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Section 2056 (Engine Mechanical - 2.5L (Hybrid)): Removal: Engine

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G07782069
 2,200# Floor Crane, Fold Away
300-OTC1819E or equivalent
G07782070
 Powertrain Lift
300-OTC1585AE or equivalent
G07782071
 Remover, Tie-Rod End
211-105 (T85M-3395-A)
G07782072
 Spreader Bar
303-D089 (D93P-6001-A3) (part of 303-DS086) or equivalent
G07782073
 Adjustable Grip Arm, 1735A
014-00001 or equivalent
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.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING & CABLES -- FUSION, MILAN & MKZ article.
  4. Depower the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY -- FUSION HYBRID, MILAN HYBRID & MKZ HYBRID article.
  5. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS -- FUSION, MILAN & MKZ (HYBRID) article.
    6. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
    Fig 1: Holding Steering Wheel
    G07782074Courtesy of FORD MOTOR CO.
  6. Place the steering wheel in the straight-ahead position and the ignition key in the OFF position.
  7. Remove the 2 nuts and the steering joint cover.
    Fig 2: Locating Steering Joint Cover And Mounting Nuts
    G07782075Courtesy of FORD MOTOR CO.
    8. NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM -- FUSION, MILAN & MKZ article.
    Fig 3: Locating Steering Column Shaft And Mounting Bolts
    G07782076Courtesy of FORD MOTOR CO.
  8. Remove the bolt and disconnect the steering column shaft from the steering gear.
  9. Remove the 7 screws and the underbody cover.
    Fig 4: Locating Underbody Cover Mounting Screws
    G07782077Courtesy of FORD MOTOR CO.
  10. Drain the cooling system. For additional information, refer to ENGINE COOLING SYSTEM -- (HYBRID) article.
  11. Drain the Motor Electronics Cooling System (MECS). For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION COOLING -- ECVT - HYBRID article.
  12. Remove the engine Air Cleaner (ACL) pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - (HYBRID) article.
  13. Remove the front wheels and tires. For additional information, refer to WHEELS & TIRES article.
  14. Remove the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM -- FUSION, MILAN & MKZ article.
  15. Remove the 4 screws and position the RH fender splash shield aside.
    Fig 5: Locating RH Fender Splash Shield Mounting Screws
    G07782078Courtesy of FORD MOTOR CO.
  16. Remove the 6 pin-type retainers and the RH splash shield.
    Fig 6: Locating Splash Shield Mounting Retainers
    G07782079Courtesy of FORD MOTOR CO.
  17. Remove the bolt and the Electronic Power Assist Steering (EPAS) wiring ground wire from in the RH front wheel well.
    Fig 7: Locating Electronic Power Assist Steering (EPAS) Wiring Mounting Bolt
    G07782080Courtesy of FORD MOTOR CO.
  18. Remove the 4 screws and position the LH fender splash shield aside.
    Fig 8: Locating Fender Splash Shield Mounting Screws
    G07782081Courtesy of FORD MOTOR CO.
  19. Remove the 6 pin-type retainers (4 shown in illustration) and the LH splash shield.
    Fig 9: Locating Splash Shield Mounting Retainers
    G07782082Courtesy of FORD MOTOR CO.
  20. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
    21. NOTE: The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.
    Fig 10: Locating Steering Gear-To-Dash Seal Clips
    G07782083Courtesy of FORD MOTOR CO.
  21. Release the 4 clips (2 shown in illustration) and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
  22. Remove the engine roll restrictor bolt.
    Fig 11: Locating Engine Roll Restrictor Bolt
    G07782084Courtesy of FORD MOTOR CO.
    23. NOTE: RH shown in illustration, LH similar.
    Fig 12: Locating Tie-Rod Ends Cotter Pins And Nuts
    G07782085Courtesy of FORD MOTOR CO.
  23. Remove the cotter pins and nuts from the tie-rod ends.
    24. NOTE: RH shown in illustration, LH similar.
    Fig 13: Separating Tie-Rod Ends From Steering Knuckles Using Tie-Rod End Remover
    G07782086Courtesy of FORD MOTOR CO.
  24. Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.
    25. NOTE: RH shown in illustration, LH similar.
    Fig 14: Locating Stabilizer Bar Links And Fastener
    G07782087Courtesy of FORD MOTOR CO.
  25. Remove the nuts and separate the stabilizer bar links from the struts.
  26. Disconnect the 2 EPAS electrical connectors near the front of the subframe.
    • Detach the connector retainer from the subframe.
    Fig 15: Locating Subframe EPAS Electrical Connectors
    G07782088Courtesy of FORD MOTOR CO.
  27. Detach the auxiliary coolant hose retainer from the subframe.
    Fig 16: Locating Auxiliary Coolant Hose Retainer
    G07782089Courtesy of FORD MOTOR CO.
  28. Detach the 3 wiring harness retainers (2 shown in illustration) from the LH front of the subframe.
    Fig 17: Locating Subframe Wiring Harness Retainers
    G07782090Courtesy of FORD MOTOR CO.
