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Removal & Installation: Engine: Removal

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect both battery ground cables. Loosen the clamps and remove the air cleaner outlet tube.
  2. Remove the air intake tube and adapter. Loosen the air intake tube clamp. See Fig 1. Remove the air intake tube adapter bolts. Lift the tube and adapter, disconnect the wastegate pressure hose, and remove the tube and adapter from the vehicle.
  3. Partially drain the cooling system. See COOLING SYSTEM BLEEDING . Remove the wing bolt and lug wrench. Squeeze the clamp and remove the overflow hose.
  4. Remove the degas bottle retaining bolts. See Fig 2. Squeeze the clamp and remove the degas bottle supply hose. Remove the degas bottle.
  5. On vehicles equipped with A/C, recover the refrigerant. Discharge A/C system, using approved refrigerant recovery/recycling equipment. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
  6. Remove the radiator grille, and the radiator grille opening panel. See RADIATOR GRILLE (EXCURSION & "F" SERIES) . Remove the bolts and position the hood latch aside. Remove the right side air deflector push pins. See Fig 3.
  7. Remove the air charge cooler retainers. See Fig 4. Remove the radiator bolts and the brackets. See Fig 5. Detach the battery cable retainers and position the battery cables aside.
    8. NOTE: Right side shown, left side similar.
  8. Remove the 8 radiator upper support bolts and the radiator upper support. See Fig 6. Remove the radiator sight shield. See Fig 7.
  9. On vehicles equipped with A/C, disconnect the A/C condenser core inlet and outlet tubes. See Fig 8. Remove the A/C condenser.
    10. NOTE: Both the inlet and outlet ducts are removed the same way. Only the outlet duct is shown.
  10. On all vehicles, loosen the inlet and outlet duct clamps and remove the inlet and outlet ducts from the charge air cooler. See Fig 9. Detach the ducts from the air charge cooler.
  11. Remove the air charge cooler. Disconnect the upper radiator hose from the radiator. Remove the bolts and position the fan shroud on the fan. See Fig 10.
  12. Raise and support the vehicle. Disconnect the degas supply and lower radiator hoses from the radiator. Lower the vehicle. Remove the radiator and fan shroud.
    13. CAUTION: The large clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it.
  13. Using the Fan Pulley Holding Wrench (303-478, T94T-6312-AH) and Fan Clutch Nut Wrench (303-214, T83T-6312-B), remove the fan and the fan clutch from the water pump pulley. Rotate the belt tensioner counterclockwise and remove the drive belt.
  14. Disconnect the Manifold Absolute Pressure (MAP) sensor hose from the turbocharger compressor manifold. See Fig 11. Remove the engine ground cable from the right side of the engine block. Remove the ground cable nut. See Fig 12. Remove the starter wire retaining bracket. Remove the engine ground cable.
  15. On vehicles equipped with A/C, disconnect the A/C compressor electrical connector. Disconnect the A/C manifold from the A/C compressor.
  16. On all vehicles, disconnect the power steering hoses from power steering pump. Disconnect the generator electrical connectors.
  17. Remove the generator mounting bracket bolts. See Fig 13. Remove the generator mounting bracket. Remove the bolt from the left front of the engine block. See Fig 14.
  18. Disconnect the engine control sensor wiring electrical connector. See Fig 15.
  19. On vehicles equipped with dual generators, disconnect the lower generator electrical connectors.
  20. Remove the fusible link retaining nuts. See Fig 16. Disconnect the cable and the fusible link. Disconnect the ground strap. See Fig 17. Disconnect the heater return hose. See Fig 18.
  21. Disconnect the heater supply hose. See Fig 19. Remove the turbocharger. See TURBOCHARGER . Using the Fuel Line Tool (310-5039, T90T-9550-S), disconnect the fuel lines. See Fig 20.
    22. NOTE: The fuel line retaining bolt must be removed before installing the engine lift adapters.
  22. Remove the fuel line retaining bolt. See Fig 21. Remove the idler pulley bolt and remove the idler pulley. See Fig 22.
  23. Remove the nuts and position the glow plug and intake air heater relays aside. See Fig 23. Remove the bolts and the water outlet tube. See Fig 24. Install 2 engine lift adapters. See Fig 25. Install the Lifting Eye (303-D099, D94T-6000-C) on the right side cylinder head. See Fig 26.
  24. On vehicles equipped with an automatic transmission, raise and support the vehicle. Disconnect the starter electrical connector nuts. See Fig 27. Remove the battery cable. Remove the starter solenoid wire.
  25. Remove the 3 bolts and the starter. See Fig 28. Remove the torque converter housing cover. Mark one stud and the flexplate for assembly reference and remove the torque converter-to-flexplate nuts.
