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Section 1495 (Engine Mechanical - 3.5L): Removal: Engine

WARNING: This page is about a different car, the 2011 Lincoln MKZ and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G07784595
 2,200# Floor Crane, Fold Away
300-OTC1819E
G07784596
 Adjustable Grip Arm, 1735A
014-00001 or equivalent
G07784597
 Engine Lift Eye
303-1245
G07784598
 Powertrain Lift
300-OTC1585AE
G07784599
 Remover, Tie-Rod End
211-105
G07784600
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
  3. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS -- FUSION, MILAN & MKZ (EXCEPT HYBRID) article.
  4. Remove the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE - 3.5L -- FUSION & MKZ article.
  5. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
  6. If equipped, remove the 6 screws and the underbody shield.
    Fig 1: Locating Underbody Shield Screws
    G07784601Courtesy of FORD MOTOR CO.
  7. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable drain pan.
    Fig 2: Locating Power Steering Cooler Tube
    G07784602Courtesy of FORD MOTOR CO.
  8. Drain the cooling system. For additional information, refer to ENGINE COOLING SYSTEM (EXCEPT HYBRID) article.
  9. Remove the degas bottle. For additional information, refer to ENGINE COOLING SYSTEM (EXCEPT HYBRID) article.
  10. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 3.5L -- FUSION & MKZ article.
  11. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING & CABLES -- FUSION, MILAN & MKZ article.
  12. Disconnect the 2 engine wiring harness electrical connectors.
    Fig 3: Locating Engine Wiring Harness Electrical Connectors
    G07784603Courtesy of FORD MOTOR CO.
  13. Detach the 2 wiring harness retainers from the transmission mount and the battery tray bracket.
    Fig 4: Locating Wiring Harness Retainers At Transmission Mount And Battery Tray Bracket
    G07784604Courtesy of FORD MOTOR CO.
  14. Remove the 2 nuts and the battery cables from the positive battery cable.
    Fig 5: Locating Nuts, Battery Cables And Positive Battery Cable
    G07784605Courtesy of FORD MOTOR CO.
  15. Remove the bolt and position aside the ground wire.
    Fig 6: Identifying Ground Wire Bolt
    G07784606Courtesy of FORD MOTOR CO.
  16. Disconnect the vacuum hose and the Evaporative Emission (EVAP) tube from the upper intake manifold.
    Fig 7: Identifying Vacuum Hose And Evaporative Emission Tube
    G07784607Courtesy of FORD MOTOR CO.
  17. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
    Fig 8: Locating Upper Radiator Hose, Lower Radiator Hose And Heater Hoses At Thermostat Housing
    G07784608Courtesy of FORD MOTOR CO.
  18. Disconnect the transaxle control cable from the control lever.
    Fig 9: Locating Transaxle Control Cable At Control Lever
    G07784609Courtesy of FORD MOTOR CO.
  19. Remove the 3 nuts and position the transaxle control cable bracket aside.
    Fig 10: Locating Transaxle Control Cable Bracket Nuts
    G07784610Courtesy of FORD MOTOR CO.
  20. Remove the bolt and position the ground wire aside.
    Fig 11: Locating Ground Wire And Bolt
    G07784611Courtesy of FORD MOTOR CO.
  21. If equipped, detach the engine block heater harness from the radiator support, power steering hose, A/C tube and the engine wiring harness.
  22. Detach the coolant tube retainer clips from the A/C tube.
    Fig 12: Locating Coolant Tube Retainer Clips On A/C Tube
    G07784612Courtesy of FORD MOTOR CO.
  23. Remove the nut and disconnect the A/C tube from the condenser.
    • Discard the O-ring seal.
    Fig 13: Locating A/C Tube Nut
    G07784613Courtesy of FORD MOTOR CO.
  24. Remove the 2 A/C tube bracket bolts.
    Fig 14: Locating A/C Tube Bracket Bolts
    G07784614Courtesy of FORD MOTOR CO.
  25. Remove the A/C tube bracket bolt.
    Fig 15: Locating A/C Tube Bracket Bolt
    G07784615Courtesy of FORD MOTOR CO.
  26. Remove the 2 nuts and disconnect the A/C tubes.
    • Discard the O-ring seal.
    Fig 16: Locating A/C Tubes Nuts
    G07784616Courtesy of FORD MOTOR CO.
  27. Detach the 2 wiring harness retainers.
    Fig 17: Locating Wiring Harness Retainers
    G07784617Courtesy of FORD MOTOR CO.
  28. Disconnect the 2 engine wiring harness electrical connectors.
