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Home >> Ford >> 2015 >> Explorer Limited, 3.5L Eng VIN 8, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine - 3.5L GTDI) >> Removal >> Engine

Section 3 (Engine - 3.5L GTDI): Removal: Engine

WARNING: This page is about a different variant/trim than selected.
Special Tool(s)

GFD34410Courtesy of FORD MOTOR COMPANY
 2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
GFD34105Courtesy of FORD MOTOR COMPANY
 Adjustable Grip Arm, 1735A 014-00001 or equivalent
GFD34413Courtesy of FORD MOTOR COMPANY
 Disconnect Tool, Transmission Cooler Line 307-569
GFD34414Courtesy of FORD MOTOR COMPANY
 Eye, Engine Lift 303-1245
GFD34421Courtesy of FORD MOTOR COMPANY
 Powertrain Lift 300-OTC1585AE or equivalent
GFD34628Courtesy of FORD MOTOR COMPANY
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
General Equipment

Hose Clamp Remover/Installer
Spreader Bar
Wooden Block
WARNING: Before beginning any service procedure in this article, refer to Safety Warnings in SERVICE INFORMATION .
NOTE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

  1. 1.

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

  1. 2.

    Recover the A/C system. REFER to Climate Control DATC or REFER to Climate Control EMTC .

  1. 3.

    Release the fuel system pressure. REFER to Fuel System General Information .

  1. 4.

    Remove the cowl panel. REFER to Front End Body Panels .

  1. 5.

    Remove the engine ACL and ACL outlet pipe. REFER to Intake Air Distribution and Filtering .

  1. 6.

    Remove the battery tray. REFER to Battery, Mounting and Cables .

  1. 7.

    Remove the nut and disconnect the 2 battery feed cables from the positive battery terminal.
GFD34426Courtesy of FORD MOTOR COMPANY

  1. 8.

    Disconnect the engine wiring harness electrical connector and remove the retainer and the ground wires.
GFD35007Courtesy of FORD MOTOR COMPANY

  1. 9.

    Remove the front wheels and tires. REFER to Wheels and Tires .
    NOTE: RH shown, LH similar.

  1. 10.
    Remove the 2 RH and 2 LH lower pin-type retainers from the engine splash shields and position the shields aside.
GFD34430Courtesy of FORD MOTOR COMPANY

  1. 11.

    Remove the 3 twist lock retainers and the underbody air duct.
GFD34445Courtesy of FORD MOTOR COMPANY

  1. 12.

    Remove the accessory dive belt. REFER to Accessory Drive .

  1. 13.

    Drain the cooling system. REFER to Engine Cooling .

  1. 14.

    Remove the nut and disconnect the A/C tube.
    • Discard the O-ring seal and gasket seal.
GFD34431Courtesy of FORD MOTOR COMPANY

  1. 15.

    Remove the degas bottle. REFER to Engine Cooling .
    NOTE: Index marks the LH Charge Air Cooler (CAC) tube for installation.

  1. 16.
    Disconnect the Turbocharger Boost Pressure (TCBP) /Charge Air Cooler Temperature (CACT) electrical connector and loosen the 2 clamps and remove the CAC outlet pipe.
GFD34979Courtesy of FORD MOTOR COMPANY

  1. 17.

    Disconnect the brake booster vacuum hose quick connect coupling from the intake manifold, brake booster and CAC. REFER to Fuel System General Information .
    • Detach the brake booster vacuum hose from strut tower brace.
GFD35008Courtesy of FORD MOTOR COMPANY

  1. 18.

    Remove the 4 nuts and the strut tower brace.
GFD35009Courtesy of FORD MOTOR COMPANY

  1. 19.

    Disconnect the fuel supply tube. REFER to Fuel System General Information .
GFD35078Courtesy of FORD MOTOR COMPANY

  1. 20.

    Remove the EVAP canister purge valve. REFER to Evaporative Emissions .

  1. 21.

    Remove the bolt and ground wire from the engine front cover.
    • Disconnect the upper radiator hose from the intake manifold coolant tube.
GFD34918Courtesy of FORD MOTOR COMPANY

  1. 22.

    Disconnect the engine harness electrical connector.
GFD35010Courtesy of FORD MOTOR COMPANY

  1. 23.

    Disconnect the rear PCM electrical connector.
GFD35011Courtesy of FORD MOTOR COMPANY

  1. 24.

    Remove the engine wiring harness retainer from the bulkhead.

    1. 1.

      Push the tab in.

    1. 2.

      Slide the wiring harness up and out of the bulkhead.
GFD34439Courtesy of FORD MOTOR COMPANY

  1. 25.

    Disconnect the transaxle control cable from the control lever.
GFD34442Courtesy of FORD MOTOR COMPANY

  1. 26.

    Disconnect the transaxle control cable from the shift cable bracket.
GFD34443Courtesy of FORD MOTOR COMPANY

  1. 27.

