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Home >> Ford >> 2016 >> Flex SE >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine - 3.5L Ti-VCT >> Removal >> Engine

Engine - 3.5L Ti-VCT: Removal: Engine

SPECIAL TOOL(S)

GFD56740Courtesy of FORD MOTOR COMPANY
 2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
GFD56741Courtesy of FORD MOTOR COMPANY
 Adjustable Grip Arm, 1735A 014-00001 or equivalent
GFD56742Courtesy of FORD MOTOR COMPANY
 Disconnect Tool, Transmission Cooler Line 307-569
GFD56743Courtesy of FORD MOTOR COMPANY
 Eye, Engine Lift 303-1245
GFD56744Courtesy of FORD MOTOR COMPANY
 Powertrain Lift 300-OTC1585AE or equivalent
GFD56745Courtesy of FORD MOTOR COMPANY
 Spreader Bar 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.

All vehicles 

  1. 1.

    With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting .

  1. 2.

    Release the fuel system pressure. For additional information, refer to Fuel System - General Information .

  1. 3.

    Recover the A/C system. For additional information, refer to Climate Control System - General Information and Diagnostics .

  1. 4.

    Remove the cowl panel grille. For additional information, refer to Front End Body Panels .

  1. 5.

    Remove the 4 nuts and the strut tower brace.
GFD56746Courtesy of FORD MOTOR COMPANY

  1. 6.

    Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering .

  1. 7.

    Remove the battery tray. For additional information, refer to Battery, Mounting and Cables .

  1. 8.

    Remove the nut and disconnect the 2 battery feed cables from the positive battery terminal.
GFD56747Courtesy of FORD MOTOR COMPANY

  1. 9.

    Remove the retainer and the ground wire cable.
GFD56748Courtesy of FORD MOTOR COMPANY

  1. 10.

    Disconnect the engine wiring harness electrical connector.
GFD56749Courtesy of FORD MOTOR COMPANY

  1. 11.

    If equipped, release the 4 retainers and remove the underbody shield.
GFD56607Courtesy of FORD MOTOR COMPANY

  1. 12.

    Drain the cooling system. For additional information, refer to Engine Cooling .

  1. 13.

    Remove the front wheels and tires. For additional information, refer to Wheels and Tires .

  1. 14.

    Remove the 3 pin-type retainers and position aside.
GFD56624Courtesy of FORD MOTOR COMPANY

  1. 15.

    Remove the accessory drive belt. For additional information, refer to Accessory Drive .

  1. 16.

    Remove the nut and disconnect the A/C tube.
    • Discard the O-ring seal and gasket seal.
GFD56621Courtesy of FORD MOTOR COMPANY

  1. 17.

    Disconnect the A/C pressure switch electrical connector.
GFD56750Courtesy of FORD MOTOR COMPANY

  1. 18.

    Remove the nut and the A/C tube from the condenser.
    • Discard the O-ring seal and gasket seal.
GFD56751Courtesy of FORD MOTOR COMPANY

  1. 19.

    Remove the degas bottle. For additional information, refer to Engine Cooling .

  1. 20.

    Disconnect the degas bottle coolant hose from the engine coolant tube.
GFD56752Courtesy of FORD MOTOR COMPANY

  1. 21.

    Disconnect the brake booster vacuum hose from the upper intake manifold.
GFD56753Courtesy of FORD MOTOR COMPANY

  1. 22.

    Disconnect the Evaporative Emission (EVAP) tube and the fuel supply tube quick connect coupling. For additional information, refer to Fuel System - General Information .
GFD56754Courtesy of FORD MOTOR COMPANY

  1. 23.

    Disconnect the engine harness electrical connector.
    • Detach the wiring harness retainer.
GFD147989Courtesy of FORD MOTOR COMPANY

  1. 24.

    Disconnect the PCM electrical connector.
GFD147990Courtesy of FORD MOTOR COMPANY

  1. 25.

    Remove the engine wiring harness retainer from the bulkhead.

    1. 1.

      Push the wiring harness retainer tab in.

    1. 2.

      Slide the wiring harness up and out of the bulkhead.
GFD147991Courtesy of FORD MOTOR COMPANY

  1. 26.

    Remove the bolt and ground wire from the RH shock tower.
GFD56758Courtesy of FORD MOTOR COMPANY

  1. 27.

    Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
GFD56759Courtesy of FORD MOTOR COMPANY

  1. 28.

