Removal
1. Disconnect battery ground cable.
2. Remove engine appearance cover retaining bolt and nuts and remove engine appearance cover from vehicle.
Engine Appearance Cover
3. Disconnect engine control sensor wiring from the IAT sensor connector and crankcase ventilation tube from air cleaner outlet tube.
4. Completely loosen air cleaner outlet tube to throttle body bolt.
5. Loosen clamp on air cleaner outlet tube to engine air cleaner (ACL) and disconnect air cleaner outlet tube.
6. Remove remaining bolt from engine air cleaner outlet tube bracket on RH valve cover to air cleaner outlet tube.
7. Remove air cleaner outlet tube and engine intake air resonator.
Air Cleaner Outlet Tube
8. Drain engine cooling system. Refer to Engine Cooling. Cooling System
9. Remove windshield wiper module assembly. Refer to Wiper and Washer Systems. Wiper and Washer Systems
10. Recover air conditioning system. Refer to Heating and Air Conditioning. Heating and Air Conditioning
11. Disconnect secondary air injection pump tube from the fan shroud.
12. Disconnect secondary air injection valve inlet tube from secondary air injection pump outlet hose.
13. Remove cooling fan motor, fan blade and fan shroud assembly. Refer to Engine Cooling. Cooling System
14. Relieve fuel system pressure and disconnect fuel tubes. Refer to Fuel Delivery and Air Induction. Fuel Delivery and Air Induction
15. Remove 42-pin connector from retaining bracket on LH fender well.
16. Disconnect 42-pin connector and position out of the way.
17. Remove power distribution box and harness and disconnect generator B+ wiring connector from inside of power distribution box.
18. Disconnect engine control sensor wiring from evaporative emission canister purge valve (EVAP canister purge valve).
19. Disconnect accelerator cable and speed control actuator cable from throttle body and also from accelerator cable bracket.
20. Disconnect evaporative emission canister purge vacuum line at throttle body connector.
21. Disconnect chassis vacuum supply hose at connection on cowl support.
22. Disconnect heater inlet and outlet tubes at rear of RH cylinder head.
23. Disconnect upper radiator hose at water bypass tube.
24. Disconnect and drain radiator overflow hose from radiator coolant recovery reservoir.
25. Remove power steering return hose from power steering pump and drain. Remove power steering pressure hose from power steering pump at power steering pump. Remove reservoir retaining bolt and stud from LH ignition coil bracket. Remove power steering pump.
26. Remove upper fluid cooler inlet tube from radiator.
27. Install engine lifting brackets from Rotunda Engine Lifting Set 014-00340 or equivalent.
28. Disconnect A/C compressor lines and disconnect retaining clips from A/C compressor.
29. Partially raise vehicle on hoist. Refer to Vehicle Lifting and Jacking Points.
30. Remove front wheels and tires. Refer to Wheels and Tires. Wheels and Tires
31. Disconnect RH and LH ride height sensor wiring connectors.
32. Remove RH and LH front disc brake caliper bolts. Remove disc brake calipers and support to vehicle using mechanic's wire.
33. Disconnect RH and LH front suspension upper arms from front wheel hub and spindles.
34. Raise vehicle.
35. Drain engine oil.
36. Remove dual converter Y pipe from both LH and RH exhaust manifolds. Refer to Exhaust System. Exhaust System
37. Disconnect ground strap from RH front fender apron.
38. Disconnect power steering pressure hose from steering gear at power steering pump connection.
39. Disconnect lower radiator hosee.
40. Remove RH and LH strut to front suspension lower arm bolts and nuts.
41. Disconnect engine control sensor wiring and gear selector linkage.
42. Disconnect lower fluid cooler tube from radiator.
43. Index driveshaft centering socket yoke to rear axle universal joint flange.
44. Remove four bolts connecting driveshaft centering socket yoke to rear axle universal joint flange. Support rear axle assembly with jack stand.
45. Remove two nut and bolt assemblies retaining the front of the rear axle assembly to the rear sub-frame.
46. Loosen rear differential bracket to body bolts and lower rear differential bracket.
47. Slide driveshaft rearward until it is free of extension housing.
48. Disconnect vacuum supply tube from secondary air injection diverter valve.
49. Disconnect secondary air injection tube gaskets from the exhaust manifolds.
50. Disconnect electrical harness clip from secondary air injection manifold tube.
51. Remove the LH secondary air injection tube bracket to LH cylinder head retaining bolt.
52. Remove the RH secondary air injection tube bracket to RH cylinder head retaining bolt.
53. Disconnect RH secondary air injection tube gasket from LH secondary air injection tube gasket.
54. Remove LH secondary air injection tube gasket.
55. Remove RH secondary air injection tube gasket.
56. Remove secondary air injection diverter valve.
57. Remove two retaining nuts from bottom front cover studs and remove positive battery cable.
58. Disconnect low oil level sensor connector and engine control sensor wiring from oil pan.
59. Disconnect starter motor and remove. Refer to Starting System. Starting System
60. Support front sub-frame using Rotunda Powertrain Lift 014-00765 and Adapter 014-00341 or equivalent.
61. Remove rear engine support insulator retaining bolts.
62. Disconnect steering coupling at pinch bolt joint.
63. Remove eight front sub-frame bolts.
64. Lower engine and transmission from vehicle.
65. Remove two front engine support insulator through bolts.
66. Connect engine lifting spreader bar from Rotunda Engine Lift Bracket Set 014-00340 or equivalent to lifting eyes on engine. Lift engine and transmission from front sub-frame with hoist.
67. Lower engine and transmission. Support transmission on a level, stationary surface for transmission storage.
68. Remove transmission-to-cylinder block mounting bolts and separate engine from transmission/torque converter assembly.
69. Place engine on suitable work stand.
70. Remove engine lifting equipment.
71. Remove RH and LH front engine support insulators from cylinder block.
72. Remove RH and LH water jacket pipe plugs in cylinder block and drain balance of engine coolant. Reinstall pipe plugs. Coat threads of pipe plugs with Pipe Sealant with Teflon� D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 and ESR-M18P7-A.
73. Disconnect EGR valve to exhaust manifold tube from EGR valve tube to manifold connector, EGR backpressure transducer hose connections and loosen EGR valve to exhaust manifold tube at EGR valve (EGR valve). Remove EGR valve to exhaust manifold tube.
74. Remove eight nuts retaining LH exhaust manifold to cylinder head.
75. Remove LH exhaust manifold and LH exhaust manifold gaskets. Discard exhaust manifold gaskets.