    Fig 18: Locating Engine Control Wiring Harness Electrical Connectors
    G07784618Courtesy of FORD MOTOR CO.
  29. Remove the 2 wiring harness retainers from the LH valve cover stud bolts and position the wiring harness aside.
    Fig 19: Locating Wiring Harness Retainers At LH Valve Cover Stud Bolts
    G07784619Courtesy of FORD MOTOR CO.
  30. Remove the oil level indicator.
    Fig 20: Identifying Oil Level Indicator
    G07784620Courtesy of FORD MOTOR CO.
  31. Disconnect the hose from the power steering reservoir.
    • Detach the pin-type retainer from the engine mount brace.
    Fig 21: Locating Pin-Type Retainer At Engine Mount Brace
    G07784621Courtesy of FORD MOTOR CO.
  32. Using a small screwdriver, release the retaining clip and detach the power steering reservoir from the cowl.
    Fig 22: Removing Power Steering Reservoir Retaining Clip Using Small Screwdriver
    G07784622Courtesy of FORD MOTOR CO.
  33. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
    Fig 23: Locating Fuel Supply Tube
    G07784623Courtesy of FORD MOTOR CO.
  34. Remove the bolt and the ground wire from the engine mount brace.
    Fig 24: Locating Bolt And Ground Wire On Engine Mount Brace
    G07784624Courtesy of FORD MOTOR CO.
  35. Remove the 3 bolts and the engine mount brace.
    Fig 25: Identifying Bolts And Engine Mount Brace
    G07784625Courtesy of FORD MOTOR CO.
  36. Disconnect the PCM electrical connectors and pin-type retainers.
    Fig 26: Locating PCM Electrical Connectors And Pin-Type Retainers
    G07784626Courtesy of FORD MOTOR CO.
  37. Remove the Power Steering Pressure (PSP) hose bracket bolt.
    Fig 27: Locating Power Steering Pressure Hose Bracket Bolt
    G07784627Courtesy of FORD MOTOR CO.
  38. Remove and discard the PSP hose banjo bolt and the 2 seals from the steering gear.
    Fig 28: Locating PSP Hose Banjo Bolt
    G07784628Courtesy of FORD MOTOR CO.
    39. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
    Fig 29: Holding Steering Wheel In Straight-Ahead Position Using Suitable Holding Device
    G07784629Courtesy of FORD MOTOR CO.
  39. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
  40. Remove the 2 nuts and the steering joint cover.
    Fig 30: Locating Nuts And Steering Joint Cover
    G07784630Courtesy of FORD MOTOR CO.
    41. NOTE: 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 -- FUSION, MILAN & MKZ article.
    NOTE: Index-mark the steering column shaft position to the steering gear for reference during installation.
    Fig 31: Locating Steering Column Shaft Position Mark And Bolt
    G07784631Courtesy of FORD MOTOR CO.
  41. Remove the bolt and disconnect the steering column shaft from the steering gear.
    • Discard the bolt.
  42. Remove the 4 screws and position the LH fender splash shield aside.
    Fig 32: Locating LH Fender Splash Shield Screws
    G07784632Courtesy of FORD MOTOR CO.
  43. Remove the 6 pin-type retainers (4 shown in illustration) and the LH splash shield.
    Fig 33: Locating Pin-Type Retainers And LH Splash Shield
    G07784633Courtesy of FORD MOTOR CO.
    44. NOTE: The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.
    Fig 34: Locating Clips And Steering Gear-To-Dash Seal
    G07784634Courtesy of FORD MOTOR CO.
  44. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
  45. Disconnect the transaxle cooler hoses.
    Fig 35: Locating Transaxle Cooler Hoses
    G07784635Courtesy of FORD MOTOR CO.
  46. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
    Fig 36: Identifying Engine Drain Plug
    G07784636Courtesy of FORD MOTOR CO.
  47. Remove and discard the engine oil filter.
  48. Remove the 6 nuts and the Y-pipe assembly.
    • Discard the gaskets and nuts.
    Fig 37: Locating Nuts And Y-Pipe Assembly
    G07784637Courtesy of FORD MOTOR CO.
  49. Remove the 4 oil pan-to-transaxle bolts.
    Fig 38: Locating Oil Pan-To-Transaxle Bolts
    G07784638Courtesy of FORD MOTOR CO.
  50. Remove the 2 fasteners and the inspection cover.
    Fig 39: Locating Inspection Cover And Fasteners
    G07784639Courtesy of FORD MOTOR CO.
  51. Remove and discard the 4 torque converter nuts.
    Fig 40: Locating Torque Converter Nuts
    G07784640Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

