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Engine - Manual 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

G08019539
 2, 200# Floor Crane, Fold Away
300-OTC1819E or equivalent
G08019540
 Powertrain Lift
300-OTC1585AE or equivalent
G08019541
 Remover, Tie-Rod End
211-105
G08019542
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G08019543
 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
    G08019544Courtesy of FORD MOTOR CO.
  7. Disconnect the engine wiring harness electrical connector.
    Fig 2: Locating Engine Wiring Harness Electrical Connector
    G08019545Courtesy of FORD MOTOR CO.
  8. Remove the bolt and the ground wire from the body.
    Fig 3: Locating Ground Wire And Bolt
    G08019546Courtesy 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
    G08019547Courtesy of FORD MOTOR CO.
  10. Disconnect the 2 engine harness electrical connector.
    Fig 5: Locating Engine Harness Electrical Connector
    G08019548Courtesy of FORD MOTOR CO.
  11. Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
    • Using a suitable holding device, hold the steering wheel in the straight-ahead position.
      Fig 6: Holding Steering Wheel In Straight-Ahead Position Using Suitable Holding Device
      G08019549Courtesy of FORD MOTOR CO.
  12. Remove the 2 nuts and the steering joint cover.
    Fig 7: Locating Steering Joint Cover And Nuts
    G08019550Courtesy 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
      G08019551Courtesy of FORD MOTOR CO.
  14. If equipped, remove the 7 screws and the underbody cover.
    Fig 9: Locating Underbody Cover Screws
    G08019552Courtesy of FORD MOTOR CO.
  15. Drain the cooling system. For additional information, refer to ENGINE COOLING .
    16. 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
    G08019553Courtesy of FORD MOTOR CO.
  16. 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.
  17. Remove the engine roll restrictor bolt.
    Fig 11: Locating Engine Roll Restrictor Bolt
    G08019554Courtesy of FORD MOTOR CO.
  18. Remove the 4 screws and position the RH fender splash shield aside.
    Fig 12: Locating RH Fender Splash Shield Mounting Screws
    G08019555Courtesy of FORD MOTOR CO.
  19. Remove the 6 pin-type retainers (4 shown in illustration) and the RH splash shield.
    Fig 13: Locating RH Splash Shield And Pin-Type Retainers
    G08019556Courtesy of FORD MOTOR CO.
  20. Remove the 4 screws and position the LH fender splash shield aside.
    Fig 14: Locating LH Fender Splash Shield Mounting Screws
    G08019557Courtesy of FORD MOTOR CO.
  21. Remove the 6 pin-type retainers (4 shown in illustration) and the LH splash shield.
    Fig 15: Locating LH Fender Splash Shield Pin-Type Retainers
    G08019558Courtesy of FORD MOTOR CO.
  22. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  23. Disconnect the 2 Electronic Power Assist Steering (EPAS) system electrical connectors.
    Fig 16: Locating Electronic Power Assist Steering (EPAS) System Electrical Connectors
    G08019559Courtesy of FORD MOTOR CO.
  24. Detach the 2 EPAS system wiring harness pin-type retainers from the subframe.
    Fig 17: Locating EPAS System Wiring Harness Pin-Type Retainer
    G08019560Courtesy of FORD MOTOR CO.
  25. 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
    G08019561Courtesy of FORD MOTOR CO.
  26. Remove the bolt and the EPAS system wiring harness ground.
    Fig 19: Locating EPAS System Wiring Harness Ground Mounting Bolt
    G08019562Courtesy of FORD MOTOR CO.
    27. NOTE: LH shown in illustration, RH similar.
    Fig 20: Locating Tie-Rod Ends Nuts And Cotter Pin
    G08019563Courtesy of FORD MOTOR CO.
  27. Remove the cotter pins and nuts from the tie-rod ends.
    28. NOTE: LH shown in illustration, RH similar.
    Fig 21: Separating Tie-Rod Ends From Steering Knuckles Using Tie-Rod End Remover (211-105)
    G08019564Courtesy of FORD MOTOR CO.
  28. Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.
    29. NOTE: LH shown in illustration, RH similar.
    Fig 22: Locating Stabilizer Bar Link Nut
    G08019565Courtesy of FORD MOTOR CO.
  29. Remove the nuts and separate the sway bar links from the struts.
  30. Position the Powertrain Lift under the subframe assembly.
    Fig 23: Identifying Powertrain Lift Under Subframe
    G08019566Courtesy of FORD MOTOR CO.
    31. NOTE: LH shown in illustration, RH similar.
    Fig 24: Locating Front Subframe Bracket-To-Body Bolts
    G08019567Courtesy of FORD MOTOR CO.
  31. Remove the subframe bracket-to-body bolts.
    32. NOTE: LH shown in illustration, RH similar.
    Fig 25: Locating Rear Subframe Nut
    G08019568Courtesy of FORD MOTOR CO.
  32. Remove the rear subframe nuts and the subframe brackets.
    33. NOTE: LH shown in illustration, RH similar.
    Fig 26: Locating Front Subframe Nut
    G08019569Courtesy of FORD MOTOR CO.
  33. Remove the front subframe nuts.
  34. Lower the subframe assembly from the vehicle.
  35. 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
      G08019570Courtesy of FORD MOTOR CO.
  36. Remove the engine oil filter.
  37. Remove the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .
  38. Disconnect the crankcase vent tube from the valve cover.
    Fig 28: Locating Crankcase Vent Tube Of Valve Cover
    G08019571Courtesy of FORD MOTOR CO.
