Engine Mechanical - 3.5L: Component Locations

Special Tool(s)

SPECIAL TOOL DESCRIPTION CHART Handle 205-153 (T80T-4000-W) Installer, VCT Spark Plug Tube Seal 303-1247/2 Remover, VCT Spark Plug Tube Seal 303-1247/1

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Scheme 131: Special Tool(s)

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SPECIAL TOOL DESCRIPTION CHART Handle 205-153 (T80T-4000-W) Installer, VCT Spark Plug Tube Seal 303-1247/2 Remover, VCT Spark Plug Tube Seal 303-1247/1

SPECIAL TOOL DESCRIPTION CHART 3 Jaw Puller 303-D121 or equivalent Installer, Front Cover Oil Seal 303-335 Replacer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Strap Wrench 303-D055 (D85L-6000-A) or equivalent

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Scheme 134: Special Tool(s)

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SPECIAL TOOL DESCRIPTION CHART Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Crankshaft Seal 303-1251 Remover, Oil Seal 303-409 (T92C-6700CH)

SPECIAL TOOL DESCRIPTION CHART Handle 205-153 (T80T-4000-W) Installer, Rear Main Seal 303-1250 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Slide Hammer 307-005 (T59L-100-B)

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SPECIAL TOOL DESCRIPTION CHART 3 Jaw Puller 303-D121 or equivalent Alignment Pins 307-399 Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Installer, Front Crankshaft Seal 303-1251 Oil Pan Holding Fixture 303-1295 Remover, Oil Seal 303-409 (T92C-6700CH) Replacer, Crankshaft Vibration Damper 303-102 (T74P-6312-B) Strap Wrench 303-D055 (D85L-6000-A) or equivalent

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SPECIAL TOOL DESCRIPTION CHART Tool, Camshaft Holding 303-1248

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Scheme 139: Special Tool(s)

SPECIAL TOOL DESCRIPTION CHART Oil Pan Holding Fixture 303-1295

SPECIAL TOOL DESCRIPTION CHART Tool, Camshaft Holding 303-1248

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Scheme 140: Special Tool(s)

SPECIAL TOOL DESCRIPTION CHART Disconnect Tool, Transmission Cooler Line 307-569 Eye, Engine Lift 303-1245 Halfshaft Remover 205-832 Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 or equivalent Remover, Front Wheel Hub 205-D070 (D93P-1175-B) or equivalent Slide Hammer 100-001 (T50T-100-A) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-00001 or equivalent

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Scheme 141: Special Tool(s)

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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

