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Section 81 (Engine Mechanical - 4.0L SOHC): Removal: Engine: Removal

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Rotating the crankshaft pulley bolt counterclockwise could cause a reduction in clamp load on the crankshaft pulley and timing sprocket, which could cause severe engine damage.

All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
  3. Disconnect the battery ground and positive cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  4. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  5. Release the 2 windshield washer hose retainers and the one hood insulation pin-type retainer.
    6. Fig 1: Locating Windshield Washer Hose Retainers
    GF0015095Courtesy of FORD MOTOR CO.
  6. Position the hood insulation aside and disconnect the windshield washer hose.
    7. Fig 2: Locating Windshield Washer Hose
    GF0015096Courtesy of FORD MOTOR CO.
    NOTE: Index-mark the hood hinge location to aid in hood installation.
  7. Remove the 4 bolts and the hood.
  8. Drain the cooling system. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

    9. Vehicles with automatic transmission 

  9. Remove the transmission. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - 5R55S .

    10. Vehicles with manual transmission 

  10. Remove the clutch. For additional information, refer to CLUTCH .

    11. All vehicles 

  11. Disconnect the 2 Heated Oxygen Sensor (HO2S) and the 2 Catalyst Monitor Sensor (CMS) electrical connectors.
    12. Fig 3: Locating Heated Oxygen Sensor (HO2S)
    GF0015097Courtesy of FORD MOTOR CO.
    NOTE: LH side shown, RH side similar.
  12. Remove the 4 catalytic converter-to-exhaust manifold nuts.
    • Discard the nuts.
    13. Fig 4: Locating Catalytic Converter-To-Exhaust Manifold Nuts
    GF0015098Courtesy of FORD MOTOR CO.
  13. Remove the stud bolt and detach the ground strap.
    • Position the ground strap aside.
    14. Fig 5: Locating Ground Strap Stud Bolt
    GF0015064Courtesy of FORD MOTOR CO.
  14. Remove the oil pan drain plug and drain the engine oil.
    • Install the drain plug and tighten to 26 Nm (19 lb-ft).
  15. Disconnect the upper radiator hose from the thermostat housing.
    16. Fig 6: Locating Upper Radiator Hose On Thermostat Housing
    GF0015099Courtesy of FORD MOTOR CO.
  16. Disconnect the lower radiator hose from the coolant pump.
    17. Fig 7: Locating Lower Radiator Hose On Coolant Pump
    GF0015100Courtesy of FORD MOTOR CO.
  17. Remove the nut and Power Steering Pressure (PSP) tube bracket from the A/C compressor.
    18. Fig 8: Identifying Power Steering Pressure Tube Bracket Nut
    GF0015101Courtesy of FORD MOTOR CO.
  18. Remove the bolt and detach the power steering supply hose bracket from the Front End Accessory Drive (FEAD) bracket.
    19. Fig 9: Locating Power Steering Supply Hose Bracket Bolt
    GF0015065Courtesy of FORD MOTOR CO.
  19. Disconnect the PSP switch electrical connector.
    20. Fig 10: Locating Power Steering Pressure (PSP) Switch Electrical Connector
    GF0015102Courtesy of FORD MOTOR CO.
  20. Disconnect the A/C compressor and A/C high pressure switch electrical connectors.
    21. Fig 11: Locating A/C Compressor And A/C High Pressure Switch Electrical Connectors
    GF0015103Courtesy of FORD MOTOR CO.
  21. Detach the 2 wiring retainers from the FEAD bracket.
    22. Fig 12: Locating Wiring Retainers On FEAD Bracket
    GF0015104Courtesy of FORD MOTOR CO.
  22. Disconnect the fuel supply tube coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    23. Fig 13: Locating Fuel Supply Tube Coupling
    GF0015105Courtesy of FORD MOTOR CO.
  23. Loosen the 3 bolts on the power steering pump pulley.
    24. Fig 14: Locating Power Steering Pump Pulley Bolts
    GF0015067Courtesy of FORD MOTOR CO.
  24. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
    25. Fig 15: Rotating Accessory Drive Belt Tensioner
    GF0015054Courtesy of FORD MOTOR CO.
  25. Remove the 3 bolts and the power steering pump pulley.
    26. Fig 16: Locating Power Steering Pump Pulley Bolts
    GF0015067Courtesy of FORD MOTOR CO.
  26. Remove the 3 bolts and position the power steering pump aside.
    27. Fig 17: Locating Power Steering Pump Bolts
    GF0015068Courtesy of FORD MOTOR CO.
  27. Remove the 3 bolts, the nut and position the FEAD bracket and A/C compressor aside.
