Section 9 (Engine - 2.5L DURATEC (125KW/170PS)): Removal: Engine

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING .

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	300-OTC1819E2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	303-476 (T94P-9472-A) Socket, Exhaust Gas Oxygen Sensor TKIT-1994-LM/M TKIT-1994-F TKIT-1994-FLM/FM
Courtesy of FORD MOTOR COMPANY	307-566 Retainer, Torque Converter TKIT-2006C-FFMFLM TKIT-2006C-LM TKIT-2006C-ROW
Strap Wrench
Magnetic Socket
Tie Rod End Remover
Lifting Bracket
Oil Drain Equipment
Cable Ties
Hose Clamp(s)
Hose Clamp Remover/Installer
Center Punch
Mounting Table Set
3.5 mm Drill Bit

1. Follow the health and safety precautions. Refer to: Health and Safety Precautions .
2. With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
3. Release the fuel system pressure. Refer to: Fuel System Pressure Release .
4. Remove the cowl panel. Refer to: Cowl Panel .
5. Remove the battery tray. Refer to: Battery Tray - 2.5L Duratec (125kW/170PS) .
6. Remove the engine compartment fuse box cover.

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7. Disconnect the main wiring harness from the fuse box and the battery feed cable.

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8. Disconnect the HO2S electrical connector and catalyst monitor sensor electrical connector. Disconnect the wire retainers.

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9. Drain the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
10. NOTE: Be prepared to collect escaping fluid.

    Drain the engine oil.

    Use the General Equipment: Oil Drain Equipment

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11. NOTE: Be prepared to collect escaping fluid.

    Remove and discard the engine oil filter.

    Use the General Equipment: Strap Wrench

    Use the General Equipment: Oil Drain Equipment

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12. NOTE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.

    Support the exhaust flexible pipe with a support wrap or suitable splint. Install the General Equipment: Cable Ties

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13. 1. Remove the nuts.
    2. Position back the exhaust system, remove and discard the gasket.

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14. Using the special tool, remove the HO2S.

    Use Special Service Tool: 303-476 (T94P-9472-A) Socket, Exhaust Gas Oxygen Sensor.

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15. Remove the bolts and position aside the exhaust manifold heat shield.

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16. Remove the exhaust support bracket bolts.

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17. Remove the bolts for the exhaust manifold bracket.

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18. Remove and discard the nuts. Position back the exhaust manifold.

    Use the General Equipment: Cable Ties

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19. Remove and discard the exhaust manifold gasket.

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20. Remove the bolts and disconnect the wire harness retainers from the frame rail.

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21. Remove the bolts and disconnect the transmission shift cable. Position aside the transmission shift cable.

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22. • Disconnect the electrical connector, disconnect the wiring retainers and position aside the wiring harness.
    • Remove the nuts and the battery tray bracket.

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23. Remove the bolt and disconnect the transmission cooling tube.

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24. NOTE: Make sure that no component falls off during removal.

    Remove the seal and the backing ring.

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25. Remove the bolt and position aside the transmission cooling tube.

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26. NOTE: Make sure that no component falls off during removal.

    Remove the seal and the backing ring.

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27. Disconnect the coolant hose. Remove the nuts, bolt, stud and position aside the transmission fluid cooler.

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28. Disconnect the brake booster tube from the intake manifold.

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29. Disconnect the fuel vapor tube. Refer to: Quick Release Coupling .

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30. NOTE: Be prepared to collect escaping fluid.

    Disconnect the fuel supply tube. Refer to: Spring Lock Couplings .

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31. Disconnect the coolant hoses and the engine vent hose.

    Use the General Equipment: Hose Clamp Remover/Installer

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32. Disconnect the retainer and position aside the radiator coolant hose.

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33. If equipped, disconnect the block heater electrical connector.

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34. NOTE: Be prepared to collect escaping fluid.
    • Release the clamps and disconnect the lower radiator hose. Use the General Equipment: Hose Clamp Remover/Installer
    • Release the clamp and disconnect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

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35. • Release the clamp, disconnect the lower and upper coolant hoses. Disconnect the hose retainer.
    • Remove the degas bottle. Use the General Equipment: Hose Clamp Remover/Installer

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36. Remove the A/C compressor belt. Refer to: Air Conditioning (A/C) Compressor Belt .
37. Disconnect the A/C compressor electrical connector.

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38. Remove the A/C compressor nut and stud.

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39. Remove the bolts and position aside the A/C compressor.

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40. NOTE: LH shown in illustration, RH similar.

    Remove the bolts and the side frame supports.

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41. Remove the fender splash shield. Refer to: Fender Splash Shield .

    Vehicles without powertrain control module (PCM) security shield 

42. Remove the retainers and the PCM housing cover.

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    Vehicles with powertrain control module (PCM) security shield 

43. Remove the retainers and the PCM housing cover. Use the General Equipment: 3.5 mm Drill BitUse the General Equipment: Center Punch

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    All vehicles 

44. Disconnect the retainers and the PCM electrical connectors.

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45. Remove the bolts and position aside the roll restrictor.

