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Section 1322 (Engine Mechanical - 5.4L (4V)): Removal: Engine

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.
Special Tools

Illustration Tool Name Tool Number
GF0000536Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0000162Courtesy of FORD MOTOR CO.
 Lifting Bracket, Engine (2 required) 303-D087 (D93P-6001-A1) or equivalent
GF0000267Courtesy of FORD MOTOR CO.
 Lifting Bracket, Engine 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.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  2. Release the 2 windshield washer hose retainers and the one hood insulation pin-type retainer.
    3. Fig 1: Locating Windshield Washer Hose Retainers
    GF0015095Courtesy of FORD MOTOR CO.
  3. Position the hood insulation aside and disconnect the windshield washer hose.
    4. Fig 2: Locating Windshield Washer Hose
    GF0015096Courtesy of FORD MOTOR CO.
    NOTE: Index-mark the hood hinge location to aid in hood installation.
  4. Remove the 4 bolts and the hood.
  5. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
  6. Remove the 4 nuts and the strut tower cross brace.
    7. Fig 3: Locating Strut Tower Cross Brace & Nuts
    GF0000372Courtesy of FORD MOTOR CO.
  7. Remove the battery and tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  8. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  9. Remove the 2 steering column dash boot nuts.
    10. Fig 4: Locating Steering Column Dash Boot Nuts
    GF0000537Courtesy of FORD MOTOR CO.
  10. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  11. Drain the Supercharger (SC) cooling system. For additional information, refer to SUPERCHARGER COOLING .
  12. Remove the engine coolant degas bottle. For additional information, refer to ENGINE COOLING .
  13. Remove the SC coolant degas bottle. For additional information, refer to SUPERCHARGER COOLING .
  14. Disconnect the upper radiator hose from the thermostat housing.
    15. Fig 5: Disconnecting Upper Radiator Hose From Thermostat Housing
    GF0000538Courtesy of FORD MOTOR CO.
  15. Disconnect the cooling fan electrical connector.
    16. Fig 6: Disconnecting Cooling Fan Electrical Connector
    GF0000539Courtesy of FORD MOTOR CO.
    NOTE: RH bolt shown, LH similar.
  16. Remove the 2 bolts and the cooling fan assembly.
    17. Fig 7: Locating Cooling Fan Assembly Bolts
    GF0000540Courtesy of FORD MOTOR CO.
  17. Disconnect the coolant hose from the Charge Air Cooler (CAC).
    18. Fig 8: Disconnecting Coolant Hose From Charge Air Cooler (CAC)
    GF0000541Courtesy of FORD MOTOR CO.
  18. Disconnect the coolant hose from the coolant tube assembly (above the generator).
    19. Fig 9: Disconnecting Coolant Hose From Coolant Tube Assembly
    GF0000542Courtesy of FORD MOTOR CO.
  19. Disconnect the coolant hose from the thermostat housing.
    20. Fig 10: Disconnecting Coolant Hose From Thermostat Housing
    GF0000543Courtesy of FORD MOTOR CO.
  20. Disconnect the coolant hose from the coolant pump.
    21. Fig 11: Disconnecting Coolant Hose From Coolant Pump
    GF0000544Courtesy of FORD MOTOR CO.
  21. Disconnect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    22. Fig 12: Locating Fuel Supply Tube
    GF0000545Courtesy of FORD MOTOR CO.
  22. Disconnect the Evaporative Emission (EVAP) tube and brake booster vacuum supply tube from the Throttle Body (TB) spacer.
    23. Fig 13: Disconnecting Evaporative Emissions (EVAP) Tube & Brake Booster Vacuum Supply Tube From Throttle Body (TB) Spacer
    GF0000546Courtesy of FORD MOTOR CO.
  23. Disconnect the lower EVAP tube and electrical connector from the EVAP canister purge valve.
    • Remove the EVAP canister purge valve.
    24. Fig 14: Disconnecting Lower EVAP Tube & Electrical Connector From EVAP Canister Purge Valve
    GF0000547Courtesy of FORD MOTOR CO.
