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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 797 (Engine - 4.6L And 5.4L) >> Removal >> Engine >> Special Tool(s)

Special Tool(s)

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G03886715
 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
G03886108
 Wrench, Fan Clutch Nut 303 - 240 (T84T-6312-D)
G03886917
 Holding Wrench, Fan Pulley 303-239 (T84T-6312-C)

    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 1: Disconnecting Hose
      G03886599Courtesy of FORD MOTOR CO.
  6. Remove the pushpin retainers and the splash shield.
    Fig 2: Identifying Pushpin Retainers And Splash Shield
    G03885266Courtesy of FORD MOTOR CO.
  7. Disconnect the transmission cooler hoses and drain the fluid into a suitable container.
    Fig 3: Disconnecting Transmission Cooler Hoses
    G03886172Courtesy of FORD MOTOR CO.
  8. Disconnect the exhaust system from the LH and RH exhaust manifolds.
    Fig 4: Disconnecting Exhaust System From LH And RH Exhaust Manifolds
    G03885547Courtesy of FORD MOTOR CO.
  9. Drain the engine oil.
    Fig 5: Locating Drain Plug
    G03885548Courtesy of FORD MOTOR CO.
  10. Disconnect the oil cooler hoses and set aside.
    Fig 6: Locating Cooler Hoses
    G03885411Courtesy of FORD MOTOR CO.
  11. Remove the oil filter.
    Fig 7: Removing Oil Filter
    G03885412Courtesy of FORD MOTOR CO.
    12. CAUTION: The oil cooler must be replaced or severe damage to the engine can occur.
    Fig 8: Removing Oil Cooler
    G03885413Courtesy of FORD MOTOR CO.
  12. Loosen the threaded insert and remove and discard the oil cooler.
  13. Remove the starter motor solenoid terminal cover.
    Fig 9: Removing Starter Motor Solenoid Terminal Cover
    G03886928Courtesy of FORD MOTOR CO.
  14. Disconnect the starter motor electrical connections.
    Fig 10: Disconnecting Starter Motor Electrical Connections
    G03886608Courtesy of FORD MOTOR CO.
  15. Remove the starter motor.
    1. Remove the stud bolt.
    2. Remove the two bolts.
    3. Remove the starter.
      Fig 11: Removing Starter Motor
      G03886609Courtesy of FORD MOTOR CO.
  16. Remove the flexplate inspection cover.
    Fig 12: Locating Flexplate Inspection Cover Bolts
    G03885458Courtesy of FORD MOTOR CO.
  17. Remove the cylinder block opening cover.
    Fig 13: Removing Cylinder Block Opening Cover
    G03886115Courtesy 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 14: Locating Torque Converter-To-Flexplate Nuts
      G03885557Courtesy of FORD MOTOR CO.
  19. Disconnect the shift cable and the mounting bracket.
    1. Disconnect the clip.
    2. Remove the bolts.
      Fig 15: Disconnecting Clip
      G03885558Courtesy of FORD MOTOR CO.
  20. Remove the two transmission-to-engine bolts and position the shifter cable support bracket, mounting bracket and cable aside.
    Fig 16: Removing Two Transmission-To-Engine Bolts
    G03885559Courtesy of FORD MOTOR CO.
  21. Remove the RH lower transmission-to-engine bolt.
    Fig 17: Removing RH Lower Transmission-To-Engine Bolt
    G03885560Courtesy of FORD MOTOR CO.
    22. NOTE: RH shown; LH similar.
    Fig 18: Removing Four Engine Mount Nuts
    G03885561Courtesy 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 19: Disconnecting Power Steering Reservoir Hose
      G03885562Courtesy of FORD MOTOR CO.
  24. Remove the nut and position the transmission fluid cooler support bracket aside.
    Fig 20: Removing Transmission Fluid Cooler Support Bracket Aside
    G03885563Courtesy 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 21: Disconnecting Upper Radiator Hose
    G03885564Courtesy of FORD MOTOR CO.
