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Engine - Automatic Transaxle

WARNING: This page is about a different car, the 2012 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G08019471
 Disconnect Tool, Transmission Cooler Line
307-569
G08019472
 2, 200# Floor Crane, Fold Away
300-OTC1819E or equivalent
G08019473
 Powertrain Lift
300-OTC1585AE or equivalent
G08019474
 Remover, Tie-Rod End
211-105
G08019475
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G08019476
 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 .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
  3. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L .
  4. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
  5. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  6. Remove the 2 nuts and the battery cables from the positive battery cable.
    Fig 1: Locating Battery Cables And Nuts
    G08019477Courtesy of FORD MOTOR CO.
  7. Disconnect the engine wiring harness electrical connector.
    Fig 2: Locating Engine Wiring Harness Electrical Connector
    G08019478Courtesy of FORD MOTOR CO.
  8. Remove the bolt and the ground wire from the body.
    Fig 3: Locating Ground Wire And Bolt
    G08019479Courtesy of FORD MOTOR CO.
  9. Detach the 2 negative battery cable pin-type retainers from the transaxle mount and battery tray bracket.
    Fig 4: Locating Negative Battery Cable Pin-Type Retainers
    G08019480Courtesy of FORD MOTOR CO.
  10. Disconnect the 2 engine harness electrical connectors.
    Fig 5: Locating Engine Harness Electrical Connector
    G08019481Courtesy of FORD MOTOR CO.
    11. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
    Fig 6: Holding Steering Wheel In Straight-Ahead Position Using Suitable Holding Device
    G08019482Courtesy of FORD MOTOR CO.
  11. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
  12. Remove the 2 nuts and the steering joint cover.
    Fig 7: Locating Steering Joint Cover And Nuts
    G08019483Courtesy of FORD MOTOR CO.
    13. 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 .
  13. Remove the bolt and disconnect the steering column shaft from the steering gear.
    • Discard the bolt.
      Fig 8: Locating Steering Column Shaft And Mounting Bolts
      G08019484Courtesy of FORD MOTOR CO.
  14. If equipped, remove the 7 screws and the underbody cover.
    Fig 9: Locating Underbody Cover And Screws
    G08019485Courtesy of FORD MOTOR CO.
  15. Drain the transaxle. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - AISIN AW21 .
  16. Drain the cooling system. For additional information, refer to ENGINE COOLING .
    17. 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 And Clips
    G08019486Courtesy of FORD MOTOR CO.
  17. 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.
  18. Remove the engine roll restrictor bolt.
    Fig 11: Locating Engine Roll Restrictor Bolt
    G08019487Courtesy of FORD MOTOR CO.
  19. Remove the 4 screws and position the RH fender splash shield aside.
    Fig 12: Locating RH Fender Splash Shield Mounting Screws
    G08019488Courtesy of FORD MOTOR CO.
  20. Remove the 6 pin-type retainers (4 shown in illustration) and the RH splash shield.
    Fig 13: Locating Pin-Type Retainers And RH Splash Shield
    G08019489Courtesy of FORD MOTOR CO.
  21. Remove the 4 screws and position the LH fender splash shield aside.
    Fig 14: Locating LH Fender Splash Shield Mounting Screws
    G08019490Courtesy of FORD MOTOR CO.
  22. Remove the 6 pin-type retainers (4 shown in illustration) and the LH splash shield.
    Fig 15: Locating LH Splash Shield And Pin-Type Retainers
    G08019491Courtesy of FORD MOTOR CO.
  23. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  24. Disconnect the 2 Electronic Power Assist Steering (EPAS) system electrical connectors.
    Fig 16: Locating Electronic Power Assist Steering (EPAS) System Electrical Connectors
    G08019492Courtesy of FORD MOTOR CO.
  25. Detach the 2 EPAS system wiring harness pin-type retainers from the subframe.
    Fig 17: Locating EPAS System Wiring Harness Pin-Type Retainer
    G08019493Courtesy of FORD MOTOR CO.
  26. Detach the EPAS system wiring harness pin-type retainer from the subframe under the LH fender splash shield.
    Fig 18: Locating EPAS System Wiring Harness Pin-Type Retainer
    G08019494Courtesy of FORD MOTOR CO.
  27. Remove the bolt and the EPAS system wiring harness ground.
    Fig 19: Locating EPAS System Wiring Harness And Bolt
    G08019495Courtesy of FORD MOTOR CO.
    28. NOTE: LH shown in illustration, RH similar.
    Fig 20: Locating Tie-Rod Ends Nuts And Cotter Pin
    G08019496Courtesy of FORD MOTOR CO.