  24. Disconnect the 2 heater hoses from the coolant tube assembly at the rear of the engine.
    25. Fig 15: Disconnecting Heater Hoses From Coolant Tube Assembly At Rear Of Engine
    GF0000548Courtesy of FORD MOTOR CO.
  25. Detach the pin-type wire harness retainer from the cowl.
    26. Fig 16: Detaching Pin-Type Wire Harness Retainer From Cowl
    GF0000549Courtesy of FORD MOTOR CO.
  26. Detach the pin-type wiring harness retainer.
    27. Fig 17: Locating Pin-Type Wiring Harness Retainer
    GF0046360Courtesy of FORD MOTOR CO.
  27. Remove the Power Distribution Box (PDB) cover.
  28. Detach the PDB upper housing from the lower housing, loosen the bolt, then disconnect the 68-pin connector from the PDB.
    29. Fig 18: Locating Power Distribution Box Upper Housing Bolt
    GF0015119Courtesy of FORD MOTOR CO.
  29. Disconnect the jumper harness electrical connector.
    30. Fig 19: Identifying Jumper Harness Electrical Connector
    GF0000551Courtesy of FORD MOTOR CO.
  30. Disconnect the upper and lower PCM electrical connectors.
    31. Fig 20: Identifying Upper & Lower Powertrain Control Module (PCM) Electrical Connectors
    GF0015115Courtesy of FORD MOTOR CO.
  31. Disconnect the 16-pin electrical connector and detach the 2 wiring retainers.
    32. Fig 21: Locating 16-Pin Electrical Connector
    GF0015116Courtesy of FORD MOTOR CO.
  32. Disconnect the hose from the power steering reservoir.
    • Drain the power steering fluid into a suitable container.
    33. Fig 22: Power Steering Reservoir Hose
    GF0000552Courtesy of FORD MOTOR CO.
  33. Disconnect the A/C pressure transducer electrical connector.
    34. Fig 23: A/C Pressure Transducer Electrical Connector
    GF0000553Courtesy of FORD MOTOR CO.
  34. Rotate the SC drive belt tensioner clockwise and remove the drive belt from the SC drive pulley.
    35. Fig 24: Rotating SC Belt Tensioner Clockwise & Remove SC Belt Off SC
    GF0046329Courtesy of FORD MOTOR CO.
  35. Disconnect the coolant hose from the oil cooler.
    36. Fig 25: Disconnecting Coolant Hose From Oil Cooler
    GF0000554Courtesy of FORD MOTOR CO.
  36. Disconnect the lower radiator hose from the radiator.
    • Remove the lower radiator hose assembly from the vehicle.
    37. Fig 26: Disconnecting Lower Radiator Hose From Radiator
    GF0000555Courtesy of FORD MOTOR CO.
  37. Disconnect the Power Steering Pressure (PSP) tube fitting.
    • Discard the Teflon® seal.
    38. Fig 27: Locating Power Steering Pressure (PSP) Tube Fitting
    GF0000556Courtesy of FORD MOTOR CO.
  38. Disconnect the power steering return hose.
    39. Fig 28: Locating Power Steering Return Hose
    GF0000557Courtesy of FORD MOTOR CO.
  39. Remove the nut and disconnect the B+ wire from the generator.
    40. Fig 29: Locating B+ Wire From Generator
    GF0046361Courtesy of FORD MOTOR CO.
  40. Detach the wiring harness retainer from the oil pan stud bolt.
    41. Fig 30: Detaching Wiring Harness Retainer From Oil Pan Stud Bolt
    GF0000559Courtesy of FORD MOTOR CO.
  41. Remove the nut and wire harness bracket from the oil pan stud bolt.
    42. Fig 31: Removing Nut & Wire Harness Bracket From Oil Pan Stud Bolt
    GF0000560Courtesy of FORD MOTOR CO.
  42. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
    43. Fig 32: Locating Crankshaft Position (CKP) Sensor Electrical Connector
    GF0000561Courtesy of FORD MOTOR CO.
  43. Detach the wire harness retainer from the A/C compressor stud bolt.
    44. Fig 33: Locating Wire Harness Retainer From A/C Compressor Stud Bolt
    GF0000562Courtesy of FORD MOTOR CO.
