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Section 178 (Engine Mechanical - 3.5L-GTDI - F150): Removal: Engine

WARNING: This page is about a different car, the 2012 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G06260116
 Bar, Engine Spreader
303-1454
G06126494
 Lifting Bracket, Engine
303-F047 (014-00073) or equivalent
G07958925
 Lift Eye, Right Front
303-1566
G07958971
 2, 200# Floor Crane, Fold Away
300-OTC1819E or equivalent
G06097256
 Retainer, Torque Converter
307-346 (T97T-7902-A) 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 & LIFTING .
    2. NOTE: Index-mark the hood hinge location to aid in hood installation.
    NOTE: RH shown in illustration, LH similar.
    Fig 1: Identifying Hood Bolts
    G06126496Courtesy of FORD MOTOR CO.
  2. Remove the 4 bolts (2 shown in illustration) and the hood.
  3. Release the fuel system pressure. For additional information, REFER to FUEL SYSTEM - GENERAL INFORMATION .
  4. Disconnect the battery ground cable. For additional information, REFER to BATTERY, MOUNTING AND CABLES .
  5. If equipped, disconnect the block heater electrical connector at the thermostat housing.
    • Detach the block heater wiring harness retainer from the LH valve cover stud bolt and position aside.
      Fig 2: Locating Block Heater Electrical Connector At Thermostat Housing
      G07958974Courtesy of FORD MOTOR CO.
  6. Remove the cooling module. For additional information, refer ENGINE COOLING .
  7. Remove the LH and RH turbocharger intake tubes. For additional information, refer to 3.5L Gasoline Turbocharged Direct Injection (GTDI) Charge Air Cooler (CAC) and Tubes Exploded View in INTAKE AIR DISTRIBUTION & FILTERING .
  8. Remove the 2 Charge Air Cooler (CAC) inlet tubes and the CAC outlet tube. For additional information, refer to 3.5L Gasoline Turbocharged Direct Injection (GTDI) Charge Air Cooler (CAC) and Tubes Exploded View in INTAKE AIR DISTRIBUTION & FILTERING .
  9. Disconnect the Battery Junction Box (BJB) wiring harness and the A/C pressure transducer electrical connectors.
    Fig 3: Locating BJB Wiring Harness And A/C Pressure Transducer Electrical Connectors
    G07958975Courtesy of FORD MOTOR CO.
  10. Remove the nut and disconnect the A/C tube.
    • Discard the O-ring seal and gasket seal.
      Fig 4: Locating A/C Tube And Nut
      G07958976Courtesy of FORD MOTOR CO.
  11. Remove the nut and the transmission cooler line bracket from the engine front cover stud bolt.
    Fig 5: Locating Transmission Cooler Tube Bracket And Nut
    G07410347Courtesy of FORD MOTOR CO.
  12. Detach the generator wiring harness from the engine front cover.
    Fig 6: Locating Generator Wiring Harness From Engine Front Cover
    G07407004Courtesy of FORD MOTOR CO.
  13. Disconnect the A/C compressor electrical connector.
    • Detach the A/C compressor wiring harness from the A/C compressor.
      Fig 7: Locating A/C Compressor Electrical Connector
      G07958979Courtesy of FORD MOTOR CO.
  14. Remove the generator. For additional information, REFER to CHARGING SYSTEM .
  15. Remove the A/C compressor belt. For additional information, REFER to ACCESSORY DRIVE .
  16. Disconnect the PCM electrical connector and the engine wire harness electrical connector.
    • Detach the wiring harness retainers from the fender splash shield.
      Fig 8: Locating Wiring Harness Retainers From Fender Splash Shield
      G07958980Courtesy of FORD MOTOR CO.
  17. Remove the fuel injection pump. For additional information, REFER to FUEL CHARGING AND CONTROLS - 3.5L GTDI .
  18. Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD  .
  19. Disconnect the 2 heater hose couplings at the RH rear of the engine.
    Fig 9: Locating Heater Hose Couplings
    G07958981Courtesy of FORD MOTOR CO.
