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How to Replace Engine on 2009 Ford Taurus?

The details are similar for both 2008 and 2009 ford Taurus.


Engine
REMOVAL & INSTALLATION

The procedure with complete details and diagram is shown below:-----


  1. On all vehicles, position it on a hoist.
  2. Release the fuel system pressure. Refer to Fuel Pressure Release.
  3. Recover the A/C system. Refer to Heating & Air Conditioning.
  4. Drain the cooling system.
  5. Remove the front wheels and tires.
  6. Remove the accessory drive belt and the power steering belt.
  7. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable container.
  8. Remove the degas bottle..
  9. Remove the engine air cleaner and air cleaner outlet pipe.
  10. Remove the battery.
  11. Detach the 4 pin-type wiring harness fasteners from the side of the battery tray.
  12. Detach the 2 pin-type wiring harness fasteners from the front of the battery tray.
  13. Remove the 2 lower battery tray bracket bolts.
  14. Remove the nut, bolt and the battery tray and bracket.
  15. Disconnect the engine wiring harness electrical connector.
  16. Remove the nut and disconnect the power feed wire from the positive battery terminal.
  17. Remove the nut and disconnect the ground cable from the negative battery terminal.
  18. Disconnect the vacuum hose and the evaporative emissions (EVAP) tube from the upper intake manifold.
  19. Detach the EVAP tube pin-type retainer from the upper intake manifold.
  20. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
  21. Disconnect the transaxle control cable from the control lever.
  22. Disconnect the transaxle control cable from the shift cable bracket and detach the 2 wiring harness pin-type retainers.
  23. If equipped, detach the engine block heater harness from the radiator support and the power steering tube.
  24. 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.
  25. Remove the 2 nuts and disconnect the A/C tubes. Discard the O-ring seals.
  26. Remove the nut and the A/C tube. Discard the O-ring seal.
  27. Disconnect the fuel supply tube from the fuel rail.
  28. Disconnect the 2 engine wiring harness electrical connectors.
  29. Detach the electrical connector from the LH valve cover.
  30. Detach the wire harness retainer from the RH valve cover stud bolt.
  31. Remove the bolt and the ground cable from the engine.
  32. Remove the oil level indicator.
  33. Disconnect the hose from the power steering reservoir.
  34. Disconnect the transaxle control electrical connector.
  35. Detach the transaxle control wire harness retainer from the transaxle stud bolt.
  36. Place the steering wheel in the straight-ahead position and the ignition key in the OFF position.
    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. Refer to Clockspring Centering in Air Bag.


    NOTE
    Index-mark the steering column shaft position to the steering gear for reference during installation.
  37. Remove the bolt and disconnect the steering column shaft from the steering gear. Discard the bolt.
  38. Remove the 4 Y-pipe-to-catalytic converter nuts.
  39. Discard the nuts.
  40. Remove the 2 Y-pipe flange nuts.
  41. Detach the exhaust hanger and remove the Y-pipe. Discard the gaskets and nuts.
  42. On All wheel drive (AWD) vehicles, index-mark the driveshaft for installation.
  43. Remove the 4 bolts and support the driveshaft with a length of mechanic's wire.
  44. On all vehicles, remove the drain plug and drain the engine oil.
  45. Install the drain plug and tighten to 20 ft. lbs. (27 Nm).
  46. Remove and discard the engine oil filter.
  47. Remove the power steering pressure (PSP) tube bracket-to-steering gear bolt.
  48. Remove the bolt, rotate the clamp plate clockwise and disconnect the PSP tube from the steering gear. Discard the O-ring seal.
  49. Remove the 2 engine roll restrictor-to-transaxle bolts.
  50. 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 nuts.
  51. Remove and discard the tie-rod end nuts.
  52. Separate the tie-rod ends from the wheel knuckles.
  53. Remove and discard the lower ball joint-to-wheel knuckle nuts.
  54. Separate the ball joints from the wheel knuckles.
  55. Position the special tool under the subframe assembly.
  56. Remove the subframe bracket-to-body bolts.
  57. Remove the rear subframe bolts and the subframe brackets.
  58. Remove the front subframe bolts.
  59. Lower the subframe assembly from the vehicle.
  60. Using the special tools, separate the LH halfshaft from the transaxle and support halfshaft with a length of mechanic's wire.
  61. Remove and discard the RH halfshaft nut.
  62. Using the special tool, separate the RH halfshaft from the hub.
  63. Remove the 2 RH halfshaft carrier bearing nuts.
  64. Remove the RH halfshaft.
  65. Remove the 2 RH halfshaft support bracket studs.
  66. Remove the 4 bolts and the RH halfshaft support bracket.
  67. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
  68. Using the special tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
  69. Remove the 2 fasteners and the inspection cover.
  70. Remove and discard the 3 torque converter bolts.
  71. Remove the 4 oil pan-to-transaxle bolts.
  72. On All wheel drive (AWD) vehicles, disconnect the RH catalyst monitor electrical connector.
  73. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and gasket.
  74. Remove the 5 bolts and the power transfer unit (PTU) support bracket.
  75. Remove the 5 bolts and the PTU.
  76. On all vehicles, position a block of wood under the transaxle.
  77. Install the special tools.

