Section 771 (Engine - 3.0L (4V)): Removal: Engine

WARNING: This page is about a different car, the 2006 Mercury Milan, 2006 Lincoln Zephyr, and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S)

Courtesy of FORD MOTOR CO.	Separator, Ball joint 205-592
Courtesy of FORD MOTOR CO.	Adapter for 204-592 204-592/1
Courtesy of FORD MOTOR CO.	Remover, Halfshaft 205-832
Courtesy of FORD MOTOR CO.	Slide Hammer 100-001
Courtesy of FORD MOTOR CO.	Remover, Halfshaft 205-243
Courtesy of FORD MOTOR CO.	Powertrain Lift 014-00765
Courtesy of FORD MOTOR CO.	Universal Adapter Brackets 014-0001 Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent
Courtesy of FORD MOTOR CO.	Lifting Brackets, Engine 134-00243 or equivalent
Courtesy of FORD MOTOR CO.	Engine Lifting Bracket Set 303-1140
Courtesy of FORD MOTOR CO.	Lifting Bracket, Engine 303-050 (T70P-6000)
Courtesy of FORD MOTOR CO.	Heavy Duty Floor Crane 014-00071 or equivalent
Courtesy of FORD MOTOR CO.	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
Courtesy of FORD MOTOR CO.	Tie-Rod End Remover 211-105 (T85M-3395-A)

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.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Recover the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS
Place the steering wheel in the straight ahead position and the ignition key in the OFF position.
Remove the 2 nuts and the steering joint cover.

Fig 1: Locating Steering Joint Cover And Nuts
Courtesy of FORD MOTOR CO.

CAUTION: 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 .

NOTE: Index the steering column shaft position to the steering gear for reference during installation.

Fig 2: Locating Steering Column Shaft Bolt

Courtesy of FORD MOTOR CO.

Remove the bolt and disconnect the steering column shaft from the steering gear.
Drain the cooling system. For additional information, refer to ENGINE COOLING .
If equipped, remove the 7 screws and the underbody cover.

Fig 3: Locating Underbody Cover Screws
Courtesy of FORD MOTOR CO.
Disconnect the power steering cooler tube and drain the power steering fluid into a suitable drain pan.

Fig 4: Locating Power Steering Cooler Tube
Courtesy of FORD MOTOR CO.
Remove the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .

CAUTION: The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.

Fig 5: Locating Steering Gear-To-Dash Seal Clips

Courtesy of FORD MOTOR CO.

Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
Remove the power steering pressure (PSP) hose bracket bolt.

Fig 6: Locating Power Steering Pressure (PSP) Hose Bracket Bolt
Courtesy of FORD MOTOR CO.
Remove and discard the PSP hose banjo bolt and the 2 seals from the steering gear.

Fig 7: Locating PSP Hose Banjo Bolt
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the heat shield.

Fig 8: Locating Heat Shield And Bolts
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the engine roll restrictor.

Fig 9: Identifying Engine Roll Restrictor And Bolts
Courtesy of FORD MOTOR CO.
Remove the 4 screws and position the RH fender splash shield aside.

Fig 10: Locating RH Fender Splash Shield Screws
Courtesy of FORD MOTOR CO.
Remove the 6 pin-type retainers (4 shown) and the RH splash shield.

Fig 11: Locating Splash Shield Pin-Type Retainers
Courtesy of FORD MOTOR CO.
Remove the 4 screws and position the LH fender splash shield aside.

Fig 12: Locating LH Fender Splash Shield Screws
Courtesy of FORD MOTOR CO.
Remove the 6 pin-type retainers (4 shown) and the LH splash shield.

Fig 13: Locating LH Splash Shield Pin-Type Retainers
Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 14: Locating Tie-Rod Ends Nuts And Cotter Pins

Courtesy of FORD MOTOR CO.

Remove the cotter pins and nuts from the tie-rod ends.

NOTE: LH shown, RH similar.

Fig 15: Identifying Special Tool (211-105)

Courtesy of FORD MOTOR CO.

Using the special tool, separate the tie-rod ends from the steering knuckles.

NOTE: LH shown, RH similar.

