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Section 4 (Engine - 2.3L - (Hybrid)): Removal: Engine

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL(S) DESCRIPTION

G03898823
 Heavy Duty Floor Crane 014-00071 or equivalent
G03898617
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
G03897842
 Powertrain Lift (014-00765)
G03899013
 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 AND LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  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 ENGINE COOLING - HYBRID .
  6. Drain the motor electronics cooling system. For additional information, refer to TRANSAXLE-TRANSMISSION COOLING - HYBRID .
  7. 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 .
  9. Remove the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
  10. Remove the engine coolant degas bottle. For additional information, refer to ENGINE COOLING - HYBRID .
  11. Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - HYBRID .
  12. Remove the LH front drive halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .

    13. 4x4 vehicles 

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

    14. 4x2 vehicles 

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

    16. All vehicles 

  16. Remove the oil filter element. For additional information, refer to ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW .
  17. Drain the engine oil.
  18. Disconnect the heater hoses from the heater core.
    Fig 2: Locating Heater Hoses At Heater Core
    G03897868Courtesy of FORD MOTOR CO.
  19. Detach the heater hose retaining clip from the transaxle mount stud.
    Fig 3: Detaching Heater Hose Retaining Clip From Transaxle Mount Stud
    G03898829Courtesy of FORD MOTOR CO.
  20. Disconnect the upper radiator and coolant vent hoses.
    Fig 4: Disconnecting Upper Radiator And Coolant Vent Hoses
    G03898830Courtesy of FORD MOTOR CO.
  21. Disconnect the following electrical connectors:
    • Transaxle mount control solenoid
    • Purge valve
      Fig 5: Disconnecting Electrical Connectors
      G03898831Courtesy of FORD MOTOR CO.
  22. Disconnect the engine control harness.
    • Release the powertrain control module (PCM) connector.
    • Remove the harness retaining nut.
      Fig 6: Removing Harness Retaining Nut
      G03898832Courtesy of FORD MOTOR CO.
  23. Disconnect the 2 engine control harness electrical connectors and the 2 pin-type retainers.
    Fig 7: Disconnecting Engine Control Harness Electrical Connectors
    G03898833Courtesy of FORD MOTOR CO.
  24. Remove the bolt and disconnect the transaxle harness electrical connector.
    Fig 8: Removing Bolt And Transaxle Harness Electrical Connector
    G03898834Courtesy of FORD MOTOR CO.
  25. Disconnect the DC-to-DC converter electrical connector and pin-type retainer.
    Fig 9: Disconnecting DC-To-DC Converter Electrical Connector
    G03898835Courtesy of FORD MOTOR CO.
  26. Disconnect and remove the fuel supply tube and evaporative emissions (EVAP) tube.
    Fig 10: Disconnecting Fuel Supply Tube And Evaporative Emissions (EVAP) Tube
    G03898836Courtesy of FORD MOTOR CO.
    27. 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 11: Removing Harness Retainer Clips
      G03898837Courtesy of FORD MOTOR CO.
  28. Remove the 2 bolts and disconnect the auxiliary coolant pump electrical connector. Position the auxiliary coolant pump aside.
    Fig 12: Removing Bolts And Coolant Pump Electrical Connector
    G03898838Courtesy of FORD MOTOR CO.
  29. Remove the bolts and the transaxle control snow shield.
    Fig 13: Locating Bolts And Transaxle Control Snow Shield
    G03898839Courtesy 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 14: Removing Nuts From Transaxle Control Cable Bracket
      G03898840Courtesy of FORD MOTOR CO.