    Click image to see an enlarged view
    Fig. Special tools to support engine and transaxle assembly on lift table
  78. Remove the transaxle mount through bolt and nut.
  79. Remove the bolt, 3 nuts and the transaxle mount bracket.
  80. Remove the nut, bolt and engine mount brace.
  81. Remove the 4 engine mount nuts.
  82. Remove the 3 bolts and the engine mount.
  83. Lower the engine and transaxle assembly from the vehicle.
  84. If equipped, remove the starter motor solenoid cover.
  85. Remove the 2 nuts and the starter motor wiring terminals.
  86. Disconnect the wiring harness retainer from the starter motor stud bolt.
  87. Remove the stud bolt, bolt and the starter.
  88. Install the special tool on the LH cylinder head.
  89. Using the special tools and a suitable engine crane, remove the engine and transaxle from the lift table.
  90. Remove the 2 engine-to-transaxle bolts.
  91. Remove the 5 transaxle-to-engine bolts.
  92. Separate the transaxle from the engine.
To install:
  1. On all vehicles, using the special tools, align the transaxle to the engine.
  2. Install the 5 transaxle-to-engine bolts. Tighten to 35 ft. lbs. (48 Nm).
  3. Install the 2 engine-to-transaxle bolts. Tighten to 35 ft. lbs. (48 Nm).
  4. Using the special tools, position the engine and transaxle onto the lift table.
    NOTE
    Position a block of wood under the transaxle.



    Click image to see an enlarged view
    Fig. Special tools to support engine and transaxle assembly on lift table
  5. Install the special tools.
  6. Install the starter, the stud bolt and bolt. Tighten to 20 ft. lbs. (27 Nm).
  7. Connect the wiring harness retainer to the starter motor stud bolt.
  8. Attach the starter wire terminals and install the 2 nuts. Tighten to 106 inch lbs. (12 Nm). Tighten to 44 inch lbs. (5 Nm).
  9. If equipped, install the starter motor solenoid cover.
  10. Raise the engine and transaxle assembly into the vehicle.
  11. Install the engine mount and the 3 bolts. Tighten to 66 ft. lbs. (90 Nm).
  12. Install the 4 engine mount nuts. Tighten to 46 ft. lbs. (63 Nm).
  13. Install the engine mount brace, nut and bolt. Tighten to 15 ft. lbs. (20 Nm).
  14. Install the transaxle mount bracket and the 4 nuts. Tighten to 59 ft. lbs. (80 Nm).
  15. Install the transaxle mount through bolt and nut. Tighten to 129 ft. lbs. (175 Nm).
  16. On All wheel drive (AWD) vehicles, position the power transfer unit (PTU) in place and install the 5 bolts. Tighten to 66 ft. lbs. (90 Nm).
  17. Position the PTU support bracket in place and install the 5 bolts. Tighten to 52 ft. lbs. (70 Nm).
    NOTE
    A new PTU seal must be installed whenever the intermediate shaft is removed.
  18. Install a new PTU seal.
  19. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 30 ft. lbs. (40 Nm).
  20. Connect the RH catalyst monitor electrical connector.
  21. On all vehicles, install the RH halfshaft support bracket and the 4 bolts.
  22. Tighten the halfshaft support-to-cylinder block bolts to 30 ft. lbs. (40 Nm).
  23. Tighten the catalytic converter-to-halfshaft support bolts to 15 ft. lbs. (20 Nm).
  24. Install the 2 halfshaft support bracket studs. Tighten to 89 inch lbs. (10 Nm).
  25. Install the RH halfshaft into the transaxle and the wheel hub and install the 2 carrier bearing nuts. Tighten to 30 ft. lbs. (40 Nm).
  26. Install the 4 oil pan-to-transaxle bolts. Tighten to 35 ft. lbs. (48 Nm).
  27. Install 3 new torque converter bolts. Tighten to 41 ft. lbs. (55 Nm).
  28. Install the inspection cover and the 2 fasteners.
  29. Connect the transaxle cooling tubes and install the safety clips.
    NOTE
    Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.
  30. Install the LH halfshaft into the transaxle.
  31. Using the special tool, raise the subframe into the installed position.
  32. Install the 2 front subframe bolts. Tighten to 111 ft. lbs. (150 Nm).
  33. Position the subframe brackets and install the 4 bolts finger-tight.
  34. Install the 2 rear subframe bolts. Tighten to 111 ft. lbs. (150 Nm).
  35. Tighten the 4 subframe bracket-to-body bolts to 76 ft. lbs. (103 Nm).
  36. Install new lower ball joint-to-wheel knuckle nuts. Tighten to 85 ft. lbs. (115 Nm).
    NOTE
    The hex holding feature can be used to prevent turning of the stud while removing the nuts.
  37. Install new tie-rod end nuts. Tighten to 85 ft. lbs. (115 Nm).
  38. Install new upper stabilizer bar link nuts. Tighten to 41 ft. lbs. (55 Nm).
    NOTE
    Install and tighten the new front axle wheel end nut to specification in a continuous rotation. Stopping the rotation during installation will cause the nylon lock to seat incorrectly. This will cause incorrect torque readings while tightening the front axle wheel end nut and lead to bearing failure. Always install a new front axle wheel end nut after loosening or when not tightened to specifications in a continuous rotation.