Fig 16: Locating Stabilizer Bar Links Nut

Courtesy of FORD MOTOR CO.

Remove the nuts and separate the stabilizer bar links from the struts.

NOTE: LH shown, RH similar.

Fig 17: Locating Lower Ball Joint Nuts

Courtesy of FORD MOTOR CO.

Remove the lower ball joint nuts.

CAUTION: When the lower ball joint is separated from the wheel knuckle, the lower arm may strike the outer constant velocity (CV) joint boot with enough force to damage the boot clamp. This will result in a loss of grease from the outer CV joint. Place a block of wood, or similar item, between the lower arm and the outer CV joint to prevent the lower arm from striking the outer CV joint.

NOTE: Once pressure is applied to the ball joint with the special tool, it may be necessary to tap the wheel knuckle at the ball joint area to separate the ball joint from the wheel knuckle.

NOTE: LH shown, RH similar.

Fig 18: Identifying Special Tools (204-592/1 And 204-592)

Courtesy of FORD MOTOR CO.

Using the special tools, separate the lower ball joints from the lower control arms.

NOTE: LH shown, RH similar.

Fig 19: Locating Lower Control Arms Bolts

Courtesy of FORD MOTOR CO.

Remove the through bolts from the lower control arms.
Position the special tool under the subframe assembly.

Fig 20: Identifying Special Tools (014-00765)
Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 21: Locating Subframe Bracket-To-Body Bolts

Courtesy of FORD MOTOR CO.

Remove the subframe bracket-to-body bolts.

NOTE: LH shown, RH similar.

Fig 22: Locating Subframe Nuts

Courtesy of FORD MOTOR CO.

Remove the subframe nuts and the subframe brackets.

NOTE: LH shown, RH similar.

Fig 23: Locating Front Subframe Nuts

Courtesy of FORD MOTOR CO.

Remove the front subframe nuts.
Lower the subframe assembly from the vehicle.
Disconnect the transaxle cooler hoses.

Fig 24: Locating Transaxle Cooler Hoses Clamps
Courtesy of FORD MOTOR CO.
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 Bolts
  Courtesy of FORD MOTOR CO.
Remove and discard the engine oil filter.

Fig 26: Locating Engine Oil Filter
Courtesy of FORD MOTOR CO.
Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.3L .
Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the nut and disconnect the power feed wire from the battery terminal.

Fig 27: Locating Power Feed Wire Nut
Courtesy of FORD MOTOR CO.
Disconnect the 2 engine wiring harness electrical connectors.

Fig 28: Locating Engine Wiring Harness Electrical Connectors
Courtesy of FORD MOTOR CO.
Remove the bolt and position aside the ground wire.

Fig 29: Locating Ground Wire Bolt
Courtesy of FORD MOTOR CO.
Disconnect the powertrain control module (PCM) electrical connector and the pin-type retainer.

Fig 30: Locating Powertrain Control Module (PCM) Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Disconnect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the heater hose from the thermostat housing.

Fig 31: Locating Heater Hose From Thermostat Housing
Courtesy of FORD MOTOR CO.
Disconnect the heater hose inline connection.

Fig 32: Locating Heater Hose Inline Connection
Courtesy of FORD MOTOR CO.
Disconnect the throttle body coolant hose.

Fig 33: Locating Throttle Body Coolant Hose
Courtesy of FORD MOTOR CO.
Disconnect the evaporative emissions (EVAP) hose.

Fig 34: Locating Evaporative Emissions (EVAP) Hose
Courtesy of FORD MOTOR CO.
Disconnect the upper and lower radiator hoses from the thermostat housing.

Fig 35: Locating Upper And Lower Radiator Hoses From Thermostat Housing
Courtesy of FORD MOTOR CO.
Disconnect the transaxle control cable from the transaxle selector lever.

Fig 36: Locating Transaxle Selector Lever
Courtesy of FORD MOTOR CO.
Remove the 3 transaxle control cable bracket bolts and position the cable aside.

Fig 37: Locating Transaxle Control Cable Bracket Bolts
Courtesy of FORD MOTOR CO.
Remove the bolt and position the ground wire aside.