  26. On vehicles equipped with manual transmissions, remove the transmission. See CLUTCHES article for 2002 models or MANUAL TRANSMISSION for 2003 models.
  27. On all vehicles, remove the oil filter and disconnect the block heater electrical connector. See Fig 29. Remove the engine mount nuts. See Fig 30.
  28. On vehicles equipped with an automatic transmission. Remove the transmission-to-engine bolts. Lower the vehicle. Use a wood block and a suitable jack to support the transmission. See Fig 31. Remove the transmission oil level indicator tube. See Fig 32.
  29. On all vehicles, install the Heavy Duty Floor Crane (014-00071) and the Diesel Engine Lifting Bracket (303-D043, D83T-6000-B) on the engine. See Fig 33. Raise the engine high enough to clear the No. 1 crossmember and pull the engine forward out of the vehicle. Remove the engine lifting equipment from the engine.
Fig 1: Removing & Installing Air Intake Tube & Adapter
G00209354Courtesy of FORD MOTOR CO.
Fig 2: Removing & Installing Degas Bottle
G00209357Courtesy of FORD MOTOR CO.
Fig 3: Locating Air Deflector Push Pins
G00209355Courtesy of FORD MOTOR CO.
Fig 4: Locating Air Charge Cooler Retainer (Left Side Shown; Right Side Similar)
G00209356Courtesy of FORD MOTOR CO.
Fig 5: Removing & Installing Radiator Brackets
G00209358Courtesy of FORD MOTOR CO.
Fig 6: Removing & Installing Upper Support Brackets
G00209359Courtesy of FORD MOTOR CO.
Fig 7: Locating Radiator Sight Shield
G00209360Courtesy of FORD MOTOR CO.
Fig 8: Removing & Installing A/C Inlet & Outlet Tubes
G00209361Courtesy of FORD MOTOR CO.
Fig 9: Removing & Installing Air Charge Cooler Ducts
G00209362Courtesy of FORD MOTOR CO.
Fig 10: Removing & Installing Fan Shroud Retainers
G00209363Courtesy of FORD MOTOR CO.
Fig 11: Removing & Installing Mass Air Pressure Sensor Vacuum Line
G00209364Courtesy of FORD MOTOR CO.
Fig 12: Removing & Installing Lower Generator Ground Cable
G00209336Courtesy of FORD MOTOR CO.
Fig 13: Removing & Installing Generator Mounting Bracket
G00209365Courtesy of FORD MOTOR CO.
Fig 14: Removing & Installing Negative Battery Cable Bolt On Left Side Of Engine Block
G00209366Courtesy of FORD MOTOR CO.
Fig 15: Locating Engine Control Sensor & Lower Generator Electrical Connectors
G00209367Courtesy of FORD MOTOR CO.
Fig 16: Disconnecting & Connecting Fusible Link & Cable
G00209368Courtesy of FORD MOTOR CO.
Fig 17: Locating Ground Strap
G00209369Courtesy of FORD MOTOR CO.
Fig 18: Locating Heater Return Hose
G00209370Courtesy of FORD MOTOR CO.
Fig 19: Locating Heater Supply Hose
G00209371Courtesy of FORD MOTOR CO.
Fig 20: Locating Fuel Lines
G00209372Courtesy of FORD MOTOR CO.
Fig 21: Removing & Installing Fuel Tube Retaining Bolt
G00209346Courtesy of FORD MOTOR CO.
Fig 22: Removing & Installing Idler Pulley
G00209373Courtesy of FORD MOTOR CO.
Fig 23: Locating Glow Plug & Intake Air Heater Relays
G00209374Courtesy of FORD MOTOR CO.
Fig 24: Removing & Installing Water Outlet
G00209375Courtesy of FORD MOTOR CO.
Fig 25: Locating Engine Lift Adapters
G00209347Courtesy of FORD MOTOR CO.
Fig 26: Removing & Installing Lifting Eye
G00209376Courtesy of FORD MOTOR CO.
Fig 27: Identifying Starter Solenoid Electrical Connections
G00209348Courtesy of FORD MOTOR CO.
Fig 28: Removing & Installing Starter
G00209349Courtesy of FORD MOTOR CO.
Fig 29: Locating Block Heater Harness Connector
G00209351Courtesy of FORD MOTOR CO.
Fig 30: Locating Engine Mount Nuts
G00209350Courtesy of FORD MOTOR CO.
Fig 31: Supporting Transmission
G00209377Courtesy of FORD MOTOR CO.
Fig 32: Removing & Installing Transmission Fluid Indicator Tube
G00209379Courtesy of FORD MOTOR CO.
Fig 33: Removing & Installing Engine
G00209378Courtesy of FORD MOTOR CO.
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