  28. Remove the cotter pins and nuts from the tie-rod ends.
    29. NOTE: LH shown in illustration, RH similar.
    Fig 21: Separating Tie-Rod Ends From Steering Knuckles Using Tie-Rod End Remover (211-105)
    G08019497Courtesy of FORD MOTOR CO.
  29. Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.
    30. NOTE: LH shown in illustration, RH similar.
    Fig 22: Locating Sway Bar Link Nut
    G08019498Courtesy of FORD MOTOR CO.
  30. Remove the nuts and separate the sway bar links from the struts.
  31. Position the Powertrain Lift under the subframe assembly.
    Fig 23: Identifying Powertrain Lift Under Subframe
    G08019499Courtesy of FORD MOTOR CO.
    32. NOTE: LH shown in illustration, RH similar.
    Fig 24: Locating Subframe Bracket-To-Body Bolts
    G08019500Courtesy of FORD MOTOR CO.
  32. Remove the subframe bracket-to-body bolts.
    33. NOTE: LH shown in illustration, RH similar.
    Fig 25: Locating Rear Subframe Nut And Subframe Bracket
    G08019501Courtesy of FORD MOTOR CO.
  33. Remove the subframe nuts and the subframe brackets.
    34. NOTE: LH shown in illustration, RH similar.
    Fig 26: Locating Front Subframe Nut
    G08019502Courtesy of FORD MOTOR CO.
  34. Remove the front subframe nuts.
  35. Lower the subframe assembly from the vehicle.
  36. Remove the engine oil pan drain plug and drain the engine oil.
    • Install the drain plug and tighten to 28 Nm (21 lb-ft).
      Fig 27: Locating Engine Oil Pan Drain Plug
      G08019503Courtesy of FORD MOTOR CO.
  37. Remove the engine oil filter.
  38. Remove the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .
  39. Disconnect the crankcase vent tube from the valve cover.
    Fig 28: Locating Crankcase Vent Tube Of Valve Cover
    G08019504Courtesy of FORD MOTOR CO.
  40. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
    Fig 29: Locating Brake Booster Vacuum Supply Tube Of Intake Manifold And Locking Ring
    G08019505Courtesy of FORD MOTOR CO.
  41. Disconnect the fuel vapor return tube.
    Fig 30: Locating Fuel Vapor Return Tube
    G08019506Courtesy of FORD MOTOR CO.
  42. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 31: Locating Fuel Supply Tube Quick Connect Coupling
    G08019507Courtesy of FORD MOTOR CO.
  43. Detach the coolant hose retainer.
    Fig 32: Identifying Coolant Hose Retainer
    G08019508Courtesy of FORD MOTOR CO.
  44. Disconnect the upper radiator and heater hoses from the coolant outlet and disconnect the heater hose in-line connector.
    Fig 33: Locating Coolant Outlet Heater Hoses
    G08019509Courtesy of FORD MOTOR CO.
  45. Disconnect the shift cable from the transaxle manual lever and remove the transaxle shift cable from the bracket.
    Fig 34: Locating Shift Cable Of Transaxle Manual Lever
    G08019510Courtesy of FORD MOTOR CO.
  46. Remove the 2 secondary latches from the transaxle fluid cooler tubes.
    Fig 35: Locating Secondary Latches Of Transaxle Fluid Cooler Tubes
    G08019511Courtesy of FORD MOTOR CO.
  47. Using the Transmission Cooler Line Disconnect Tool, disconnect the 2 transaxle fluid cooler tubes (1 shown in illustration).
    Fig 36: Disconnecting Transaxle Fluid Cooler Tubes
    G08019512Courtesy of FORD MOTOR CO.
  48. Remove the bolt and the ground wire from the engine mount.
    Fig 37: Locating Engine Mount Ground Wire And Bolt
    G08019513Courtesy of FORD MOTOR CO.
  49. Remove the A/C tube/windshield washer reservoir bracket bolt.
    Fig 38: Locating A/C Tube/Windshield Washer Reservoir Bracket Bolt
    G08019514Courtesy of FORD MOTOR CO.
  50. Remove the nut and disconnect the A/C tube.
    • Discard the O-ring seal.
      Fig 39: Locating A/C Tube Nut And O-Ring Seal
      G08019515Courtesy of FORD MOTOR CO.
  51. Detach the coolant vent hose retaining clip from the A/C tube.
    Fig 40: Locating Coolant Vent Hose Retaining Clip Of A/C Tube
    G08019516Courtesy of FORD MOTOR CO.
  52. Remove the nut and disconnect the upper A/C tube from the condenser.
    • Discard the O-ring seal.
      Fig 41: Locating A/C Condenser Tube Mounting Nut
      G08019517Courtesy of FORD MOTOR CO.