  31. Disconnect the pin-type retainer.
    Fig 15: Disconnecting Pin-Type Retainer
    G03898841Courtesy of FORD MOTOR CO.
  32. Disconnect the pin-type retainer and position the transaxle control cable aside.
    Fig 16: Disconnecting Pin-Type Retainer
    G03898842Courtesy of FORD MOTOR CO.
  33. Disconnect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
    Fig 17: Disconnecting Transaxle Coolant Temperature Sensor Electrical Connector
    G03898843Courtesy of FORD MOTOR CO.
  34. Disconnect the transaxle coolant hoses.
    Fig 18: Disconnecting Transaxle Coolant Hoses
    G03898844Courtesy of FORD MOTOR CO.
  35. Remove the nut and the ground cable.
    Fig 19: Removing Nut And Ground Cable
    G03898845Courtesy of FORD MOTOR CO.
  36. Remove the 2 bolts and position the motor electronics coolant pump aside.
    Fig 20: Removing Bolts
    G03898846Courtesy of FORD MOTOR CO.
  37. Disconnect the lower radiator hose from the radiator.
    Fig 21: Locating Lower Radiator Hose At Radiator
    G03897882Courtesy 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 22: Removing Bolts And A/C Compressor Electrical Connector
    G03898848Courtesy of FORD MOTOR CO.
  39. Remove the front roll restrictor bolt.
    Fig 23: Removing Front Roll Restrictor Bolt
    G03898849Courtesy of FORD MOTOR CO.
  40. Remove the rear roll restrictor bolt.
    Fig 24: Removing Rear Roll Restrictor Bolt
    G03898850Courtesy of FORD MOTOR CO.
  41. Remove the nut, bolts and the engine support crossmember.
    Fig 25: Removing Nut, Bolts And Engine Support Crossmember
    G03898851Courtesy of FORD MOTOR CO.
    42. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
    Fig 26: Removing Transaxle-To-Engine Bolts
    G03898852Courtesy of FORD MOTOR CO.
  42. Remove the 2 transaxle-to-engine bolts.
    43. NOTE: The transaxle-to-engine bolts differ in length, mark the bolts for correct installation.
    Fig 27: Removing Transaxle-To-Engine Bolts
    G03898853Courtesy of FORD MOTOR CO.
  43. Remove the 2 transaxle-to-engine bolts.
    44. CAUTION: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the lift table.
    Fig 28: Identifying Engine Lift Table
    G03897890Courtesy of FORD MOTOR CO.
  44. Using the special tools, secure the engine to the lift table.
  45. Remove the engine mount bracket bolt.
    Fig 29: Removing Engine Mount Bracket Bolt
    G03898855Courtesy of FORD MOTOR CO.
  46. Remove the nuts and the engine mount bracket.
    Fig 30: Removing Nuts And Engine Mount Bracket
    G03898856Courtesy of FORD MOTOR CO.
  47. Remove the RH transaxle mount bracket nut.
    Fig 31: Removing RH Transaxle Mount Bracket Nut
    G03898857Courtesy of FORD MOTOR CO.
  48. Remove the bolts and the RH transaxle mount bracket.
    Fig 32: Removing Bolts And RH Transaxle Mount Bracket
    G03898858Courtesy of FORD MOTOR CO.
  49. Remove the bolt, nut and the rear transaxle mount brace.
    Fig 33: Removing Bolt, Nut And Rear Transaxle Mount Brace
    G03898859Courtesy of FORD MOTOR CO.
  50. Remove the nuts, bolt and rear transaxle mount.
    Fig 34: Removing Nuts, Bolt And Rear Transaxle Mount
    G03898860Courtesy 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 35: Disconnecting Wiring Harness Electrical Connector
    G03898861Courtesy of FORD MOTOR CO.
  54. Disconnect the 2 high voltage wiring harness electrical connectors and position the harness aside.
    Fig 36: Disconnecting High Voltage Wiring Harness Electrical Connectors
    G03898862Courtesy of FORD MOTOR CO.
    55. 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.
    56. 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.
    Fig 37: Removing Bolts And Transaxle Damper
    G03898863Courtesy of FORD MOTOR CO.
  56. Remove the bolts and the transaxle damper.
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