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Section 1507 (Engine - 2.3L - (Hybrid)): Removal: Engine

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G04619018Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04619019Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04619020Courtesy of FORD MOTOR CO.
 Powertrain Lift
(014-00765)
G04619021Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets 014-0001
Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE .
  3. Disconnect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION .
  4. Disable the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY .
  5. Drain the cooling system. For additional information, refer to DRAINING .
  6. Drain the motor electronics cooling system. For additional information, refer to DRAINING .
  7. Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  8. Remove the engine air cleaner. For additional information, refer to REMOVAL AND INSTALLATION .
  9. Remove the catalytic converter. For additional information, refer to REMOVAL AND INSTALLATION .
  10. Remove the engine coolant degas bottle. For additional information, refer to REMOVAL AND INSTALLATION .
  11. Remove the LH front drive halfshaft. For additional information, refer to REMOVAL .

    12. 4x4 vehicles 

  12. Remove the transfer case. For additional information, refer to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .

    13. 4x2 vehicles 

  13. Remove the front drive intermediate halfshaft. For additional information, refer to REMOVAL AND INSTALLATION .
  14. Remove the bolts and the lateral support crossmember.
    Fig 1: Identifying Lateral Support Crossmember And Bolts
    G03897847Courtesy of FORD MOTOR CO.

