Engine - 2.0L GTDI: Removal: Engine
For information on Ford Color Coded Illustrations refer to OEM COLOR CODING .
Special Tool(s)
| 2, 200# Floor Crane, Fold Away 300-OTC1819E |
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| Adjustable Grip Arm, 1735A 014-00001 |
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| Disconnect Tool, Transaxle Cooler Tube 307-569 |
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| Halfshaft Remover 205-832 |
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| Powertrain Lift 300-OTC1585AE |
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| Retainer, Torque Converter 307-566 |
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| Slide Hammer 100-001 (T50T-100-A) |
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| Spreader Bar 303-D089 (D93P-6001-A3) 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.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking And Lifting .
- Release the fuel system pressure. For additional information, refer to Fuel System - General Information .
- Drain the engine cooling system. For additional information, refer to Engine Cooling .
- Remove the cowl panel grille. For additional information, refer to Front End Body Panels .
- Remove the engine ACL and ACL outlet pipe assembly. For additional information, refer to Intake Air Distribution and Filtering .
- Remove the battery tray. For additional information, refer to Charging System (Battery, Battery Mounting and Battery Cables) .
- Remove the nut and disconnect the power feed from the battery terminal.
- Remove the nut and ground wire.
- Disconnect the wiring harness electrical connector.
- Loosen the 2 clamps and disconnect the upper radiator hose and the heater hose.
- Disconnect the heater hose quick connect coupling.
- Detach the hoses from the 2 retaining clips.
- Disconnect the vacuum tube quick connect coupling from the power brake booster. For additional information, refer to Fuel System - General Information
.
- Detach the vacuum tube retaining clip.
- Disconnect the transaxle selector lever cable end from the manual control lever, remove the 2 bracket bolts and position the selector lever cable and bracket aside.
- Loosen the clamp and disconnect the CAC outlet tube.
- Loosen the clamp and disconnect the coolant hose from the degas bottle.
- Loosen the clamp and disconnect the lower radiator hose from the engine.
- Detach the 2 wiring harness retainers from the valve cover stud bolts.
- Loosen the clamp and disconnect the CAC inlet tube.
- Disconnect the fuel supply tube quick connect coupling. For additional information, refer to Fuel System - General Information
.
- Disconnect the EVAP tube from the EVAP purge valve. For additional information, refer to Fuel System - General Information
.
- Remove the bolt and the ground wire from the RH inner fender.
- Disconnect the 2 wiring harness electrical connectors.
- Push the wiring harness retainer tab in.
- Slide the wiring harness up and off of the bulkhead.
- Loosen the 4 retainers and remove the underbody shield.
- Remove the catalytic converter. For additional information, refer to Exhaust System .
- Remove the engine roll restrictor. For additional information, refer to Automatic Transaxle Transmission - 6F35 .
- Remove the front subframe. For additional information, refer to Uni-Body, Subframe and Mounting System .
- Remove the 2 secondary latches from the transaxle fluid cooler tubes.
- Using the Transaxle Cooler Tube Disconnect Tool, disconnect the transaxle cooling tubes.
- Remove the 2 transaxle-to-oil pan bolts.
- Remove the drain plug and drain the engine oil.
- Install the drain plug and tighten to 27 Nm (20 lb-ft).
- Remove and discard the engine oil filter.
- Remove the 2 nuts and slide the RH halfshaft assembly out of the transaxle.
- Position the halfshaft aside and support with a length of mechanics wire.
- Using the Halfshaft Remover and Slide Hammer, separate the halfshaft from the transmission.
- Position the halfshaft aside and support with a length of mechanics wire.
- Remove the A/C compressor drive belt. For additional information, refer to Accessory Drive .
- Remove the A/C tube bracket nut.
- Disconnect the 2 A/C compressor electrical connectors.
- Detach the wiring harness retainer from the A/C tube stud bolt.
- Remove the A/C compressor nut, stud and the 2 bolts.
- Position the A/C compressor aside and support with a length of mechanics wire.
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NOTE: Position a block of wood under the transaxle.
Install the Powertrain Lift and Adjustable Grip Arms.
- Remove the transaxle support insulator through bolt and nut.
- Remove the 3 nuts, the bolt and the transaxle support insulator bracket.
- Remove the 4 nuts, the 3 bolts and the engine mount.
- Lower the engine and transaxle assembly from the vehicle.
- Remove the starter cable cover and the 2 nuts.
- Detach the 2 wire terminals from the starter.
- Remove the nut and the ground wire from the starter stud bolt.
- Remove the 2 stud bolts and the starter.
- Remove the starter insulator.
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NOTE: Only rotate the engine in a clockwise direction or engine damage will occur.NOTE: Mark one stud and the flexplate for assembly reference.
Remove and discard the 4 torque converter nuts.
- Disconnect the coolant hose from the transmission fluid temperature control valve.
- Position the generator cap aside and remove the nut and wire terminal.
- Disconnect the wire harness electrical connector.
- Detach the 4 wiring harness retainers from the engine.
- Disconnect the crankcase pressure sensor electrical connector and detach the wiring harness retainer.
- Disconnect the Positive Crankcase Ventilation(PCV) tube from the turbocharger inlet pipe and position it aside.
- Using the Floor Crane and Spreader Bar, remove the engine and transaxle from the powertrain table.
- Detach the 2 wiring harness retainers.
- Detach the 2 wiring harness retainers.
- Disconnect the 2 transaxle electrical connectors.
- Detach the 2 wiring harness retainers.
- Remove the 3 transaxle-to-engine bolts.
- Remove the 3 engine-to-transaxle bolts.
- Remove the transaxle-to-engine bolt and 2 stud bolts.
- Separate the engine and transaxle.
- Install the Torque Converter Retainer and bolt.