Section 1500 (Engine - 2.0L DURATEC-He (125KW/170PS) - Mi4): Removal: Engine

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Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	300-OTC1585AE Powertrain Lift
Courtesy of FORD MOTOR COMPANY	300-OTC1819E2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	303-D089 (D93P-6001-A3) Spreader Bar
Magnetic Socket
Adjustable Mounting Arm
Hose Clamp Remover/Installer
Wooden Block

1. WARNING: Before beginning any service procedure in this article, refer to Safety Warnings in GENERAL INFORMATION (EXCEPT ELECTRIC) . Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions .

2. With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
3. Evacuate the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging - Vehicles With: R134A Refrigerant .
4. Release the fuel system pressure. Refer to: Fuel System Pressure Release .
5. Remove the bolts and the underbody shield.

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6. Drain the cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding . Refer to: Cooling System Draining, Filling and Bleeding .
7. Remove the following items:
   1. Remove the degas bottle. Refer to: Degas Bottle .
   2. Remove the battery tray. Refer to: Battery Tray .
   3. Remove the air cleaner and the air cleaner outlet pipe. Refer to: Air Cleaner . Refer to: Air Cleaner Outlet Pipe .

8. If equipped with automatic transmission. Detach the wire retainer.

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9. Remove the nut for the ground strap.

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10. Detach the ground cable retainer.

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11. Remove the PCM. Refer to: Powertrain Control Module (PCM) .
12. NOTE: The electrical connector is located behind the PCM case.

    Disconnect the engine harness electrical connector.

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13. Detach the ground cable retainer and remove the bolts for the ground cable.

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14. Detach the wiring harness retainers.

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15. Remove and position aside the wiring harness.

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16. Remove the hose clips, disconnect the coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer

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17. Disconnect the coolant hoses from the heater core, detach the hose retainers.

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18. If equipped. Disconnect the block heater electrical connector.

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19. Remove the HO2S. Refer to: Heated Oxygen Sensor (HO2S) .
20. Disconnect the catalyst monitor sensor electrical connector and wire retainer.

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21. Remove the bolts, and position aside the catalyst monitor sensor wiring harness and remove the exhaust manifold heat shield.

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22. Remove the bolts for the exhaust manifold.

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23. NOTE: Discard the gasket.

    Remove the catalytic converter manifold-to-muffler and tailpipe nuts.

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24. Remove the tailpipe mount bracket bolts.

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25. NOTE: Discard the catalytic converter nuts and gasket.

    Remove and discard the nuts, and position aside the manifold.

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26. Remove and discard the manifold stud bolts.

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27. Disconnect the fuel tube quick release coupling. Refer to: Quick Release Coupling .

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28. Disconnect the electrical connector and the fuel tube quick release coupling. Refer to: Quick Release Coupling .

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29. Disconnect the vacuum tube quick release coupling at the rear of the intake manifold.

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30. If equipped with an automatic transmission. Disconnect the selector lever cable end from the manual control lever.

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31. If equipped with an automatic transmission. Detach the selector lever cable retainer.

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32. If equipped with an automatic transmission. Detach the selector lever cable retainer.

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33. If equipped with an automatic transmission. Remove the bolts and position aside the shift cable.

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34. NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

    If equipped with a manual transmission. Disconnect the clutch hydraulic tube.

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35. If equipped with a manual transmission. Disconnect the shift cable, remove the nuts and position aside.

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36. Refer to: Front Halfshaft RH . Refer to: Front Halfshaft LH .
37. Remove the A/C pipe bracket bolt.

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38. NOTE: Discard the O-ring seals.

    Remove the nuts and the bolt, disconnect the A/C pipes from the A/C compressor.

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39. Loosen the clamp, remove the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

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40. Drain and install the drain plug.

    Torque

    : 20 lb.ft (27 Nm)

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41. Remove and discard the engine oil filter.

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42. Remove the coolant fan motor and shroud. Refer to: Cooling Fan Motor and Shroud .
43. NOTE: Automatic transmission shown, manual transmission similar.

    Remove the oil pan-to-transmission bolt.

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44. NOTE: Automatic transmission shown, manual transmission similar.

    Remove the oil pan bolts.

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45. Remove the engine mounting roll restrictor bolts.

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46. NOTE: Position a block of wood under the transmission.

    Use Special Service Tool: 300-OTC1585AE Powertrain Lift. Use the General Equipment: Wooden Block. Use the General Equipment: Adjustable Mounting Arm

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47. • Remove the nuts.
    • Remove the bolts and the engine mount.

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48. Remove the transmission mount bolt.

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49. Lower the powertrain from the vehicle.
50. Clean and inspect the catalytic converter flange. Refer to: Exhaust Manifold Cleaning and Inspection .
51. If equipped with automatic transmission. Disconnect the electrical connector.

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52. Detach the wiring harness retainer.

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53. Remove the starter motor. Refer to: Starter Motor .
54. Remove the stater motor isolator.

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55. NOTE: Rotate the engine in a clockwise direction only or engine damage may occur.
    NOTE: Note the position of the components before removal.
    NOTE: If equipped with automatic transmission.

    Remove the torque converter nut and discard. Use the General Equipment: Magnetic Socket

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56. Install the engine lift equipment. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away., 303-D089 (D93P-6001-A3) Spreader Bar.

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57. NOTE: Automatic transmission shown, manual transmission similar.

    Remove the engine-to-transmission bolts.

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58. Remove the nut and ground wire.

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59. NOTE: Automatic transmission shown, manual transmission similar.
    • If equipped with a automatic transmission, remove the 4 bellhousing-to-engine fasteners.
    • If equipped with a manual transmission, remove the 5 bellhousing-to-engine fasteners.

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60. Separate the transaxle from the engine.