Engine Removal - 4-cyl Ford Thunderbird IX

1.6L (98")

1. Mark hinges for reinstallation and remove hood. Remove air cleaner, hot air tube, alternator air tube, and air flow sensor, if equipped. Disconnect negative battery cable at both ends. Drain cooling system.
2. Remove all drive belts. Remove alternator mounting bolts and position alternator aside. If equipped, disconnect thermactor pump hoses and remove pump. Disconnect upper and lower radiator hoses at engine. If equipped, disconnect transaxle oil cooler lines at radiator.
3. Disconnect heater return hose at engine. Disconnect all electrical wiring and vacuum hoses at engine. Disconnect fuel lines at pump (carburetor) or intake manifold (EFI/Turbo). Remove fan motor and shroud assembly.
4. On automatic transaxle, remove transaxle cooler line routing clip. On all models, remove radiator. Disconnect heater hose at steel tube. If equipped, remove power steering pump filler tube and plug pump opening.
5. If equipped, disconnect throttle kickdown linkage, accelerator cable and bracket at engine. Disconnect vacuum hose from thermactor valve. Disconnect accelerator cable and remove cable routing bracket screws. Disconnect vapor hose at carbon canister tube.
6. Raise vehicle on hoist. Remove clamp from heater supply and return tubes. Disconnect battery cable from starter motor. Remove brace at front of starter motor. On manual transaxle, remove roll restrictor. On turbo engine, remove oil cooler.
7. On all models, remove starter motor and brace rear section. Disconnect exhaust pipe at manifold or turbocharger. Remove converter/flywheel cover and brackets.
8. On all models, remove crankshaft pulley. On manual transaxle, remove lower timing belt cover bolts. Remove lower clutch housing bolts. On automatic transaxle, remove torque converter-to-drive plate nuts. Remove lower converter/flywheel housing bolts.
9. On all models, remove coolant by-pass hose at intake manifold. Remove lower right side engine mount bolt and nut. Lower vehicle. Attach engine lift to brackets. Remove right side engine mount through bolt and remove engine mount.
10. On manual transaxle, remove timing belt cover. Remove insulator attaching bracket from engine. Position floor jack under transaxle and support transaxle.
11. Remove upper converter/flywheel housing attaching bolts. Remove engine, making sure converter studs clear drive plate.

2.3L (140") Overhead Cam

1. Raise hood and secure in vertical position. Drain cooling system. Drain crankcase. Remove air cleaner. Remove exhaust manifold shroud. Remove upper and lower radiator hoses. On automatic transmission models, use cooler line disconnect tool (T82L-9500-AH) to remove oil cooler lines from radiator. Remove radiator and fan. Disconnect ground cable.
2. Disconnect all wiring, vacuum hoses and linkages from engine. If equipped, remove A/C compressor from mounting bracket. Position compressor aside with lines connected. Disconnect flexible fuel line at fuel pump and plug.
3. Remove starter. Raise vehicle on hoist. Remove upper converter/flywheel housing bolts. Disconnect muffler inlet pipe from exhaust manifold. Disconnect right and left motor mounts at crossmember pedestal. Remove converter/flywheel housing cover.
4. If equipped with manual transmission, remove flywheel housing lower attaching bolts. If equipped with automatic transmission, remove bolts attaching converter to drive plate. Disconnect oil cooler lines from engine if attached to pan rail. Remove converter housing lower attaching bolts.
5. Lower vehicle. Support transmission with a jack. Attach engine lift and remove engine.

Note. Engine/Transaxle is removed as assembly.

High Swirl Combustion

1. Mark hinges for reinstallation. Remove hood. Disconnect negative battery cable. Remove air cleaner assembly. Drain cooling system. Remove upper and lower radiator hoses. If equipped, disconnect transaxle cooler lines at hoses below radiator.
2. Remove coil assembly. Disconnect cooling fan. Remove radiator shroud and fan as assembly. Remove radiator. Discharge A/C system and disconnect hoses at compressor. Disconnect all electrical and vacuum lines.
3. On automatic transaxle, disconnect TV linkage. Disconnect clutch cable on manual transaxle. Disconnect accelerator linkage, fuel lines at engine, and thermactor discharge hose at pump.
4. If equipped, disconnect power steering hoses at pump. Remove hose bracket at cylinder head. Attach engine support tool to lifting eye. Raise vehicle.
5. Remove starter cable, hose from catalytic converter, exhaust pipe bracket bolt at oil pan, and exhaust pipe-to-manifold nuts. Remove exhaust system from grommets and set aside. Disconnect speedometer cable at transaxle.
6. Disconnect heater hoses at engine. Remove water pump inlet tube and clamps. Disconnect control arms at body. Remove stabilizer bar brackets. Remove half-shaft assemblies and install alignment plugs in differential side gears. See AXLE SHAFT Removal and Installation in DRIVE AXLE Section.
7. On manual transaxle, remove roll restrictor, shift stabilizer bar-to-transaxle bolts, and shift mechanism-to-shift shaft bolt. On automatic transaxle, disconnect manual shift cable clip and remove manual shift linkage bracket.
8. Remove left-hand rear insulator mount bracket. Remove left-hand front insulator-to-transaxle mount bolts. Lower vehicle. Attach engine hoist to lifting eyes. Remove engine support tool. CAUTION: Do not allow front wheels to touch floor.
9. Remove right-hand insulator intermediate bracket from engine bracket and insulator. Lower engine/transaxle assembly to floor.

Note. Engine/Transaxle is removed as assembly.

2.0L (122") Diesel

1. Mark hinges for reinstallation and remove hood. Disconnect negative cable from battery (located in luggage compartment). Remove air cleaner assembly. Remove upper and lower radiator hoses. Drain coolant.
2. Disconnect wiring at cooling fan. Remove shroud and cooling fan as assembly. Remove radiator. If equipped, discharge A/C system. Disconnect hoses at compressor. Remove cable at starter.
3. Disconnect all vacuum lines as necessary. Disconnect clutch cable at transaxle, injection pump throttle linkage, and fuel hoses at engine.
4. Disconnect both engine harness connectors and glow plug relay connectors at dash panel. Connectors are located under plastic shield on dash panel. Remove and save plastic retainer pins. Disconnect alternator connector on right-hand fender apron.
5. If equipped, disconnect power steering hoses at pump. Remove hose bracket from cylinder head. Attach engine support tool to lifting eye. Raise vehicle.
6. Disconnect exhaust bracket at oil pan. Disconnect both exhaust pipes from manifold. Pull exhaust system from grommets and set aside. Disconnect speedometer cable from transaxle. Disconnect heater hoses at water pump inlet tube and at oil cooler.
7. Disconnect control arms at body. Remove stabilizer bar brackets. Remove half-shaft assemblies and install alignment plugs in differential side gears. See AXLE SHAFT Removal and Installation in DRIVE AXLE Section.
8. On manual transaxle models, remove shift stabilizer bar-to-transaxle bolts. Remove shift mechanism-to-shift shaft attaching bolt at transaxle.
9. Remove left-hand rear insulator mount bracket from body bracket. Remove left-hand front insulator-to-transaxle bolts. Lower vehicle. Attach engine hoist to lifting eyes. Remove engine support tool. CAUTION: Do not allow front wheels to touch ground.
10. Disconnect right-hand insulator intermediate bracket from engine bracket and insulator. Remove bracket. Lower engine and transaxle assembly to floor.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS (1)