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With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
Recover the A/C system. For additional information, Refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-372762) .
Remove the cowl panel grille. For additional information, Refer to «FRONT END BODY PANELS»(ref-372798) .
Detach the brake booster vacuum hose retainer from the strut tower brace.
Remove the 4 nuts (2 shown in illustration) and the strut tower brace.
Release the fuel system pressure. For additional information, Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-372809) .
Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-372794) .
Remove the battery tray. For additional information, Refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .
Disconnect the engine wiring harness electrical connector.
Remove the nut and disconnect the 2 power feed wires from the positive battery terminal.
Remove the nut and disconnect the ground cable from the negative battery terminal.
Drain the cooling system. For additional information, Refer to «ENGINE COOLING»(ref-372804) .
Remove the LF wheel and tire. For additional information, Refer to «WHEELS AND TIRES»(ref-372756) .
Remove the accessory drive belt and the power steering belt. For additional information, Refer to «ACCESSORY DRIVE»(ref-372765) .
Remove the 3 pin-type retainers, 7 bolts and the front valance.
Disconnect the power steering cooler tube located at the left front subframe and drain the power steering fluid into a suitable container.
Remove the nut and disconnect the A/C tube. Discard the O-ring seal and gasket seal.
Remove the nut and the A/C tube. Discard the O-ring seal and gasket seal.
Remove the degas bottle. For additional information, Refer to «ENGINE COOLING»(ref-372804) .
Disconnect the vacuum hose and the Evaporative Emission (EVAP) tube from the upper intake manifold.
Detach the EVAP tube pin-type retainer from the upper intake manifold.
Remove the EVAP canister purge valve. For additional information, Refer to «EVAPORATIVE EMISSIONS»(ref-372810) .
Disconnect the PCM and engine harness electrical connectors. Detach the wiring harness retainer.
Disconnect the 2 PCM electrical connectors.
Remove the engine wiring harness retainer from the bulkhead. Push the wiring harness retainer tab in. Slide the wiring harness up and out of the bulkhead.
Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
Disconnect the transaxle control cable from the control lever.
Disconnect the transaxle control cable from the shift cable bracket and detach the wiring harness pin-type retainer.
If equipped, detach the engine block heater harness from the radiator support.
Disconnect the A/C pressure switch and remove the nut and disconnect the upper A/C tube from the condenser. Discard the O-ring seal.
Disconnect the fuel supply tube from the fuel rail. For additional information, Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-372809) .
Detach the engine wiring harness retainer.
Detach the wire harness retainer from the RH valve cover stud bolt.
Remove the bolt and the ground cable from the engine.
Disconnect the hose from the power steering reservoir.
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.
NOTE: Apply the brake to keep the halfshafts from rotating. NOTE: RH shown in illustration, LH similar. Remove the RH and LH halfshaft nuts. Do not discard at this time.
NOTE: RH shown in illustration, LH similar. Using the Front Wheel Hub Remover, separate the RH and LH halfshaft from the wheel hubs.
Remove the 2 lower scrivets from the rubber shield and position the shield aside.
Remove the bolt from the RH brake hose bracket.
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»(ref-372796) . 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.
Remove the 4 Y-pipe-to-catalytic converter nuts. Discard the nuts.
Remove the 2 Y-pipe flange nuts. Detach the exhaust hanger and remove the Y-pipe. Discard the gaskets and nuts. All-Wheel Drive (AWD) vehicles
NOTE: Index-mark the driveshaft for installation. Remove and discard the 4 bolts and support the driveshaft with a length of mechanic's wire. All vehicles
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 engine oil filter.
If equipped, detach the oil cooler hose support clip from the subframe.
Remove the Power Steering Pressure (PSP) tube bracket-to-steering gear bolt.
Remove the bolt, rotate the clamp plate clockwise and disconnect the PSP tube from the steering gear. Discard the O-ring seal.
Remove the 2 rear engine roll restrictor-to-transaxle bolts.
Remove the 2 front engine roll restrictor-to-transaxle bolts.
NOTE: RH shown in illustration, LH similar. Remove and discard the upper stabilizer link nuts.
NOTE: The hex-holding feature can be used to prevent turning of the stud while removing the nut. NOTE: RH shown in illustration, LH similar. Remove and discard the tie-rod end nuts. Separate the tie-rod ends from the wheel knuckles.
NOTE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part number or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. NOTE: Use care when releasing the lower arm and knuckle into the resting position or damage to the ball joint seal or Constant Velocity (CV) boot may occur. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. NOTE: RH shown in illustration, LH similar. Remove and discard the lower ball joint-to-wheel knuckle nuts. Separate the lower ball joints from the wheel knuckles.
Position the Powertrain Lift under the subframe assembly.
NOTE: RH shown in illustration, LH similar. Remove the subframe bracket-to-body bolts.
NOTE: RH shown in illustration, LH similar. Remove the rear subframe bolts and the subframe brackets.
NOTE: RH shown in illustration, LH similar. Remove the front subframe bolts.
Lower the subframe assembly from the vehicle.
Pull the RH wheel knuckle outward and rotate it toward the rear of the vehicle. Secure the RH wheel knuckle assembly.
Remove the 2 intermediate shaft bracket nuts.
Remove the intermediate and halfshaft assembly.
NOTE: The sharp edges on the stub shaft splines can slice or puncture the oil seal. Use care when inserting the stub shaft into the transmission or damage to the component may occur. Using the Slide Hammer and Halfshaft Remover, remove the halfshaft from the transmission.
Remove and discard the circlip from the stub shaft.
If equipped, disconnect the oil cooler coolant hoses.
Remove the 2 RH halfshaft support bracket studs.
Remove the 4 bolts and the RH halfshaft support bracket.
Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
Remove the 2 fasteners and the inspection cover.
Remove and discard the 3 torque converter bolts.
Remove the 4 oil pan-to-transaxle bolts. AWD vehicles
Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.
Remove the 4 nuts and the RH catalytic converter. Discard the nuts and gasket.
Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket.
Remove the 5 bolts and the PTU . All vehicles
NOTE: Position a block of wood under the transaxle. Install the Powertrain Lift and Universal Adapter Brackets.
Remove the transaxle support insulator through bolt and nut.
Remove the bolt, 3 nuts and the transaxle support insulator bracket.
Remove the nut, bolt and engine mount brace.
Remove the 4 engine mount nuts.
Remove the 3 bolts and the engine mount.
Lower the engine and transaxle assembly from the vehicle.
Remove the starter motor solenoid cover.
Remove the 2 nuts and the starter motor wiring terminals.
Disconnect the wiring harness retainer from the starter motor stud bolt.
Remove the bolt, stud bolt and the starter.
Install the Engine Lift Eye on the LH cylinder head.
Disconnect the transaxle control electrical connector.
Detach the transaxle control wire harness retainer from the transaxle stud bolt.
Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table.
Remove the 2 engine-to-transaxle bolts.
Remove the 5 transaxle-to-engine bolts. Separate the transaxle from the engine.

