Engine Mechanical - 2.0L: Removal: Engine

SPECIAL TOOLS

	2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
	Lifting Bracket, Engine 303-050 (T70P-6000)
	Powertrain Lift 300-OTC1585AE or equivalent
	Retainer, Torque Converter 307-346 (T97T-7902-A)
	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
	Adjustable Grip Arm, 1735A 014-00001 or equivalent

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
2. Remove the 2 bolts, pin-type retainer and the LH front splash shield.
   Fig 1: Locating LH Front Splash Shield, Pin-Type Retainer And Bolts

   Courtesy of FORD MOTOR CO.
3. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
4. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
5. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
6. Disconnect the crankcase vent tube from the valve cover.
   Fig 2: Locating Crankcase Vent Tube

   Courtesy of FORD MOTOR CO.
7. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
8. Remove the nut and disconnect cable from the positive battery cable terminal.
   Fig 3: Locating Positive Battery Cable Terminal And Nut

   Courtesy of FORD MOTOR CO.
9. Detach the 3 positive battery cable wire harness retainers.
   Fig 4: Locating Positive Battery Cable Wire Harness Retainers

   Courtesy of FORD MOTOR CO.
10. Remove the bolt and the negative battery cable ground.
    Fig 5: Locating Negative Battery Cable Ground Bolt

    Courtesy of FORD MOTOR CO.
NOTE: The vehicle should be given adequate time to completely cool prior to disconnecting the fuel tube quick connecting coupling. This area is directly above the exhaust manifold and precautions should be taken to avoid any fuel spillage.
Fig 6: Locating Fuel Tube Quick Connect Coupling From Fuel Tube Near Bulkhead
Courtesy of FORD MOTOR CO.
11. Disconnect the fuel tube quick connect coupling from the fuel tube near the bulkhead. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
12. Disconnect the Evaporative Emission (EVAP) tube and position aside. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 7: Locating Evaporative Emission (EVAP) Tube And Position Aside

    Courtesy of FORD MOTOR CO.
13. Disconnect the power brake booster vacuum tube.
    • Depress the quick connect locking ring.
    • Pull the vacuum tube out of the quick connect fitting.
      Fig 8: Locating Vacuum Tube Of Quick Release Fitting

      Courtesy of FORD MOTOR CO.
14. Detach and disconnect the 2 engine harness electrical connectors.
    Fig 9: Locating Engine Harness Electrical Connectors

    Courtesy of FORD MOTOR CO.
15. Detach the engine harness from the coolant outlet bracket harness retainer.
    Fig 10: Locating Engine Harness Of Coolant Outlet Bracket Harness Retainer

    Courtesy of FORD MOTOR CO.
16. Remove the nut and the ground wire from the negative battery terminal.
    Fig 11: Locating Nut And Ground Wire From Negative Battery Terminal

    Courtesy of FORD MOTOR CO.
17. Disconnect the 3 PCM electrical connectors.
    Fig 12: Locating PCM Electrical Connectors

    Courtesy of FORD MOTOR CO.
18. Disconnect the starter wire harness electrical connector.
    Fig 13: Locating Starter Wire Harness Electrical Connector

    Courtesy of FORD MOTOR CO.
19. Disconnect the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical connectors and detach the wire harness retainer.
    Fig 14: Locating Heated Oxygen Sensor And Catalyst Monitor Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
20. Disconnect the transaxle shift cable from the lever and bracket.
    Fig 15: Locating Transaxle Shift Cable

    Courtesy of FORD MOTOR CO.
21. Remove the transmission fluid cooler tube secondary latches.
    Fig 16: Locating Transmission Fluid Cooler Tube Secondary Latches

    Courtesy of FORD MOTOR CO.
NOTE: Transaxle fluid cooler inlet tube shown in illustration, transaxle fluid cooler outlet tube similar.
22. Disconnect the 2 transaxle fluid cooler tubes from the transaxle.
    1. Squeeze the tabs together.
    2. Slide the transaxle fluid cooler tube lock up and remove the transaxle fluid cooler tubes from the transaxle.
       Fig 17: Sliding Transaxle Fluid Cooler Tube Lock Up

       Courtesy of FORD MOTOR CO.
23. Remove the engine oil level indicator.
    Fig 18: Locating Engine Oil Level Indicator

