Section 22 (Engine Mechanical - 6.2L): Removal: Engine

	Fan Clutch Nut Wrench 303-214 (T83T-6312-B)
	Fan Pulley Holding Wrench 303-478 (T94T-6312-AH)
	Lifting Bracket, Engine 303-F047 (014-00073) or equivalent
	Remover, Power Steering Pump Pulley 211-016 (T69L-10300-B)
	Support Brackets, Engine 303-1507 or equivalent

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
2. NOTE: Index-mark the hood hinge location to aid in hood installation.

   Remove the 4 bolts and the hood.

   Fig 1: Locating Hood Hinge Bolts

   Courtesy of FORD MOTOR CO.
3. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

   Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD .

4. Remove the accessory drive belt.
5. Remove the cooling module. For additional information, refer to ENGINE COOLING - GASOLINE ENGINES .

   Manual transmission vehicles 

6. Remove the clutch and pressure plate. For additional information, refer to ENGINE EMISSION CONTROL .

   All vehicles 

7. Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the cooling fan.
   Fig 2: Identifying Fan Clutch Pulley Holding Wrench And Fan Clutch Hub Nut Wrench

   Courtesy of FORD MOTOR CO.
8. Detach the generator wiring harness pin-type retainer and position aside.
   Fig 3: Locating Generator Wiring Harness Pin-Type Retainer

   Courtesy of FORD MOTOR CO.
9. Disconnect the A/C compressor electrical connector and detach wiring harness retainer from A/C compressor stud bolt.
   Fig 4: Locating A/C Compressor Electrical Connector And Wiring Harness Retainer

   Courtesy of FORD MOTOR CO.
10. Disconnect the PCM electrical connector and detach the wiring harness pin-type retainer.
    Fig 5: Locating PCM Electrical Connector

    Courtesy of FORD MOTOR CO.
11. Disconnect the engine harness electrical connector and detach the pin-type retainer from the battery case.
    Fig 6: Locating Engine Harness Electrical Connector And Pin-Type Retainer

    Courtesy of FORD MOTOR CO.
12. Remove the bolt and the ground strap from the bulk head.
    Fig 7: Locating Bolt And Ground Strap

    Courtesy of FORD MOTOR CO.
13. Detach the wiring harness pin-type retainer from the rear of the RH valve cover.
    Fig 8: Locating Wiring Harness Pin-Type Retainer

    Courtesy of FORD MOTOR CO.
14. Remove the 3 bolts and the A/C compressor.
    Fig 9: Locating A/C Compressor Bolts

    Courtesy of FORD MOTOR CO.
15. Remove the nut and the transmission cooler lines and starter motor wiring harness brackets.
    Fig 10: Locating Transmission Cooler Lines, Starter Motor Wiring Harness Brackets And Nut

    Courtesy of FORD MOTOR CO.
16. Using the Power Steering Pump Pulley Removal, remove the power steering pump pulley.
    Fig 11: Removing Power Steering Pump Pulley Using Special Tool

    Courtesy of FORD MOTOR CO.
17. Remove the bolt and the power steering pump pressure line.
    Fig 12: Locating Bolt And Power Steering Pump Pressure Line

    Courtesy of FORD MOTOR CO.
18. Remove the 3 bolts and position the power steering pump aside.
    Fig 13: Locating Power Steering Pump Bolts

    Courtesy of FORD MOTOR CO.
19. Remove the clip and disconnect the lower radiator hose from the block.
    Fig 14: Locating Clip And Lower Radiator Hose

    Courtesy of FORD MOTOR CO.

    Automatic transmission vehicles 

20. Remove the transmission fluid indicator.
    Fig 15: Locating Transmission Fluid Indicator

    Courtesy of FORD MOTOR CO.
21. Remove the 2 bolts and the transmission fluid level indicator tube. Discard the O-ring seal.
    Fig 16: Locating Bolts And Transmission Fluid Level Indicator Tube

    Courtesy of FORD MOTOR CO.
22. Disconnect the 2 Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical connectors (one shown).
    Fig 17: Locating Catalyst Monitor Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.

