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Home >> Lincoln >> 2003 >> Navigator 4WD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine-5.4L >> Removal >> Engine >> Removal and Installation

Removal and Installation

  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the radiator. For additional information, refer to ENGINE COOLING .
  3. Recover the A/C system refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  4. Remove the lower intake manifold. For additional information, refer to LOWER INTAKE MANIFOLD .
  5. Disconnect the powertrain control module (PCM) electrical connectors.
    Fig 1: Disconnecting Powertrain Control Module (PCM) Electrical Connectors
    G01563096Courtesy of FORD MOTOR CO.
  6. Remove the PCM mounting bolts and the PCM.
    Fig 2: Removing Pcm Mounting Bolts And PCM
    G01563097Courtesy of FORD MOTOR CO.
  7. Remove the bolts and the PCM mounting bracket.
    Fig 3: Removing Bolts And PCM Mounting Bracket
    G01563098Courtesy of FORD MOTOR CO.
  8. Disconnect the auxiliary heater hoses at the right side valve cover.
    Fig 4: Disconnecting Auxiliary Heater Hoses At Right Side Valve Cover
    G01563099Courtesy of FORD MOTOR CO.
  9. Disconnect the heater hoses at the heater core.
    Fig 5: Disconnecting Heater Hoses At Heater Core
    G01563100Courtesy of FORD MOTOR CO.
  10. Disconnect the A/C hoses from the junction block.
    Fig 6: Disconnecting A/C Hoses From Junction Block
    G01563101Courtesy of FORD MOTOR CO.
  11. Remove the safety clips and disconnect the spring lock couplers at the evaporator core. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 7: Disconnecting Spring Lock Couplers At Evaporator Core
    G01563102Courtesy of FORD MOTOR CO.
  12. Rotate the belt tensioner counterclockwise and remove the drive belt.
    Fig 8: Removing Drive Belt
    G01563103Courtesy of FORD MOTOR CO.
    13. NOTE: Position the rubber boot aside to access the B+ cable.
    Fig 9: Disconnecting Generator Electrical Connectors
    G01563104Courtesy of FORD MOTOR CO.
  13. Disconnect the generator electrical connectors.
  14. Remove the bolts and the generator.
    Fig 10: Removing Bolts And Generator
    G01563105Courtesy of FORD MOTOR CO.
  15. Using the special tool, remove the power steering pump pulley.
    Fig 11: Removing Power Steering Pump Pulley Using Special Tool
    G01563106Courtesy of FORD MOTOR CO.
  16. Disconnect the power steering pressure hose.
    • Drain the power steering fluid into a suitable container.
      Fig 12: Draining Power Steering Fluid Into Container
      G01563107Courtesy of FORD MOTOR CO.
  17. Remove the three bolts and position the power steering pump out of the way.
    Fig 13: Removing Bolts
    G01563108Courtesy of FORD MOTOR CO.
  18. Remove the engine noise shield.
    Fig 14: Removing Engine Noise Shield
    G01563109Courtesy of FORD MOTOR CO.
  19. Squeeze the clamps and disconnect the hoses.
    • Remove the positive crankcase ventilation (PCV) valve and hose assembly from the vehicle.
      Fig 15: Removing Positive Crankcase Ventilation (PCV) Valve And Hose Assembly
      G01563110Courtesy of FORD MOTOR CO.
  20. Remove the bolt.
    Fig 16: Removing Bolt
    G01563111Courtesy of FORD MOTOR CO.
  21. Remove the tube.
    Fig 17: Removing Tube
    G01563112Courtesy of FORD MOTOR CO.
  22. Remove the bolt and disconnect the ground wire.
    Fig 18: Disconnecting Ground Wire
    G01563113Courtesy of FORD MOTOR CO.
  23. Disconnect the vacuum hose and remove the vacuum harness.
    Fig 19: Disconnecting Vacuum Hose
    G01563114Courtesy of FORD MOTOR CO.