    Disconnect the transaxle control cable from the control lever.
GFD56760Courtesy of FORD MOTOR COMPANY

  1. 29.

    Disconnect the transaxle control cable from the shift cable bracket and position aside.
    • Detach the wiring harness pin-type retainer from the shift cable bracket.
GFD56761Courtesy of FORD MOTOR COMPANY

  1. 30.

    If equipped, detach the engine block heater harness from the radiator support.

  1. 31.

    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.

GFD56762Courtesy of FORD MOTOR COMPANY

  1. 32.

    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 Supplemental Restraint System .
    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.
GFD56763Courtesy of FORD MOTOR COMPANY

  1. 33.

    Remove the exhaust Y-pipe. For additional information, refer to Exhaust System .

All-Wheel Drive (AWD) vehicles 

  1. 34.

    NOTE: Index-mark the driveshaft for installation.

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

GFD56764Courtesy of FORD MOTOR COMPANY

All vehicles 

  1. 35.

    Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
GFD56625Courtesy of FORD MOTOR COMPANY

  1. 36.

    Remove and discard the engine oil filter.
GFD56692Courtesy of FORD MOTOR COMPANY

  1. 37.

    Remove the 2 fasteners and the inspection cover.
GFD56709Courtesy of FORD MOTOR COMPANY

  1. 38.

    Remove and discard the 3 torque converter bolts.
GFD56765Courtesy of FORD MOTOR COMPANY

  1. 39.

    Remove the 4 oil pan-to-transaxle bolts.
GFD56725Courtesy of FORD MOTOR COMPANY

  1. 40.

    If equipped, disconnect the 2 oil cooler coolant hoses.
GFD56766Courtesy of FORD MOTOR COMPANY

  1. 41.

    If equipped, unlatch the cooler hose retainer latch and pry up on the oil cooler hose retainer to release the retainer and remove it from the subframe.
GFD56767Courtesy of FORD MOTOR COMPANY

  1. 42.

    Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
GFD56768Courtesy of FORD MOTOR COMPANY

  1. 43.

    Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
GFD56769Courtesy of FORD MOTOR COMPANY

  1. 44.

    NOTE: LH shown in illustration, RH similar.

    Remove the bolt and the wheel speed sensor.

GFD56770Courtesy of FORD MOTOR COMPANY

  1. 45.

    NOTE: LH shown in illustration, RH similar.

    Remove and discard the upper stabilizer link nut.

GFD56771Courtesy of FORD MOTOR COMPANY

  1. 46.

    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.
GFD56772Courtesy of FORD MOTOR COMPANY

  1. 47.

    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.

GFD56773Courtesy of FORD MOTOR COMPANY

  1. 48.

    NOTE: LH shown in illustration, RH similar.

    Remove the LH and RH halfshaft nuts.

    • Do not discard at this time.
GFD56774Courtesy of FORD MOTOR COMPANY

  1. 49.

    NOTE: LH shown in illustration, RH similar.

    Separate the LH and RH halfshaft from the wheel hubs.

GFD56775Courtesy of FORD MOTOR COMPANY

  1. 50.

    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.
GFD56776Courtesy of FORD MOTOR COMPANY

  1. 51.

    Install the Adjustable Grip Arm from the powertrain lift table to the LH engine-to-transmission bolt hole.
GFD56777Courtesy of FORD MOTOR COMPANY

  1. 52.

    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.

  1. 53.

    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.
GFD56778Courtesy of FORD MOTOR COMPANY

  1. 54.

    Remove the transaxle support insulator through bolt and nut.
GFD56779Courtesy of FORD MOTOR COMPANY

  1. 55.

    Remove the bolt, 3 nuts and the transaxle support insulator bracket.
GFD56780Courtesy of FORD MOTOR COMPANY

  1. 56.

    Remove the 4 engine mount nuts.
GFD56627Courtesy of FORD MOTOR COMPANY

  1. 57.

    Remove the 3 bolts and the engine mount.
GFD56628Courtesy of FORD MOTOR COMPANY

  1. 58.

    NOTE: RH shown in illustration, LH similar.

    Remove the subframe bracket-to-body bolts.

GFD56781Courtesy of FORD MOTOR COMPANY

  1. 59.

    NOTE: RH shown in illustration, LH similar.

    Remove the rear subframe bolts and the subframe brackets.