    NOTE
    Never use power tools to tighten the front axle wheel end nut.


    NOTE
    Apply the brake to keep the halfshaft from rotating.
  39. Install the new halfshaft nut. Tighten to 258 ft. lbs. (350 Nm).
  40. Install the 2 engine roll restrictor-to-transaxle bolts. Tighten to 76 ft. lbs. (103 Nm).
  41. Using a new O-ring seal, install the PSP tube onto the steering gear, rotate the clamp plate and install the bolt. Tighten to 18 ft. lbs. (25 Nm).
  42. Install the PSP tube bracket-to-steering gear bolt. Tighten to 89 inch lbs. (10 Nm).
    NOTE
    Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
  43. Install a new engine oil filter. Tighten to 44 inch lbs. (5 Nm) and then rotate an additional 180 degrees.
  44. On All wheel drive (AWD) vehicles, line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts. Tighten to 52 ft. lbs. (70 Nm).
  45. On all vehicles, using a new gasket, install the Y-pipe and install the 2 new nuts. Tighten to 30 ft. lbs. (40 Nm).
  46. Attach the exhaust hanger.
  47. Install the Y-pipe assembly and 4 new nuts. Tighten to 30 ft. lbs. (40 Nm).
    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.


    NOTE
    Align the index marks made during removal.
  48. Install the steering intermediate shaft onto the steering gear and install a new bolt. Tighten to 17 ft. lbs. (23 Nm).
  49. Connect the transaxle control electrical connector.
  50. Attach the transaxle control wire harness retainer to the transaxle stud bolt.
  51. Connect the hose to the power steering reservoir.
  52. Install the oil level indicator.
  53. Install the ground cable and bolt. Tighten to 106 inch lbs. (12 Nm).
  54. Attach the wire to the RH valve cover stud bolt.
  55. Connect the 2 engine wiring harness electrical connectors.
  56. Attach the electrical connector to the LH valve cover.
  57. Connect the fuel supply tube to the fuel rail.
  58. Using a new O-ring seal, install the A/C tube and the nut. Tighten to 11 ft. lbs. (15 Nm).
  59. Using new O-ring seals, connect the A/C tubes and install the 2 nuts. Tighten to 11 ft. lbs. (15 Nm).
  60. Using a new O-ring seal, connect the upper A/C tube to the condenser and install the nut and connect the A/C pressure switch electrical connector. Tighten to 11 ft. lbs. (15 Nm).
  61. If equipped, attach the engine block heater harness to the radiator support and the power steering tube.
  62. Connect the transaxle control cable to the shift cable bracket and attach the 2 wiring harness pin-type retainers.
  63. Connect the transaxle control cable to the control lever.
  64. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
  65. Disconnect the vacuum hose and the evaporative emissions (EVAP) tube from the upper intake manifold.
  66. Attach the EVAP tube pin-type retainer to the upper intake manifold.
  67. Connect the ground cable to the negative battery terminal and install the nut. Tighten to 53 inch lbs. (6 Nm).
  68. Connect the power feed wire to the positive battery terminal and install the nut. Tighten to 53 inch lbs. (6 Nm).
  69. Connect the engine wiring harness electrical connector.
  70. Install the battery tray and bracket and the nut and bolt. Tighten to 80 inch lbs. (9 Nm).
  71. Install the 2 lower battery tray bracket bolts. Tighten to 80 inch lbs. (9 Nm).
  72. Attach the 2 pin-type wiring harness fasteners to the front of the battery tray.
  73. Attach the 4 pin-type wiring harness fasteners to the side of the battery tray.
  74. Install the battery.
  75. Install the engine air cleaner and air cleaner outlet pipe.
  76. Install the degas bottle.
  77. Connect the power steering cooler tube.
  78. Install the accessory drive belt and the power steering belt.
  79. Install the front wheels and tires.
  80. Fill the engine with clean engine oil.
  81. Fill and bleed the cooling system.
  82. Fill the power steering system.
  83. Recharge the A/C system. Refer to Heating & Air Conditioning.


This will help.
Thanks.




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