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46. Remove the bolts and the RH roll restrictor bracket.

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47. Remove the LH flexible brake hose bolt.

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48. NOTE: Do not use a prying device to open the slot in the knuckle to separate the lower ball joint from the knuckle assembly. Damage to the knuckle assembly may occur.
    NOTE: Do not use a prying device or separator fork between the ball joint and the wheel knuckle. Damage to the ball joint or ball joint seal may result. Only use the pry bar by inserting it into the lower arm body opening.
    NOTE: Use care when releasing the lower arm and wheel knuckle into the resting position or damage to the ball joint seal may occur.

    Remove and discard the LH lower ball joint nut and bolt. Disconnect the LH lower arm and position aside the ball joint seal.

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49. Rotate the steering wheel fully to the RH side.

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50. Using a pry bar, Separate the LH halfshaft from the transmission.

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51. NOTE: Make sure that the strut is not moved more than necessary to prevent damage to top mount.
    NOTE: The inner constant velocity (CV) joint must not be bent more than 18°.
    NOTE: The outer constant velocity (CV) joint must not be bent more than 45°.

    Remove and support the LH halfshaft from the transmission.

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52. Remove and discard the LH halfshaft retaining circlip.

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53. NOTE: Do not use a hammer to separate the tie-rod end from the wheel knuckle or damage to the wheel knuckle can result.
    NOTE: Use care when installing the tie-rod end separator or damage to the outer tie-rod end boot may occur.

    Remove and discard the RH tie rod end nut and then detach the tie rod. Use the General Equipment: Tie Rod End Remover

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54. Remove the RH flexible brake hose bolt.

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55. NOTE: Do not use a prying device to open the slot in the knuckle to separate the lower ball joint from the knuckle assembly. Damage to the knuckle assembly may occur.
    NOTE: Do not use a prying device or separator fork between the ball joint and the wheel knuckle. Damage to the ball joint or ball joint seal may result. Only use the pry bar by inserting it into the lower arm body opening.
    NOTE: Use care when releasing the lower arm and wheel knuckle into the resting position or damage to the ball joint seal may occur.

    Remove and discard the RH lower ball joint nut and bolt. Disconnect the RH lower arm and position aside the ball joint seal.

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56. Remove and discard the halfshaft bearing retaining strap and nuts.

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57. Rotate the steering wheel fully to the LH side.

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58. NOTE: Make sure that the strut is not moved more than necessary to prevent damage to top mount.
    NOTE: The inner constant velocity (CV) joint must not be bent more than 18°.
    NOTE: The outer constant velocity (CV) joint must not be bent more than 45°.

    Remove and support the RH halfshaft from the transmission.

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59. Disconnect the oil cooler hoses.

    Use the General Equipment: Hose Clamp(s)

    Use the General Equipment: Hose Clamp Remover/Installer

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60. Disconnect the oil pressure switch.

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61. Remove the bolts and the oil filter assembly.

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62. Remove the bolts.

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63. Remove the bolt.

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64. WARNING: Make sure that the engine and transmission assembly is on wooden blocks and secured with suitable retaining straps.

    Position the engine on the table. Install the General Equipment: Mounting Table Set

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65. Remove the bolt and the transmission support insulator.

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66. NOTE: Note the position of the component before removal.

    Remove the bolts, nuts and engine mount.

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67. Raise the vehicle.
68. Remove and discard the exhaust manifold studs.

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69. Remove the bolts and exhaust manifold bracket.

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70. Remove the bolts and the front axle shaft bearing bracket.

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71. 1. Rotate the accessory drive belt tensioner counter clockwise.
    2. Remove the accessory drive belt.
    3. Release the accessory drive belt tensioner.

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72. Remove the bolt.

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73. Disconnect the wire retainer. Remove the nut and disconnect the generator electrical connectors.

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74. Remove the bracket bolt, nut and the generator.

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75. Disconnect the EGR valve coolant hose. Disconnect the hose retainer and remove the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

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76. Remove the bolt and the ground cable.

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77. Disconnect the wire harness retainers and the coolant hose retainer.

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78. 1. Disconnect the engine wire harness and position it aside.
    2. Remove the nuts and the starter motor bracket.

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79. 1. Remove the starter motor cable nut.
    2. Remove the starter motor control wire nut and position aside the wiring.

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80. Remove the stud bolts and the starter motor.

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81. Remove the starter motor insulator.

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82. NOTE: Make sure that the component terminals are not bent or damaged.

    Disconnect the wiring harness retainers and disconnect the transmission electrical connectors.

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83. NOTE: Only rotate the crankshaft in a clockwise direction.
    NOTE: Note the position of the component before removal.

    Index-mark the torque converter nuts. Remove and discard the torque converter nuts. Use the General Equipment: Magnetic Socket

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84. Install the engine floor crane.

    Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.

    Install the General Equipment: Lifting Bracket

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85. Remove the engine from the table.

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86. Remove the transmission-to-engine bolts.

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87. Remove the transmission-to-engine bolts and remove the engine from the transmission.

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88. Install the special tool.

    Use Special Service Tool: 307-566 Retainer, Torque Converter.

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