    52. NOTE: Index-mark the driveshaft for installation.
    Fig 41: Locating Driveshaft Bolts
    G07784641Courtesy of FORD MOTOR CO.
  52. Remove and discard the 4 bolts (3 shown in illustration) and support the driveshaft with a length of mechanic's wire.

    All vehicles 

  53. Remove the engine roll restrictor-to-subframe through bolt.
    Fig 42: Locating Engine Roll Restrictor-To-Subframe Through Bolt
    G07784642Courtesy of FORD MOTOR CO.
    54. NOTE: LH shown in illustration, RH similar.
    Fig 43: Locating Tie-Rod End Nut And Cotter Pin
    G07784643Courtesy of FORD MOTOR CO.
  54. Remove the cotter pins and nuts from the tie-rod ends.
    55. NOTE: LH shown in illustration, RH similar.
    Fig 44: Separating Tie-Rod Ends From Steering Knuckles Using Tie-Rod End Remover
    G07784644Courtesy of FORD MOTOR CO.
  55. Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.
    56. NOTE: LH shown in illustration, RH similar.
    Fig 45: Locating Stabilizer Bar Link Nut
    G07784645Courtesy of FORD MOTOR CO.
  56. Remove the nuts and separate the stabilizer bar links from the struts.
  57. Using a wax pencil, mark the relationship of the front subframe to the underbody at the mounting locations.
  58. Position the Powertrain Lift under the subframe assembly.
    Fig 46: Identifying Powertrain Lift Under Subframe Assembly
    G07784646Courtesy of FORD MOTOR CO.
    59. NOTE: LH shown in illustration, RH similar.
    Fig 47: Locating Subframe Bracket-To-Body Bolts
    G07784647Courtesy of FORD MOTOR CO.
  59. Remove the 4 subframe bracket-to-body bolts.
    60. NOTE: LH shown in illustration, RH similar.
    Fig 48: Locating Rear Subframe Nut And Subframe Bracket
    G07784648Courtesy of FORD MOTOR CO.
  60. Remove the 2 rear subframe nuts and the 2 subframe brackets.
    61. NOTE: LH shown in illustration, RH similar.
    Fig 49: Locating Front Subframe Nut
    G07784649Courtesy of FORD MOTOR CO.
  61. Remove the 2 front subframe nuts.
  62. Lower the subframe assembly from the vehicle.
  63. Remove the 2 RH catalytic converter bracket bolts.
    Fig 50: Locating RH Catalytic Converter Bracket Bolts
    G07784650Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

