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Section 2154 (Engine - 2.3L - (Hybrid)): Removal: Engine

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0009877Courtesy of FORD MOTOR CO.
 Front Drive Halfshaft Remover 205-241 (T86P-3514-A)
GF0000536Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0017081Courtesy of FORD MOTOR CO.
 Powertrain Lift (014-00765)
GF0000218Courtesy of FORD MOTOR CO.
 Slide Hammer 100-001 (T50T-100-A)
GF0000267Courtesy of FORD MOTOR CO.
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0010812Courtesy of FORD MOTOR CO.
 Tie-Rod End Remover 211-105 (T85M-3395-A)
GF0024108Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets 014-0001
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

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. Place the steering wheel in the straight-ahead position and the ignition key in the OFF position.
  5. Disable the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.
  6. Drain the cooling system. For additional information, refer to ENGINE COOLING - HYBRID article.
  7. Drain the motor electronics cooling system. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING - HYBRID article.
  8. Remove the engine coolant degas bottle. For additional information, refer to ENGINE COOLING - HYBRID article.
  9. Remove the engine air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID article.
  10. Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - HYBRID article.
  11. Disconnect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
    12. Fig 1: Identifying Fuel Supply Tube
    GF0042152Courtesy of FORD MOTOR CO.
  12. Remove the front wheels and tires. For additional information, refer to WHEELS AND TIRES article.
  13. Remove the bolts and the lateral support crossmember.
    14. Fig 2: Identifying Lateral Support Crossmember And Bolts
    G03897847Courtesy of FORD MOTOR CO.
  14. Remove the catalytic converter. For additional information, refer to EXHAUST SYSTEM article.
  15. Remove the brake hose retainer and the ABS sensor retaining bolt from the LH strut.
    16. Fig 3: Identifying Bolt And Strut
    GF0042037Courtesy of FORD MOTOR CO.
  16. Disconnect the LH suspension.
    1. Remove the nut and disconnect the stabilizer bar link.
    2. Remove the tie-rod end retaining nut.
    3. Remove the lower control arm knuckle bolt.
    17. Fig 4: Identifying Stabilizer Bar Link, Nut And Bolt
    GF0042038Courtesy of FORD MOTOR CO.
  17. Remove the brake hose retainer and the ABS sensor retaining bolt from the RH strut.
    18. Fig 5: Identifying Bolt And Strut
    GF0042039Courtesy of FORD MOTOR CO.
  18. Disconnect the RH suspension.
    1. Remove the nut and disconnect the stabilizer bar link.
    2. Remove the tie-rod end retaining nut.
    3. Remove the lower control arm knuckle bolt.
    19. Fig 6: Identifying Stabilizer Bar Link, Nut And Bolt
    GF0042040Courtesy of FORD MOTOR CO.
  19. Using the special tool, disconnect the LH and RH tie-rod end from the steering knuckle.
    20. Fig 7: Disconnecting LH And RH Tie Rod End From Steering Knuckle
    GF0024860Courtesy of FORD MOTOR CO.
  20. Separate the LH and RH lower control arms from the lower ball joints and position the steering knuckles aside.
  21. Drain the transmission fluid. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - ELECTRONICALLY CONTROLLED CONTINUOUSLY VARIABLE TRANSMISSION (ECVT) article.
  22. Using a suitable tool, separate the LH halfshaft from the transaxle and secure the halfshaft aside.
  23. Using the special tools, remove the RH halfshaft from the intermediate shaft and secure the halfshaft aside.
    24. Fig 8: Removing RH Outer Halfshaft Using Special Tools
    GF0024825Courtesy of FORD MOTOR CO.
  24. Remove the 2 intermediate shaft retaining nuts.
    25. Fig 9: Locating Intermediate Shaft Retaining Nuts
    GF0024826Courtesy of FORD MOTOR CO.
  25. Remove the intermediate shaft.
    26. Fig 10: Locating Intermediate Shaft
    GF0024827Courtesy of FORD MOTOR CO.

    All wheel drive (AWD) vehicles 

  26. Remove the driveshaft. For additional information, refer to DRIVESHAFT article.
  27. Remove the 3 power transfer unit (PTU) heat shield bolts and the PTU heat shield.
    28. Fig 11: Transfer Case Heat Shield & Bolts
    GF0025217Courtesy of FORD MOTOR CO.
  28. Remove the bolts and the PTU-to-engine bracket.
    29. Fig 12: Transfer Case-To-Engine Bracket Bolts
    GF0025218Courtesy of FORD MOTOR CO.
  29. Disconnect the PTU vent hose and position it aside.
    30. Fig 13: Transfer Case Vent Hose
    GF0025219Courtesy of FORD MOTOR CO.
  30. Remove the 4 PTU-to-transaxle bolts and remove the PTU.
    31. Fig 14: Transfer Case-To-Transaxle Bolts
    GF0025220Courtesy of FORD MOTOR CO.

