Section 1230 (Engine - 2.0L ECOBOOST (177KW/240PS) - 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	300-OTC1585AE Powertrain Lift
Courtesy of FORD MOTOR COMPANY	300-OTC1819E 2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	307-566 Retainer, Torque Converter TKIT-2006C-FFMFLM TKIT-2006C-LM TKIT-2006C-ROW
Magnetic Socket
Adjustable Mounting Arm
Oil Drain Equipment
Hose Clamp Remover/Installer
Punch
Wooden Block
Copper Hammer

LHD AWD/LHD FWD 

1. With the vehicle in neutral, position it on a hoist. refer to: Jacking and lifting - overview .
2. Release the fuel system pressure. refer to: Fuel system pressure release .
3. Install a holding tool with the steering wheel in straight ahead position.

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4. • Remove and discard the bolt.
   • Detach the steering column shaft from steering input shaft.

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5. NOTE: Do not pull the engine appearance cover forward or sideways to remove. Failure to press straight upward on the underside of the cover at the attachment points may result in damage to the cover or engine components.
   1. Place your hand under the engine appearance cover at each grommet location and push straight up to release each grommet from the studs.
   2. After all of the grommets have been released from the studs, remove the appearance cover from the engine.

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6. Evacuate the a/c system. refer to: Air conditioning (a/c) system recovery, evacuation and charging .
7. • Remove the retainers and the underbody shield.
   • Remove the retainers and the stone guard.

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8. Remove the retainers and the underbody side panels.

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9. Drain the cooling system. refer to: Cooling system draining, vacuum filling and bleeding .
10. Disconnect the battery ground cable. refer to: Battery disconnect and connect .
11. If equipped with block heater, detach the retainers.

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12. Release the tab and remove the BJB cover

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13. Remove the following items:
    1. Refer to: Air cleaner .
    2. Upper air cleaner outlet pipe. refer to: Air cleaner outlet pipe .

14. Disconnect the main wiring harness from the BJB and detach the retainers.

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15. Remove the nuts and position the wiring harness aside.

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16. Remove the battery tray. refer to: Battery tray .
17. 1. Detach the wiring harness retainer.
    2. Disconnect the wiring harness electrical connector.

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18. Remove the nut and position the wiring harness aside.

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19. If equipped, detach the wiring harness retainer, remove the nuts and the battery tray support bracket.

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20. Remove the bolt, the ground wire and detach the wiring harness retainer.

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21. • Remove the bolt and the ground wire.
    • Detach the wiring harness retainer.

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22. Disconnect the vacuum tube and detach the retainer.

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23. 1. Disconnect the fuel hose spring lock coupling. refer to: Spring lock couplings .
    • Disconnect the fuel pressure sensor electrical connector.
    • Disconnect the EVAP canister purge valve quick release coupling. refer to: Quick release coupling .

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24. Disconnect the coolant hoses. Use the general equipment: hose clamp remover/installer

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25. Remove the degas bottle. refer to: Degas bottle .
26. Remove the transmission control unit nut.

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27. Remove the bolts and position the transmission control unit aside.

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28. Remove the nut and the bracket.

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29. Disconnect the lower radiator hose from the thermostat housing. Use the general equipment: hose clamp remover/installer

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30. Disconnect the upper radiator hose and retainer. Use the general equipment: hose clamp remover/installer

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31. 1. Rotate the heater hose tabs.
    2. Disconnect the heater hoses.

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32. Disconnect the shift cable, remove the bolts and position aside.

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33. Remove the front wheels and tires. refer to: Wheel and tire .
34. NOTE: Transmission mount removed from graphic for clarity.

    Remove the transmission tubes from the transmission fluid cooler bypass valve.

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35. • Detach the wiring harness connectors.
    • Disconnect the wiring harness electrical connectors.
    • Remove the nut and position the transmission cooling tube bracket aside.

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36. Loosen the clamp and position the CAC tube aside.

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37. Disconnect the bypass hose, electrical connector and the wire retainer. Use the general equipment: hose clamp remover/installer

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38. Loosen the clamp, remove the nuts and the CAC tube.

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39. Loosen the clamps and remove the CAC outlet tube.

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40. 1. Disconnect the a/c pressure sensor electrical connector and the wiring harness retainer.
    2. NOTE: Discard the o-ring seals and gaskets.

       Remove the nuts and disconnect the a/c tubes.

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41. • Remove the oil pan drain bolt and drain the engine oil. Use the general equipment: oil drain equipment
    • Install the oil pan drain bolt.

      Torque: 20 lb.ft (27 nm)

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42. Remove and discard the engine oil filter.

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43. Remove the nuts, bolts and the cross support.

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44. If equipped, disconnect the exhaust gas temperature sensor electrical connector and the retainers.

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45. If equipped, disconnect the exhaust pressure sensor hose. Use the general equipment: hose clamp remover/installer

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46. Remove and discard the exhaust nuts and position exhaust rearward.

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47. NOTE: Clean the catalytic converter-to-muffler sealing surfaces.

    Remove and discard the muffler inlet pipe gasket.

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    LHD AWD 

48. Remove and discard the driveshaft-to-pinion flange bolts.

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49. 1. Mark the driveshaft and power transfer unit flange alignment.
    2. Using a punch and a copper hammer, separate the driveshaft from the power transfer unit flange. Use the general equipment: punch use the general equipment: copper hammer
    3. Remove the driveshaft from the power transfer unit flange.

