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Section 214 (Engine Mechanical - 3.5L GTDI): Removal: Engine

WARNING: This page is about a different car, the 2013 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S) DESCRIPTION

G09069909
 2, 200# Floor Crane, Fold Away
300-OTC1819E  or equivalent
G09069910
 Adjustable Grip Arm, 1735A
014-00001  or equivalent
G09069911
 Disconnect Tool, Transmission Cooler Line
307-569 
G09069912
 Eye, Engine Lift
303-1245 
G09069913
 Powertrain Lift
300-OTC1585AE  or equivalent
G09069914
 Spreader Bar
303-D089  (D93P-6001-A3) or equivalent
GENERAL EQUIPMENT

Hose Clamp Remover/Installer
Spreader Bar
Wooden Block
WARNING: Before beginning any service procedure, refer to SAFETY WARNINGS . Failure to follow this instruction may result in serious personal injury.
NOTE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.
  1. With the vehicle in NEUTRAL, position it on a hoist. REFER to JACKING AND LIFTING .
  2. Recover the A/C system. REFER to AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING for DATC, or AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING for EMTC.
  3. Release the fuel system pressure. REFER to FUEL SYSTEM PRESSURE RELEASE .
  4. Remove the cowl panel. REFER to COWL PANEL .
  5. Remove the engine ACL and ACL outlet pipe. REFER to INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW .
  6. Remove the battery tray. REFER to BATTERY AND BATTERY TRAY - EXPLODED VIEW .
  7. Remove the nut and disconnect the 2 battery feed cables from the positive battery terminal.
    G09069915
  8. Disconnect the engine wiring harness electrical connector and remove the retainer and the ground wires.
    G09069916
  9. Remove the front wheels and tires. REFER to WHEEL AND TIRE .
  10. NOTE: RH shown in illustration, LH similar.

    Remove the 2 RH and 2 LH lower pin-type retainers from the engine splash shields and position the shields aside.

    G09069917
  11. Remove the 3 twist lock retainers and the underbody air duct.
    G09069918
  12. Remove the accessory drive belt. Refer to ACCESSORY DRIVE BELT -- 3.5L GTDI .
  13. Drain the cooling system. Refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  14. Remove the nut and disconnect the A/C tube.
    • Discard the O-ring seal and gasket seal.
      G09069919
  15. Remove the degas bottle. REFER to DEGAS BOTTLE .
  16. NOTE: Index marks the LH Charge Air Cooler (CAC) tube for installation.

    Disconnect the Turbocharger Boost Pressure (TCBP)/Charge Air Cooler Temperature (CACT) electrical connector and loosen the 2 clamps and remove the CAC  outlet pipe.

    G09069920
  17. Disconnect the brake booster vacuum hose quick connect coupling from the intake manifold, brake booster and CAC  . REFER to QUICK CONNECT COUPLING .
    • Detach the brake booster vacuum hose from strut tower brace.
      G09069921
  18. Remove the 4 nuts and the strut tower brace.
    G09069922
  19. Disconnect the fuel supply tube. REFER to QUICK CONNECT COUPLING .
    G09069923
  20. Remove the EVAP canister purge valve. Refer to EVAPORATIVE EMISSION CANISTER PURGE VALVE -- 3.5L GTDI .
  21. Remove the bolt and ground wire from the engine front cover.
    • Disconnect the upper radiator hose from the intake manifold coolant tube.
      G09069924
  22. Disconnect the engine harness electrical connector.
    G09069925
  23. Disconnect the rear PCM electrical connector.
    G09069926
  24. Remove the engine wiring harness retainer from the bulkhead.
    1. Push the tab in.
    2. Slide the wiring harness up and out of the bulkhead.
      G09069927
  25. Disconnect the transaxle control cable from the control lever.
    G09069928
  26. Disconnect the transaxle control cable from the shift cable bracket.
    G09069929
  27. If equipped, detach the engine block heater harness from the radiator support wiring harness.
    G09069930
  28. NOTE: Index marks the LH Charge Air Cooler (CAC) tube for installation.

    Loosen the 2 clamps and remove the RH CAC  tube.

    G09069931
  29. Disconnect the 2 heater hoses from the intake manifold.
    G09069932
  30. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).

    Using a suitable holding device, hold the steering wheel in the straight-ahead position.

    G09069933
  31. NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to CLOCKSPRING , and CLOCKSPRING ADJUSTMENT .
    NOTE: Index-mark the steering column shaft position to the steering gear for reference during installation.

    Remove the bolt and disconnect the steering column shaft from the steering gear.

    • Discard the bolt.
      G09069934
  32. Remove the RH and LH catalytic converter. Refer to CATALYTIC CONVERTER -- LH, 3.5L GTDI , and CATALYTIC CONVERTER -- RH, 3.5L GTDI .
  33. NOTE: Index-mark the driveshaft for installation.

    Remove and discard the 4 bolts and support the driveshaft with a length of mechanic's wire.

    G09069935
  34. Remove the A/C tube bracket bolt from the rear of the compressor.
    G09069936
  35. Remove the nut and disconnect the upper A/C tube from the compressor and position aside.
    • Discard the O-ring seal and gasket seal.
      G09069937
  36. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
      G09069938
  37. Remove and discard the engine oil filer.
    G09069939
  38. NOTE: Index marks the LH Charge Air Cooler (CAC) tube for installation.

    Loosen the clamp and disconnect the LH CAC  tube from the LH turbocharger.