    If equipped, detach the engine block heater harness from the radiator support wiring harness.
GFD35013Courtesy of FORD MOTOR COMPANY
    NOTE: Index marks the LH Charge Air Cooler (CAC) tube for installation.

  1. 28.
    Loosen the 2 clamps and remove the RH CAC tube.
GFD35014Courtesy of FORD MOTOR COMPANY

  1. 29.

    Disconnect the 2 heater hoses from the intake manifold.
GFD34915Courtesy of FORD MOTOR COMPANY
    NOTE: Use a steering wheel holding device (such as Hunter ® 28-75-1 or equivalent).

  1. 30.
    Using a suitable holding device, hold the steering wheel in the straight-ahead position.
GFD34444Courtesy of FORD MOTOR COMPANY
    NOTE: Index-mark the steering column shaft position to the steering gear for reference during installation.
    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 .

  1. 31.
    Remove the bolt and disconnect the steering column shaft from the steering gear.
    • Discard the bolt.
GFD34446Courtesy of FORD MOTOR COMPANY

  1. 32.

    Remove the RH and LH catalytic converter. REFER to Exhaust System .
    NOTE: Index-mark the driveshaft for installation.

  1. 33.
    Remove and discard the 4 bolts and support the driveshaft with a length of mechanic's wire.
GFD34447Courtesy of FORD MOTOR COMPANY

  1. 34.

    Remove the A/C tube bracket bolt from the rear of the compressor.
GFD35015Courtesy of FORD MOTOR COMPANY

  1. 35.

    Remove the nut and disconnect the upper A/C tube from the compressor and position aside.
    • Discard the O-ring seal and gasket seal.
GFD35016Courtesy of FORD MOTOR COMPANY

  1. 36.

    Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
GFD34864Courtesy of FORD MOTOR COMPANY

  1. 37.

    Remove and discard the engine oil filer.
GFD34924Courtesy of FORD MOTOR COMPANY
    NOTE: Index marks the LH Charge Air Cooler (CAC) tube for installation.

  1. 38.
    Loosen the clamp and disconnect the LH CAC tube from the LH turbocharger.
GFD35017Courtesy of FORD MOTOR COMPANY

  1. 39.

    Disconnect the lower radiator hose from the radiator.
    • Detach the lower radiator hose retainer from the cooling fan and shroud.
GFD35018Courtesy of FORD MOTOR COMPANY

  1. 40.

    Remove the 2 fasteners and the inspection cover.
GFD34629Courtesy of FORD MOTOR COMPANY

  1. 41.

    Remove 3 new torque converter bolts.
GFD34630Courtesy of FORD MOTOR COMPANY

  1. 42.

    Remove the 4 oil pan-to-transaxle bolts.
GFD34631Courtesy of FORD MOTOR COMPANY

  1. 43.

    Disconnect the 2 PTU cooling lines.
GFD35019Courtesy of FORD MOTOR COMPANY

  1. 44.

    Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
GFD34453Courtesy of FORD MOTOR COMPANY

  1. 45.

    Special Tool(s): Disconnect Tool, Transmission Cooler Line 307-569.
GFD34454Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 46.
    Remove the bolt and the wheel speed sensor.
GFD34455Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 47.
    Remove and discard the upper stabilizer link nut.
GFD34456Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.
    NOTE: Do not allow the brake caliper to hang from the brake flexible hose or damage to the hose may occur.

  1. 48.
    Remove the brake caliper guide pin bolts and calipers.
    • Support the calipers.
GFD34457Courtesy of FORD MOTOR COMPANY
    NOTE: RH shown, LH similar.

  1. 49.
    Using a wax pencil, mark the relationship of the front and rear subframe to the underbody at the mounting locations on both side.
GFD34458Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 50.
    Remove the LH and RH halfshaft nuts.
    • Do not discard at this time.
GFD34459Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 51.
    Separate the LH and RH halfshaft from the wheel hubs.
GFD33826Courtesy of FORD MOTOR COMPANY

  1. 52.

    Position a 2 x 6 board, 36 in (914.4 mm) in length and two 2 x 6 boards 24 in (609.6 mm) in length onto the powertrain lift.
    • Position the powertrain lift table with:
      • the long board towards the rear of the subframe.
      • the short boards under the engine and transmission.
GFD34460Courtesy of FORD MOTOR COMPANY

  1. 53.

    Install the Adjustable Grip Arm from the powertrain lift table to the LH engine-to-transmission bolt hole.
GFD34461Courtesy of FORD MOTOR COMPANY

  1. 54.

    Install a ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe, to secure the subframe to the powertrain lift table.
    NOTE: The halfshafts are not being remove from the transmission.
    NOTE: LH shown, RH similar.

  1. 55.
    Remove the strut-to-wheel knuckle nuts and bolts.
    • Remove the strut from the wheel knuckle and the halfshafts from the wheel knuckle.
GFD34462Courtesy of FORD MOTOR COMPANY

  1. 56.