    Courtesy of FORD MOTOR CO.
24. Remove the 2 front wheels and tires. For additional information, refer to WHEELS AND TIRES .
25. Remove the accessory drive belt and tensioner. For additional information, refer to ACCESSORY DRIVE .
26. Remove the generator. For additional information, refer to CHARGING SYSTEM .
27. Detach the 2 B+ battery cable wire harness retainers from the valve cover stud bolts and remove the wiring harness.
    Fig 19: Locating B+ Battery Cable Wire Harness Retainers From Valve Cover Stud Bolts

    Courtesy of FORD MOTOR CO.
28. Remove the 2 A/C tube nuts from the A/C compressor.
    Fig 20: Locating A/C Tube-To-Compressor Nuts

    Courtesy of FORD MOTOR CO.
29. Disconnect the 2 A/C tubes from the compressor.
    • Discard the 2 O-ring seals.
      Fig 21: Locating A/C Tube O-Rings

      Courtesy of FORD MOTOR CO.
30. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
31. Remove the cooling fan motor and shroud. For additional information, refer to ENGINE COOLING .
32. Disconnect the lower radiator hose from the radiator.
    Fig 22: Locating Lower Radiator Hose From Radiator

    Courtesy of FORD MOTOR CO.
33. Drain the engine oil.
    • Install the drain plug and tighten to 28 Nm (21 lb-ft).
      Fig 23: Locating Drain Plug

      Courtesy of FORD MOTOR CO.
34. Remove the engine oil filter and discard.
    Fig 24: Locating Engine Oil Filter

    Courtesy of FORD MOTOR CO.
35. Remove the LH and RH halfshafts. For additional information, refer to FRONT DRIVE HALFSHAFTS .
36. Remove the bolt and the power steering tube clip.
    Fig 25: Locating Power Steering Tube Clip Bolt

    Courtesy of FORD MOTOR CO.
37. Remove the bolt and the power steering tubes from the steering gear.
    • Discard the 2 power steering tube O-ring seals.
      Fig 26: Locating Power Steering Tubes And Bolt

      Courtesy of FORD MOTOR CO.
38. Disconnect the power steering cooler tube.
    Fig 27: Locating Power Steering Cooler Tube

    Courtesy of FORD MOTOR CO.
39. Remove the exhaust manifold. For additional information, refer to EXHAUST MANIFOLD  .
40. Remove the power steering pump. For additional information, refer to POWER STEERING .
41. Release the retaining clip and disconnect the coolant degas bottle hose.
    Fig 28: Locating Coolant Degas Bottle Hose And Retaining Clip

    Courtesy of FORD MOTOR CO.
42. Disconnect the coolant degas bottle vent hose from the coolant bypass and position it aside.
    Fig 29: Locating Coolant Degas Bottle Vent Hose From Coolant Bypass

    Courtesy of FORD MOTOR CO.
43. Disconnect the upper radiator hose and the heater hose from the coolant bypass.
    Fig 30: Locating Upper Radiator Hose And Heater Hose From Coolant Bypass

    Courtesy of FORD MOTOR CO.
44. Disconnect the heater hose from the coolant tube.
    Fig 31: Locating Heater Hose Of Coolant Tube

    Courtesy of FORD MOTOR CO.
45. Remove the transaxle fluid level indicator.
    Fig 32: Locating Transaxle Fluid Level Indicator

    Courtesy of FORD MOTOR CO.
NOTE: The bolts are different lengths, mark the bolts for installation.
Fig 33: Locating Transaxle Roll Restrictor And Bolts
Courtesy of FORD MOTOR CO.
46. Remove the 2 bolts and the transaxle roll restrictor.
47. Remove the 2 lower bellhousing-to-oil pan bolts.
    Fig 34: Locating Lower Bellhousing-To-Oil Pan Bolts

    Courtesy of FORD MOTOR CO.
48. Remove the 2 oil pan-to-bellhousing bolts.
    Fig 35: Locating Oil Pan-To-Bell Housing Bolts

    Courtesy of FORD MOTOR CO.
49. Using the Powertrain Lift and Adjustable Grip Arm, secure the engine to the lift table.
    Fig 36: Securing Engine To Lift Table Using Powertrain Lift And Adjustable Grip Arm

