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Engine - 4.6L: Removal: Engine: Removal

  1. Remove the hood.
  2. Recover the air conditioning system. For additional information, refer to AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION & CHARGING .
  3. Remove the air cleaner outlet tube.
  4. Disconnect the fuel lines. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION or FUEL SYSTEM - GENERAL INFORMATION - NATURAL GAS .
  5. Remove the wiper arm and pivot shaft. For additional information, refer to WIPER MOTOR .
  6. Drain the engine cooling system.
  7. Drain the engine oil.
    • Install the oil drain plug after draining.
  8. Lower the vehicle.
  9. Disconnect the lower radiator hose from the oil filter adapter.
    Fig 1: Identifying Lower Radiator Hose Clamp
    G01941417Courtesy of FORD MOTOR CO.
    10. NOTE: For oil cooler-equipped vehicles only.
    Fig 2: Identifying Oil Cooler
    G01941418Courtesy of FORD MOTOR CO.
  10. Disconnect the two coolant hoses, and remove the oil cooler and secure it to the front of the engine.
  11. Remove the battery. For additional information, refer to BATTERY, MOUNTING & CABLES .
  12. Disconnect the hoses from the transmission fluid cooler.
    • Position the clamp out of the way.
    • Remove the hoses.
    Fig 3: Identifying Transmission Fluid Cooler Hoses
    G01941419Courtesy of FORD MOTOR CO.
  13. Disconnect the hoses from the power steering fluid cooler.
    • Position the clamps out of the way.
    • Disconnect the hoses.
    Fig 4: Identifying Power Steering Fluid Cooler Hoses
    G01941420Courtesy of FORD MOTOR CO.
  14. Remove the radiator upper sight shield.
  15. Reposition the clamp and disconnect the upper radiator hose from the water hose connection. Secure the hose to the radiator assembly.
    Fig 5: Identifying Upper Radiator Hose Clamp
    G01941421Courtesy of FORD MOTOR CO.
  16. Disconnect the electrical connection from the fan motor and position out of the way.
    Fig 6: Identifying Fan Motor Electrical Connection
    G01941422Courtesy of FORD MOTOR CO.
  17. Remove the nuts and separate the lines from the A/C condenser core.
    Fig 7: Identifying A/C Condenser Core Nuts
    G01941423Courtesy of FORD MOTOR CO.
  18. Remove the bolts and the radiator support brackets.
    Fig 8: Identifying Radiator Support Bracket Bolts
    G01941424Courtesy of FORD MOTOR CO.
  19. Remove the radiator assembly.
    Fig 9: Identifying Radiator Assembly
    G01941425Courtesy of FORD MOTOR CO.
  20. Disconnect the engine bulkhead connectors.
    Fig 10: Identifying Engine Bulkhead Connectors
    G01941426Courtesy of FORD MOTOR CO.
  21. Disconnect the accelerator cable (9A758) and the speed control actuator cable (9A825):
    • Remove the bolts.
    • Disconnect the cables.
    Fig 11: Identifying Accelerator Cable & Speed Control Actuator Cable
    G01941427Courtesy of FORD MOTOR CO.

    Gasoline Engines 

  22. Remove the accelerator cable and the speed control actuator cable from the clips and position out of the way.
    Fig 12: Identifying Accelerator Cable & Speed Control Actuator Cable Clips
    G01941428Courtesy of FORD MOTOR CO.

    All Engines 

  23. Disconnect the main vacuum supply hose.
    Fig 13: Identifying Main Vacuum Supply Hose
    G01941429Courtesy of FORD MOTOR CO.
  24. Remove the bolt.
    Fig 14: Identifying Ground Cable Bolt
    G01941430Courtesy of FORD MOTOR CO.
  25. Raise the vehicle.
  26. Remove the starter motor:
    • Disconnect the electrical connections.
    • Remove the bolts.
    • Remove the starter motor.
    Fig 15: Identifying Starter Motor Electrical Connections, Bolts & Starter Motor
    G01941431Courtesy of FORD MOTOR CO.
  27. Support the exhaust and remove the four nuts.
    Fig 16: Identifying Exhaust Manifold Flange Nuts
    G01941432Courtesy of FORD MOTOR CO.
  28. Remove the bolts and the inspection cover.
    Fig 17: Identifying Flexplate Inspection Cover Bolts
    G01941433Courtesy of FORD MOTOR CO.
    29. NOTE: Mark one stud and the flexplate for assembly reference.
    Fig 18: Identifying Torque Converter Nut Access Plug
    G01941434Courtesy of FORD MOTOR CO.
  29. Remove the torque converter nut access plug.
    • Remove the four nuts.
  30. Remove the bolt.
    Fig 19: Identifying Transmission Cooler Line Bracket Bolt
    G01941435Courtesy of FORD MOTOR CO.
  31. Remove the nut and the ground wire.
    Fig 20: Identifying Ground Wire Nut
    G01941436Courtesy of FORD MOTOR CO.
  32. Remove the five bolts and one stud.
    Fig 21: Identifying Bolt & Stud
    G01941437Courtesy of FORD MOTOR CO.

