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Section 217 (Engine Mechanical - 2.0L GTDI): Removal: Engine

WARNING: This page is about a different car, the 2014 Ford Edge. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL DESCRIPTION

G09292397
 2, 200# Floor Crane, Fold Away
300-OTC1819E 
G09292236
 Adjustable Grip Arm, 1735A
014-00001 
G06126910
 Disconnect Tool, Transaxle Cooler Tube
307-569 
G06065029
 Halfshaft Remover
205-832 
G09292241
 Powertrain Lift
300-OTC1585AE 
G06097256
 Retainer, Torque Converter
307-566 
G06064997
 Slide Hammer
100-001  (T50T-100-A)
G06251558
 Spreader Bar
303-D089  (D93P-6001-A3) 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 .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
  3. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
  4. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
  5. Remove the engine Air Cleaner (ACL) and ACL  outlet pipe assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  6. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  7. Disconnect the Transmission Control Module (TCM) electrical connector and detach the 3 wiring harness retainers.
    • Remove the nut and the TCM bracket.
      G09291555
  8. Remove the 2 nuts and disconnect the power feed from the battery terminal.
    • Disconnect the generator current sensor electrical connector.
      G09294620
  9. Remove the nut and the ground wire.
    • Disconnect the battery current sensor electrical connector.
      G09294621
  10. Detach the wiring harness retainer from the transaxle mount bracket stud bolt.
    G09294622
  11. Disconnect the wiring harness electrical connector.
    G09294623
  12. Loosen the 2 clamps and disconnect the upper radiator hose and the heater hose.
    • Disconnect the heater hose quick connect coupling.
    • Detach the hoses from the 2 retaining clips.
      G09294624
  13. Disconnect the transaxle selector lever cable end from the manual control lever, remove the 2 bracket bolts and position the selector lever cable and bracket aside.
    G08031035
  14. Loosen the clamp and disconnect the Charge Air Cooler (CAC) outlet tube.
    G08030997
  15. Loosen the 2 clamps and remove the CAC  inlet tube.
    G08653431
  16. Disconnect the 2 engine wiring harness electrical connectors.
    • Detach the wiring harness retainer from the cowl.
      G09294628
  17. Detach the wiring harness retainer from the valve cover stud bolt.
    G09294479
  18. Remove the nut and the ground wire from the RH inner fender.
    G09294630
  19. Disconnect the Evaporative Emission (EVAP) tube from the EVAP  purge valve. For additional information, refer to the QUICK CONNECT COUPLING .
    G08653605
  20. Disconnect the vacuum check valve from the power brake booster.
    G09291554
  21. Slide the fuel supply tube release clip back and disconnect the fuel tube from the high pressure fuel pump.
    G09295173
  22. Remove the catalytic converter. For additional information, refer to EXHAUST SYSTEM
  23. Remove the front subframe. For additional information, refer to UNI-BODY, SUBFRAME AND MOUNTING SYSTEM .
  24. Remove the 2 secondary latches from the transaxle fluid cooler tubes.
    G08653609
  25. Using the Transaxle Cooler Tube Disconnect Tool, disconnect the transaxle cooling tubes.
    G08653610
  26. Remove the 2 transaxle-to-oil pan bolts.
    G08028781
  27. Loosen the clamp and disconnect the lower radiator hose.
    G09294637
  28. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
      G08028662
  29. Remove and discard the engine oil filter.
    G08028649
  30. Detach the 2 wiring harness retainers from the RH halfshaft support stud bolts.
    G09294640
  31. Remove the 2 nuts and slide the RH halfshaft assembly out of the transaxle.
    • Position the halfshaft aside and support with a length of mechanics wire.
      G08031043
  32. Using the Halfshaft Remover and Slide Hammer, separate the halfshaft from the transmission.
    • Position the halfshaft aside and support with a length of mechanics wire.
      G08031044
  33. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt from the A/C compressor.
    G09297527
  34. Disconnect the 2 A/C compressor electrical connectors.
    • Detach the wiring harness retainer from the A/C tube stud bolt.
      G08028667
  35. Remove the A/C compressor nut and the 2 bolts.
    • Position the A/C compressor aside and support with a length of mechanics wire.
      G09294645
  36. Disconnect the return hose from the power steering pump.
    G09294646
  37. NOTE: Position a block of wood under the transaxle.

    Install the Powertrain Lift and Adjustable Grip Arms.

    G08028788
  38. Remove the transaxle support insulator through bolt and nut.
    G09294648
  39. Remove the 3 nuts, the bolt and the transaxle support insulator bracket.
    G09294649
  40. Remove the 4 nuts, the 3 bolts and the engine mount.
    • Lower the engine and transaxle assembly from the vehicle.
      G09294482
  41. Remove the starter cable cover and the 2 nuts.
    • Detach the 2 wire terminals from the starter.
    • Remove the nut and the ground wire from the starter stud bolt.
      G08030517
  42. Remove the 2 stud bolts and the starter.
    G08030518
  43. Remove the starter insulator.
    G08031039
  44. NOTE: Only rotate the engine in a clockwise direction or engine damage will occur.
    NOTE: Mark one stud and the flexplate for assembly reference.

    Remove and discard the 4 torque converter nuts.

    G08031040
  45. Position the generator cap aside and remove the nut and wire terminal.
    • Disconnect the wire harness electrical connector.
    • Detach the 2 wiring harness retainers from the engine.
      G09294655
  46. Loosen the clamp and disconnect the heater hose.
    G09294656
  47. Disconnect the Positive Crankcase Ventilation (PCV) tube from the turbocharger inlet pipe and position it aside.
    G08028797
  48. Using the Floor Crane and Spreader Bar, remove the engine and transaxle from the powertrain table.
    G08028798
  49. Remove the 3 transaxle-to-engine bolts.
    G08028799
  50. Remove the 3 engine-to-transaxle bolts.
    G08028800
  51. Remove the 3 transaxle-to-engine bolts.
    G08614461
  52. Separate the engine and transaxle and install the Torque Converter Retainer and bolt.
    G08028802
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