  29. Disconnect the MECS electrical connector and detach the pump from the bracket.
    Fig 18: Locating MECS Electrical Connector
    G07782091Courtesy of FORD MOTOR CO.
  30. Position the Powertrain Lift under the subframe assembly.
    Fig 19: View Of Powertrain Lift Under Subframe Assembly
    G07782092Courtesy of FORD MOTOR CO.
    31. NOTE: LH shown in illustration, RH similar.
    Fig 20: Locating Subframe Bracket-To-Body Bolts
    G07782093Courtesy of FORD MOTOR CO.
  31. Remove the subframe bracket-to-body bolts.
  32. Remove the subframe nuts and the subframe brackets.
    Fig 21: Locating Subframe Nuts And Subframe Brackets
    G07782094Courtesy of FORD MOTOR CO.
    33. NOTE: LH shown in illustration, RH similar.
    Fig 22: Locating Front Subframe Nuts
    G07782095Courtesy of FORD MOTOR CO.
  33. Remove the front subframe nuts.
  34. Lower the subframe assembly from the vehicle.
  35. Disconnect the vacuum pump assembly electrical connector and detach the wiring retainer.
    Fig 23: Locating Vacuum Pump Assembly Electrical Connector
    G07782096Courtesy of FORD MOTOR CO.
  36. Disconnect the transaxle coolant temperature sensor and the Transmission Range (TR) sensor electrical connectors.
    • Detach the wiring harness retainer.
    Fig 24: Locating Transaxle Coolant Temperature Sensor And Transmission Range (TR) Sensor Electrical Connectors
    G07782097Courtesy of FORD MOTOR CO.
  37. Remove the transaxle ground wire and nut.
    Fig 25: Locating Transaxle Ground Wire And Nut
    G07782098Courtesy of FORD MOTOR CO.
  38. Disconnect the transaxle shift cable from the transaxle.
    Fig 26: Locating Transaxle Shift Cable
    G07782099Courtesy of FORD MOTOR CO.
  39. Remove the 2 nuts and the transaxle shift cable bracket.
    Fig 27: Locating Transaxle Shift Cable Bracket And Mounting Nuts
    G07782100Courtesy of FORD MOTOR CO.
  40. Detach the transaxle shift cable routing retainer from the transaxle.
    Fig 28: Locating Transaxle Shift Cable Routing Retainer
    G07782101Courtesy of FORD MOTOR CO.
  41. Remove the drain plug and drain the engine oil.
    • Install the drain plug.
    • Tighten to 28 Nm (21 lb-ft).
    Fig 29: Locating Drain Plug
    G07782102Courtesy of FORD MOTOR CO.
  42. Remove the engine oil filter.
    Fig 30: Locating Engine Oil Filter
    G07782103Courtesy of FORD MOTOR CO.
    43. NOTE: Lower radiator hose shown in illustration, upper similar.
    Fig 31: Disconnecting Upper And Lower Radiator Hose
    G07782104Courtesy of FORD MOTOR CO.
  43. Remove the retaining clips and disconnect the upper and the lower radiator hose.
  44. If equipped, detach the 3 block heater wiring retainers.
    Fig 32: Locating Block Heater Wiring Retainers
    G07782105Courtesy of FORD MOTOR CO.
  45. Remove the nut and disconnect the A/C tube.
    • Discard the gasket.
    Fig 33: Locating A/C Tube Mounting Nut
    G07782106Courtesy of FORD MOTOR CO.
  46. Remove the A/C tube bracket bolt from the strut tower.
    Fig 34: Locating Strut Tower A/C Tube Bracket Bolt
    G07782107Courtesy of FORD MOTOR CO.
  47. Remove the A/C tube bracket bolt.
    Fig 35: Locating A/C Tube Bracket Bolt
    G07782108Courtesy of FORD MOTOR CO.
  48. Remove the nut and disconnect the A/C tube from the A/C compressor.
    Fig 36: Locating A/C Compressor Mounting Nut
    G07782109Courtesy of FORD MOTOR CO.
  49. Remove the nut and disconnect the A/C tube from the A/C condenser.
    • Discard the gasket.
    Fig 37: Locating A/C Condenser Tube Mounting Nut
    G07782110Courtesy of FORD MOTOR CO.
  50. Disconnect the 2 vehicle high voltage electrical system electrical connectors.
    • Detach the wiring harness retainer.
    Fig 38: Locating Vehicle High Voltage Electrical System Electrical Connectors
    G07782111Courtesy of FORD MOTOR CO.
  51. Detach the 2 block heaters (if equipped) and the high voltage electrical system wiring retainers from the valve cover stud bolts.
    Fig 39: Locating Valve Cover Stud Bolts
    G07782112Courtesy of FORD MOTOR CO.
  52. Disconnect the 2 heater hoses.
    Fig 40: Locating Heater Hoses
    G07782113Courtesy of FORD MOTOR CO.
  53. Detach the engine wiring harness retainer from the bracket.
    Fig 41: Locating Engine Wiring Harness Retainer
    G07782114Courtesy of FORD MOTOR CO.