  24. Disconnect the main engine harness electrical connector.
    Fig 20: Disconnecting Main Engine Harness Electrical Connector
    G01563115Courtesy of FORD MOTOR CO.
  25. Raise the vehicle. .
  26. Remove the bolts and the skid plate, if equipped.
    27. NOTE: The bolt is accessed through the RH fender well.
    Fig 21: Removing Transmission Filler Tube-To-Engine Block Bolt
    G01563116Courtesy of FORD MOTOR CO.
  27. Remove the transmission filler tube-to-engine block bolt.
    28. NOTE: Right side shown, left side similar.
    Fig 22: Disconnecting Heated Oxygen Sensor (HO2S) Electrical Connectors
    G01563117Courtesy of FORD MOTOR CO.
  28. Disconnect the heated oxygen sensor (HO2S) electrical connectors.
    29. NOTE: Left side shown, right side similar.
    Fig 23: Removing Nuts
    G01563118Courtesy of FORD MOTOR CO.
  29. Remove the nuts and detach the dual converter Y-pipe.
  30. Remove the bolt and detach the wire harness bracket.
    Fig 24: Removing Bolt
    G01563119Courtesy of FORD MOTOR CO.
  31. Remove the starter. For additional information, refer to STARTERS .
  32. Disconnect the A/C clutch electrical connector.
  33. Remove the bolts and position the A/C compressor aside.
    Fig 25: Removing Bolts
    G01563120Courtesy of FORD MOTOR CO.
  34. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 26: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector
    G01563121Courtesy of FORD MOTOR CO.
  35. Remove the nuts and disconnect the transmission cooler tube and the power steering hose brackets.
    Fig 27: Disconnecting Transmission Cooler Tube And Power Steering Hose Brackets
    G01563122Courtesy of FORD MOTOR CO.
  36. Remove the oil filter.
    Fig 28: Removing Oil Filter
    G01563123Courtesy of FORD MOTOR CO.
  37. Remove the drain plug and drain the engine oil.
    • Install the drain plug when finished.
      Fig 29: Removing Drain Plug
      G01563124Courtesy of FORD MOTOR CO.
  38. Squeeze the clamps and disconnect the hoses.
    • Remove the lower radiator hose.
      Fig 30: Removing Lower Radiator Hose
      G01563125Courtesy of FORD MOTOR CO.
  39. Remove the flexplate-to-torque converter nut access plug.
    Fig 31: Removing Flexplate-To-Torque Converter Nut Access Plug
    G01563126Courtesy of FORD MOTOR CO.
    40. NOTE: Mark one stud and the flexplate for assembly reference.
  40. Remove the four torque converter nuts.
    • Rotate the crankshaft, using the crankshaft pulley bolt.
      Fig 32: Removing Torque Converter Nuts
      G01563127Courtesy of FORD MOTOR CO.
  41. Remove the five lower transmission-to-engine bolts.
    Fig 33: Removing Lower Transmission-To-Engine Bolts
    G01563128Courtesy of FORD MOTOR CO.
    42. NOTE: The caged nut on the frame may break during bolt removal. If necessary, install a new nut.
    Fig 34: Removing Bolt From LH Motor Mount
    G01563129Courtesy of FORD MOTOR CO.
  42. Remove the bolt from the LH motor mount.
  43. Remove the nut from the RH motor mount.
    Fig 35: Removing Nut From RH Motor Mount
    G01563130Courtesy of FORD MOTOR CO.
  44. Lower the vehicle.
  45. Remove the two upper transmission-to-engine bolts.
    46. NOTE: The alternator bolts may be used to attach the special tool to the front of the engine. The two bolts used to attach the special tool to the rear of the engine must be shorter than the transmission-to-engine mounting bolts.
    Fig 36: Identifying Special Tool
    G01563131Courtesy of FORD MOTOR CO.
  46. Install the special tool.
  47. Support the transmission, using a block of wood and a floor jack.
  48. Using a floor crane, remove the engine from the vehicle.
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