
  31. Remove the radiator from the vehicle.
    Fig 27: Removing Radiator From Vehicle
    G02763077Courtesy of FORD MOTOR CO.
  32. Disconnect the A/C pressure cutoff switch electrical connector.
    Fig 28: Disconnecting A/C Pressure Cutoff Switch Electrical Connector
    G02763078Courtesy of FORD MOTOR CO.
    33. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.
    Fig 29: Disconnecting Compressor Suction Tube
    G02763079Courtesy of FORD MOTOR CO.
  33. Disconnect the compressor suction tube.
    34. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.
    Fig 30: Disconnecting Condenser Core Refrigerant Tubes
    G02763080Courtesy of FORD MOTOR CO.
  34. Disconnect the condenser core refrigerant tubes.
    1. Disconnect the compressor discharge tube.
    2. Disconnect the condenser-to-evaporator tube.
    35. NOTE: RH shown, LH similar.
    Fig 31: Removing A/C Condenser Core
    G02763081Courtesy of FORD MOTOR CO.
  35. Remove the A/C condenser core.
    1. Remove the bolts.
    2. Remove the A/C condenser brackets.
    3. Remove the A/C condenser core.
  36. Set the hood latch aside.
    1. Remove the hood latch bolts.
    2. Disengage the cable routing clip.
    Fig 32: Removing Hood Latch Bolts
    G02763082Courtesy of FORD MOTOR CO.
  37. Remove the bolts and set the power steering reservoir aside.
    Fig 33: Removing Bolts
    G02763083Courtesy of FORD MOTOR CO.
    38. NOTE: Cover removed for clarity.
    Fig 34: Removing Nuts And Battery Feed Cable At Power Distribution Box
    G02763084Courtesy of FORD MOTOR CO.
  38. Remove the nuts and the battery feed cable at the power distribution box.
  39. Set aside the battery feed wiring harness to the power distribution box.
    • Disengage the routing clips.
    Fig 35: Disengaging Routing Clips
    G02763085Courtesy of FORD MOTOR CO.
    40. NOTE: RH shown, LH similar.
    Fig 36: Removing Bolts And Upper Radiator Support
    G02763086Courtesy of FORD MOTOR CO.
  40. Remove the eight bolts and the upper radiator support.
    41. NOTE: RH shown, LH similar.
    Fig 37: Removing Pin-Type Retainers And RH And LH Air Deflectors
    G02763087Courtesy of FORD MOTOR CO.
  41. Remove the pin-type retainers and the RH and LH air deflectors.
  42. Set aside the LH side of the headlamp dash panel junction wiring harness.
    1. Remove the screw.
    2. Disengage the routing clips.
    Fig 38: Removing Screw
    G02763088Courtesy of FORD MOTOR CO.
  43. Set aside the RH side of the headlamp dash panel junction wiring harness.
    1. Disconnect the electrical connector.
    2. Remove the screw.
    3. Disengage the routing clips.
    Fig 39: Disconnecting Electrical Connector
    G02763089Courtesy of FORD MOTOR CO.
  44. Remove the 12 bolts and the lower radiator support.
    Fig 40: Removing Bolts And Lower Radiator Support
    G02763090Courtesy of FORD MOTOR CO.
  45. Disconnect the lower radiator hose from the oil filter adapter water inlet and set aside.
    Fig 41: Disconnecting Lower Radiator Hose From Oil Filter Adapter Water Inlet
    G02763091Courtesy of FORD MOTOR CO.
    46. NOTE: Typical shown.
    Fig 42: Removing Drive Belt
    G02763092Courtesy of FORD MOTOR CO.
  46. Rotate the tensioner clockwise to release belt tension and remove the drive belt.
  47. Disconnect the generator electrical connections.
    1. Remove the B+ terminal nut and disconnect the terminal.
    2. Disconnect the S electrical connector.
    3. Disconnect the ASI electrical connector.
    Fig 43: Disconnecting Generator Electrical Connections
    G02763093Courtesy of FORD MOTOR CO.
  48. Remove the bolts and the generator.
    Fig 44: Removing Bolts And Generator
    G02763094Courtesy of FORD MOTOR CO.
    49. NOTE: Windsor engine shown, Romeo engine similar.
    Fig 45: Removing Ground Strap And Mounting Bracket
    G02763095Courtesy of FORD MOTOR CO.
  49. Disconnect the electrical connectors, remove the nut, and remove the ground strap and mounting bracket.
  50. Remove the engine oil filler tube support strap bolt.
    Fig 46: Removing Engine Oil Filler Tube Support Strap Bolt
    G02763096Courtesy of FORD MOTOR CO.
  51. Remove the fluid level indicator and disconnect the attachments at the transmission fluid filler tube.
    1. Remove the fluid level indicator.
    2. Disconnect the rear heater hose hanger.
    Fig 47: Removing Fluid Level Indicator
    G02763097Courtesy of FORD MOTOR CO.
  52. Disconnect the evaporative emission canister purge valve electrical connector.
    Fig 48: Disconnecting Evaporative Emission Canister Purge Valve Electrical Connector
    G02763098Courtesy of FORD MOTOR CO.
  53. Remove the nut and the transmission fluid filler tube, and allow the fluid to drain into a suitable container.
    Fig 49: Removing Nut And Transmission Fluid Filler Tube
    G02763099Courtesy of FORD MOTOR CO.
  54. Release the wiring retainers from the heater outlet tube bracket.
    1. Release the knock sensor electrical connector retainer.
    2. Release the engine harness routing clip retainer.
    Fig 50: Releasing Wiring Retainers From Heater Outlet Tube Bracket
    G02763100Courtesy of FORD MOTOR CO.
  55. Disconnect the hose from the heater outlet tube.
    Fig 51: Disconnecting Hose From Heater Outlet Tube
    G02763101Courtesy of FORD MOTOR CO.
  56. Remove the heater outlet tube studs.
    Fig 52: Removing Heater Outlet Tube Studs
    G02763102Courtesy of FORD MOTOR CO.
  57. Remove the heater outlet tube.
    Fig 53: Removing Heater Outlet Tube
    G02763103Courtesy of FORD MOTOR CO.
  58. Release the transmission wiring harness connector retainer from the bracket. Disconnect the transmission wiring harness and the LH and RH heated oxygen sensor (HO2S) electrical connectors.
    Fig 54: Disconnecting Transmission Wiring Harness And LH And RH Heated Oxygen Sensor (HO2S) Electrical Connectors
    G02763104Courtesy of FORD MOTOR CO.
  59. Remove the four upper transmission-to-engine bolts and the fuel line, and the LH HO2S brackets.
    Fig 55: Removing Upper Transmission-To-Engine Bolts And Fuel Line, And LH HO2S Brackets
    G02763105Courtesy of FORD MOTOR CO.
  60. Install the special tool as shown.
    Fig 56: Installing Special Tool
    G02763106Courtesy of FORD MOTOR CO.
  61. Support the transmission with a jack.
  62. Remove the engine from the vehicle.
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