Engine - 3.5L GTDI: Removal: Engine

Courtesy of FORD MOTOR COMPANY	Bar, Engine Spreader 303-1454
Courtesy of FORD MOTOR COMPANY	Lift Eye, Right Front 303-1529
Courtesy of FORD MOTOR COMPANY	2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
Courtesy of FORD MOTOR COMPANY	Retainer, Torque Converter 307-346 (T97T-7902-A) or equivalent

• 1.
  
  With the vehicle in NEUTRAL, position it on a hoist. Refer to Jacking and Lifting .

NOTE: RH shown, LH similar.
NOTE: Index-mark the hood hinge location to aid in hood installation.
• 2.
  Remove the bolts (2 shown) and the hood.

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• 3.
  
  Release the fuel system pressure. Refer to Fuel System General Information .

• 4.
  
  Disconnect the battery ground cable. Refer to Battery, Mounting and Cables .

• 5.
  
  Remove the cooling module. Refer to Engine Cooling .

• 6.
  
  Remove the Air Cleaner Outlet Pipe. Refer to Intake Air Distribution and Filtering .

• 7.
  
  Release the retainers and remove the ACL upper tray.

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• 8.
  
  Remove the oil filler cap and the engine appearance cover.
  • Install the oil filler cap.

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• 9.
  
  
  • Disconnect electrical connector and the fuel vapor tube quick connect coupling. Refer to Fuel System General Information .
  • Disconnect the Charge Air Cooler (CAC) -to-Throttle Body (TB) pipe from the CAC.
  • Loosen the clamp and remove the Charge Air Cooler (CAC) -to-Throttle Body (TB) pipe.

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• 10.
  
  

  • 1.
    
    Disconnect the PCV pressure sensor electric connector.

  • 2.
    
    Disconnect the PCV tube quick connect couplings and remove the PCV tube. Refer to Fuel System General Information .

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• 11.
  
  Disconnect the quick connect couplings and disconnect the turbocharger bypass tube. Refer to Fuel System General Information .

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• 12.
  
  

  • 1.
    
    Release the turbocharger inlet tube from the turbocharger inlet tube bracket grommet.

  • 2.
    
    Loosen the turbocharger inlet tube clamp and remove the turbocharger inlet tube.

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• 13.
  
  Release the turbocharger outlet tube from the retaining clamp and release the turbocharger outlet tube from the turbocharger outlet tube bracket grommet. Loosen the turbocharger outlet tube clamp and remove the turbocharger outlet tube.

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• 14.
  
  Disconnect the turbocharger inlet pipe hose.

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• 15.
  
  Detach the turbocharger inlet pipe from the bracket. Loosen the turbocharger inlet pipe clamp and remove the turbocharger inlet pipe.

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• 16.
  
  Disconnect the turbocharger outlet pipe hose and detach the turbocharger outlet pipe from the bracket. Loosen the turbocharger outlet pipe clamps and remove the turbocharger outlet pipe.

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• 17.
  
  Disconnect and remove the air bypass tube assembly from the air cooler.

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• 18.
  
  Disconnect the A/C pressure transducer electrical connectors.

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• 19.
  
  Disconnect the Battery Junction Box (BJB) wiring harness.

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• 20.
  
  Remove the nut and disconnect the A/C tube.
  • Discard the O-ring seal and gasket seal.

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• 21.
  
  Remove the nut and the transmission cooler line bracket from the engine front cover stud bolt.

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• 22.
  
  Detach the generator wiring harness from the engine front cover.

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• 23.
  
  Remove the generator. Refer to Generator and Regulator .

• 24.
  
  Disconnect the PCM electrical connector and the engine wire harness electrical connector.
  • Detach the wiring harness retainers from the fender splash shield.

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• 25.
  
  Remove the fuel injection pump. Refer to Engine Controls - Fuel Charging And Controls - 3.5L GTDI .

• 26.
  
  Remove the intake manifold. Refer to Intake Manifold .

• 27.
  
  Disconnect the heater hose couplings at the RH rear of the engine.

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• 28.
  
  Using a hose clamp remover/installer, loosen clamp and position the heater hose aside.

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• 29.
  
  Disconnect the hoses from the degas bottle.

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• 30.
  
  Detach the wiring harness retainers from the rear of the RH valve cover stud bolt and the rear of the vacuum pump.

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• 31.
  
  Disconnect the vacuum pump tube and position aside.

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• 32.
  
  Remove the nut and the ground strap from the cowl.

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• 33.
  
  Remove the cowl panel grille. Refer to Front End Body Panels .