Fig 38: Locating Ground Wire And Bolt
Courtesy of FORD MOTOR CO.
Remove the vacuum tube bracket bolt.

Fig 39: Locating Vacuum Tube Bracket Bolt
Courtesy of FORD MOTOR CO.
Disconnect the vacuum hose from the intake manifold.

Fig 40: Locating Vacuum Hose From Intake Manifold
Courtesy of FORD MOTOR CO.
If equipped, detach the block heater cable retaining clips from the cooling fan shroud.

Fig 41: Locating Block Heater Cable Retaining Clips
Courtesy of FORD MOTOR CO.
Disconnect the power steering hose from the power steering reservoir.

Fig 42: Locating Power Steering Hose From Power Steering Reservoir
Courtesy of FORD MOTOR CO.
Detach the power steering hose retaining clip from the LH valve cover stud bolt and the engine wiring harness.

Fig 43: Locating Power Steering Hose Retaining Clip
Courtesy of FORD MOTOR CO.
Disconnect the coolant hose from the degas bottle.

Fig 44: Locating Degas Bottle Coolant Hose Clamp
Courtesy of FORD MOTOR CO.
Detach the coolant hose retaining clip and position the coolant hose aside.

Fig 45: Locating Coolant Hose Retaining Clip
Courtesy of FORD MOTOR CO.
Remove the 2 A/C tube bracket bolts.

Fig 46: Locating A/C Tube Bracket Bolts
Courtesy of FORD MOTOR CO.
Remove the 2 nuts and disconnect the A/C tubes.

Fig 47: Locating A/C Tubes Nuts
Courtesy of FORD MOTOR CO.
Remove the bolt and the ground wire from the engine mount bracket.

Fig 48: Locating Ground Wire And Bolt
Courtesy of FORD MOTOR CO.
Remove the bolt and separate the A/C manifold from the A/C compressor.

Fig 49: Locating A/C Manifold And Bolt
Courtesy of FORD MOTOR CO.
Using the special tools, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.

Fig 50: Identifying Special Tools (100-001, 205-243 And 205-832)
Courtesy of FORD MOTOR CO.
Disconnect the crankshaft position (CKP) sensor electrical connector and pin-type retainer.

Fig 51: Locating (CKP) Sensor Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Disconnect the power steering pressure (PSP) switch electrical connector.

Fig 52: Locating Power Steering Pressure (PSP) Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the catalyst monitor sensor (CMS) electrical connector and pin-type retainer.

Fig 53: Locating (CMS) Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Remove the 2 RH halfshaft carrier bearing bracket bolts.

Fig 54: Locating RH Halfshaft Carrier Bearing Bracket Bolts
Courtesy of FORD MOTOR CO.
Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.

Fig 55: Locating RH Halfshaft
Courtesy of FORD MOTOR CO.
Remove the torque converter nut access plug.

Fig 56: Locating Torque Converter Nut Access Plug
Courtesy of FORD MOTOR CO.
Remove the 3 torque converter nuts.

Fig 57: Locating Torque Converter Nuts
Courtesy of FORD MOTOR CO.
Remove the 2 oil pan-to-transaxle bolts.

Fig 58: Locating Oil Pan-To-Transaxle Bolts
Courtesy of FORD MOTOR CO.

NOTE: Position a suitable block of wood under the transaxle.

Install the special tools onto the engine.
- Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
  
  Fig 59: Identifying Special Tools (303-D095, 014-00765)
  Courtesy of FORD MOTOR CO.
Remove the 2 transaxle mount bolts.

Fig 60: Locating Transaxle Mount Bolts
Courtesy of FORD MOTOR CO.
Remove the bolt and damper.

Fig 61: Locating Damper And Bolt
Courtesy of FORD MOTOR CO.
Remove the bolt, 3 nuts and the engine mount bracket.

Fig 62: Locating Engine Mount Bracket, Bolt And Nuts
Courtesy of FORD MOTOR CO.
Lower the engine and transaxle from the vehicle.
Install the special tools.

Fig 63: Identifying Special Tools (303-050 And 014-0001)
Courtesy of FORD MOTOR CO.
Detach the wiring harness retainer from the PSP hose bracket.