SPECIAL TOOL DESCRIPTION CHART 3 Jaw Puller 303-D121 Disconnect Tool, Transmission Cooler Tube 307-569 Halfshaft Remover 205-832 Handle 205-153 (T80T-4000-W) Powertrain Lift 014-00765 or equivalent Remover, Front Wheel Hub 205-D070 (D93P-1175-B) or equivalent Remover, Oil Seal 303-409 (T92C-6700CH) Remover, VCT Spark Plug Tube Seal 303-1247/1 Slide Hammer 100-001 (T50T-100-A) Strap Wrench 303-D055 (D85L-6000-A) Tool, Camshaft Holding 303-1248 Universal Adapter Brackets 014-00001 or equivalent

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SPECIAL TOOL DESCRIPTION CHART Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249

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Scheme 218: Special Tool(s)

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Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

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Remove the valve tappets from the cylinder being serviced. For additional information, refer to «VALVE TAPPETS»(ref-372749-S23008481062010093000000) .
Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke.
NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal or engine damage may occur. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. NOTE: If a valve drops into the cylinder, remove the cylinder head. For additional information, refer to «CYLINDER HEAD - RH»(ref-372749-S28016336302010093000000) or «CYLINDER HEAD - LH»(ref-372749-S09985811362010093000000) . Pressurize the cylinder using compressed air.
Using the Valve Spring Compressors, remove the keys, retainer and spring.
Remove and discard the valve stem seal.

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SPECIAL TOOL DESCRIPTION CHART 3 Jaw Puller 303-D121 Handle 205-153 (T80T-4000-W) Remover, Oil Seal 303-409 (T92C-6700CH) Remover, VCT Spark Plug Tube Seal 303-1247/1 Strap Wrench 303-D055 (D85L-6000-A)

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SPECIAL TOOL DESCRIPTION CHART Heavy Duty Floor Crane 014-00071 or equivalent Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Slide Hammer 307-005 (T59L-100-B) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

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SPECIAL TOOL DESCRIPTION CHART 3 Jaw Puller 303-D121 Handle 205-153 (T80T-4000-W) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Remover, Oil Seal 303-409 (T92C-6700CH) Remover, VCT Spark Plug Tube Seal 303-1247/1 Slide Hammer 307-005 (T59L-100-B) Strap Wrench 303-D055 (D85L-6000-A) Tool, Camshaft Holding 303-1248

SPECIAL TOOL DESCRIPTION CHART Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249 Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

SPECIAL TOOL DESCRIPTION CHART Alignment Pins 307-399 Compressor, Piston Ring 303-D032 (D81L-6002-C) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Engine Lift Eye 303-1245 Handle 205-153 (T80T-4000-W) Heavy Duty Floor Crane 014-00071 or equivalent Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 Installer, Front Crankshaft Seal 303-1251 Installer, Rear Main Seal 303-1250 Installer, VCT Spark Plug Tube Seal 303-1247/2 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Strap Wrench 303-D055 (D85L-6000-A) Tool, Camshaft Holding 303-1248

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SPECIAL TOOL DESCRIPTION CHART Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-00001 or equivalent

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Scheme 228: Special Tool(s)

SPECIAL TOOL DESCRIPTION CHART Alignment Pins 307-399 Handle 205-153 (T80T-4000-W) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 Installer, Front Crankshaft Seal 303-1251 Installer, VCT Spark Plug Tube Seal 303-1247/2 Powertrain Lift 014-00765 or equivalent Strap Wrench 303-D055 (D85L-6000-A) Tool, Camshaft Holding 303-1248

SPECIAL TOOL DESCRIPTION CHART Alignment Pins 307-399 Handle 205-153 (T80T-4000-W) Heavy Duty Floor Crane 014-00071 or equivalent Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Crankshaft Seal 303-1251 Installer, Front Cover Oil Seal 303-335 Installer, VCT Spark Plug Tube Seal 303-1247/2 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Strap Wrench 303-D055 (D85L-6000-A)

SPECIAL TOOL DESCRIPTION CHART Handle 205-153 (T80T-4000-W) Heavy Duty Floor Crane 014-00071 or equivalent Installer, Rear Main Seal 303-1250 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

Engine Mechanical - 3.5L: Component Locations Ford Flex I