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    Ford Taurus/Sable 1996-1999 Repair Guide

    Engine

    Print

    REMOVAL & INSTALLATION



    In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as disconnect the exhaust system or remove the radiator. In most instances, a detailed removal procedure can be found elsewhere in this guide.

    It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

    Removal and installation of the engine can be made easier if you follow these basic points:



    If you have to drain any of the fluids, use a suitable container.
     
    Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
     
    Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation.
     
    After unbolting the transaxle, always make sure it is properly supported.
     
    If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
     
    When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
     
    Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
     
    After the engine is clear of the compartment, place it on an engine stand or workbench.
     
    After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined in this guide.
     

    Except 3.4L DOHC Engines

    If your vehicle is equipped with air conditioning, refer to General Information & Maintenance for information regarding the implications of servicing your A/C system yourself. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

    1. If your vehicle is equipped with A/C have the system evacuated by a qualified technician using a recovery/recycling station.
    2.  
    3. Disconnect the battery cables, negative cable first.
    4.  


    CAUTION
    Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

    1. Drain the cooling system.
    2.  
    3. Mark the position of the hood on the hinges and remove the hood.
    4.  
    5. Disconnect the steering coupling at the pinch bolt joint inside the passenger compartment.
    6.  
    7. On 3.0L DOHC engines, remove the cowl extension and windshield wiper, then disconnect the main emission vacuum control connector at the two connectors located at the right hand side of the dash panel.
    8.  
    9. Disconnect the wiring from the Mass Air Flow (MAF) sensor, and the Intake Air Temperature (IAT) sensor.
    10.  

    Label all electrical connectors and vacuum hoses prior to removal so they can be reinstalled in their proper locations.

    1. Remove the air cleaner outlet tube.
    2.  
    3. Remove the air cleaner retaining bolts at the air cleaner body.
    4.  
    5. Disconnect the engine intake air resonator by pushing in the top and bottom tube surfaces at the engine air cleaner and pulling the air cleaner outward. Lift the air cleaner up and out of the engine compartment.
    6.  


    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

    1. Properly relieve the fuel system pressure.
    2.  
    3. Disconnect the fuel lines from the fuel injection supply manifold.
    4.  
    5. Disconnect the chassis vacuum supply hose at the connection on the intake manifold. Position the hose aside.
    6.  
    7. Remove the ground straps from the dash panel.
    8.  
    9. Disconnect the control sensor wiring from the Powertrain Control Module (PCM) and position aside.
    10.  
    11. Remove the connectors for the engine control sensor wiring from the retaining bracket on the power brake booster. Disconnect the engine control sensor wiring at the two connectors.
    12.  
    13. Disconnect engine control sensor wiring from the evaporative emission canister purge valve.
    14.  
    15. Disconnect the evaporative emission hose at the crankcase vent connector and hose. Position the hose aside.
    16.  
    17. Remove the shield and disconnect the accelerator cable and the speed control actuator from the throttle body and from the accelerator cable bracket. Position the cables aside.
    18.  
    19. Remove the retaining nut and disconnect the manual control lever from the manual control lever shaft at the Transmission Range (TR) sensor.
    20.  
    21. Remove the connectors for the engine control sensor wiring from the retaining bracket on top of the transaxle. Disconnect the engine control sensor wiring at the two connectors.
    22.  
    23. Disconnect the wiring connector from the secondary air injection pump relay located on the retaining bracket on top of the transaxle.
    24.  
    25. Disconnect the main emission vacuum control connector at the connection near the fan shroud.
    26.  
    27. Disconnect the oil cooler inlet tube from the transaxle.
    28.  
    29. Disconnect the heater water hose from the water pump and water hose connection.
    30.  
    31. Disconnect the upper radiator hose and degas tube from the water hose connection.
    32.  
    33. Remove the power steering return hose from the power steering oil reservoir and drain.
    34.  
    35. Disconnect the alternator wiring harness from the alternator at the BAT terminal and stator connector plug. Remove the wiring harness retaining clip from the alternator mounting bracket.
    36.  
    37. On 3.0L OHV engines, disconnect the retaining clips and the A/C compressor lines from the compressor. On 3.0L DOHC engines, disconnect the A/C compressor line from the heater core inlet tube. Cap all openings to prevent the entrance of dirt or moisture.
    38.  
    39. Raise and safely support the vehicle. Remove the front wheel and tire assemblies.
    40.  
    41. Remove both front stabilizer bar links from the front stabilizer bar.
    42.  
    43. Remove both halfshafts using the procedure in this information.
    44.  
    45. Remove the splash shield from the radiator support and front bumper.
    46.  