    All vehicles 

  31. Remove the oil filter element. For additional information, refer to Engine Lubrication Components - Exploded View  and Oil Filter Element .
  32. Drain the engine oil.
    • Install the drain plug.
    • Tighten to 28 Nm (21 lb-ft).
  33. Disconnect the heater hoses from the heater core.
    34. Fig 15: Locating Heater Hoses
    G03897868Courtesy of FORD MOTOR CO.
  34. Detach the heater hose retaining clip from the transaxle mount stud.
    35. Fig 16: Heater Hose Retaining Clip
    GF0024376Courtesy of FORD MOTOR CO.
  35. Disconnect the upper radiator and coolant vent hoses.
    36. Fig 17: Identifying Radiator And Coolant Vent Hoses
    GF0042153Courtesy of FORD MOTOR CO.
  36. Disconnect the PCM electrical connector.
    • Remove the wiring harness retainer nut.
    37. Fig 18: Powertrain Control Module (PCM) Connector & Nut
    GF0025221Courtesy of FORD MOTOR CO.
  37. Disconnect the engine control harness electrical connector.
    38. Fig 19: Identifying Connector
    GF0042154Courtesy of FORD MOTOR CO.
  38. Disconnect the upper evaporative emissions (EVAP) tube quick connect coupling from the purge valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
    39. Fig 20: Identifying Upper Evaporative Emissions (EVAP) Tube Quick Connect Coupling
    GF0042155Courtesy of FORD MOTOR CO.
  39. Remove the selector lever cable fasteners from the stud bolts on the transaxle.
    40. Fig 21: Selector Lever Cable Fasteners
    GF0025223Courtesy of FORD MOTOR CO.
  40. Remove the stud bolt and disconnect the transaxle harness electrical connector.
    41. Fig 22: Identifying Stud Bolt And Connector
    GF0042156Courtesy of FORD MOTOR CO.
  41. Disconnect the 2 low voltage electrical connectors and the engine harness-to-body harness retainer.
    42. Fig 23: Low Voltage Electrical Connectors
    GF0025224Courtesy of FORD MOTOR CO.
  42. Disconnect the DC-to-DC converter electrical connector and 2 wire harness retainers (1 shown).
    43. Fig 24: DC-To-DC Converter Electrical Connector
    GF0024382Courtesy of FORD MOTOR CO.
  43. Remove the 3 nuts and position aside the DC-to-DC converter.
    44. Fig 25: DC-To-DC Converter & Nuts
    GF0024383Courtesy of FORD MOTOR CO.
  44. If equipped, disconnect the block heater electrical connector.
    • Detach the harness retainer clips and position harness aside.
    45. Fig 26: Block Heater Electrical Connector
    GF0024121Courtesy of FORD MOTOR CO.
  45. Remove the 2 bolts and disconnect the auxiliary coolant pump electrical connector.
    • Position the auxiliary coolant pump aside.
    46. Fig 27: Auxiliary Coolant Pump Electrical Connector & Bolts
    GF0024386Courtesy of FORD MOTOR CO.
  46. Remove the bolts and the transaxle control snow shield.
    47. Fig 28: Transaxle Control Splash Shield
    GF0024387Courtesy of FORD MOTOR CO.
  47. Disconnect the transaxle control cable.
    • Release the transaxle control cable from the control lever.
    • Remove the nuts from the transaxle control cable bracket.
    48. Fig 29: Selector Lever Cable Bracket Nuts
    GF0024388Courtesy of FORD MOTOR CO.
  48. Disconnect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
    49. Fig 30: Motor Electronics Coolant Temperature Sensor Electrical Connector
    GF0024391Courtesy of FORD MOTOR CO.
  49. Disconnect the transaxle coolant hoses.
    50. Fig 31: Transaxle Coolant Hoses
    GF0024392Courtesy of FORD MOTOR CO.
  50. Remove the 2 harness fasteners, the nut and the ground cable.
    51. Fig 32: Ground Cable
    GF0025227Courtesy of FORD MOTOR CO.
  51. Remove the 2 bolts and position the motor electronics coolant pump and ground strap aside.
    52. Fig 33: Motor Electronics Coolant Pump & Ground Strap
    GF0024394Courtesy of FORD MOTOR CO.
  52. Disconnect the lower radiator hose from the radiator.
    53. Fig 34: Locating Lower Radiator Hose
    G03897882Courtesy of FORD MOTOR CO.
  53. 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.
    54. Fig 35: A/C Compressor Electrical Connector & Bolts
    GF0024395Courtesy of FORD MOTOR CO.
  54. Remove the front roll restrictor bolt.
    55. Fig 36: Front Roll Restrictor Bolt
    GF0024396Courtesy of FORD MOTOR CO.
  55. Remove the rear roll restrictor bolt.
    56. Fig 37: Rear Insulator Bolt
    GF0024397Courtesy of FORD MOTOR CO.
  56. Remove the nut, bolts and the engine support crossmember.
    • Discard the nut.
    57. Fig 38: Engine Support Crossmember & Fasteners
    GF0024398Courtesy of FORD MOTOR CO.
    NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
  57. Remove the 2 transaxle-to-engine bolts.
    58. Fig 39: Transaxle-To-Engine Bolts
    GF0024399Courtesy of FORD MOTOR CO.
    NOTE: The transaxle-to-engine bolts differ in length, mark the bolts for correct installation.
  58. Remove the 2 transaxle-to-engine bolts.
    59. Fig 40: Transaxle-To-Engine Bolts
    GF0024400Courtesy of FORD MOTOR CO.