    27. CAUTION: The large clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it.
  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.
      Fig 22: Removing Fan Blade And Fan Clutch
      G03885565Courtesy of FORD MOTOR CO.
  28. Disconnect the degas hose retainer from the fan shroud.
    Fig 23: Disconnecting Degas Hose Retainer From Fan Shroud
    G03885566Courtesy of FORD MOTOR CO.
  29. Remove the fan shroud, fan and fan clutch.
    1. Remove the bolts.
    2. Lift the fan shroud, fan and fan clutch from the vehicle.
      Fig 24: Lifting Fan Shroud, Fan And Fan Clutch From Vehicle
      G03885567Courtesy of FORD MOTOR CO.
    30. NOTE: LH shown; RH similar.
    Fig 25: Removing Radiator Support Brackets
    G03886623Courtesy of FORD MOTOR CO.
  30. Remove the bolts and the radiator support brackets.
  31. Remove the radiator from the vehicle.
    Fig 26: Removing Radiator From Vehicle
    G03886624Courtesy of FORD MOTOR CO.
  32. Disconnect the A/C pressure cutoff switch electrical connector.
    Fig 27: Disconnecting A/C Pressure Cutoff Switch Electrical Connector
    G03886625Courtesy of FORD MOTOR CO.
    33. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.
    Fig 28: Disconnecting Compressor Suction Tube
    G03885571Courtesy 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.
  34. Disconnect the condenser core refrigerant tubes.
    1. Disconnect the compressor discharge tube.
    2. Disconnect the condenser-to-evaporator tube.
      Fig 29: Disconnecting Condenser-To-Evaporator Tube
      G03885572Courtesy of FORD MOTOR CO.
    35. NOTE: RH shown; LH similar.
  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.
      Fig 30: Removing A/C Condenser Core
      G03885573Courtesy of FORD MOTOR CO.
  36. Set the hood latch aside.
    1. Remove the hood latch bolts.
    2. Disengage the cable routing clip.
      Fig 31: Disengaging Cable Routing Clip
      G03886629Courtesy of FORD MOTOR CO.
  37. Remove the bolts and set the power steering reservoir aside.
    Fig 32: Removing Power Steering Reservoir Bolts
    G03886630Courtesy of FORD MOTOR CO.
    38. NOTE: Cover removed for clarity.
    Fig 33: Removing Nuts And Battery Feed Cable At Power Distribution Box
    G03885576Courtesy 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 34: Disengaging Routing Clips
      G03885577Courtesy of FORD MOTOR CO.
  40. If equipped, disconnect the air temperature sensor electrical connector.
    Fig 35: Disconnecting Air Temperature Sensor Electrical Connector
    G03885578Courtesy of FORD MOTOR CO.
  41. Disconnect the front impact severity sensor electrical connector.
    Fig 36: Disconnecting Front Impact Severity Sensor Electrical Connector
    G03885579Courtesy of FORD MOTOR CO.
  42. Disconnect the horn electrical connector.
    Fig 37: Disconnecting Horn Electrical Connector
    G03885580Courtesy of FORD MOTOR CO.
    43. NOTE: RH shown; LH similar.
    Fig 38: Removing Upper Radiator Support Bolts
    G03886636Courtesy of FORD MOTOR CO.
  43. Remove the eight bolts and the upper radiator support.
    44. NOTE: RH shown; LH similar.
    Fig 39: Removing RH And LH Air Deflectors
    G03885582Courtesy of FORD MOTOR CO.
  44. Remove the pin-type retainers and the RH and LH air deflectors.
  45. Set aside the LH side of the headlamp dash panel junction wiring harness.
    1. Remove the screw.
    2. Disengage the routing clips.
      Fig 40: Disengaging Routing Clips
      G03885583Courtesy of FORD MOTOR CO.