    Courtesy of FORD MOTOR CO.
50. Remove the 2 engine mount nuts.
    Fig 37: Locating Engine Mount Nuts

    Courtesy of FORD MOTOR CO.
51. Remove the 3 bolts and the engine mount.
    Fig 38: Locating Engine Mount And Bolts

    Courtesy of FORD MOTOR CO.
52. Remove the 5 transaxle mount nuts and the transaxle mount plate.
    Fig 39: Locating Transaxle Mount Nuts

    Courtesy of FORD MOTOR CO.
53. Lower the engine and transaxle assembly from the vehicle.
54. Remove the nut for the HO2S and CMS wire connector bracket.
    Fig 40: Locating HO2S And CMS Wire Connector Bracket Nut

    Courtesy of FORD MOTOR CO.
55. Remove the nut and position the HO2S and CMS wire connector bracket aside.
    Fig 41: Locating HO2S And CMS Wire Connector Bracket And Nut

    Courtesy of FORD MOTOR CO.
56. Disconnect the Output Shaft Speed (OSS) sensor electrical connector.
    Fig 42: Locating Output Shaft Speed Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
57. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.
    Fig 43: Locating Turbine Shaft Speed Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
58. Disconnect the 2 transaxle electrical connectors.
    Fig 44: Locating Transaxle Electrical Connectors

    Courtesy of FORD MOTOR CO.
59. Disconnect the A/C compressor electrical connector.
    Fig 45: Locating A/C Compressor Electrical Connector

    Courtesy of FORD MOTOR CO.
60. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
    Fig 46: Locating Power Steering Pressure Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
61. Detach the wiring harness pin-type retainer from the intake manifold.
    Fig 47: Locating Wiring Harness Pin-Type Retainer From Intake Manifold

    Courtesy of FORD MOTOR CO.
62. Detach the 2 Crankshaft Position (CKP) sensor wire harness retainers.
    Fig 48: Locating Crankshaft Position (CKP) Sensor Wire Harness Retainers

    Courtesy of FORD MOTOR CO.
63. Disconnect the CKP sensor electrical connector.
    Fig 49: Locating CKP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
64. Detach the starter wire harness retainer from the starter motor stud bolt.
    Fig 50: Locating Starter Wire Harness Retainer Of Starter Motor Stud Bolt

    Courtesy of FORD MOTOR CO.
65. Remove the nut from the starter motor stud bolt and remove the power steering tube bracket.
    Fig 51: Locating Starter Motor Stud Bolt And Power Steering Tube Bracket

    Courtesy of FORD MOTOR CO.
66. Remove the bolt and the engine ground wire.
    Fig 52: Locating Engine Ground Wire Bolt

    Courtesy of FORD MOTOR CO.
67. Remove the nut from the A/C compressor stud bolt and remove the power steering tube bracket.
    Fig 53: Locating A/C Compressor Stud Bolt And Nut

    Courtesy of FORD MOTOR CO.
68. Remove the 2 power steering tubes and the wiring harness as an assembly.
    Fig 54: Locating Power Steering Tubes And Wiring Harness

    Courtesy of FORD MOTOR CO.
69. Remove the 2 nuts and disconnect the starter motor electrical terminals.
    Fig 55: Locating Starter Motor Electrical Terminals Nuts

    Courtesy of FORD MOTOR CO.
70. Remove the bolt, stud bolt and the starter.
    Fig 56: Locating Starter Stud Bolt And Bolt

    Courtesy of FORD MOTOR CO.
71. Remove the starter isolator.
    Fig 57: Locating Starter Isolator

    Courtesy of FORD MOTOR CO.
NOTE: Mark one stud and the flexplate for assembly reference.
Fig 58: Locating Torque Converter Nut
Courtesy of FORD MOTOR CO.
72. Remove the 4 torque converter nuts.
NOTE: Lower the engine to within a few inches of the floor.
Fig 59: Raising Engine
Courtesy of FORD MOTOR CO.
73. Using the Floor Crane, Engine Lifting Bracket and Spreader Bar, remove the engine and transaxle assembly from the lift table.
74. Remove the 4 bellhousing-to-engine bolts and the one stud bolt and separate the engine and transmission.
75. Install the Torque Converter Retainer, to prevent damage to the torque converter.
    Fig 60: Identifying Torque Converter Retainer

    Courtesy of FORD MOTOR CO.