Section 1991 (Engine - 2.3L - (Hybrid)): Removal: Engine

Illustration	Tool Name	Tool Number
	Heavy Duty Floor Crane	014-00071 or equivalent
	Spreader Bar	303-D089 (D93P-6001-A3) or equivalent
	Powertrain Lift	(014-00765)
	Universal Adapter Brackets	014-0001
Lifting Bracket Set, Engine		303-D095 (D94L-6001-A) or equivalent

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
4. Disable the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.
5. Drain the cooling system. For additional information, refer to ENGINE COOLING - HYBRID article.
6. Drain the motor electronics cooling system. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING - HYBRID article.
7. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

   Remove the intake manifold. For additional information, refer to Intake Manifold .

8. Remove the engine air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID article.
9. Remove the catalytic converter. For additional information, refer to EXHAUST SYSTEM article.
10. Remove the engine coolant degas bottle. For additional information, refer to ENGINE COOLING - HYBRID article.
11. Remove the LH front drive halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.

All wheel drive (AWD) vehicles 

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

Front wheel drive (FWD) vehicles 

13. Remove the front drive intermediate halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
14. Remove the bolts and the lateral support crossmember.
Fig 1: Identifying Lateral Support Crossmember And Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

15. Remove the oil filter element. For additional information, refer to Engine Lubrication Components - Exploded View  and Oil Filter Element  in this section.
16. Drain the engine oil.
17. Disconnect the heater hoses from the heater core.
Fig 2: Locating Heater Hoses
Courtesy of FORD MOTOR CO.
18. Detach the heater hose retaining clip from the transaxle mount stud.
Fig 3: Heater Hose Retaining Clip
Courtesy of FORD MOTOR CO.
19. Disconnect the upper radiator and coolant vent hoses.
Fig 4: Upper Radiator & Coolant Vent Hoses
Courtesy of FORD MOTOR CO.
20. Disconnect the following electrical connectors:
    • Transaxle mount control solenoid
    • Purge valve
Fig 5: Transaxle Mount Control Solenoid & Purge Valve Electrical Connectors
Courtesy of FORD MOTOR CO.
21. Disconnect the engine control harness.
    • Release the powertrain control module (PCM) connector.
    • Remove the harness retaining nut.
Fig 6: Powertrain Control Module (PCM) Connector & Nut
Courtesy of FORD MOTOR CO.
22. Disconnect the 2 engine control harness electrical connectors and the 2 pin-type retainers.
Fig 7: Engine Control Harness Electrical Connectors
Courtesy of FORD MOTOR CO.
23. Remove the bolt and disconnect the transaxle harness electrical connector.
Fig 8: Transaxle Harness Electrical Connector & Bolt
Courtesy of FORD MOTOR CO.
24. Disconnect the DC-to-DC converter electrical connector and pin-type retainer.
Fig 9: DC-To-DC Converter Electrical Connector
Courtesy of FORD MOTOR CO.
25. Remove the 3 nuts and position aside the DC-to-DC converter.
Fig 10: DC-To-DC Converter & Nuts
Courtesy of FORD MOTOR CO.
26. Disconnect and remove the fuel supply tube and evaporative emissions (EVAP) tube.
Fig 11: Fuel Supply Tube And Evaporative Emissions (EVAP) Tube
Courtesy of FORD MOTOR CO.
NOTE: Parts removed from view for clarity.
27. 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 12: Block Heater Wiring Harness
Courtesy of FORD MOTOR CO.
28. Remove the 2 bolts and disconnect the auxiliary coolant pump electrical connector. Position the auxiliary coolant pump aside.
Fig 13: Auxiliary Coolant Pump Electrical Connector & Bolts
Courtesy of FORD MOTOR CO.
29. Remove the bolts and the transaxle control snow shield.