    CAUTION
    The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

    1. Drain the engine oil.
    2.  
    3. Remove the converter Y-pipe.
    4.  
    5. Disconnect the power steering pressure hose from the power steering/transaxle oil cooler connection. Position the hose aside.
    6.  
    7. Disconnect the lower radiator hose at the radiator and at the radiator overflow hose.
    8.  
    9. Disconnect the wiring at the starter motor, and remove the starter motor.
    10.  
    11. Disconnect the lower cooler line from the transaxle.
    12.  
    13. Support the front subframe and engine/transaxle assembly using Powertrain Lift 014-00765 and Universal Powertrain Removal Bracket 014-00766 or equivalents.
    14.  
    15. Remove the four subframe retaining bolts.
    16.  
    17. Lower the engine/transaxle and front subframe from the vehicle.
    18.  
    19. Disconnect the power steering pressure hose from the power steering pump.
    20.  
    21. Install suitable engine lifting brackets on the engine and transaxle assembly.
    22.  
    23. Remove the front engine support insulator, rear engine support insulator and engine and transaxle support.
    24.  
    25. Lift the engine and transaxle from the subframe.
    26.  
    27. Lower the engine and transaxle. Support the transaxle on a level, stationary surface for transaxle storage.
    28.  
    29. Remove the transaxle-to-cylinder block mounting bolts and separate the engine from the transaxle/torque converter assembly.
    30.  
    31. Place the engine on a safe suitable workstand.
    32.  

    To install:
    1. Installation is the reverse of removal but please note the following important steps.
    2.  
    3. Install the transaxle/torque converter assembly to the engine. Tighten the mounting bolts to 30-44 ft. lbs. (40-60 Nm) on 3.0L OHV engines or 25-33 ft. lbs. (34-46 Nm) on 3.0L DOHC engines. Tighten the torque converter nuts to 20-33 ft. lbs. (27-46 Nm).
    4.  
    5. Raise the engine, transaxle and subframe into position using the powertrain lifting tool.
    6.  
    7. Align the front subframe to the body and install the subframe-to-body bolts. Tighten the bolts to 57-76 ft. lbs. (77-103 Nm).
    8.  


    WARNING
    Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

    1. Fill the cooling system. Fill the crankcase with the proper type of motor oil to the required level.
    2.  
    3. Connect the battery cables, negative cable last. Run the engine and check for leaks.
    4.  
    5. Install and align the hood.
    6.  

    Whenever the vehicles subframe is removed or lowered, the wheel alignment should be checked.

    1. Check the front wheel alignment. Road test the vehicle and check the engine and transaxle for proper operation.
    2.  
    3. Have the A/C system evacuated and recharged by a qualified technician using a recovery/recycling station.
    4.  

    3.4L DOHC Engines

    If your vehicle is equipped with air conditioning, refer to General Information & Maintenance for information regarding the implications of servicing your A/C system yourself. Only an MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