  54. Disconnect the engine wiring harness connector and detach it from the bracket.
    Fig 42: Locating Engine Wiring Harness Connector
    G07782115Courtesy of FORD MOTOR CO.
  55. Disconnect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
    Fig 43: Locating Fuel Supply Tube
    G07782116Courtesy of FORD MOTOR CO.
  56. Disconnect the upper Evaporative Emission (EVAP) tube quick connect coupling from the purge valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
    Fig 44: Locating Upper Evaporative Emission (EVAP) Tube Quick Connect Coupling
    G07782117Courtesy of FORD MOTOR CO.
  57. Remove the MECS coolant expansion tank nut and bolt.
    Fig 45: Locating MECS Coolant Expansion Tank Nut And Bolt
    G07782118Courtesy of FORD MOTOR CO.
  58. Disconnect the hose from the transaxle and remove the MECS coolant expansion tank.
    Fig 46: Locating MECS Coolant Expansion Tank Clamp
    G07782119Courtesy of FORD MOTOR CO.
  59. Remove the bolt and detach the wiring retainer.
    • Disconnect the transaxle harness electrical connector.
    Fig 47: Locating Transaxle Harness Electrical Connector
    G07782120Courtesy of FORD MOTOR CO.
  60. Remove the 2 bolts and position the master cylinder reservoir aside.
    Fig 48: Locating Master Cylinder Reservoir Mounting Bolts
    G07782121Courtesy of FORD MOTOR CO.
  61. Disconnect the 2 transaxle electrical connectors.
    Fig 49: Locating Transaxle Electrical Connectors
    G07782122Courtesy of FORD MOTOR CO.
  62. Disconnect the 2 engine wiring harness connectors and detach the wiring retainer.
    Fig 50: Locating Engine Wiring Harness Connectors
    G07782123Courtesy of FORD MOTOR CO.
  63. Disconnect the brake booster vacuum hose.
    Fig 51: Locating Brake Booster Vacuum Hose Clamp
    G07782124Courtesy of FORD MOTOR CO.
    64. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
    Fig 52: Locating Transaxle-To-Engine Bolts
    G07782125Courtesy of FORD MOTOR CO.
  64. Remove the 2 transaxle-to-engine bolts.
    65. NOTE: The transaxle-to-engine bolts differ in length, mark the bolts for correct installation.
    Fig 53: Locating Transaxle-To-Engine Bolts
    G07782126Courtesy of FORD MOTOR CO.
  65. Remove the 2 transaxle-to-engine bolts.
    66. NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the Powertrain Lift.
    Fig 54: Mounting Engine To Powertrain Lift Using Powertrain Lift And Adjustable Grip Arm
    G07782127Courtesy of FORD MOTOR CO.
  66. Using the Powertrain Lift and Adjustable Grip Arm, secure the engine to the Powertrain Lift.
  67. Remove the engine mount bracket bolt.
    Fig 55: Locating Engine Mount Bracket Bolts
    G07782128Courtesy of FORD MOTOR CO.
  68. Remove the nuts and the engine mount bracket.
    Fig 56: Locating Engine Mount Bracket And Nuts
    G07782129Courtesy of FORD MOTOR CO.
  69. Remove the 3 nuts from the upper transaxle insulator.
    Fig 57: Locating Upper Transaxle Insulator Mounting Nuts
    G07782130Courtesy of FORD MOTOR CO.
  70. Lower the engine and transaxle from the vehicle.
  71. Remove the 3 bolts and position aside the auxiliary coolant pump and bracket.
    Fig 58: Locating Auxiliary Coolant Pump And Bracket Mounting Bolts
    G07782131Courtesy of FORD MOTOR CO.
  72. Remove the 2 engine cover studs from the valve cover stud bolts.
    Fig 59: Locating Engine Cover Studs
    G07782132Courtesy of FORD MOTOR CO.
  73. Disconnect the 2 heater hoses from the coolant outlet.
    Fig 60: Locating Heater Hoses And Clamps
    G07782133Courtesy of FORD MOTOR CO.
  74. Using the Floor Crane and the Spreader Bar, remove the engine and transaxle from the Powertrain Lift.
    75. NOTE: The transaxle-to-engine bolts differ in length, mark the bolts for correct installation.
    Fig 61: Locating Transaxle-To-Engine Bolts
    G07782134Courtesy of FORD MOTOR CO.
  75. Remove the 2 transaxle bolts.
  76. Remove the transaxle bolt.
    Fig 62: Locating Transaxle Mounting Bolt
    G07782135Courtesy of FORD MOTOR CO.
  77. Remove the 3 transaxle bolts and separate the engine and transaxle.
    Fig 63: Locating Transaxle Mounting Bolts
    G07782136Courtesy of FORD MOTOR CO.
    78. 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.
  78. Remove the bolts and the transaxle damper.
Fig 64: Locating Transaxle Damper Bolts
G07782137Courtesy of FORD MOTOR CO.
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