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50. Loosen 5 mm (0.197).

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    LHD AWD/LHD FWD 

51. If equipped, remove the rh and LH front suspension height sensors. refer to: Front suspension height sensor .
52. NOTE: LH shown, rh similar.

    Both sides. disconnect the electrical connector.

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53. NOTE: Use the internal or external hex-holding feature to prevent the ball and stud from turning while removing or installing the stabilizer bar link nuts. The link boot seal must not be allowed to twist while tightening the link nuts or damage to the boot seal will occur.
    NOTE: LH shown, rh similar.

    Both sides. remove the nut and position the sway bar links aside.

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54. Remove the front brake discs. refer to: Brake disc .
55. NOTE: The struts will need to slide out of the knuckles when the powertrain and subframe assembly is lowered.
    NOTE: LH shown, rh similar.

    Both sides. remove the strut to knuckle bolt and discard the bolt.

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56. • Detach the wiring harness retainer.
    • Remove the bolt and position the ground cable aside.
    • NOTE: This bolt will be used to mount the adjustable mounting arm to the powertrain.

      Remove the bolt and position a/c tube aside.

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57. Remove the transmission-to-engine bolts.

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58. Remove the engine-to-transmission bolt.

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59. Remove the fasteners and position the fender splash shield aside.

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60. NOTE: Front bumper cover removed for clarity.

    Disconnect the turbocharger boost pressure and charge air temperature sensor electrical connector.

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61. Remove the a/c compressor belt. refer to: Air conditioning (a/c) compressor belt .
62. Remove the retainers and position the splash shield aside.

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63. NOTE: LH shown, rh similar.

    Both sides. remove the bolts, nuts, studs and the subframe support bracket.

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64. Remove the retainers and the PCM cover.

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65. Detach the wiring harness grommet.

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66. Disconnect the electrical connectors and remove the PCM.

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67. • Remove the bolts and the PCM housing.
    • Detach the wiring harness retainer.

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68. Disconnect the wiring harness electrical connector.

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69. Position a 2 x 6 board, 30 in (762 mm) in length and one 1 x 6 board 30 in (762 mm) in length onto the powertrain lift. install special service tool: 300-OTC1585AE powertrain lift. Use the general equipment: wooden block

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70. Position the powertrain lift table with the boards under the engine and transmission.

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71. Install. Use the general equipment: adjustable mounting arm

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72. Remove the bolt and the transmission support insulator.

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73. 1. Remove and discard the engine mount nuts.
    2. Remove and discard the engine mount stud bolts and remove the engine mount.

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74. 1. Remove and discard the 2 bolts.
    2. Remove the 4 bolts and the subframe support brackets.

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75. Remove the forward subframe bolts.

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76. NOTE: Make sure the struts slide out of the knuckles when lowered.

    Using the powertrain lift, lower the powertrain and subframe assembly.

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77. Disconnect the HO2S and catalyst monitor sensor electrical connectors.
    • Detach the wiring harness retainer.

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78. Remove the catalytic converter support bracket bolts.

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79. Remove the catalytic converter support bracket-to-transmission bolts.

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80. • Remove the nuts and the catalytic converter.
    • Discard the nuts.

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81. NOTE: Clean the catalytic converter-to-turbocharger sealing surfaces.

    Remove and discard the catalytic converter gasket.

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82. If equipped, detach the wiring harness retainer, remove the nuts and position the cabin heater coolant pump aside.

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83. NOTE: Vehicle equipped with cabin heater coolant pump, others similar.
    1. Detach the wiring harness retainers.
    2. Remove the nut and the starter motor bracket.

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84. Remove the nuts and position the harness aside.

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85. Remove the stud bolts and the starter motor.

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86. Remove the starter motor insulator.

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87. NOTE: Only rotate the crankshaft in a clockwise direction.
    NOTE: Index mark one stud and the flexplate for assembly reference.

    Remove and discard the 4 torque converter nuts. Use the general equipment: magnetic socket

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88. • Disconnect the coolant solenoid electrical connector and detach the wiring harness retainer.
    • Slide the clip up and disconnect the coolant hose.

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89. Disconnect the coolant hose from the transmission fluid warmer.

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90. Remove the halfshaft support bracket bolts.

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    LHD AWD 

91. Detach transfer case vent hose retainer from the engine block.

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92. Remove the bolts and the transfer case heat shield.

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93. Remove the bolts and the transfer case support bracket.

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94. Loosen the transfer case bolts 5 mm (0.019) and position the transfer case aside.

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95. Remove the engine-to-transmission bolts.

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    LHD FWD 

96. Remove the engine-to-transmission bolts.

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    LHD AWD/LHD FWD 

97. Disconnect the crankcase pressure sensor electrical connector and remove the crankcase vent tube.

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98. • Loosen the turbocharger inlet pipe clamp.
    • Remove the engine appearance cover stud.
    • Remove the bolt and the turbocharger inlet pipe.

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99. Install the engine lift equipment. Use special service tool: 300-OTC1819E 2, 200# floor crane, fold away.

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100. Remove. Use the general equipment: adjustable mounting arm

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101. 1. Remove the transmission-to-engine bolts.
     2. Remove the transmission-to-engine bolt.
     3. Separate the engine from the transmission.

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102. Install special service tool: 307-566 retainer, torque converter.

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