Fig 64: Locating PSP Hose Bracket Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Remove the bolt and detach the PSP hose bracket from the cylinder head.

Fig 65: Locating PSP Hose Bracket Bolt
Courtesy of FORD MOTOR CO.
Detach the heated oxygen sensor (HO2S) electrical connector from the PSP bracket.

Fig 66: Locating Heated Oxygen Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the bolt and detach the PSP hose bracket from the cylinder head.

Fig 67: Locating PSP Hose Bracket Bolt
Courtesy of FORD MOTOR CO.
Remove the bolt and detach the PSP hose bracket from the power steering reservoir.

Fig 68: Locating PSP Hose Bracket Bolt
Courtesy of FORD MOTOR CO.
Remove the banjo bolt and the PSP hose.
- Discard the banjo bolt and 2 seals.
  
  Fig 69: Locating Banjo Bolt
  Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 70: Identifying Special Tools (134-00243)
Courtesy of FORD MOTOR CO.
Disconnect the exhaust gas recirculation (EGR) valve electrical connector.

Fig 71: Locating Exhaust Gas Recirculation Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Loosen the EGR tube-to-EGR valve nut.

Fig 72: Locating EGR Tube-To-EGR Valve Nut
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the EGR valve.
- Discard the gasket.
  
  Fig 73: Locating EGR Valve And Bolts
  Courtesy of FORD MOTOR CO.
Loosen the EGR tube-to-catalytic converter nut and remove the EGR tube.

Fig 74: Locating EGR Tube-To-Catalytic Converter Nut And EGR Tube
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the heat shield.

Fig 75: Locating Heat Shield Bolts
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the catalytic converter bracket.

Fig 76: Locating Catalytic Converter Bracket And Bolts
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the catalytic converter bracket assembly.

Fig 77: Locating Catalytic Converter Bracket And Bolts
Courtesy of FORD MOTOR CO.

NOTE: When installing the lower half of the lifting bracket it will be easier to loosely install the upper bolt first then install the lower bolt.

Fig 78: Identifying Lower Half Of Lifting Hook

Courtesy of FORD MOTOR CO.

Install the lower half of the special tool.
Install the upper half of the special tool.

Fig 79: Identifying Upper Half Of Lifting Hook
Courtesy of FORD MOTOR CO.
Using the special tools and a suitable engine crane, remove the engine and transaxle from the lift table.

Fig 80: Identifying Special Tools
Courtesy of FORD MOTOR CO.
Remove the bolt and the ground wire.

Fig 81: Locating Ground Wire And Bolt
Courtesy of FORD MOTOR CO.
Remove the bolt and the catalyst monitor sensor (CMS) electrical connector bracket.

Fig 82: Locating Catalyst Monitor Sensor (CMS) Electrical Connector Bracket Bolt
Courtesy of FORD MOTOR CO.
Disconnect the transmission control module (TCM) electrical connector.

Fig 83: Locating Transmission Control Module (TCM) Electrical Connector
Courtesy of FORD MOTOR CO.
Detach the wiring harness pin-type retainer.

Fig 84: Locating Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Remove the 2 nuts and the starter motor wiring.

Fig 85: Locating Starter Motor Wiring Nuts
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the starter motor.

Fig 86: Locating Starter Motor Bolts
Courtesy of FORD MOTOR CO.
Remove the engine-to-transaxle bolt.

Fig 87: Locating Engine-To-Transaxle Bolt
Courtesy of FORD MOTOR CO.
Remove the 3 transaxle-to-engine bolts.

Fig 88: Locating Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
Detach the wiring harness retainer from the stud bolt.

Fig 89: Locating Wiring Harness Retainer Stud Bolt
Courtesy of FORD MOTOR CO.
Remove the transaxle-to-engine stud bolt, bolt and nut.

Fig 90: Locating Transaxle-To-Engine Stud Bolt, Bolt And Nut
Courtesy of FORD MOTOR CO.
Using the special tools and a suitable engine crane, separate the engine and transaxle.

Fig 91: Identifying Special Tools
Courtesy of FORD MOTOR CO.