  64. Remove the 2 nuts and remove the RH catalytic converter bracket.
    Fig 51: Locating Nuts And RH Catalytic Converter Bracket
    G07784651Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

  65. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 52: Identifying RH Catalyst Monitor Sensor Electrical Connector
    G07784652Courtesy of FORD MOTOR CO.
  66. Remove the 4 nuts and the RH catalytic converter.
    • Discard the gasket.
    Fig 53: Locating RH Catalytic Converter Nuts
    G07784653Courtesy of FORD MOTOR CO.
  67. Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket.
    Fig 54: Locating Power Transfer Unit Support Bracket Bolts
    G07784654Courtesy of FORD MOTOR CO.
  68. Remove the 5 bolts and the PTU.
    Fig 55: Locating PTU Bolts
    G07784655Courtesy of FORD MOTOR CO.

    All vehicles 

    69. NOTE: Position a block of wood under the transaxle.
    Fig 56: Installing Powertrain Lift And Adjustable Grip Arms
    G07784656Courtesy of FORD MOTOR CO.
  69. Install the Powertrain Lift and Adjustable Grip Arms.
  70. Remove the transaxle support insulator through bolt and nut.
    Fig 57: Locating Transaxle Support Insulator Through Bolt And Nut
    G07784657Courtesy of FORD MOTOR CO.
  71. Remove the transaxle support insulator bracket bolt and the 2 nuts.
    Fig 58: Locating Transaxle Support Insulator Bracket Bolt And Nuts
    G07784658Courtesy of FORD MOTOR CO.
  72. Remove the 4 engine mount nuts.
    • Remove the 2 engine mount spacers.
    Fig 59: Locating Engine Mount Nuts
    G07784659Courtesy of FORD MOTOR CO.
  73. Remove the nut, 2 bolts and the engine mount.
    Fig 60: Locating Engine Mount Nut And Bolts
    G07784660Courtesy of FORD MOTOR CO.
  74. Lower the engine and transaxle assembly from the vehicle.
  75. Disconnect the wiring harness fasteners from the transaxle-to-engine stud bolt and the starter.
    Fig 61: Locating Wiring Harness Fasteners From Transaxle-To-Engine Stud Bolt
    G07784661Courtesy of FORD MOTOR CO.
  76. Remove the bolt and ground wire.
    Fig 62: Locating Bolt And Ground Wire
    G07784662Courtesy of FORD MOTOR CO.
  77. Disconnect the Transmission Control Module (TCM) electrical connector.
    Fig 63: Locating Transmission Control Module Electrical Connector
    G07784663Courtesy of FORD MOTOR CO.
  78. Remove the 2 nuts and the starter motor wiring.
    Fig 64: Locating Nuts And Starter Motor Wiring
    G07784664Courtesy of FORD MOTOR CO.
  79. Remove the 2 bolts and the starter.
    Fig 65: Locating Starter Bolts
    G07784665Courtesy of FORD MOTOR CO.
  80. Install the Engine Lift Eye on the LH cylinder head.
    Fig 66: Identifying Engine Lift Eye On LH Cylinder Head
    G07784666Courtesy of FORD MOTOR CO.
  81. Using the Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table.
    Fig 67: Identifying Floor Crane And Spreader Bar Positioning Engine And Transaxle
    G07784667Courtesy of FORD MOTOR CO.
  82. Remove the 2 engine-to-transaxle bolts.
    Fig 68: Locating Engine-To-Transaxle Bolts
    G07784668Courtesy of FORD MOTOR CO.
  83. Remove the transaxle-to-engine stud bolt and the 4 transaxle-to-engine bolts.
    • Separate the transaxle from the engine.
    Fig 69: Locating Transaxle-To-Engine Bolts And Transaxle-To-Engine Stud Bolt
    G07784669Courtesy of FORD MOTOR CO.
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