    Remove the 4 transmission support insulator-to-frame rail bolts.
GFD34463Courtesy of FORD MOTOR COMPANY

  1. 57.

    Remove the 3 nuts, the bolt and the transaxle support insulator assembly.
GFD34464Courtesy of FORD MOTOR COMPANY

  1. 58.

    Remove the 4 engine mount nuts, the 3 engine mount bolts and the engine mount.
GFD34465Courtesy of FORD MOTOR COMPANY
    NOTE: RH shown, LH similar.

  1. 59.
    Remove the subframe bracket-to-body bolts.
GFD34466Courtesy of FORD MOTOR COMPANY
    NOTE: RH shown, LH similar.

  1. 60.
    Remove the rear subframe bolts and the subframe brackets.
GFD34467Courtesy of FORD MOTOR COMPANY
    NOTE: RH shown, LH similar.

  1. 61.
    Remove the front subframe bolts.
GFD34468Courtesy of FORD MOTOR COMPANY

  1. 62.

    Lower the subframe and powertrain assembly from the vehicle.

  1. 63.

    Disconnect the 2 quick connect couplings and remove the crankcase vent tube. REFER to Fuel System General Information .
    • Remove the engine cover mounting stud and detach the 3 wiring harness retainers.
GFD34980Courtesy of FORD MOTOR COMPANY

  1. 64.

    Remove the nut and the oil supply tube bracket from the LH valve cover stud bolt.
GFD34982Courtesy of FORD MOTOR COMPANY

  1. 65.

    Remove the 3 bolts and the LH exhaust manifold heat shield.
GFD35079Courtesy of FORD MOTOR COMPANY

  1. 66.

    Install the Special Tool(s): Eye, Engine Lift 303-1245.
GFD35080Courtesy of FORD MOTOR COMPANY

  1. 67.

    Install the Special Tool(s): 2, 200# Floor Crane, Fold Away 300-OTC1819E.
GFD35081Courtesy of FORD MOTOR COMPANY

  1. 68.

    Remove the starter motor solenoid cover.
GFD34634Courtesy of FORD MOTOR COMPANY

  1. 69.

    Remove the 2 nuts and the starter motor wiring terminals.
GFD34635Courtesy of FORD MOTOR COMPANY

  1. 70.

    Disconnect the wiring harness retainer from the starter motor stud bolt.
GFD34636Courtesy of FORD MOTOR COMPANY

  1. 71.

    Remove the bolt, stud bolt and the starter.
GFD34637Courtesy of FORD MOTOR COMPANY

  1. 72.

    Remove the bolt and the ground wire from the RH cylinder head.
GFD34614Courtesy of FORD MOTOR COMPANY

  1. 73.

    Disconnect the generator electrical connector and position the generator B+ cable cover aside.
GFD34592Courtesy of FORD MOTOR COMPANY

  1. 74.

    Remove the nut and disconnect the generator B+ cable.
GFD34593Courtesy of FORD MOTOR COMPANY

  1. 75.

    Disconnect the A/C compressor and the pressure relief valve electrical connectors.
    • Detach the 3 wiring harness retainers.
GFD35082Courtesy of FORD MOTOR COMPANY

  1. 76.

    Disconnect the transaxle control electrical connector.
GFD34639Courtesy of FORD MOTOR COMPANY

  1. 77.

    Detach the transaxle control wire harness retainer from the transaxle stud bolt.
GFD34640Courtesy of FORD MOTOR COMPANY

  1. 78.

    Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket.
GFD34643Courtesy of FORD MOTOR COMPANY

  1. 79.

    Remove the Adjustable Grip Arm.
GFD34644Courtesy of FORD MOTOR COMPANY

  1. 80.

    Remove the ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe.
    NOTE: LH shown, RH similar.

  1. 81.
    Install the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.
GFD34645Courtesy of FORD MOTOR COMPANY

  1. 82.

    Using the Floor Crane, remove the powertrain and subframe as an assembly from the powertrain lift table and set on the ground.
    • Position wood blocks under the engine and transmission.
GFD35081Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 83.
    Remove the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.
GFD34645Courtesy of FORD MOTOR COMPANY

  1. 84.

    Remove the 2 intermediate shaft bracket nuts and the 2 studs.
GFD35083Courtesy of FORD MOTOR COMPANY

  1. 85.

    Remove the 2 bolts and the RH halfshaft support bracket.
GFD35084Courtesy of FORD MOTOR COMPANY

  1. 86.

    Remove the 2 engine-to-transaxle bolts.
GFD34648Courtesy of FORD MOTOR COMPANY

  1. 87.

    Remove the 5 transaxle-to-engine bolts.
    • Separate the transaxle from the engine.
GFD34649Courtesy of FORD MOTOR COMPANY

  1. 88.

    Using the Floor Crane, remove the engine from the transaxle.
GFD35081Courtesy of FORD MOTOR COMPANY
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