  53. Detach the Knock Sensor (KS) electrical connector from the intake manifold.
    Fig 42: Locating Knock Sensor (KS) Electrical Connector Of Intake Manifold
    G08019518Courtesy of FORD MOTOR CO.
  54. Remove the lower radiator hose from the thermostat housing.
    Fig 43: Locating Lower Radiator Hose Of Thermostat Housing
    G08019519Courtesy of FORD MOTOR CO.
  55. If equipped, position the block heater shield aside and disconnect the block heater electrical connector.
    • Detach the 8 block heater wiring harness retainers (1 shown in illustration) and remove the block heater wiring harness.
      Fig 44: Locating Block Heater Electrical Connector And Wiring Harness Retainer
      G08019520Courtesy of FORD MOTOR CO.
  56. Detach the lower radiator hose pin-type retainer from the cooling fan shroud.
    Fig 45: Locating Lower Radiator Hose Pin-Type Retainer Of Cooling Fan Shroud
    G08019521Courtesy of FORD MOTOR CO.
  57. Remove the 2 bellhousing-to-oil pan bolts.
    Fig 46: Locating Bellhousing-To-Oil Pan Bolts
    G08019522Courtesy of FORD MOTOR CO.
  58. Remove the 2 oil pan-to-bellhousing bolts.
    Fig 47: Locating Oil Pan-To-Bellhousing Bolts
    G08019523Courtesy of FORD MOTOR CO.
    59. NOTE: Position a block of wood under the transaxle.
  59. Install the Powertrain Lift and Adjustable Grip Arm onto the engine.
    • Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
      Fig 48: Identifying Powertrain Lift And Adjustable Grip Arm Onto Engine
      G08019524Courtesy of FORD MOTOR CO.
  60. Remove the nut and the transaxle mount through bolt.
    Fig 49: Locating Transaxle Mount Through Bolt And Nut
    G08019525Courtesy of FORD MOTOR CO.
  61. Remove the bolt, 2 nuts and the engine mount bracket.
    Fig 50: Locating Engine Mount Bracket Nuts And Bolts
    G08019526Courtesy of FORD MOTOR CO.
  62. Lower the engine and transaxle from the vehicle.
  63. Disconnect the A/C compressor electrical connector.
    Fig 51: Locating A/C Compressor Electrical Connector
    G08019527Courtesy of FORD MOTOR CO.
  64. Detach the A/C compressor wiring harness pin-type retainer from the intake manifold.
    Fig 52: Locating A/C Compressor Wiring Harness Pin-Type Retainer
    G08019528Courtesy of FORD MOTOR CO.
  65. Remove the 2 nuts and disconnect the starter motor wires.
    Fig 53: Locating Starter Motor Harness Wire Nuts
    G08019529Courtesy of FORD MOTOR CO.
  66. Remove the nut and the ground wire from the starter motor stud bolt.
    Fig 54: Locating Ground Wire And Starter Motor Stud Bolt
    G08019530Courtesy of FORD MOTOR CO.
  67. Remove the bolt, stud bolt and the starter motor.
    Fig 55: Locating Starter With Bolts And Studs
    G08019531Courtesy of FORD MOTOR CO.
  68. Remove the starter motor isolator.
    Fig 56: Locating Starter Motor Isolator
    G08019532Courtesy of FORD MOTOR CO.
  69. Press the locking tab to release the generator air duct and remove.
    Fig 57: Locating Locking Tab And Generator Air Duct
    G08019533Courtesy of FORD MOTOR CO.
  70. Disconnect the generator electrical connection.
    Fig 58: Locating Generator Electrical Connection
    G08019534Courtesy of FORD MOTOR CO.
  71. Remove the nut and the generator B+ wiring harness.
    Fig 59: Locating Nut And Generator B+ Wiring Harness
    G08019535Courtesy of FORD MOTOR CO.
  72. Detach the 4 wiring harness retainers (3 shown in illustration) from the valve cover stud bolts.
    Fig 60: Locating Wiring Harness Retainers Of Valve Cover Stud Bolts
    G08019536Courtesy of FORD MOTOR CO.
  73. Remove the 4 torque converter nuts.
    Fig 61: Locating Torque Converter Nut
    G08019537Courtesy of FORD MOTOR CO.
  74. Install the Floor Crane and Spreader Bar and remove the engine and transaxle from the Powertrain Lift table.
    Fig 62: Removing Engine And Transaxle From Powertrain Lift Table
    G08019538Courtesy of FORD MOTOR CO.
  75. Remove the remaining bellhousing-to-engine retainers.
    • Separate the engine and transaxle.
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