Engine - 2.0L DURATEC-He (110KW/150PS) - Mi4: Removal: Engine

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING .

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	307-566 Retainer, Torque Converter TKIT-2006C-FFMFLM TKIT-2006C-LM TKIT-2006C-ROW
Magnetic Socket
Floor Crane
Adjustable Mounting Arm
Oil Drain Equipment
Cable Ties
Hose Clamp Remover/Installer
Powertrain Jack
Wooden Block

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
2. Evacuate the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging .
3. Drain the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
4. Release the fuel system pressure. Refer to: Fuel System Pressure Release .
5. Remove the following items:
   1. Remove the cowl panel. Refer to: Cowl Panel .
   2. Remove the degas bottle. Refer to: Degas Bottle .
   3. Remove the battery tray. Refer to: Battery Tray - 2.0L Duratec-HE (110kW/150PS) - MI4 .
   4. Remove the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
   5. Remove the LH fender splash shield. Refer to: Fender Splash Shield .
   6. Remove the A/C compressor belt. Refer to: Air Conditioning (A/C) Compressor Belt .
   7. Remove the cooling fan motor and shroud. Refer to: Cooling Fan Motor and Shroud .

6. Disconnect the electrical connector.

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7. Remove the retainers and the PCM cover.

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8. Disconnect the PCM electrical connector.

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9. NOTE: Be prepared to collect escaping fluid.

   Release the clamps and detach the hoses.

   Use the General Equipment: Hose Clamp Remover/Installer

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10. Remove the LH front halfshaft. Refer to: Front Halfshaft LH .
11. Remove the RH front halfshaft. Refer to: Front Halfshaft RH .
12. 1. Remove the rear roll restrictor bracket bolt.
    2. Remove the engine roll restrictor bracket bolts.
    3. Remove and discard the engine roll restrictor bolt.
    4. Remove and discard the bolt and remove the engine roll restrictor and bracket.

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13. Remove the nuts and catalytic converter bracket.

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14. • Remove and discard the nuts.
    • Position aside the muffler and tailpipe and discard the gasket.
    • Make sure that the mating faces are clean and free of foreign material.

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15. NOTE: Make sure that all openings are sealed with clean blanking caps.
    • Remove the A/C compressor inlet line nut and position aside line.
    • Remove the A/C compressor outlet line nut and position aside line.

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16. NOTE: Be prepared to collect escaping fluid.

    Release the clamps and detach the radiator lower hose.

    Use the General Equipment: Hose Clamp Remover/Installer

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17. NOTE: The oil drain plug with O-ring seal is to be reused unless damaged.

    Drain and install the drain plug.

    Use the General Equipment: Oil Drain Equipment

    Torque: 20 lb.ft (27 Nm)

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18. Remove and discard the engine oil filter.

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19. Remove the bell housing bolt.

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20. Remove the bell housing bolts.

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21. Remove the bell housing bolts.

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22. • Disconnect the electrical connector, disconnect the wiring retainers and position aside the wiring harness.
    • Remove the nuts and the battery tray bracket.

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23. Remove the nut and position the battery feed cable from the positive battery cable.

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24. Remove the bolt, detach retainer and position the ground wire aside.

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25. Detach the retainers from the bracket and disconnect the electrical connector.

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26. Detach the upper radiator hose retainer from the transmission bracket.

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27. 1. Release and detach the coolant hoses from the coolant outlet connector.

       Use the General Equipment: Hose Clamp Remover/Installer

    2. Release the quick release couplings, detach the coolant hoses from the coolant outlet connector. Refer to: Quick Release Coupling .
    • Detach the retainer from the coolant hose.

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28. Remove the bolts and disconnect the transmission shift cable. Position aside the transmission shift cable.

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29. • Remove the retainers and detach the degas line from the intake manifold.
    • Disconnect the vacuum line from the intake manifold. Refer to: Quick Release Coupling .

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30. Disconnect the high pressure fuel line. Refer to: Quick Release Coupling .

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31. Disconnect the EVAP line. Refer to: Quick Release Coupling .

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32. Disconnect the HO2S (heated oxygen sensor) electrical connector.

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33. Disconnect the catalyst monitor sensor electrical connector.

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34. Remove the bolts and the catalytic converter heat shield.

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35. Remove and discard the nuts. Position back the catalytic converter.

    Use the General Equipment: Cable Ties

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36. Remove and discard the catalytic converter gasket.

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37. • Disconnect the oil pressure switch electrical connector.
    • Remove and discard the oil pressure switch.

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38. • Position the powertrain jack and boards under the engine and transmission. Use the General Equipment: Powertrain Jack. Use the General Equipment: Wooden Block
    • Install adjustable mounting arm.

      Use the General Equipment: Adjustable Mounting Arm

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39. • Remove and discard the engine mount nuts.
    • Remove and discard the bolts and remove the engine mount.

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40. Remove the bolt and the transmission support insulator.

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41. NOTE: Make sure that no components catch.

    Lower the powertrain from the vehicle.

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42. • Detach the wiring harness retainers and position the wiring harness aside.
    • Remove the starter motor bracket nuts and then remove the starter motor bracket.

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43. Remove the battery terminal cap.

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44. 1. Remove the starter motor solenoid control wire retaining nut.
    2. Remove the starter motor solenoid positive battery cable retaining nut and position the starter motor solenoid battery cable aside.

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45. Remove the starter motor retaining stud bolts and then remove the starter motor.

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46. Remove the starter motor insulator.

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47. NOTE: Only rotate the crankshaft clockwise.
    NOTE: Note the position of the component before removal.

    Remove the torque converter nuts.

    Use the General Equipment: Magnetic Socket

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48. Install the floor crane and engine lift equipment.

    Use the General Equipment: Floor Crane

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49. Remove the adjustable mounting arm.

    Use the General Equipment: Adjustable Mounting Arm

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50. • Remove the generator B+ cable nut cover.
    • Disconnect the A/C compressor and the auxiliary coolant pump electrical connectors and detach the wiring harness retainers.

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51. • Remove the nut and the B+ cable.
    • Disconnect the generator electrical connector.
    • Detach the generator and A/C wiring harness retainer and position the wiring harness on the transmission.

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52. Release the clamp and position the auxiliary coolant pump hose aside.

    Use the General Equipment: Hose Clamp Remover/Installer

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53. Disconnect the transmission wiring harness electrical connectors and the retainers.

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54. Remove the nut and detach the wiring harness retainers.

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55. Remove the bell housing stud bolts.

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56. Using the floor crane and engine lift equipment, separate the engine from the transmission.

    Use the General Equipment: Floor Crane

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57. Install Special Service Tool: 307-566 Retainer, Torque Converter.

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