Ford Fusion: Engine - 1.5L EcoBoost (118kW/160PS) – I4 / Engine. Removal

Special Tool(s) / General Equipment

	300-OTC1585AE Powertrain Lift
	300-OTC1819E 2,200# Floor Crane, Fold Away
	303-1502 Lifting Device Engine TKIT-2012A-FL TKIT-2012A-ROW
	307-569 Disconnect Tool TOC Line (1/2) TKIT-2006U-F/FM TKIT-2006U-FLM/LM TKIT-2006U-ROW1 TKIT-2006U-ROW2
Strap Wrench
Adjustable Mounting Arm
Oil Drain Equipment
Hose Clamp Remover/Installer
Wooden Block

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. Release the fuel system pressure.
   Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
   

1. Keep the steering wheel in the straight-ahead position.
   

1. Remove and discard the bolt. Detach the steering column shaft from steering input shaft.
   Torque: 18 lb.ft (25 Nm)

1. Remove the engine appearance cover.
   

1. Recover the A/C system.
   Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging - Vehicles With: R1234YF Refrigerant (412-00 Climate Control System - General Information, General Procedures).
   

1. Drain the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine Cooling - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
   

1. Remove the following items:
   1. Remove the air cleaner.
      Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
      
   2. Remove the upper air cleaner outlet pipe.
      Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
      
   3. Remove the battery tray.
      Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
      

1. NOTE: Always wrap the fuel line connection with a towel before disconnecting it.

   Detach the retainers, disconnect the couplings and position the fuel tube aside.
   

1. Detach the retainer and disconnect the coupling and position the vacuum tube aside.
   

1. Disconnect the crankcase pressure sensor wiring harness electrical connector and wire harness retainer.
   

1. Remove the EVAP canister purge valve.
   Refer to: Evaporative Emission Canister Purge Valve (303-13A Evaporative Emissions - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. Remove the stud bolt and position the wiring harness aside.
   

1. Release the tabs and position the fuse box aside.
   

1. Release the tabs and open the battery cable terminal cover.
   

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

1. Detach the retainers, remove the bolts and position the wiring harness aside.
   

1. Disconnect the coolant hose.
   Use the General Equipment: Hose Clamp Remover/Installer

1. Remove the transmission fluid cooler tubes secondary latches.
   

1. Using the special tool, disconnect the transmission fluid cooler tubes.
   Use Special Service Tool: 307-569  Disconnect Tool TOC Line (1/2).

1. Detach the retainer and disconnect the coolant tube.
   Use the General Equipment: Hose Clamp Remover/Installer

1. NOTE: If equipped with block heater.

   Detach the retainers and disconnect the coolant tube.
   

1. Remove the bolts and disconnect the gearshift cable end from selector lever assembly.
   

1. NOTE: Note the position of the coolant hoses for installation.

   Disconnect the coolant hoses from the heater core.
   Use the General Equipment: Hose Clamp Remover/Installer

1. Release the clamps and disconnect the coolant hoses from the transmission fluid heater coolant control valve.
   Use the General Equipment: Hose Clamp Remover/Installer

1. Disconnect the coolant hose.
   Use the General Equipment: Hose Clamp Remover/Installer

1. Disconnect the PCM electrical connector.
   

1. Detach the wiring harness retainer, disconnect the electrical connector and position the wiring harness aside.
   

1. • Disconnect the coolant hoses.
     Use the General Equipment: Hose Clamp Remover/Installer
   • Release the tab, remove the retainer and the degas bottle.
     

1. Support the cooling module.
   

1. Remove the accessory drive belt.
   Refer to: Accessory Drive Belt (303-05A Accessory Drive - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. Remove the RH and LH front wheels and tires.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Remove the retainers and the stone guard.
   

1. Remove the retainers and the deflector shields.
   

1. NOTE: LH inner fender well removed for clarity.

   Disconnect the electrical connector.
   

1. Remove the retainers and the lower radiator support.
   

1. Disconnect the coolant hoses and detach the retainers.
   Use the General Equipment: Hose Clamp Remover/Installer

1. Disconnect the coolant hose.
   Use the General Equipment: Hose Clamp Remover/Installer

1. Disconnect the electrical connectors, detach the retainers and position wiring harness aside.
   

1. NOTE: Discard the O-ring seals and gasket seals.

   Remove the nuts and position the A/C lines aside.
   