  20. Disconnect the 2 coolant hoses from the degas bottle.
    Fig 10: Locating Coolant Hoses From Degas Bottle
    G07958982Courtesy of FORD MOTOR CO.
  21. Detach the wiring harness retainers from the rear of the RH valve cover stud bolt and the rear of the RH cylinder head.
    Fig 11: Locating Wiring Harness Retainers From Rear Of RH Valve Cover Stud Bolt And Rear Of RH Cylinder Head
    G07958983Courtesy of FORD MOTOR CO.
  22. Remove the bolt and the ground strap from the cowl.
    Fig 12: Locating Ground Strap And Bolt
    G06126817Courtesy of FORD MOTOR CO.
  23. Remove the cowl panel grille. For additional information, REFER to FRONT END BODY PANELS .
  24. Remove the 6 screws and release the 2 cowl panel clips and remove the cowl panel.
    Fig 13: Locating Cowl Panel Clips And Screws
    G07958930Courtesy of FORD MOTOR CO.
  25. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector from the engine wiring harness at the rear of the LH cylinder head.
    • Disconnect the HO2S electrical connector from the wiring harness retainer.
      Fig 14: Locating HO2S Electrical Connector From Wiring Harness Retainer
      G07958986Courtesy of FORD MOTOR CO.
  26. Release the 4 fasteners and the splash shield.
    Fig 15: Locating Splash Shield And Fasteners
    G07410085Courtesy of FORD MOTOR CO.
    27. NOTE: Only one wire harness retainer and one electrical connector shown in illustration, others similar.
  27. Disconnect the 2 HO2S electrical connectors.
    • Disconnect the 2 HO2S electrical connector retainers.
    • If equipped, disconnect the 5 transmission wire harness retainers from the transfer case wire harness.
      Fig 16: Locating Transmission Wire Harness Retainers
      G07958786Courtesy of FORD MOTOR CO.
  28. Disconnect the HO2S electrical connector at the LH rear of the transmission.
    • Disconnect the electrical connector retainer from the bracket at the rear of the transmission.
      Fig 17: Locating HO2S Electrical Connector
      G07958787Courtesy of FORD MOTOR CO.
    29. NOTE: Do not pull on the wire harness to disconnect the connector or damage to the connector will occur.
    Fig 18: Locating Transmission Vehicle Harness Connector
    G06127319Courtesy of FORD MOTOR CO.
  29. Disconnect the transmission vehicle harness connector by twisting the outer shell and pulling back on the connector.
  30. Remove the 4 bolts and the skid plate.
  31. If equipped, remove the front driveshaft. For additional information, REFER to DRIVESHAFT .
  32. Remove the starter motor. For additional information, REFER to STARTING SYSTEM .
  33. Detach the starter motor wiring harness retainer from the oil pan.
    Fig 19: Locating Starter Motor Wiring Harness Retainer From Oil Pan
    G07407002Courtesy of FORD MOTOR CO.
  34. Remove the 2 pin-type retainers and the access cover.
    Fig 20: Locating Access Cover And Pin-Type Retainers
    G07476065Courtesy of FORD MOTOR CO.
    35. NOTE: Index-mark the end of one torque converter stud and the flexplate for installation.
    Fig 21: Locating Torque Converter Nuts
    G07476066Courtesy of FORD MOTOR CO.
  35. Remove the 4 torque converter nuts.
  36. Remove the 2 exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolts and separate.
    • Discard the bolts.
      Fig 22: Locating Exhaust Y-Pipe Dual Catalytic Converter-To-Exhaust Intermediate Pipe Bolts
      G07958936Courtesy of FORD MOTOR CO.
    37. NOTE: LH shown in illustration, RH similar.
    Fig 23: Locating LH And RH Catalytic Converter-To-Turbocharger Nuts
    G07958937Courtesy of FORD MOTOR CO.