  39. 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
    G08019572Courtesy of FORD MOTOR CO.
  40. Disconnect the fuel vapor return tube.
    Fig 30: Locating Fuel Vapor Return Tube
    G08019573Courtesy of FORD MOTOR CO.
  41. 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
    G08019574Courtesy of FORD MOTOR CO.
  42. Detach the coolant hose retainer.
    Fig 32: Locating Coolant Hose Retainer
    G08019575Courtesy of FORD MOTOR CO.
  43. 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
    G08019576Courtesy of FORD MOTOR CO.
  44. Disconnect the transaxle control cables from the control levers.
    • Detach the control cables from the bracket.
      Fig 34: Locating Transaxle Control Cable Of Control Lever
      G08019577Courtesy of FORD MOTOR CO.
  45. Remove the 2 clutch tube bracket bolts.
    Fig 35: Locating Clutch Tube Bracket Bolts
    G08019578Courtesy of FORD MOTOR CO.
  46. Remove the 2 bolts and position the clutch slave cylinder aside.
    Fig 36: Locating Clutch Slave Cylinder Bolts
    G08019579Courtesy of FORD MOTOR CO.
  47. Remove the bolt and the ground wire from the engine mount.
    Fig 37: Locating Engine Mount Ground Wire And Nut
    G08019580Courtesy of FORD MOTOR CO.
  48. Remove the A/C tube/windshield washer reservoir bracket bolt.
    Fig 38: Locating A/C Tube/Windshield Washer Reservoir Bracket Bolt
    G08019581Courtesy of FORD MOTOR CO.
  49. 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
      G08019582Courtesy of FORD MOTOR CO.
  50. Detach the coolant vent hose retaining clip from the A/C tube.
    Fig 40: Identifying Coolant Vent Hose Retaining Clip Of A/C Tube
    G08019583Courtesy of FORD MOTOR CO.
  51. 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
      G08019584Courtesy of FORD MOTOR CO.
  52. Detach the Knock Sensor (KS) electrical connector from the intake manifold.
    Fig 42: Locating Knock Sensor (KS) Electrical Connector Of Intake Manifold
    G08019585Courtesy of FORD MOTOR CO.
  53. Remove the lower radiator hose from the thermostat housing.
    Fig 43: Identifying Lower Radiator Hose Of Thermostat Housing
    G08019586Courtesy of FORD MOTOR CO.
  54. 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 Connectors And Wiring Harness Retainer
      G08019587Courtesy of FORD MOTOR CO.
  55. 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
    G08019588Courtesy of FORD MOTOR CO.
  56. Remove the bellhousing-to-oil pan bolt.
    Fig 46: Locating Bellhousing-To-Oil Pan Bolt
    G08019589Courtesy of FORD MOTOR CO.
  57. Remove the 2 oil pan-to-bellhousing bolts.
    Fig 47: Locating Oil Pan-To-Bellhousing Bolts
    G08019590Courtesy of FORD MOTOR CO.
    58. NOTE: Position a block of wood under the transaxle.
  58. 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 (014-00001)
      G08019591Courtesy of FORD MOTOR CO.
  59. Remove the 2 transaxle mount bolts.
    Fig 49: Locating Transaxle Mount Bolts
    G08019592Courtesy of FORD MOTOR CO.
  60. Remove the bolt, 2 nuts and the motor mount bracket.
    Fig 50: Locating Engine Mount Bracket Nuts And Bolts
    G08019593Courtesy of FORD MOTOR CO.
  61. Lower the engine and transaxle from the vehicle.
  62. Disconnect the A/C compressor electrical connector.
    Fig 51: Locating A/C Compressor Electrical Connector
    G08019594Courtesy of FORD MOTOR CO.
  63. 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 Of Intake Manifold
    G08019595Courtesy of FORD MOTOR CO.
  64. Remove the 2 nuts and disconnect the starter wires.
    Fig 53: Locating Starter Motor Harness Wire Nuts
    G08019596Courtesy of FORD MOTOR CO.
  65. Remove the nut from the starter motor stud bolt.
    Fig 54: Locating Ground Wire And Starter Motor Stud Bolt
    G08019597Courtesy of FORD MOTOR CO.
  66. Remove the bolt, stud bolt and the starter.
    Fig 55: Locating Starter With Bolts And Studs
    G08019598Courtesy of FORD MOTOR CO.
  67. Remove the starter motor isolator.
    Fig 56: Locating Starter Motor Isolator
    G08019599Courtesy of FORD MOTOR CO.
  68. Press the locking tab to release the generator air duct and remove.
    Fig 57: Locating Locking Tab And Generator Air Duct
    G08019600Courtesy of FORD MOTOR CO.
  69. Disconnect the generator electrical connection.
    Fig 58: Locating Generator Electrical Connection
    G08019601Courtesy of FORD MOTOR CO.
  70. Remove the nut and the generator wiring harness.
    Fig 59: Locating Nut And Generator Wiring Harness
    G08019602Courtesy of FORD MOTOR CO.
  71. 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
    G08019603Courtesy of FORD MOTOR CO.
  72. Install the Floor Crane and Spreader Bar and remove the engine and transaxle from the Powertrain Lift table.
    Fig 61: Removing Engine And Transaxle From Powertrain Lift Table
    G08019604Courtesy of FORD MOTOR CO.
  73. Remove the bellhousing-to-engine retainers.
    • Separate the engine and transaxle.
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