Engine - 2.0L SPI: Removal: Engine

Fig 1: Identifying Special Tool(s)

Courtesy of FORD MOTOR CO.

1. Remove the hood.
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
2. Relieve the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE .
3. Discharge the A/C system. For additional information, refer to COMPRESSOR .
4. Remove the battery tray.
5. Remove the air cleaner outlet tube.
6. Disconnect the vacuum hoses at the (1) fuel pressure regulator and the (2) intake manifold.
   Fig 2: Disconnecting Vacuum Hoses At Fuel Pressure Regulator And Intake Manifold

   Courtesy of FORD MOTOR CO.
7. Disconnect the vacuum lines from the (1) exhaust recirculation valve, the (2) positive crankcase ventilation valve, and the (3) idle air control valve.
   Fig 3: Disconnecting Vacuum Lines From Exhaust Recirculation Valve

   Courtesy of FORD MOTOR CO.
8. Disconnect the (A) two vacuum lines, remove the (B) two bolts, and position the (C) vacuum tree aside.
   Fig 4: Disconnecting Vacuum Lines, Removing Bolts

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9. Disconnect the (1) speed control cable (if equipped) and the (2) accelerator cable (9A758) from the throttle control lever (9A776).
   Fig 5: Disconnecting Speed Control Cable And Accelerator Cable From Throttle Control Lever

   Courtesy of FORD MOTOR CO.
10. Remove the (A) nut and the (B) clip; disconnect the shift cable from the bracket and set aside.
    Fig 6: Disconnecting Shift Cable From Bracket

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11. Remove the nut and the clip; disconnect the shift cable from the bracket and set aside.
12. Remove the constant control relay module (CCRM).
    1. Disconnect the CCRM
    Fig 7: Disconnecting Constant Control Relay Module Connectors
    Courtesy of FORD MOTOR CO.
    2. Remove the two bolts, the CCRM, and the bracket.
    Fig 8: Removing Constant Control Relay Module
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13. Disconnect the (A) EGR backpressure transducer electrical connector, disconnect the (B) two vacuum hoses, and remove the (C) two nuts and the transducer.
    Fig 9: Disconnecting EGR Backpressure Transducer Electrical Connector

    Courtesy of FORD MOTOR CO.
14. Disconnect the (A) transmission range sensor electrical connector, the (B) transaxle solenoid electrical connector, and the (C) turbine speed sensor electrical connector.
    Fig 10: Disconnecting Transmission Range Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
15. Disconnect the vehicle speed sensor (VSS) electrical connector.
    Fig 11: Disconnecting Vehicle Speed Sensor (VSS) Electrical Connector

    Courtesy of FORD MOTOR CO.
16. Disconnect the upstream heated oxygen sensor (HO2S) electrical connector mounted on the cooling fan shroud.
    Fig 12: Disconnecting Upstream Heated Oxygen Sensor (HO2S) Electrical Connector

    Courtesy of FORD MOTOR CO.
17. Disconnect the downstream HO2S electrical connector.
    Fig 13: Disconnecting Downstream HO2S Electrical Connector

    Courtesy of FORD MOTOR CO.
18. Remove the screw and position the ground strap aside.
    Fig 14: Removing Screw

    Courtesy of FORD MOTOR CO.
19. Disconnect the engine cooling fan electrical connector.
    Fig 15: Disconnecting Engine Cooling Fan Electrical Connector

    Courtesy of FORD MOTOR CO.
20. Remove the (A) three bolts and position the (B) power steering pressure hose aside.
    Fig 16: Removing Bolts

    Courtesy of FORD MOTOR CO.
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
Fig 17: Disconnecting Fuel Supply Line From Fuel Injection Supply Manifold Using Special Tool
Courtesy of FORD MOTOR CO.
21. Use Disconnect Tool to disconnect the fuel supply line from the fuel injection supply manifold.
22. Remove the (A) five nuts and remove the (B) exhaust manifold heat shield.
    Fig 18: Removing Nuts And Removing Exhaust Manifold Heat Shield

    Courtesy of FORD MOTOR CO.
23. Remove the four exhaust manifold-to-three way catalytic converter (TWC) nuts.
    Fig 19: Removing Exhaust Manifold-To-Three Way Catalytic Converter (TWC) Nuts

    Courtesy of FORD MOTOR CO.
24. Remove one upper starter bolt and position the bracket aside.
    Fig 20: Removing One Upper Starter Bolt

    Courtesy of FORD MOTOR CO.
25. Disconnect the transaxle fluid cooler lines from the transaxle.
    Fig 21: Disconnecting Transaxle Fluid Cooler Lines From Transaxle

    Courtesy of FORD MOTOR CO.
26. Remove the A/C line bracket bolt.
    Fig 22: Removing A/C Line Bracket Bolt

    Courtesy of FORD MOTOR CO.
27. Disconnect the A/C manifold and tube spring lock coupling at the accumulator/drier. For additional information, refer to COMPRESSOR .
    Fig 23: Disconnecting A/C Manifold And Tube Spring Lock Coupling At Accumulator/Drier

    Courtesy of FORD MOTOR CO.
28. Disconnect the A/C manifold and tube spring lock coupling at the condenser. For additional information, refer to COMPRESSOR .
    Fig 24: Disconnecting A/C Manifold And Tube Spring Lock Coupling At Condenser

