Section 416 (Engine - 2.0L DURATEC-He (125KW/170PS) - Mi4 (Except Electric Vehicle)): Removal: Engine

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	300-OTC1585AE Powertrain Lift
Courtesy of FORD MOTOR COMPANY	300-OTC1819E2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	303-D089 (D93P-6001-A3) Spreader Bar
Magnetic Socket
Adjustable Mounting Arm
Hose Clamp Remover/Installer
Wooden Block

• 1.
  
  
  WARNING: Before beginning any service procedure in this service information, refer to Safety Warnings in GENERAL INFORMATION . Failure to follow this instruction may result in serious personal injury.

  Refer to: Health and Safety Precautions .

• 2.
  
  With the vehicle in NEUTRAL, position it on a hoist. REFER to: Jacking and Lifting - Overview .

• 3.
  
  Evacuate the A/C system. REFER to: Air Conditioning (A/C) System Recovery, Evacuation and Charging .

• 4.
  
  Release the fuel system pressure. REFER to: Fuel System Pressure Release .

• 5.
  
  Remove the bolts and the underbody shield.

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• 6.
  
  Drain the cooling system. REFER to: Cooling System Draining, Vacuum Filling and Bleeding . REFER to: Cooling System Draining, Filling and Bleeding .

• 7.
  
  Remove the following items:
  • Remove the degas bottle. REFER to: Degas Bottle .
  • Remove the battery tray. REFER to: Battery Tray .
  • Remove the air cleaner and the air cleaner outlet pipe. REFER to: Air Cleaner . REFER to: Air Cleaner Outlet Pipe .

• 8.
  
  If equipped with automatic transmission. Detach the wire retainer.

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• 9.
  
  Remove the nut for the ground strap.

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• 10.
  
  Detach the ground cable retainer.

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• 11.
  
  Remove the PCM. REFER to: Powertrain Control Module (PCM) .

• 12.
  
  
  NOTE: The electrical connector is located behind the PCM case.

  Disconnect the engine harness electrical connector.

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• 13.
  
  Detach the ground cable retainer and remove the bolts for the ground cable.

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• 14.
  
  Detach the wiring harness retainers.

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• 15.
  
  Remove and position aside the wiring harness.

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• 16.
  
  Remove the hose clips, disconnect the coolant hoses.

  Use the General Equipment: Hose Clamp Remover/Installer

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• 17.
  
  Disconnect the coolant hoses from the heater core, detach the hose retainers.

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• 18.
  
  If equipped. Disconnect the block heater electrical connector.

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• 19.
  
  Remove the HO2S. REFER to: Heated Oxygen Sensor (HO2S) .

• 20.
  
  Disconnect the catalyst monitor sensor electrical connector and wire retainer.

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• 21.
  
  Remove the bolts, and position aside the catalyst monitor sensor wiring harness and remove the exhaust manifold heat shield.

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• 22.
  
  Remove the bolts for the exhaust manifold.

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• 23.
  
  
  NOTE: Discard the gasket.

  Remove the catalytic converter manifold-to-muffler and tailpipe nuts.

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• 24.
  
  Remove the tailpipe mount bracket bolts.

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• 25.
  
  
  NOTE: Discard the catalytic converter nuts and gasket.

  Remove and discard the nuts, and position aside the manifold.

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• 26.
  
  Remove and discard the manifold studbolts.

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• 27.
  
  Disconnect the fuel tube quick release coupling. REFER to: Quick Release Coupling .

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• 28.
  
  Disconnect the electrical connector and the fuel tube quick release coupling. REFER to: Quick Release Coupling .

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• 29.
  
  Disconnect the vacuum tube quick release coupling at the rear of the intake manifold.

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• 30.
  
  If equipped with an automatic transmission. Disconnect the selector lever cable end from the manual control lever.

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• 31.
  
  If equipped with an automatic transmission. Detach the selector lever cable retainer.

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• 32.
  
  If equipped with an automatic transmission. Detach the selector lever cable retainer.

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• 33.
  
  If equipped with an automatic transmission. Remove the bolts and position aside the shift cable.

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• 34.
  
  
  NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

  If equipped with a manual transmission. Disconnect the clutch hydraulic tube.

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• 35.
  
  If equipped with a manual transmission. Disconnect the shift cable, remove the nuts and position aside.

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• 36.
  
  Refer to: Front Halfshaft RH . REFER to: Front Halfshaft LH .

• 37.
  
  Remove the A/C pipe bracket bolt.

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• 38.
  
  
  NOTE: Discard the O-ring seals.

  Remove the nuts and the bolt, disconnect the A/C pipes from the A/C compressor.

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• 39.
  
  Loosen the clamp, remove the coolant hose.

  Use the General Equipment: Hose Clamp Remover/Installer

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• 40.
  
  Drain and install the drain plug.

  Torque

  : 20 lb.ft (27 Nm)

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• 41.
  
  Remove and discard the engine oil filter.

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• 42.
  
  Remove the coolant fan motor and shroud. REFER to: Cooling Fan Motor and Shroud .

• 43.
  
  
  NOTE: Automatic transmission shown in illustration, manual transmission similar.

  Remove the oil pan-to-transmission bolt.

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• 44.
  
  
  NOTE: Automatic transmission shown in illustration, manual transmission similar.

  Remove the oil pan bolts.

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• 45.
  
  Remove the engine mounting Restrictor.

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• 46.
  
  
  NOTE: Position a block of wood under the transmission.

  Use Special Service Tool: 300-OTC1585AE Powertrain Lift.

  Use the General Equipment: Wooden Block

  Use the General Equipment: Adjustable Mounting Arm

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• 47.
  
  Detach the A/C line and from the routing clamp.

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• 48.
  
  
  • Remove the nuts.
  • Remove the bolts and the engine mount.

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• 49.
  
  Remove the transmission mount bolt.

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• 50.
  
  Lower the powertrain from the vehicle.

• 51.
  
  Clean and inspect the catalytic converter flange. REFER to: Exhaust Manifold Cleaning and Inspection .

• 52.
  
  If equipped with automatic transmission. Disconnect the electrical connector.

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• 53.
  
  Detach the wiring harness retainer.

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• 54.
  
  Remove the starter motor. REFER to: Starter Motor .

• 55.
  
  Remove the stater motor isolator.

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• 56.
  
  
  NOTE: Rotate the engine in a clockwise direction only or engine damage may occur.
  NOTE: Note the position of the components before removal.
  NOTE: If equipped with automatic transmission.

  Remove the torque converter nut and discard.

  Use the General Equipment: Magnetic Socket

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• 57.
  
  Install the engine lift equipment.

  Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away, 303-D089 (D93P-6001-A3) Spreader Bar.

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• 58.
  
  
  NOTE: Automatic transmission shown in illustration, manual transmission similar.

  Remove the engine-to-transmission bolts.

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• 59.
  
  Remove the nut and ground wire.

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• 60.
  
  
  NOTE: Automatic transmission shown in illustration, manual transmission similar.
  • If equipped with a automatic transmission, remove the 4 bellhousing-to-engine fasteners.
  • If equipped with a manual transmission, remove the 5 bellhousing-to-engine fasteners.

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• 61.
  
  Separate the transaxle from the engine.