    All vehicles 

23. Remove the starter. For additional information, refer to STARTING SYSTEM - GASOLINE ENGINES .
24. Detach the starter motor wiring harness pin-type retainer from the oil pan.
    Fig 18: Locating Starter Motor Wiring Harness Pin-Type Retainer

    Courtesy of FORD MOTOR CO.

    Automatic transmission vehicles 

25. Remove the 4 exhaust manifold flange nuts (2 shown).
    Fig 19: Locating Exhaust Manifold Flange Nuts

    Courtesy of FORD MOTOR CO.
26. NOTE: Failure to replace the transmission support insulator nuts may result in transmission support insulator damage. New transmission support insulator nuts will be installed during engine installation.
    NOTE: If the transmission support insulator stud loosens when the transmission support insulator nut is removed, the stud must be discarded and a new stud installed.

    Loosen the 2 transmission support insulator-to-crossmember nuts.

    Fig 20: Locating Transmission Support Insulator-To-Crossmember Nuts

    Courtesy of FORD MOTOR CO.

    All vehicles 

27. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
      Fig 21: Locating Engine Oil Drain Plug

      Courtesy of FORD MOTOR CO.
28. Remove and discard the engine oil filter.
    Fig 22: Locating Engine Oil Filter

    Courtesy of FORD MOTOR CO.
29. Disconnect the 2 oil cooler coolant hoses.
    Fig 23: Locating Oil Cooler Coolant Hoses Clamp

    Courtesy of FORD MOTOR CO.
30. NOTE: If metal foreign material is present in the oil cooler, mechanical concerns exist. To diagnose mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION . If the mechanical concern is not diagnosed and repaired, engine failure may occur.

    Loosen the bolt and remove and inspect the engine oil cooler.

    Fig 24: Locating Bolt And Engine Oil Cooler

    Courtesy of FORD MOTOR CO.

    Automatic transmission vehicles 

31. Remove the 2 bolts and the flexplate inspection cover.
    Fig 25: Locating Bolts And Flexplate Inspection Cover

    Courtesy of FORD MOTOR CO.
32. Remove the cylinder block opening cover.
    Fig 26: Locating Cylinder Block Opening Cover

    Courtesy of FORD MOTOR CO.
33. Remove the 4 torque converter-to-flexplate nuts.
    • Discard the nuts.
      Fig 27: Locating Torque Converter-To-Flexplate Nuts

      Courtesy of FORD MOTOR CO.
34. NOTE: The torque converter must be installed in it's original orientation to the flexplate or engine damage may occur.

    Rotate the flexplate so that the 2 slotted holes are shown at the 6 o'clock position and index mark the torque converter stud to the flexplate to maintain alignment during installation.

    Fig 28: Locating Flexplate Slowed Holes

    Courtesy of FORD MOTOR CO.
35. NOTE: The upper 2 transmission-to-engine bolts will be removed later.

    Remove the lower 5 transmission-to-engine bolts.

    Fig 29: Locating Transmission-To-Engine Bolts

    Courtesy of FORD MOTOR CO.

    All vehicles 

36. NOTE: The engine support insulator through bolt must be discarded and a new bolt installed, or damage to the vehicle or engine support insulator may occur.
    NOTE: Only use hand tools when removing the engine support insulator through bolt or damage to the engine support insulator may occur.

    Remove and discard the LH engine support insulator through bolt.

    Fig 30: Locating LH Engine Support Insulator Bolt

    Courtesy of FORD MOTOR CO.
37. NOTE: The engine support insulator through bolt must be discarded and a new bolt installed, or damage to the vehicle or engine support insulator may occur.
    NOTE: Only use hand tools when removing the engine support insulator through bolt or damage to the engine support insulator may occur.

    Remove and discard the RH engine support insulator through bolt.

    Fig 31: Locating RH Engine Support Insulator Bolt

    Courtesy of FORD MOTOR CO.

    Automatic transmission vehicles 

38. Remove the upper 2 transmission-to-engine bolts.
    Fig 32: Locating Transmission-To-Engine Bolts

    Courtesy of FORD MOTOR CO.

    All vehicles 

39. Install the Engine Lifting Brackets.
    Fig 33: View Of Engine Lifting Brackets

    Courtesy of FORD MOTOR CO.
40. Using a floor crane, remove the engine assembly from the vehicle.