    Courtesy of FORD MOTOR CO.
29. Remove the accessory drive belt, the auto tensioner and, if vehicle is equipped with A/C, the accessory drive belt idler. For additional information, refer to SPECIFICATIONS & DRIVE BELT ROUTING .
30. Suction out the power steering fluid from the power steering reservoir.
NOTE: Position a drain pan under the power steering reservoir.
Fig 25: Disconnecting Power Steering Pressure Hose
Courtesy of FORD MOTOR CO.
31. Disconnect the power steering lines.
    • Loosen the clamp and disconnect the (A) power steering reservoir pump hose (3691) at the reservoir.
    • Disconnect the (B) power steering pressure hose (3A719).
32. Raise and support the vehicle.
33. Remove the (A) wheel nuts (1012) and the (B) front wheel and tire assemblies.
    Fig 26: Removing Wheel Nuts And Front Wheel And Tire Assemblies

    Courtesy of FORD MOTOR CO.
34. Remove the LH splash shields.
    1. Remove the six bolts.
    2. Remove the LH splash shields.
    Fig 27: Removing LH Splash Shields

    Courtesy of FORD MOTOR CO.
35. Remove the (A) six bolts and remove the (B) RH splash shields.
    Fig 28: Removing Six Bolts And Removing RH Splash Shields

    Courtesy of FORD MOTOR CO.
36. Drain the engine coolant system. For additional information, refer to ENGINE COOLING .
37. Drain the engine oil.
38. Remove the (A) bolts and the (B) crossmember.
    Fig 29: Removing Bolts And Crossmember

    Courtesy of FORD MOTOR CO.
39. Remove the bolts for the three way catalytic converter (TWC) (5E212).
    Fig 30: Removing Bolts For Way Catalytic Converter

    Courtesy of FORD MOTOR CO.
40. Remove the (A) bolts and nuts and the (B) three way catalytic converter. Discard the gasket.
    Fig 31: Removing Bolts And Nuts And Three Way Catalytic Converter

    Courtesy of FORD MOTOR CO.
41. Remove the front wheel driveshafts and joints. For additional information, refer to AXLE SHAFTS - FRONT .
NOTE: A protective cap is installed over the B-terminal and must be replaced.
Fig 32: Disconnecting S-Terminal Wire And B-Terminal Nut And Cable From Starter Solenoid
Courtesy of FORD MOTOR CO.
42. Disconnect the (A) S-terminal wire and the (B) B-terminal nut and cable from the starter solenoid.
43. Disconnect the oil pressure switch electrical connector.
    Fig 33: Disconnecting Oil Pressure Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
44. Disconnect the A/C compressor electrical connector.
    Fig 34: Disconnecting A/C Compressor Electrical Connector

    Courtesy of FORD MOTOR CO.
45. Remove the bolts and remove the A/C compressor and manifold lines.
    Fig 35: Removing Bolts And Removing A/C Compressor And Manifold Lines

    Courtesy of FORD MOTOR CO.
46. Remove the hose clamp and disconnect the lower radiator hose from the radiator.
    Fig 36: Disconnecting Lower Radiator Hose From Radiator

    Courtesy of FORD MOTOR CO.
47. Lower the vehicle.
48. Loosen the heater hose clamp at the water outlet connection and disconnect the heater hose.
    Fig 37: Disconnecting Heater Hose

    Courtesy of FORD MOTOR CO.
49. Loosen the heater hose clamp at the bulkhead and remove the heater hose.
    Fig 38: Removing Heater Hose

    Courtesy of FORD MOTOR CO.
50. Disconnect the upper radiator hose.
    Fig 39: Disconnecting Upper Radiator Hose

    Courtesy of FORD MOTOR CO.
51. Remove the radiator. For additional information, refer to RADIATOR .
52. Disconnect the generator electrical connectors.
    1. Disconnect the two generator electrical connectors.
    2. Remove the battery positive nut and washer.
    3. Disconnect the battery positive cable.
    Fig 40: Disconnecting Generator Electrical Connectors

    Courtesy of FORD MOTOR CO.
53. Attach the Engine Lifting Bracket on the left rear side of the cylinder head.
    Fig 41: Attaching Engine Lifting Bracket On Left Rear Side Of Cylinder Head

    Courtesy of FORD MOTOR CO.
54. Install the Engine Support Bar as shown.
    Fig 42: Installing Engine Support Bar

    Courtesy of FORD MOTOR CO.
55. Raise and support the vehicle.
56. Remove the transaxle support crossmember.
    1. Remove the two crossmember nuts and the two crossmember bolts.
    2. Remove the two LH front engine support insulator (6038) nuts.
    3. Remove the two transmission support insulator (6068) nuts.
    Fig 43: Removing Transaxle Support Crossmember

    Courtesy of FORD MOTOR CO.
57. Lower the vehicle.
58. Remove the four nuts and the transaxle mount.
    Fig 44: Removing Four Nuts And Transaxle Mount

    Courtesy of FORD MOTOR CO.
59. Remove the RH engine support insulator through bolt.
    Fig 45: Removing RH Engine Support Insulator Through Bolt

    Courtesy of FORD MOTOR CO.
60. Remove the Engine Support Bar.
NOTE: Install a universal lifting eye on the transaxle and use for balance, if necessary.
Fig 46: Removing Engine Support Bar
Courtesy of FORD MOTOR CO.
61. Attach a suitable lifting device and remove the engine and transaxle assembly.
62. Separate the transaxle from the engine (6007).
63. Mount the engine on a stand and remove the lifting device.