    15. All vehicles 

  15. Remove the oil filter element. For additional information, refer to ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW  and OIL FILTER ELEMENT .
  16. Drain the engine oil.
  17. Disconnect the heater hoses from the heater core.
    Fig 2: Locating Heater Hoses
    G03897868Courtesy of FORD MOTOR CO.
  18. Detach the heater hose retaining clip from the transaxle mount stud.
    Fig 3: Locating Heater Hose Retaining Clip
    G04619024Courtesy of FORD MOTOR CO.
  19. Disconnect the upper radiator and coolant vent hoses.
    Fig 4: Locating Upper Radiator & Coolant Vent Hoses
    G04619025Courtesy of FORD MOTOR CO.
  20. Disconnect the following electrical connectors:
    • Transaxle mount control solenoid
    • Purge valve
      Fig 5: Locating Transaxle Mount Control Solenoid & Purge Valve
      G04619026Courtesy of FORD MOTOR CO.
  21. Remove the nut and the ground strap from the PCM stud.
    Fig 6: Locating Ground Strap & Bolt
    G04619027Courtesy of FORD MOTOR CO.
  22. Disconnect the engine control harness.
    • Release the powertrain control module (PCM) connector.
    • Remove the harness retaining nut.
      Fig 7: Locating Harness Retaining Nut
      G04619028Courtesy of FORD MOTOR CO.
  23. Disconnect the 2 engine control harness electrical connectors and the 2 pin-type retainers.
    Fig 8: Locating Engine Control Harness Electrical Connectors
    G04619029Courtesy of FORD MOTOR CO.
  24. Remove the bolt and disconnect the transaxle harness electrical connector.
    Fig 9: Locating Transaxle Harness Electrical Connector
    G04619030Courtesy of FORD MOTOR CO.
  25. Remove the 3 nuts and position aside the DC-to-DC converter.
    Fig 10: Locating DC-To-DC Converter
    G04619031Courtesy of FORD MOTOR CO.
  26. Disconnect the DC-to-DC converter electrical connector and pin-type retainer.
    Fig 11: Locating DC-To-DC Converter Electrical Connector
    G04619032Courtesy of FORD MOTOR CO.
  27. Disconnect and remove the fuel supply tube and evaporative emissions (EVAP) tube.
    Fig 12: Locating Fuel Supply Tube & Evaporative Emissions Tube
    G04619033Courtesy of FORD MOTOR CO.
    28. NOTE: Parts removed from view for clarity.
  28. If equipped, position the block heater wiring harness aside.
    • Detach the 3 harness retainer clips.
    • Route the harness through the radiator support into the engine compartment.
      Fig 13: Locating Harness Retainer Clips
      G04619034Courtesy of FORD MOTOR CO.
  29. Remove the 2 bolts and disconnect the auxiliary coolant pump electrical connector. Position the auxiliary coolant pump aside.
    Fig 14: Locating Auxiliary Coolant Pump Electrical Connector
    G04619035Courtesy of FORD MOTOR CO.
  30. Remove the bolts and the transaxle control snow shield.
    Fig 15: Locating Transaxle Control Snow Shield
    G04619036Courtesy of FORD MOTOR CO.
  31. Disconnect the transaxle control cable.
    • Release the transaxle control cable from the control lever.
    • Remove the nuts from the transaxle control cable bracket.
      Fig 16: Locating Transaxle Control Cable Bracket
      G04619037Courtesy of FORD MOTOR CO.
  32. Disconnect the pin-type retainer.
    Fig 17: Locating Pin-Type Retainer
    G04619038Courtesy of FORD MOTOR CO.
  33. Disconnect the pin-type retainer and position the transaxle control cable aside.
    Fig 18: Locating Pin-Type Retainer
    G04619039Courtesy of FORD MOTOR CO.
  34. Disconnect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
    Fig 19: Locating Transaxle Coolant Temperature Sensor Electrical Connector
    G04619040Courtesy of FORD MOTOR CO.
  35. Disconnect the transaxle coolant hoses.
    Fig 20: Locating Transaxle Coolant Hoses
    G04619041Courtesy of FORD MOTOR CO.
  36. Remove the nut and the ground cable.
    Fig 21: Locating Nut & Ground Cable
    G04619042Courtesy of FORD MOTOR CO.
  37. Remove the 2 bolts and position the motor electronics coolant pump aside.
    Fig 22: Locating Motor Electronics Coolant Pump
    G04619043Courtesy of FORD MOTOR CO.
  38. Disconnect the lower radiator hose from the radiator.
    Fig 23: Locating Lower Radiator Hose
    G04619044Courtesy of FORD MOTOR CO.
  39. Disconnect the A/C compressor electrical connector and remove the 3 bolts. Position the A/C compressor aside and support the compressor with a length of mechanic's wire.
    Fig 24: Identifying A/C Compressor Electrical Connector
    G04619045Courtesy of FORD MOTOR CO.
  40. Remove the front roll restrictor bolt.
    Fig 25: Locating Front Roll Restrictor Bolt
    G04619046Courtesy of FORD MOTOR CO.
  41. Remove the rear roll restrictor bolt.
    Fig 26: Locating Rear Roll Restrictor Bolt
    G04619047Courtesy of FORD MOTOR CO.
  42. Remove the nut, bolts and the engine support crossmember.
    • Discard the nut.
      Fig 27: Locating Engine Support Crossmember
      G04619048Courtesy of FORD MOTOR CO.
    43. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
    Fig 28: Locating Transaxle-To-Engine Bolts
    G04619049Courtesy of FORD MOTOR CO.
  43. Remove the 2 transaxle-to-engine bolts.
    44. NOTE: The transaxle-to-engine bolts differ in length, mark the bolts for correct installation.
    Fig 29: Locating Transaxle-To-Engine Bolts
    G04619050Courtesy of FORD MOTOR CO.
  44. Remove the 2 transaxle-to-engine bolts.
    45. CAUTION: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the lift table.
    Fig 30: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
    G03897890Courtesy of FORD MOTOR CO.
  45. Using the special tools, secure the engine to the lift table.
  46. Remove the engine mount bracket bolt.
    Fig 31: Locating Engine Mount Bracket Bolt
    G04619052Courtesy of FORD MOTOR CO.
  47. Remove the nuts and the engine mount bracket.
    Fig 32: Locating Nuts And Engine Mount Bracket
    G04619053Courtesy of FORD MOTOR CO.
  48. Remove the RH transaxle mount bracket nut.
    Fig 33: Locating RH Transaxle Mount Bracket Nut
    G04619054Courtesy of FORD MOTOR CO.
  49. Remove the bolts and the RH transaxle mount bracket.
    Fig 34: Locating RH Transaxle Mount Bracket Bolts
    G04619055Courtesy of FORD MOTOR CO.
  50. Remove the bolt, nut and the rear transaxle mount brace.
    Fig 35: Locating Rear Transaxle Mount Brace Bolt & Nut
    G04619056Courtesy of FORD MOTOR CO.
  51. Remove the nuts, bolt and rear transaxle mount.
    Fig 36: Locating Rear Transaxle Mount Nuts & Bolt
    G04619057Courtesy of FORD MOTOR CO.
  52. Lower the engine and transaxle from the vehicle.
  53. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
  54. Disconnect the high voltage wiring harness electrical connector.
    Fig 37: Locating High Voltage Wiring Harness Electrical Connector
    G04619058Courtesy of FORD MOTOR CO.
  55. Disconnect the 2 high voltage wiring harness electrical connectors and position the harness aside.
    Fig 38: Locating High Voltage Wiring Harness Electrical Connectors
    G04619059Courtesy of FORD MOTOR CO.
    56. NOTE: The transaxle-to-engine bolts differ in length, mark the bolts for correct installation.
  56. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.
    57. NOTE:
    1. Due to packaging requirements the correct bolt must be used at the damper locations.
    2. The damper contains a clutch which is designed to slip briefly during vehicle operation. It is essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use grease on transmission input shaft. Should the damper become contaminated, a new damper must be installed.
    Fig 39: Locating Transaxle Damper Bolts
    G04619060Courtesy of FORD MOTOR CO.
  57. Remove the bolts and the transaxle damper.
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