Fig 14: Transaxle Control Splash Shield
Courtesy of FORD MOTOR CO.
30. Disconnect the transaxle control cable.
    • Release the transaxle control cable from the control lever.
    • Remove the nuts from the transaxle control cable bracket.
Fig 15: Selector Lever Cable Bracket Nuts
Courtesy of FORD MOTOR CO.
31. Disconnect the pin-type retainer.
Fig 16: Pin-Type Retainer
Courtesy of FORD MOTOR CO.
32. Disconnect the pin-type retainer and position the transaxle control cable aside.
Fig 17: Pin-Type Retainer
Courtesy of FORD MOTOR CO.
33. Disconnect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
Fig 18: Motor Electronics Coolant Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
34. Disconnect the transaxle coolant hoses.
Fig 19: Transaxle Coolant Hoses
Courtesy of FORD MOTOR CO.
35. Remove the nut and the ground cable.
Fig 20: Ground Cable & Nut
Courtesy of FORD MOTOR CO.
36. Remove the 2 bolts and position the motor electronics coolant pump and ground strap aside.
Fig 21: Motor Electronics Coolant Pump & Ground Strap
Courtesy of FORD MOTOR CO.
37. Disconnect the lower radiator hose from the radiator.
Fig 22: Locating Lower Radiator Hose
Courtesy of FORD MOTOR CO.
38. 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 23: A/C Compressor Electrical Connector & Bolts
Courtesy of FORD MOTOR CO.
39. Remove the front roll restrictor bolt.
Fig 24: Front Roll Restrictor Bolt
Courtesy of FORD MOTOR CO.
40. Remove the rear roll restrictor bolt.
Fig 25: Rear Insulator Bolt
Courtesy of FORD MOTOR CO.
41. Remove the nut, bolts and the engine support crossmember.
    • Discard the nut.
Fig 26: Engine Support Crossmember & Fasteners
Courtesy of FORD MOTOR CO.
NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
42. Remove the 2 transaxle-to-engine bolts.
Fig 27: Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
NOTE: The transaxle-to-engine bolts differ in length, mark the bolts for correct installation.
43. Remove the 2 transaxle-to-engine bolts.
Fig 28: Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
CAUTION: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the lift table.
44. Using the special tools, secure the engine to the lift table.
Fig 29: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
Courtesy of FORD MOTOR CO.
45. Remove the engine mount bracket bolt.
Fig 30: Engine Mount Bracket Bolt
Courtesy of FORD MOTOR CO.
46. Remove the nuts and the engine mount bracket.
Fig 31: Engine Mount Bracket Nuts
Courtesy of FORD MOTOR CO.
47. Remove the RH transaxle mount bracket nut.
Fig 32: Right Transaxle Mount Bracket Nut
Courtesy of FORD MOTOR CO.
48. Remove the bolts and the RH transaxle mount bracket.
Fig 33: Right Transaxle Mount Bracket Bolts
Courtesy of FORD MOTOR CO.
49. Remove the bolt, nut and the rear transaxle mount brace.
Fig 34: Rear Transaxle Mount Brace & Bolts
Courtesy of FORD MOTOR CO.
50. Remove the nuts, bolt and rear transaxle mount.
Fig 35: Rear Transaxle Mount & Fasteners
Courtesy of FORD MOTOR CO.
51. Lower the engine and transaxle from the vehicle.
52. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
53. Disconnect the high voltage wiring harness electrical connector.
Fig 36: High Voltage Wiring Harness Electrical Connector
Courtesy of FORD MOTOR CO.
54. Disconnect the 2 high voltage wiring harness electrical connectors and position the harness aside.
Fig 37: High Voltage Wiring Harness Electrical Connectors
Courtesy of FORD MOTOR CO.
NOTE: The transaxle-to-engine bolts differ in length, mark the bolts for correct installation.
55. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.
NOTE: Due to packaging requirements the correct bolt must be used at the damper locations.
NOTE: 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.
56. Remove the bolts and the transaxle damper.
Fig 38: Transaxle Damper Bolts
Courtesy of FORD MOTOR CO.