  46. 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 41: Disconnecting Electrical Connector
      G03886639Courtesy of FORD MOTOR CO.
  47. Remove the 12 bolts and the lower radiator support.
    Fig 42: Removing Lower Radiator Support
    G03886640Courtesy of FORD MOTOR CO.
  48. Disconnect the lower radiator hose from the oil filter adapter water inlet and set aside.
    Fig 43: Disconnecting Lower Radiator Hose From Oil Filter Adapter Water Inlet
    G03886149Courtesy of FORD MOTOR CO.
    49. NOTE: Typical shown.
    Fig 44: Rotating Accessory Drive Belt Tensioner Clockwise
    G03886148Courtesy of FORD MOTOR CO.
  49. Rotate the tensioner clockwise to release belt tension and remove the drive belt.
  50. 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 45: Disconnecting ASI Electrical Connector
      G03885511Courtesy of FORD MOTOR CO.
  51. Remove the bolts and the generator.
    Fig 46: Removing Generator Bolts
    G03885512Courtesy of FORD MOTOR CO.
  52. Disconnect the engine wiring harness from the powertrain control module (PCM) bracket.
    Fig 47: Identifying Engine Wiring Harness To PCM Bracket Retainer
    G03885211Courtesy of FORD MOTOR CO.
  53. Disconnect the PCM electrical connectors. Position the engine wiring on the engine.
    Fig 48: Disconnecting PCM Electrical Connectors
    G03885591Courtesy of FORD MOTOR CO.
  54. Disconnect the engine wiring harness electrical connectors.
    Fig 49: Identifying Engine Wiring Harness Electrical Connectors
    G03885233Courtesy of FORD MOTOR CO.
    55. NOTE: Windsor engine shown; Romeo engine similar.
    Fig 50: Disconnecting Electrical Connectors
    G03885234Courtesy of FORD MOTOR CO.
  55. Disconnect the electrical connectors, remove the nut, ground strap and mounting bracket.
  56. Remove the engine oil filler tube support strap bolt.
    Fig 51: Removing Engine Oil Filler Tube Support Strap Bolt
    G03885594Courtesy of FORD MOTOR CO.
  57. 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 52: Disconnecting Rear Heater Hose Hanger
      G03886140Courtesy of FORD MOTOR CO.
  58. Disconnect the evaporative emission canister purge valve electrical connector.
    Fig 53: Disconnecting Evaporative Emission Canister Purge Valve Electrical Connector
    G03885596Courtesy of FORD MOTOR CO.
  59. Remove the nut and the transmission fluid filler tube, and allow the fluid to drain into a suitable container.
    Fig 54: Removing Transmission Fluid Filler Tube
    G03885597Courtesy of FORD MOTOR CO.
  60. 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 55: Releasing Engine Harness Routing Clip Retainer
      G03885598Courtesy of FORD MOTOR CO.
  61. Disconnect the hose from the heater outlet tube.
    Fig 56: Disconnecting Hose From Heater Outlet Tube
    G03885599Courtesy of FORD MOTOR CO.
  62. Remove the heater outlet tube studs.
    Fig 57: Removing Heater Outlet Tube Studs
    G03885600Courtesy of FORD MOTOR CO.
  63. Remove the heater outlet tube.
    Fig 58: Removing Heater Outlet Tube
    G03885451Courtesy of FORD MOTOR CO.
  64. 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 59: Disconnecting Transmission Wiring Harness
    G04612445Courtesy of FORD MOTOR CO.
  65. Remove the four upper transmission-to-engine bolts and the fuel line, and the LH HO2S brackets.
    Fig 60: Removing Four Upper Transmission-To-Engine Bolts
    G03886655Courtesy of FORD MOTOR CO.
  66. Install the special tool as shown in Fig 61.
    Fig 61: Identifying Special Tool
    G03885604Courtesy of FORD MOTOR CO.
  67. Support the transmission with a jack.
  68. Remove the engine from the vehicle.
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