1. Remove the drain plug, drain engine oil and install drain plug.
   Use the General Equipment: Oil Drain Equipment
   Torque: 21 lb.ft (28 Nm)

1. Remove and discard the engine oil filter.
   Use the General Equipment: Strap Wrench

1. Remove the bolts and the cross support.
   

1. Remove the nuts and position the muffler inlet pipe aside. Discard the nuts.
   

1. Remove and discard the muffler inlet pipe gasket.
   

1. Mark on subframe before removal.
   

1. Mark on subframe before removal.
   

1. Remove the bolts and position the auxiliary water pump aside.
   

1. NOTE: One of these bolts will be used to mount the Adjustable Mounting Arm to the powertrain.

   Remove the engine to transmission bolts.
   

1. Remove the nuts and the catalytic converter grommet.
   

1. Remove the bolt position the wheel speed sensor aside.
   

1. Remove the bolt position the wheel speed sensor aside.
   

1. Remove the nut and position the LH stabilizer bar link aside.
   

1. Remove the nut and position the RH stabilizer bar link aside.
   

1. Position a 2 x 8 board, 40 in (1016 mm) in length, a 2 x 6 board 28 in (711.2 mm) in length, a 1 x 6 board 28 in (711.2 mm) in length and two 2 x 4 boards 12 in (304.8 mm) in length onto the Powertrain Lift 300-OTC1585AE.
   Install Special Service Tool: 300-OTC1585AE  Powertrain Lift.
   Use the General Equipment: Wooden Block

1. Install Special Service Tool: 300-OTC1585AE  Powertrain Lift.
   Use the General Equipment: Wooden Block

1. Install the adjustable mounting arm.
   Use the General Equipment: Adjustable Mounting Arm

1. Remove the brake disc.
   Refer to: Brake Disc (206-03 Front Disc Brake, Removal and Installation).
   

1. Remove the nuts, bolts and the position the LH wheel knuckle assembly aside.
   

1. Remove the nuts, bolts and the position the RH wheel knuckle assembly aside.
   

1. Remove the transmission support insulator nut.
   

1. • Remove the nuts, bolts and the engine mount.
     
   • Discard the nuts and bolts.
     

1. 1. Remove and discard the subframe rear mounting bolts.
      
   2. Remove the bolts and the subframe support bracket.
      

1. Remove and discard the subframe front mounting bolts.
   

1. Using the powertrain lift, lower the powertrain and subframe as an assembly.
   

1. Detach the retainer and disconnect the electrical connectors.
   

1. Remove the muffler inlet pipe isolator bracket bolts.
   

1. Remove and discard the catalytic converter bolt.
   

1. Remove the bolts and the catalytic converter. Discard the bolts.
   

1. Remove and discard the catalytic converter gasket.
   

1. Detach the wiring harness retainers and disconnect the electrical connectors.
   

Vehicles with automatic start-stop

1. Disconnect the coolant hoses.
   Use the General Equipment: Hose Clamp Remover/Installer

All vehicles

1. Remove the nuts and position the starter motor cable aside.
   

1. • Detach the wiring harness retainers, disconnect the electrical connector.
     
   • Slide the generator insulator up, remove the nut and position the wiring harness aside.
     

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

1. Remove the bolts, stud bolt and the starter motor.
   

1. Remove the starter motor insulator.
   

1. NOTE: Only rotate the crankshaft in a clockwise direction.

   Index-mark the torque converter nuts. Remove and discard the torque converter nuts.
   

1. • Detach the wiring harness retainer.
     
   • Disconnect and remove the crankcase vent hose.
     Use the General Equipment: Hose Clamp Remover/Installer

1. • Detach the wiring harness retainers and disconnect the electrical connectors.
     
   • Disconnect the TC bypass hose.
     
   • Loosen the clamp, remove the bolt and the TC outlet pipe.
     

1. Loosen the clamp, remove the bolts and the TC inlet pipe.
   

1. Remove the bolts and position the halfshaft support bracket aside.
   

1. Remove the bolts and the bracket.
   

1. Install Special Service Tool: 303-1502  Lifting Device Engine.

1. Install Special Service Tool: 300-OTC1819E  2,200# Floor Crane, Fold Away.

1. Remove the bolts and the adjustable mounting arm.
   Use the General Equipment: Adjustable Mounting Arm

1. Remove the engine to transmission bolts.
   

1. Remove the engine to transmission bolts.
   

1. Remove the bolt and separate the engine from transmission.