    Gasoline Engines 

  33. Remove the evaporative emission (EVAP) canister purge valve.
    • Disconnect the three hoses.
    • Disconnect the connector.
    • Remove the nut and the EVAP canister purge valve.
    Fig 22: Removing Evaporative Emission (EVAP) Canister Purge Valve
    G01941438Courtesy of FORD MOTOR CO.
  34. Position the clamps out of the way and remove the heater water hoses.
    Fig 23: Identifying Heater Hose Clamps
    G01941439Courtesy of FORD MOTOR CO.
  35. Remove the nut and disconnect the electrical connectors on the RH inner fender.
    Fig 24: Identifying RH Inner Fender Electrical Connectors
    G01941440Courtesy of FORD MOTOR CO.

    Natural Gas Engines 

  36. Disconnect the connectors.
    Fig 25: Identifying Electrical Connectors
    G01941441Courtesy of FORD MOTOR CO.
  37. Remove the cover.
    Fig 26: Identifying Power Distribution Box Cover
    G01941442Courtesy of FORD MOTOR CO.
  38. Remove the nut and the wiring.
    Fig 27: Identifying Power Distribution Box Wiring & Nut
    G01941443Courtesy of FORD MOTOR CO.

    All Engines 

  39. Remove the bolt and the body ground.
    Fig 28: Identifying Body Ground Bolt
    G01941444Courtesy of FORD MOTOR CO.
  40. Disconnect the A/C cycling switch electrical connector.
    Fig 29: Identifying A/C Cycling Switch Electrical Connector
    G01941445Courtesy of FORD MOTOR CO.
  41. Remove the nut.
    Fig 30: Identifying A/C Bracket Nut
    G01941446Courtesy of FORD MOTOR CO.
  42. Disconnect the air conditioning lines.
    Fig 31: Identifying A/C Lines
    G01941447Courtesy of FORD MOTOR CO.
  43. Disconnect and unplug the RH heated oxygen sensor connector.
    Fig 32: Identifying RH Heated Oxygen Sensor Connector
    G01941448Courtesy of FORD MOTOR CO.
  44. Disconnect the LH heated oxygen sensor and separate the transmission harness from the rear of the LH cylinder head.
  45. Disconnect the power steering pressure hose.
    Fig 33: Identifying Power Steering Pressure Hose
    G01941450Courtesy of FORD MOTOR CO.
  46. Remove the bolt.
    Fig 34: Identifying Bolt
    G01941449Courtesy of FORD MOTOR CO.
  47. Raise the vehicle.
  48. Remove the LH bolts.
    Fig 35: Identifying LH Bolts
    G01941451Courtesy of FORD MOTOR CO.
  49. Remove the RH bolt.
    Fig 36: Identifying RH Bolt
    G01941452Courtesy of FORD MOTOR CO.
  50. Lower the vehicle.
  51. Install the engine lifting equipment.
    Fig 37: Identifying Engine Lifting Equipment
    G01941453Courtesy of FORD MOTOR CO.
  52. Support the transmission.
  53. Remove the engine assembly from the vehicle.
    Fig 38: Identifying Engine Lifting Equipment
    G01941454Courtesy of FORD MOTOR CO.
  54. Remove the flexplate (6375). For additional information, refer to FLEXPLATE .
  55. Use the (A) Rear Crank Slinger Remover and the (B) Slide Hammer to remove the (C) rear oil seal slinger.
    Fig 39: Identifying Rear Crank Slinger Remover, Slide Hammer & Rear Oil Seal Slinger
    G01941455Courtesy of FORD MOTOR CO.
  56. Use the (A) Rear Crank Seal Remover and the (B) Slide Hammer to remove the (C) rear main seal.
    Fig 40: Identifying Rear Crank Seal Remover, Slide Hammer & Rear Main Seal
    G01941456Courtesy of FORD MOTOR CO.
  57. Remove the eight bolts and the crankcase rear oil seal retainer.
    Fig 41: Identifying Crankcase Rear Oil Seal Retainer Bolts
    G01941457Courtesy of FORD MOTOR CO.
  58. Mount the engine on a suitable engine stand.
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