Engine — removal and installation Ford F150

Warning: Gasoline is extremely flammable, so take extra precautions when you work on any part of the fuel system. Don’t smoke or allow open flames or bare light bulbs near the work area, and don’t work in a garage where a gas-type appliance (such as a water heater or clothes dryer) is present. Since gasoline is carcinogenic, wear fuel-resistant gloves when there’s a possibility of being exposed to fuel, and, if you spill any fuel on your skin, rinse it off immediately with soap and water. Mop up any spills immediately and do not store fuel-soaked rags where they could ignite. The fuel system is under constant pressure, so, if any fuel lines are to be disconnected, the fuel pressure in the system must be relieved first (see Fuel and exhaust systems for more information) . When you perform any kind of work on the fuel sys­tem, wear safety glasses and have a Class B type fire extinguisher on hand.

Warning: The air conditioning system is under high pressure. DO NOT loosen any fittings or remove any components until after the system has been discharged. Air conditioning refrig­erant should be properly discharged into an EPA-approved container at a dealer service department or an automotive air condition­ing repair facility. Always wear eye protection when disconnecting air conditioning system fittings.

Warning: The engine must be completely cool before beginning this procedure.

Removal

1. Have the air conditioning system discharged by a licensed automotive air condi­tioning technician.

2. Relieve the fuel system pressure (see Fuel and exhaust systems).

3. Disconnect the cable from the negative battery terminal (see Engine electrical systems).

4. Raise the vehicle and support it securely on jackstands.

5. Remove the skid plates and splash shields, if equipped.

Crossmember mounting bolts

6. Remove the front crossmember (see illustration).

7. Remove the fender splash shields and the hood (see Body). Cover the fenders using special pads. An old bedspread or blan­ket will also work.

8. Remove the intake ducts and the air filter housing (see Fuel and exhaust systems).

9. Disconnect the quick-release connectors to the EVAP tubes (see Emissions and engine control systems) and the vacuum lines.

10. Remove the charge air cooler, cooler intake pipe and outlet pipe (see Fuel and exhaust systems).

11. On 2.7L models, remove the high-pres­sure fuel pump noise insulator, then discon­nect the fuel feed line quick-connect coupling (see Fuel and exhaust systems).

12. Disconnect the electrical connectors from the Powertrain Control Module (PCM) (see Emissions and engine control systems).

Label both ends of each wire and hose before disconnecting it

13. Clearly label and disconnect all vacuum lines, emissions hoses, wiring harness connec­tors, ground straps and fuel lines between the engine and the chassis. Masking tape and/or a touch up paint applicator work well for marking items (see illustration). Take photos or sketch the locations of components and brackets.

14. Remove the drivebelt (see Tune-up and routine maintenance).

15. Remove the alternator (see Engine electrical systems).

16. Remove the air conditioning lines from the condenser and the manifold and tube assembly at the rear of the engine compart­ment (see Cooling, heating and air conditioning systems). Remove the air condi­tioning manifold and tube bracket.

17. Drain the cooling system (see Tune-up and routine maintenance).

18. Drain the engine oil and remove the oil filter (see Tune-up and routine maintenance).

19. Remove the cooling fan(s) and shroud(s) (see Cooling, heating and air conditioning systems).

20. Detach the lower radiator hose from the engine (see Cooling, heating and air conditioning systems).

21. Remove the expansion tank and radiator (see Cooling, heating and air conditioning systems).

22. Detach the heater hoses at the firewall (see Cooling, heating and air conditioning systems). Also, remove the upper radi­ator hose.

23. If you’re working on a turbocharged model, remove the turbocharger intake and outlet tubes.

24. Remove the air conditioning compressor (see Cooling, heating and air conditioning systems). Plug the openings to prevent contamination.

25. Remove the condenser and evaporator core line nuts (see Cooling, heating and air conditioning systems), then discon­nect the lines and plug the openings to pre­vent contamination.

26. On 3.3L and 3.5L Duratec V6 models, remove the upper intake manifold.

27. Unplug the upstream oxygen sensor elec­trical connector(s). Detach the heat shields, exhaust brackets and the exhaust pipes from the exhaust manifolds (see V6 engines or V8 engines).

28. On V6 models, remove the inspection cover fasteners and cover from the side of the transmission bellhousing.

Remove the round opening cover…

29. On V8 models, remove the block open­ing cover (see illustration).

… for access to the torque converter nuts

30. Remove the torque converter nuts (see illustration). Turn the crankshaft with a wrench to bring each nut into view.

31. Remove the starter motor (see Engine electrical systems).

Attach the chain to a threaded boss or stud on the cylinder head

Attach the chain or load leveling device to the hoist and take up the slack

32. Roll the engine hoist into position and attach the chain or sling to the engine (see illustrations). Take up the slack in the sling or chain, but don’t lift the engine.

Warning: DO NOT place any part of your body under the engine when it’s supported only by a hoist or other lifting device.

33. Remove the engine mount through-bolts (see V6 engines or V8 engines).

34. Loosen the transmission mount at the rear of the transmission.

35. Support the transmission with a floor jack. Be sure to place a piece of wood on the jack head to protect the transmission.

36. Recheck to be sure nothing is still con­necting the engine to the vehicle. Disconnect anything still remaining.

37. Raise the engine slightly and inspect it thoroughly once more to make sure that nothing is still attached, then slowly raise the engine out of the engine compartment. Check carefully to make sure nothing is hanging up.

38. It may be necessary to tilt or turn the engine as it is being raised.

Warning: Don’t place any part of your body under the engine or between the engine and the vehicle.

39. Remove the driveplate (see V6 engines or V8 engines) and mount the engine on an engine stand.

40. Inspect the engine mounts (see V6 engines or V8 engines) and transmission mount (see Automatic transmission). If they’re worn or damaged, replace them.

Installation

41. Install the driveplate (see V6 engines or V8 engines).

42. Lubricate the torque converter hub with multi-purpose grease.

43. Carefully lower the engine into the engine compartment and engage it with the engine mounts and the transmission.

44. Install the transmission-to-engine bolts and tighten them securely.

Caution: DO NOT use the bolts to force the transmission and engine together!

45. Reinstall the remaining components in the reverse order of removal.

46. Add coolant, oil and transmission fluid as needed (see Tune-up and routine maintenance).

47. Reconnect the battery, run the engine and check for leaks and proper operation of all accessories, then install the hood and test drive the vehicle. The Powertrain Control Module (PCM) must relearn its idle and fuel trim strategy for optimum driveability and per­formance, which may take a few trips.

48. Have the air conditioning system recharged by the shop that discharged it.

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