    28. Fig 18: Locating FEAD Bracket And A/C Compressor Bracket Bolts
    GF0015069Courtesy of FORD MOTOR CO.
  28. Disconnect the 2 heater hoses from the coolant tube.
    29. Fig 19: Locating Heater Hoses On Coolant Tube
    GF0015106Courtesy of FORD MOTOR CO.
  29. Remove the 2 coolant tube bracket bolts.
    30. Fig 20: Locating Coolant Tube Bracket Bolts
    GF0015055Courtesy of FORD MOTOR CO.
    NOTE: When removing the ignition wires, a slight twisting motion will break the seal and ease removal.
  30. Using the Spark Plug Wire Remover, disconnect the 6 spark plug wires from the spark plugs.
    • Detach the retainers from the valve cover stud bolts and the ignition coil bracket.
    31. Fig 21: Pulling Spark Plug Wire Off Spark Plug
    G03948432Courtesy of FORD MOTOR CO.
  31. Detach the spark plug wire retainer from the intake manifold.
    32. Fig 22: Locating Spark Plug Wire Retainer On Intake Manifold
    GF0015107Courtesy of FORD MOTOR CO.
  32. Disconnect the radio ignition interference capacitor electrical connector.
    33. Fig 23: Locating Radio Ignition Interference Capacitor Electrical Connector
    GF0015108Courtesy of FORD MOTOR CO.
  33. Disconnect the ignition coil electrical connector.
    34. Fig 24: Locating Ignition Coil Electrical Connector
    GF0015109Courtesy of FORD MOTOR CO.
  34. Remove the 2 upper ignition coil bracket bolts.
    35. Fig 25: Locating Upper Ignition Coil Bracket Bolts
    GF0015110Courtesy of FORD MOTOR CO.
  35. Remove the 2 lower ignition coil bracket bolts and then remove the ignition coil and spark plug wires.
    36. Fig 26: Locating Ignition Coil Bracket Bolts
    GF0015111Courtesy of FORD MOTOR CO.
  36. Detach the crankcase vent tube from the LH valve cover and remove the tube.
    37. Fig 27: Locating Crankcase Vent Tube
    GF0015112Courtesy of FORD MOTOR CO.
  37. Disconnect the brake booster vacuum hose from the upper intake manifold.
    38. Fig 28: Locating Brake Booster Vacuum Hose On Upper Intake Manifold
    GF0015113Courtesy of FORD MOTOR CO.
  38. Disconnect the fuel vapor vent tube from the intake manifold.
    39. Fig 29: Locating Fuel Vapor Vent Tube To Intake Manifold
    GF0015114Courtesy of FORD MOTOR CO.
  39. Disconnect the upper and lower PCM electrical connectors.
    40. Fig 30: Identifying Upper & Lower Powertrain Control Module (PCM) Electrical Connectors
    GF0015115Courtesy of FORD MOTOR CO.
  40. Disconnect the 16-pin electrical connector and detach the 2 wiring retainers.
    41. Fig 31: Locating 16-Pin Electrical Connector
    GF0015116Courtesy of FORD MOTOR CO.
  41. Detach the 3 wiring harness retainers.
    42. Fig 32: Locating Wiring Harness Retainers
    GF0015117Courtesy of FORD MOTOR CO.
  42. Remove the Power Distribution Box (PDB) cover.
  43. Remove the bolt and detach the B+ terminal from the PDB.
    • Detach the pin-type retainer from the strut tower.
    44. Fig 33: Locating Pin-Type Retainer From Strut Tower
    GF0015118Courtesy of FORD MOTOR CO.
  44. Detach the PDB upper housing from the lower housing, loosen the bolt and then disconnect the 68-pin connector from the PDB.
    45. Fig 34: Locating Power Distribution Box Upper Housing Bolt
    GF0015119Courtesy of FORD MOTOR CO.
  45. Remove the bolt and detach the ground cable from the RH strut tower.
    46. Fig 35: Locating Ground Cable On Strut Tower
    GF0015120Courtesy of FORD MOTOR CO.
  46. Detach the battery cable harness pin-type retainer from the cowl.
    47. Fig 36: Locating Battery Cable Harness Pin-Type Retainer To Cowl
    GF0015121Courtesy of FORD MOTOR CO.
  47. Install the Engine Lifting Bracket to the RH cylinder head.
    48. Fig 37: Installing Special Tool 303-050 To RH Cylinder Head
    GF0009419Courtesy of FORD MOTOR CO.
  48. Install the Engine Lifting Bracket to the LH cylinder head.
    49. Fig 38: Installing Special Tool 303-050 To LH Cylinder Head
    GF0009417Courtesy of FORD MOTOR CO.
  49. Remove the LH engine mount nut.
    50. Fig 39: Locating Engine Mount Nut
    GF0015122Courtesy of FORD MOTOR CO.
  50. Remove the RH engine mount nut.
    51. Fig 40: Locating Engine Mount Nut
    GF0015123Courtesy of FORD MOTOR CO.
  51. Using the Engine Lifting Bracket and Spreader Bar, remove the engine.
    52. Fig 41: Removing Engine Using Special Tools (303-050) & (303-D089)
    GF0015124Courtesy of FORD MOTOR CO.
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