  44. Disconnect the A/C compressor electrical connector.
    45. Fig 34: Identifying A/C Compressor Electrical Connector
    GF0000563Courtesy of FORD MOTOR CO.
  45. Detach the wiring harness pin-type retainer from the back of the A/C compressor.
    46. Fig 35: Detaching Wiring Harness Pin-Type Retainer From Back Of A/C Compressor
    GF0000564Courtesy of FORD MOTOR CO.
  46. Position the SC drive belt away from the A/C compressor and detach the 2 wiring harness retainers from the A/C compressor stud bolts.
    47. Fig 36: Identifying SC Drive Belt, A/C Compressor, Wiring Harness Retainers & A/C Compressor Stud Bolts
    GF0000565Courtesy of FORD MOTOR CO.
  47. Remove the 3 stud bolts and position the A/C compressor aside.
    48. Fig 37: Identifying Stud Bolts & A/C Compressor Aside
    GF0000566Courtesy of FORD MOTOR CO.
  48. Remove the nut and the ground wire from the RH engine support insulator bracket stud bolt.
    49. Fig 38: Locating Ground Wire From RH Engine Support Insulator Bracket Stud Bolt
    GF0000567Courtesy of FORD MOTOR CO.
  49. Detach the 2 wiring harness pin-type retainers from the oil pan.
    50. Fig 39: Locating Wiring Harness Pin-Type Retainers From Oil Pan
    GF0000568Courtesy of FORD MOTOR CO.
  50. Remove the starter solenoid terminal cover.
    51. Fig 40: Locating Starter Solenoid Terminal Cover
    GF0000569Courtesy of FORD MOTOR CO.
  51. Remove the 2 nuts and disconnect the 2 wires from the starter solenoid.
    52. Fig 41: Disconnecting Wires From Starter Solenoid
    GF0000570Courtesy of FORD MOTOR CO.
  52. Remove the 3 bolts and the starter.
    53. Fig 42: Locating Starter Bolts
    GF0000571Courtesy of FORD MOTOR CO.
  53. Drain the engine oil.
    • Install the drain plug and tighten to 26 Nm (19 lb-ft).
  54. Remove and discard the engine oil filter.
    55. Fig 43: Identifying Engine Oil Filter
    GF0000447Courtesy of FORD MOTOR CO.
    NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
  55. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
    56. Fig 44: Holding Steering Wheel In Straight-Ahead Position Using A Suitable Holding Device
    GF0041294Courtesy of FORD MOTOR CO.
    NOTE: Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM .
  56. Remove the upper bolt from the intermediate steering shaft.
    • Position the intermediate steering shaft aside.
    57. Fig 45: Locating Upper Bolt From Intermediate Steering Shaft
    GF0000445Courtesy of FORD MOTOR CO.
  57. Remove the clutch disc and pressure plate. For additional information, refer to CLUTCH .
  58. Remove the bolt and the ground wire from the rear of the LH cylinder head.
    59. Fig 46: Identifying Ground Wire From Rear Of LH Cylinder Head
    GF0000572Courtesy of FORD MOTOR CO.
  59. Install the Engine Lifting Bracket.
    60. Fig 47: Identifying Special Tool 303-D087
    GF0000164Courtesy of FORD MOTOR CO.
  60. Install the Engine Lifting Bracket.
    61. Fig 48: Identifying Special Tool 303-D087
    GF0000165Courtesy of FORD MOTOR CO.
  61. Remove the RH engine support insulator nut.
    62. Fig 49: Locating RH Engine Support Insulator Nut
    GF0000573Courtesy of FORD MOTOR CO.
  62. Remove the LH engine support insulator nut.
    63. Fig 50: Locating LH Engine Support Insulator Nut
    GF0000574Courtesy of FORD MOTOR CO.
  63. Install the Heavy Duty Floor Crane and the Engine Lifting Bracket.
    • Remove the engine from the vehicle.
    64. Fig 51: Identifying Special Tools (014-00071) & (303-D089)
    GF0000575Courtesy of FORD MOTOR CO.
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