    1. If your vehicle is equipped with A/C have the system evacuated by a qualified technician using a recovery/recycling station.
    2.  
    3. Disconnect the battery cables, negative cable first.
    4.  
    5. Mark the position of the hood on the hinges and remove the hood.
    6.  
    7. Remove the battery and battery tray.
    8.  
    9. Remove the oil fill cap, unfasten the two bolts and four nuts attaching the engine appearance cover, then remove the cover.
    10.  
    11. Disconnect the engine control sensor wiring from the engine air fuel ratio bracket.
    12.  
    13. Tag and unplug the engine control sensor wiring from the Mass Air Flow (MAF) sensor.
    14.  
    15. Disconnect the air cleaner outlet tube from the throttle body.
    16.  
    17. Release the air cleaner cover and disconnect the crankcase ventilation hose from the air cleaner outlet tube.
    18.  
    19. Remove the wiper module.
    20.  
    21. Unfasten the retaining nuts from the main vacuum connector and remove the intake manifold from the vacuum connector.
    22.  
    23. Remove the wiper motor and connector and grommet from the cowl top extension, then remove the cowl top extension.
    24.  
    25. Remove the accelerator control splash shield and disconnect the speed control actuator cable from the throttle body.
    26.  
    27. Unfasten the bolts attaching the speed control actuator cable and the accelerator cable to the accelerator cable bracket. Position the cables out of the way.
    28.  
    29. Unfasten the main engine control harness screw and unplug the main harness.
    30.  
    31. Unplug the Transmission Range (TR) sensor connector and remove the transmission shift cable-to-shift cable bracket nut. Position the shift cable and bracket aside.
    32.  
    33. Remove the power steering reservoir cap.
    34.  


    CAUTION
    Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

    1. Drain the cooling system.
    2.  
    3. Disconnect the power steering return hose from the left end of the power steering fluid cooler and allow it to drain. Once drained, cap all openings to prevent contamination.
    4.  
    5. Disconnect the lower fluid cooler tube at the left rubber line.
    6.  
    7. Disconnect the heater water hose from the heater water tubes.
    8.  
    9. Tag and disconnect all necessary vacuum hoses.
    10.  
    11. Unfasten the bolt attaching the engine control sensor wiring to the Powertrain Control Module (PCM) bracket and separate the wiring from the bracket.
    12.  
    13. Unfasten the engine ground strap bolt and position the strap to one side.
    14.  
    15. Tag and unplug the electrical connection from the canister purge valve solenoid.
    16.  


    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

    1. Properly relieve the fuel system pressure.
    2.  
    3. Disconnect the fuel lines from the fuel injection supply manifold.
    4.  
    5. Disconnect the power steering pump-to-power steering reservoir hose at the pump.
    6.  
    7. Tag and disconnect all tubes from the coolant recovery reservoir.
    8.  
    9. Tag and unplug the electrical connection from the A/C pressure cut-off switch.
    10.  
    11. Loosen the A/C manifold-to-compressor bolt.
    12.  
    13. Disconnect the A/C pressure cut-off switch from the compressor and position it aside.
    14.  
    15. Disconnect the upper and lower radiator hoses from the water pump.
    16.  
    17. Disconnect the battery-to-starter relay cable at the starter motor.
    18.  
    19. Umfasten the nut that attaches the battery-to-starter relay cable to the cylinder block and position the cable aside.
    20.  
    21. Raise the vehicle and support it with jackstands.
    22.  
    23. Remove the both front wheel and tire assemblies.
    24.  
    25. Disconnect the catalyst monitor sensors and unplug the heated oxygen sensor electrical connector.
    26.  
    27. Remove the dual three-way converter and pipe.
    28.  
    29. Disconnect the wiring from the alternator.
    30.  
    31. Disconnect the ride level sensors at the front suspension lower arm.
    32.  
    33. Unfasten the stabilizer bar link-to-front suspension lower arm retaining nuts.
    34.  
    35. Disconnect the tie rod end from the wheel knuckle assembly.
    36.  
    37. Remove the front hub retaining nuts.
    38.  
    39. Disconnect the ball joints from the front suspension lower arm.
    40.  
    41. Position the wheel knuckle and shock absorber assemblies out of the way.
    42.  
    43. Secure the drive axle shafts to the subframe.
    44.  
    45. Unfasten the four flywheel-to-torque converter nuts.
    46.  
    47. Unfasten the four lower transaxle-to-engine retaining bolts.
    48.  
    49. Unfasten the steering column pinch bolt from the steering column intermediate shaft coupling at the steering gear and separate the intermediate shaft from the steering gear.
    50.  
    51. Support the front subframe and engine/transaxle assembly using Powertrain Lift 014-00765 and Universal Powertrain Removal Bracket 014-00766 or equivalents.
    52.  
    53. Remove the four subframe retaining bolts.
    54.  
    55. Lower the engine/transaxle and front subframe from the vehicle.
    56.  
    57. Install engine lift brackets 014-00793 or equivalent to the engine.
    58.  
    59. Attach engine lifting spreader bar 014-00793 or equivalent to the lifting eyes. Support the engine and transaxle.
    60.  
    61. Tag and disconnect the engine wiring from the secondary air injection pump and the transaxle.
    62.  
    63. Tag and unplug the wiring from the transmission speed sensor and the power steering pressure switch.
    64.  
    65. Unfasten the nut on the power steering left turn pressure hose, then disconnect the hose from the power steering pump and position the hose aside.
    66.  
    67. Unfasten the four upper engine-to-transaxle bolts.
    68.  
    69. Remove the right drive axle.
    70.  
    71. Unfasten the seven right hand front engine support insulator bracket retaining bolts.
    72.  
    73. Unfasten the two left hand front upper engine support insulator-to-engine support insulator bracket bolts.
    74.  
    75. Separate the engine from the transaxle/torque converter assembly.
    76.  
    77. Unfasten the flywheel retaining bolts and remove the flywheel.
    78.  
    79. Place the engine on a safe suitable workstand.
    80.  