    G09069940
  39. Disconnect the lower radiator hose from the radiator.
    • Detach the lower radiator hose retainer from the cooling fan and shroud.
      G09069941
  40. Remove the 2 fasteners and the inspection cover.
    G09069942
  41. Remove 3 new torque converter bolts.
    G09069943
  42. Remove the 4 oil pan-to-transaxle bolts.
    G09069944
  43. Disconnect the 2 PTU  cooling lines.
    G09069945
  44. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
    G09069946
  45. Special Tool(s): Disconnect Tool, Transmission Cooler Line 307-569.
    G09069947
  46. NOTE: LH shown in illustration, RH similar.

    Remove the bolt and the wheel speed sensor.

    G09069948
  47. NOTE: LH shown in illustration, RH similar.

    Remove and discard the upper stabilizer link nut.

    G09069949
  48. NOTE: Do not allow the brake caliper to hang from the brake flexible hose or damage to the hose may occur.
    NOTE: LH shown in illustration, RH similar.

    Remove the brake caliper guide pin bolts and calipers.

    • Support the calipers.
      G09069950
  49. NOTE: RH shown in illustration, LH similar.

    Using a wax pencil, mark the relationship of the front and rear subframe to the underbody at the mounting locations on both side.

    G09069951
  50. NOTE: LH shown in illustration, RH similar.

    Remove the LH and RH halfshaft nuts.

    • Do not discard at this time.
      G09069952
  51. NOTE: LH shown in illustration, RH similar.

    Separate the LH and RH halfshaft from the wheel hubs.

    G09069953
  52. Position a 2 x 6 board, 36 in (914.4 mm) in length and two 2 x 6 boards 24 in (609.6 mm) in length onto the powertrain lift.
    • Position the powertrain lift table with:
      • the long board towards the rear of the subframe.
      • the short boards under the engine and transmission.
        G09069954
  53. Install the Adjustable Grip Arm from the powertrain lift table to the LH engine-to-transmission bolt hole.
    G09069955
  54. Install a ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe, to secure the subframe to the powertrain lift table.
  55. NOTE: LH shown in illustration, RH similar.
    NOTE: The halfshafts are not being remove from the transmission.

    Remove the strut-to-wheel knuckle nuts and bolts.

    • Remove the strut from the wheel knuckle and the halfshafts from the wheel knuckle.
      G09069956
  56. Remove the 4 transmission support insulator-to-frame rail bolts.
    G09069957
  57. Remove the 3 nuts, the bolt and the transaxle support insulator assembly.
    G09069958
  58. Remove the 4 engine mount nuts, the 3 engine mount bolts and the engine mount.
    G09069959
  59. NOTE: RH shown in illustration, LH similar.

    Remove the subframe bracket-to-body bolts.

    G09069960
  60. NOTE: RH shown in illustration, LH similar.

    Remove the rear subframe bolts and the subframe brackets.

    G09069961
  61. NOTE: RH shown in illustration, LH similar.

    Remove the front subframe bolts.

    G09069962
  62. Lower the subframe and powertrain assembly from the vehicle.
  63. Disconnect the 2 quick connect couplings and remove the crankcase vent tube. Refer to QUICK CONNECT COUPLING
    • Remove the engine cover mounting stud and detach the 3 wiring harness retainers.
      G09069963
  64. Remove the nut and the oil supply tube bracket from the LH valve cover stud bolt.
    G09069964
  65. Remove the 3 bolts and the LH exhaust manifold heat shield.
    G09069965
  66. Install the Special Tool(s): Eye, Engine Lift 303-1245.
    G09069966
  67. Install the Special Tool(s): 2, 200# Floor Crane, Fold Away 300-OTC1819E.
    G09069967
  68. Remove the starter motor solenoid cover.
    G09069968
  69. Remove the 2 nuts and the starter motor wiring terminals.
    G09069969
  70. Disconnect the wiring harness retainer from the starter motor stud bolt.
    G09069970
  71. Remove the bolt, stud bolt and the starter.
    G09069971
  72. Remove the bolt and the ground wire from the RH cylinder head.
    G09069972
  73. Disconnect the generator electrical connector and position the generator B+ cable cover aside.
    G09069973
  74. Remove the nut and disconnect the generator B+ cable.
    G09069974
  75. Disconnect the A/C compressor and the pressure relief valve electrical connectors.
    • Detach the 3 wiring harness retainers.
      G09069975
  76. Disconnect the transaxle control electrical connector.
    G09069976
  77. Detach the transaxle control wire harness retainer from the transaxle stud bolt.
    G09069977
  78. Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket.
    G09069978
  79. Remove the Adjustable Grip Arm.
    G09069979
  80. Remove the ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe.
  81. NOTE: LH shown in illustration, RH similar.

    Install the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

    G09069980
  82. Using the Floor Crane, remove the powertrain and subframe as an assembly from the powertrain lift table and set on the ground.
    • Position wood blocks under the engine and transmission.
      G09069981
  83. NOTE: LH shown in illustration, RH similar.

    Remove the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

    G09069982
  84. Remove the 2 intermediate shaft bracket nuts and the 2 studs.
    G09069983
  85. Remove the 2 bolts and the RH halfshaft support bracket.
    G09069984
  86. Remove the 2 engine-to-transaxle bolts.
    G09069985
  87. Remove the 5 transaxle-to-engine bolts.
    • Separate the transaxle from the engine.
      G09069986
  88. Using the Floor Crane, remove the engine from the transaxle.
    G09069987
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