    Early build 

  59. Remove the RH transaxle mount bracket nut.
    60. Fig 41: Insulator Nut
    GF0025214Courtesy of FORD MOTOR CO.
  60. Remove the 3 bolts and the rear transaxle mount bracket.
    61. Fig 42: Insulator Bracket Bolt
    GF0025215Courtesy of FORD MOTOR CO.

    Late build 

  61. Remove the lower support insulator through bolt.
    62. Fig 43: Identifying Through Bolt
    GF0042157Courtesy of FORD MOTOR CO.
  62. Remove the 2 lower support insulator nuts and 1 bolt.
    63. Fig 44: Identifying Nuts And Bolt
    GF0042158Courtesy of FORD MOTOR CO.
  63. Remove the 2 lower support insulator studs.
    64. Fig 45: Identifying Studs
    GF0042159Courtesy of FORD MOTOR CO.
  64. Remove the lower support insulator.
    65. Fig 46: Identifying Lower Support Insulator
    GF0042160Courtesy of FORD MOTOR CO.

    All vehicles 

    NOTE: Do not allow the steering wheel to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM article.
  65. Remove and discard the steering column coupling-to-steering gear pinch bolt and separate coupling from the steering gear.
    66. Fig 47: Identifying Bolt
    GF0042161Courtesy of FORD MOTOR CO.
  66. Remove the 2 bolts and the roll restrictor bracket.
    67. Fig 48: Identifying Bolts And Roll Restrictor Bracket
    GF0042162Courtesy of FORD MOTOR CO.
  67. Using a suitable lift table, support the subframe.
    68. NOTE: Do not allow the front subframe rear bolts to come out of the lower control arm bushing.
    NOTE: RH shown, LH similar.
  68. Loosen the 2 subframe bolts.
    69. Fig 49: Identifying Bolt
    GF0042163Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  69. Remove the 2 subframe nuts and lower the subframe.
    • Remove the subframe from the lift table.
    70. Fig 50: Identifying Nut
    GF0042164Courtesy of FORD MOTOR CO.
    NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the lift table.
  70. Using the special tools, secure the engine to the lift table.
    71. Fig 51: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
    G03897890Courtesy of FORD MOTOR CO.
  71. Remove the engine mount bracket bolt.
    72. Fig 52: Engine Mount Bracket Bolt
    GF0024401Courtesy of FORD MOTOR CO.
  72. Remove the nuts and the engine mount bracket.
    73. Fig 53: Engine Mount Bracket Nuts
    GF0024402Courtesy of FORD MOTOR CO.
  73. Remove the bolt, nut and the rear transaxle mount brace.
    74. Fig 54: Rear Transaxle Mount Brace & Bolts
    GF0024405Courtesy of FORD MOTOR CO.
  74. Remove the nuts, bolt and rear transaxle mount.
    75. Fig 55: Rear Transaxle Mount & Fasteners
    GF0024406Courtesy of FORD MOTOR CO.
  75. Lower the engine and transaxle from the vehicle.
  76. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
  77. Disconnect the high voltage wiring harness electrical connector.
    78. Fig 56: High Voltage Wiring Harness Electrical Connector
    GF0024407Courtesy of FORD MOTOR CO.
    NOTE: The transaxle-to-engine bolts differ in length, mark the bolts for correct installation.
  78. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.
    79. 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, it must be replaced.
  79. Remove the bolts and the transaxle damper.
    80. Fig 57: Transaxle Damper Bolts
    GF0024409Courtesy of FORD MOTOR CO.
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