2003 Taurus/Sable Workshop Manual
SECTION 303-01A: Engine — 3.0L (2V)
REMOVAL
Page 1 of 21
2003 Taurus/Sable Workshop Manual
Engine
Special Tool(s)
Powertrain Lift With Tilting Plate
014–00765 or equivalent
Lifting Eyes
303–D030 (D81L-6001–D) or
equivalent
Spreader Bar
303-D089 (D93P-6001-A3) or
equivalent
Heavy Duty Floor Crane
014–00072 or equivalent
Engine Stand
014–00232 or equivalent
Removal
1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-01 .
2. Drain the engine cooling system. For additional information, refer to Section 303-03 .
3. Remove the cowl vent screen and cowl extension. For additional information, refer to Section 50102 .
4. Remove the engine air cleaner (ACL) (9600) and the air cleaner outlet tube (9B659). For additional
information, refer to Section 303-12 .
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 2 of 21
5. Recover the refrigerant from the A/C system. For additional information, refer to Section 412-00 .
6. Relieve the fuel system pressure. For additional information, refer to Section 310-00 .
7. Position the steering column input shaft coupling boot aside.
Remove the three nuts.
8. Separate the steering column from the steering gear.
Loosen the pinch bolt and slide the coupling off the steering gear input shaft.
9. Remove the snow shield.
Remove the pin-type retainers.
10. Disconnect the accelerator cable (9A758), speed control actuator cable (9A825) and the throttle
return spring from the throttle body.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 3 of 21
11. Position the accelerator cable bracket aside.
Remove the bolts.
12. Disconnect the chassis vacuum hose.
13. Disconnect the manual control lever cable.
Remove the nut.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 4 of 21
14. Disconnect the manual control lever cable from the bracket and position aside.
15. Loosen the bolt and disconnect the 42–pin and transmission range (TR) sensor electrical connectors.
16. Disconnect the upper radiator hose and the heater water hose from the thermostat housing.
17. Remove the battery. For additional information, refer to Section 414-01 .
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 5 of 21
18. Disconnect the ground strap electrical connector.
Remove the nut.
19. Disconnect the power steering return hose.
20. Disconnect the generator electrical connectors and position the wire harness aside.
21. Disconnect the A/C suction tube from the accumulator drier. For additional information, refer to
Section 412-00 .
22. Disconnect the fuel supply hose. For additional information, refer to Section 310-00 .
23. Disconnect the degas bottle hoses.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 6 of 21
24. Remove the nut, the bolt, and the engine roll restrictor brace.
25. Remove the bolts and the engine roll restrictor.
26. Disconnect the heater water hose.
27. Disconnect the ground electrical connectors.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 7 of 21
Remove the bolt.
28. Disconnect the evaporative emissions (EVAP) canister purge valve electrical connector.
29. Disconnect the powertrain control module (PCM) electrical connector.
Loosen the bolt.
30. Raise the vehicle on a hoist. For additional information, refer to Section 100-02 .
31. Remove the front wheels.
32. NOTE: Support the exhaust with mechanic's wire.
Remove the nuts and disconnect the three-way catalytic converter from the dual converter Y-pipe.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 8 of 21
33. Remove the nuts and the muffler clamp.
34. Separate and remove the three-way catalytic converter from the muffler pipe.
35. Disconnect the A/C discharge tube.
Remove the nut.
36. Remove the radiator support bracket.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 9 of 21
37. Disconnect the lower radiator hose from the radiator and degas bottle supply hose.
38. Disconnect the transmission oil cooler hose.
39. Disconnect the wire harness electrical connector, if equipped.
40. Disconnect the auxiliary oil cooler assembly.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 10 of 21
Disconnect the transmission oil cooler hose, if equipped.
Disconnect the power steering return hose.
41. Remove the oil pan drain plug and drain the engine oil.
Install the drain plug when finished.
42. Remove the starter motor electrical connector cover.
43. Disconnect the starter motor electrical connectors.
Remove the two nuts.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 11 of 21
44. Remove the starter motor.
Remove the two bolts.
45. Remove the engine rear plate.
Remove the bolt.
46. Remove the four torque converter nuts.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 12 of 21
47. Disconnect the LH and RH stabilizer links from the stabilizer bar.
Remove the nuts.
48. Separate the LH and RH lower control arms from the steering knuckles.
Remove the nuts.
49. Separate the LH and RH tie rod ends from the steering knuckles.
Remove the nuts.
50. Separate the LH and RH half shafts from the steering knuckles.
Remove the nuts.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 13 of 21
51. Position the special tool.
52. Remove the four front subframe-to-body bolts.
53. Using the special tool, lower the engine, transmission and subframe assembly out of the vehicle.
54. Remove the power steering pressure line bracket.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 14 of 21
Remove the nut.
55. Remove the power steering pressure line bracket.
Remove the nut.
56. Disconnect the power steering pressure line from the power steering pump.
57. Remove the LH secondary air injection tube, if equipped.
Loosen the compression nuts.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 15 of 21
58. Separate the control valve solenoid from the bracket and position aside, if equipped.
59. Disconnect the secondary air injection valve vacuum tube, if equipped.
60. Remove the secondary air injection valve and bracket, if equipped.
Remove the two nuts.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 16 of 21
61. Disconnect the ignition coil.
Disconnect the spark plug wires.
62. Disconnect the ignition coil electrical connector.
63. Disconnect the output speed sensor (OSS) and position the wire harness aside.
64. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 17 of 21
65. Disconnect the transaxle harness electrical connector and position the wire harness aside.
66. Remove the RH catalytic converter heat shield.
Remove one bolt.
Remove two nuts.
67. Remove the secondary air injection hose, if equipped.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 18 of 21
68. Install the LH engine lifting eye.
69. Install the RH engine lifting eye.
70. Using the special tools, support the engine.
71. Remove the two RH engine support insulator-to-transmission bolts.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 19 of 21
72. Remove the LH engine support insulator-to-subframe nut.
73. Remove the RH engine support insulator through bolt.
74. Disconnect the catalyst monitor sensor electrical connector.
75. Disconnect the catalyst monitor sensor electrical connector.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 20 of 21
76. Remove the bolts and the y-pipe.
77. Disconnect the lower radiator hose from the water pump.
78. Remove the transmission to engine bolts.
Remove five bolts.
Remove one stud bolt.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014
2003 Taurus/Sable Workshop Manual
Page 21 of 21
79. Separate the engine (6007) from the transmission.
80. Remove the bolts and the flexplate.
file:///C:/tso/tsocache/LAPTOP_6632/S3H~us~en~file=S3H31A30.htm~gen~ref.htm
7/14/2014