• 34.
  
  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.

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• 35.
  
  Release the fasteners and the splash shield.

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• 36.
  
  If equipped, remove the bolts and the skid plate.

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• 37.
  
  Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector and release the harness from the retainer.

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• 38.
  
  Separate the fuel lines from the retainers on the rear of the transmission.

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• 39.
  
  Separate fuel lines from the bracket on the upper bell housing.

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• 40.
  
  Disconnect transfer case electrical connector.

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• 41.
  
  Disconnect the 2 CMS electrical connectors and retainers.
  • Disconnect the transfer case electrical connector harness retainer.
  • Disconnect the transmission harness electrical connector and harness retainers.

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NOTE: Clean the cable adjustment lock of any debris.
NOTE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket.
• 42.
  Rotate the cable adjustment lock upward and remove the selector lever cable from the manual control lever.

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NOTE: The shifter cable is being positioned aside to allow for easier access to the upper transmission bolts.
• 43.
  Remove the selector lever cable bracket bolts, the selector lever cable bracket and position the cable aside.

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• 44.
  
  Remove the upper bell housing-to-engine bolts 5 mm (0.19 in).

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• 45.
  
  If equipped, remove the front driveshaft. Refer to Driveshaft .

• 46.
  
  Remove the starter motor. Refer to Starting System .

• 47.
  
  Detach the starter motor wiring harness retainer from the oil pan.

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• 48.
  
  Remove the pin-type retainers and the access cover.

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NOTE: Index-mark the end of one torque converter stud and the flexplate for installation.
• 49.
  Remove the torque converter nuts.

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• 50.
  
  Remove the exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolts and separate.
  • Discard the bolts.

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• 51.
  
  Remove and discard the RH catalytic converter-to-exhaust manifold nuts.

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• 52.
  
  
  • Remove and discard the LH catalytic converter flange nuts.
  • Position the catalytic converter assembly aside and remove and discard the gasket.

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• 53.
  
  Remove the drain plug and drain the engine oil.
  • Install the drain plug and tighten to 27 Nm (20 lb-ft).
  • Remove and discard the oil filter.

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• 54.
  
  Remove the lower bell housing bolt.

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• 55.
  
  Using a Vehicle/Axle Stand position the exhaust back and install the stand under the transmission bell housing.

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• 56.
  
  Remove the engine-to-bell housing bolt above and below the starter motor.

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• 57.
  
  Remove the LH bell housing-to-engine bolts.

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• 58.
  
  Remove the LH bell housing-to-oil pan bolts.

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NOTE: Only use hand tools when removing the engine support insulator nuts and studs or damage to the engine support insulator can occur.
• 59.
  Remove and discard the RH engine support insulator nuts and studs.

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NOTE: Only use hand tools when loosening or tightening the engine support insulator through bolts or damage to the engine support insulator-to-cylinder block bracket can occur.
• 60.
  Remove and discard the LH engine mount through bolt.

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NOTE: Do not support the transmission by the fluid pan, failure to follow this instruction may result in serious damage to the transmission.
• 61.
  Support the bell housing of the transmission with a suitable floor jack and a block of wood.

• 62.
  
  
  • If equipped, disconnect the electrical connector.
  • If equipped, using a hose clamp remover/installer, disconnect the heater hose.

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• 63.
  
  If equipped, remove the nuts, the bolt and position the heater pump aside.

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• 64.
  
  Remove the nuts and the CAC tube bracket.
  • Disconnect the coolant hose from the valve cover stud.

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• 65.
  
  Remove the A/C compressor belt. Refer to Accessory Drive .

• 66.
  
  Disconnect the A/C compressor electrical connector, remove the retainers and A/C compressor.

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NOTE: After removing the bolts leave the LH engine support insulator in place.
NOTE: Only use hand tools when removing or installing the engine support insulator-to-frame bolts or damage to the engine support insulator-to-frame nut plate can occur.
• 67.
  Remove and discard the bolts for the LH engine support insulator.

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NOTE: The use of a ratchet strap may be needed to level the engine.
NOTE: If the RH factory lifting eye is not installed, install a 303-1529 Engine Lift Eye.
• 68.
  Using the Floor Crane and Engine Spreader Bar assembly, lift the engine.

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• 69.
  
  Remove the LH engine support insulator.

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NOTE: The transmission wiring harness is part of the engine wiring harness.
• 70.
  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.

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• 71.
  
  Using the Floor Crane and Engine Spreader Bar assembly, remove the engine.

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• 72.
  
  Install the Torque Converter Retainer.

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