  37. Remove and discard the 2 LH and RH catalytic converter-to-exhaust manifold nuts.
  38. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
      Fig 24: Locating Drain Plug
      G07958791Courtesy of FORD MOTOR CO.
  39. Remove and discard the engine oil filter.
    40. NOTE: The 2 engine mount studs may come off with the nuts.
    Fig 25: Locating RH Engine Support Insulator Nuts And Studs
    G07958940Courtesy of FORD MOTOR CO.
  40. Remove the 2 RH engine support insulator nuts and studs.
  41. Remove the engine-to-bellhousing bolt.
    Fig 26: Locating Engine-To-Bellhousing Bolt
    G07958998Courtesy of FORD MOTOR CO.
  42. Remove the oil pan-to-bellhousing bolt.
    Fig 27: Locating Oil Pan-To-Bellhousing Bolt
    G07958999Courtesy of FORD MOTOR CO.
  43. Remove the 2 LH bellhousing-to-engine bolts.
    Fig 28: Locating LH Bellhousing-To-Engine Bolts
    G07959000Courtesy of FORD MOTOR CO.
  44. Remove the 4 upper bellhousing-to-engine bolts.
    Fig 29: Locating Upper Bellhousing-To-Engine Bolts
    G07958789Courtesy of FORD MOTOR CO.
  45. Remove the LH engine mount through bolt.
    Fig 30: Locating Engine Support Insulator Bolt
    G06126794Courtesy of FORD MOTOR CO.
    46. NOTE: Do not support the transmission by the fluid pan, failure to follow this instruction may result in serious damage to the transmission.
  46. Support the bellhousing of the transmission with a suitable floor jack and a block of wood.
  47. Remove the 2 LH bellhousing-to-oil pan bolts.
    Fig 31: Locating LH Bellhousing-To-Oil Pan Bolts
    G07958803Courtesy of FORD MOTOR CO.
  48. Remove the 2 nuts and the CAC tube bracket.
    • Disconnect the coolant hose from the valve cover stud.
      Fig 32: Locating CAC Tube Bracket And Nuts
      G07406968Courtesy of FORD MOTOR CO.
  49. Install the Right Front Lift Eye.
    Fig 33: Locating Right Front Lift Eye And Bolts
    G07958932Courtesy of FORD MOTOR CO.
  50. Using part of the Engine Lifting Bracket and a chain, assemble the Engine Spreader Bar as shown in illustration.
    Fig 34: Lifting Engine Spreader Bar
    G07959006Courtesy of FORD MOTOR CO.
    51. NOTE: After removing the bolts leave the LH engine support insulator in place.
    Fig 35: Locating LH Engine Support Insulator-To-Frame Bolts
    G07958941Courtesy of FORD MOTOR CO.
  51. Remove the 3 bolts for the LH engine support insulator.
    52. NOTE: The use of a ratchet strap may be needed to level the engine.
    Fig 36: Lifting Engine Using Floor Crane And Engine Spreader Bar Assembly
    G07959008Courtesy of FORD MOTOR CO.
  52. Using the Floor Crane and Engine Spreader Bar assembly, lift the engine.
  53. Remove the LH engine support insulator.
    Fig 37: Locating LH Engine Support Insulator
    G07958946Courtesy of FORD MOTOR CO.
    54. NOTE: The transmission wiring harness is part of the engine wiring harness.
  54. Detach the generator wiring harness retainer from the lower LH side of the engine block.
    • Position the transmission wiring harness on top of the engine for removal.
      Fig 38: Locating Generator Wiring Harness Retainer To Engine Block
      G07958827Courtesy of FORD MOTOR CO.
  55. Using the Floor Crane and Engine Spreader Bar assembly, remove the engine.
    Fig 39: Lifting Engine Using Floor Crane And Engine Spreader Bar Assembly
    G07959008Courtesy of FORD MOTOR CO.
  56. Install the Torque Converter Retainer.
    Fig 40: Installing Torque Converter Retainer
    G07959012Courtesy of FORD MOTOR CO.
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