GFD56782Courtesy of FORD MOTOR COMPANY

  1. 60.

    NOTE: RH shown in illustration, LH similar.

    Remove the front subframe bolts.

GFD56783Courtesy of FORD MOTOR COMPANY

  1. 61.

    Lower the subframe and powertrain assembly from the vehicle.

  1. 62.

    Install 303-1245 on the LH cylinder head.
GFD56784Courtesy of FORD MOTOR COMPANY

  1. 63.

    Install the Heavy Duty Floor Crane and Spreader Bar.
GFD56785Courtesy of FORD MOTOR COMPANY

  1. 64.

    Remove the starter motor solenoid cover.
GFD56786Courtesy of FORD MOTOR COMPANY

  1. 65.

    Remove the 2 nuts and the starter motor wiring terminals.
GFD56787Courtesy of FORD MOTOR COMPANY

  1. 66.

    Disconnect the wiring harness retainer from the starter motor stud bolt.
GFD56788Courtesy of FORD MOTOR COMPANY

  1. 67.

    Remove the bolt, stud bolt and the starter.
GFD56789Courtesy of FORD MOTOR COMPANY

  1. 68.

    Remove the bolt and the ground wire from the RH cylinder head.
GFD56790Courtesy of FORD MOTOR COMPANY

  1. 69.

    Disconnect the 2 A/C compressor electrical connectors.
    • Detach the A/C wiring harness retainer.
GFD56791Courtesy of FORD MOTOR COMPANY

  1. 70.

    Disconnect the generator electrical connector and position the generator B+ cable cover aside.
GFD56792Courtesy of FORD MOTOR COMPANY

  1. 71.

    Remove the nut and disconnect the generator B+ cable.
GFD56793Courtesy of FORD MOTOR COMPANY

  1. 72.

    Detach the 3 wiring harness retainer from the valve cover stud bolt and position the harness on transmission.
GFD56794Courtesy of FORD MOTOR COMPANY

  1. 73.

    Disconnect the transaxle control electrical connector.
GFD56795Courtesy of FORD MOTOR COMPANY

  1. 74.

    Detach the transaxle control wire harness retainer from the transaxle stud bolt.
GFD56796Courtesy of FORD MOTOR COMPANY

  1. 75.

    Disconnect the RH catalyst monitor electrical connector.
GFD56797Courtesy of FORD MOTOR COMPANY

  1. 76.

    Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.
GFD56798Courtesy of FORD MOTOR COMPANY

  1. 77.

    Remove the 4 nuts and the RH catalytic converter heat shield.
GFD56799Courtesy of FORD MOTOR COMPANY

  1. 78.

    Remove the 6 nuts and the RH catalytic converter manifold.
    • Discard the nuts and RH catalytic converter manifold gasket.
GFD56800Courtesy of FORD MOTOR COMPANY

  1. 79.

    Remove and discard the 6 RH catalytic converter manifold studs.
GFD56801Courtesy of FORD MOTOR COMPANY

AWD vehicles 

  1. 80.

    Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket.
GFD56705Courtesy of FORD MOTOR COMPANY

All vehicles 

  1. 81.

    Remove the Adjustable Grip Arm.
GFD56802Courtesy of FORD MOTOR COMPANY

  1. 82.

    Remove the ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe.

  1. 83.

    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.

GFD56803Courtesy of FORD MOTOR COMPANY

  1. 84.

    Using the Floor Crane and Spreader Bar, 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.
GFD56785Courtesy of FORD MOTOR COMPANY

  1. 85.

    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.

GFD56803Courtesy of FORD MOTOR COMPANY

  1. 86.

    Remove the 2 intermediate shaft bracket nuts and the 2 studs.
GFD56804Courtesy of FORD MOTOR COMPANY

  1. 87.

    Remove the 2 bolts and the RH halfshaft support bracket.
GFD56805Courtesy of FORD MOTOR COMPANY

  1. 88.

    Remove the 2 engine-to-transaxle bolts.
GFD56806Courtesy of FORD MOTOR COMPANY

  1. 89.

    Remove the 5 transaxle-to-engine bolts.
    • Separate the transaxle from the engine.
GFD56807Courtesy of FORD MOTOR COMPANY

  1. 90.

    Using the Floor Crane and Spreader Bar, remove the engine from the transaxle.
GFD56785Courtesy of FORD MOTOR COMPANY
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