    To install:
    1. Installation is the reverse of removal but please note the following important steps.
    2.  
    3. Tighten the flywheel-to-engine bolts in an alternating pattern (across from each other) to 54-64 ft. lbs. (73-87 Nm).
    4.  
    5. Tighten the two left hand front upper engine support insulator-to-engine support insulator bracket bolts to 44-59 ft. lbs. (60-80 Nm).
    6.  
    7. Install the seven right hand front engine support insulator bracket retaining bolts and tighten to 44-59 ft. lbs. (60-80 Nm).
    8.  
    9. Tighten the four upper engine-to-transaxle bolts to 30-44 ft. lbs. (40-60 Nm).
    10.  
    11. Connect the power steering left turn pressure hose to the pump and tighten the fitting to 25-30 ft. lbs. (33-41 Nm).
    12.  
    13. Tighten the power steering left turn pressure hose-to-surge tank nut to 71-106 inch lbs. (8-12 Nm)
    14.  
    15. Raise the engine, transaxle and subframe into position using the powertrain lifting tool.
    16.  
    17. Align the front subframe to the body and install the subframe-to-body bolts. Tighten the bolts to 57-75 ft. lbs. (77-103 Nm).
    18.  
    19. Tighten the steering gear-to-steering column shaft coupling pinch bolt to 30-37 ft. lbs. (41-51 Nm).
    20.  
    21. Tighten the lower engine-to-transaxle bolts to 30-44 ft. lbs. (40-60 Nm).
    22.  
    23. Tighten the four torque converter-to-flywheel nuts to 20-33 ft. lbs. (27-46 Nm).
    24.  
    25. Tighten the wheel hub retaining bolts to 170-202 ft. lbs. (230-275 Nm).
    26.  
    27. Tighten the A/C pressure cut-off switch-to-compressor retainer to 13-16 ft. lbs. (17-23 Nm).
    28.  
    29. Tighten the engine control sensor wiring-to-PCM bracket bolt to 32 inch lbs. (3.7 Nm).
    30.  
    31. Install the shift cable and bracket on the manual control lever and tighten the retaining nut to 15-19 ft. lbs. (20-26 Nm).
    32.  
    33. Tighten the speed control actuator cable and accelerator cable to the accelerator cable bracket retaining bolts to 45-62 ft. lbs. (5-7 Nm).
    34.  


    WARNING
    Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

    1. Fill the cooling system. Fill the crankcase with the proper type of motor oil to the required level.
    2.  
    3. Fill the power steering system.
    4.  
    5. Check the transaxle fluid level and replenish as necessary
    6.  
    7. Connect the battery cables, negative cable last. Run the engine and check for leaks.
    8.  
    9. Install and align the hood.
    10.  

    Whenever the vehicles subframe is removed or lowered, the wheel alignment should be checked.

    1. Check the front wheel alignment. Road test the vehicle and check the engine and transaxle for proper operation.
    2.  
    3. Have the A/C system evacuated and recharged by a qualified technician using a recovery/recycling station.
    4.  

     
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