Ford Fusion Manuals

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

Special Tool(s) / General Equipment

Ford Fusion. Engine. Removal 300-OTC1585AE
Powertrain Lift
Ford Fusion. Engine. Removal 300-OTC1819E
2,200# Floor Crane, Fold Away
Ford Fusion. Engine. Removal 303-1502
Lifting Device Engine
TKIT-2012A-FL
TKIT-2012A-ROW
Ford Fusion. Engine. Removal 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.
Ford Fusion. Engine. Removal
  1. Remove and discard the bolt. Detach the steering column shaft from steering input shaft.
    Torque: 18 lb.ft (25 Nm)
Ford Fusion. Engine. Removal
  1. Remove the engine appearance cover.
Ford Fusion. Engine. Removal
  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.
Ford Fusion. Engine. Removal
  1. Detach the retainer and disconnect the coupling and position the vacuum tube aside.
Ford Fusion. Engine. Removal
  1. Disconnect the crankcase pressure sensor wiring harness electrical connector and wire harness retainer.
Ford Fusion. Engine. Removal
  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.
Ford Fusion. Engine. Removal
  1. Release the tabs and position the fuse box aside.
Ford Fusion. Engine. Removal
  1. Release the tabs and open the battery cable terminal cover.
Ford Fusion. Engine. Removal
  1. Remove the nuts and position the wiring harness aside.
Ford Fusion. Engine. Removal
  1. Detach the retainers, remove the bolts and position the wiring harness aside.
Ford Fusion. Engine. Removal
  1. Disconnect the coolant hose.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Removal
  1. Remove the transmission fluid cooler tubes secondary latches.
Ford Fusion. Engine. Removal
  1. Using the special tool, disconnect the transmission fluid cooler tubes.
    Use Special Service Tool: 307-569  Disconnect Tool TOC Line (1/2).
Ford Fusion. Engine. Removal
  1. Detach the retainer and disconnect the coolant tube.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Removal
  1. NOTE: If equipped with block heater.

    Detach the retainers and disconnect the coolant tube.
Ford Fusion. Engine. Removal
  1. Remove the bolts and disconnect the gearshift cable end from selector lever assembly.
Ford Fusion. Engine. Removal
  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
Ford Fusion. Engine. Removal
  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
Ford Fusion. Engine. Removal
  1. Disconnect the coolant hose.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Removal
  1. Disconnect the PCM electrical connector.
Ford Fusion. Engine. Removal
  1. Detach the wiring harness retainer, disconnect the electrical connector and position the wiring harness aside.
Ford Fusion. Engine. Removal
    • Disconnect the coolant hoses.
      Use the General Equipment: Hose Clamp Remover/Installer
    • Release the tab, remove the retainer and the degas bottle.
Ford Fusion. Engine. Removal
  1. Support the cooling module.
Ford Fusion. Engine. Removal
  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.
Ford Fusion. Engine. Removal
  1. Remove the retainers and the deflector shields.
Ford Fusion. Engine. Removal
  1. NOTE: LH inner fender well removed for clarity.

    Disconnect the electrical connector.
Ford Fusion. Engine. Removal
  1. Remove the retainers and the lower radiator support.
Ford Fusion. Engine. Removal
  1. Disconnect the coolant hoses and detach the retainers.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Removal
  1. Disconnect the coolant hose.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Removal
  1. Disconnect the electrical connectors, detach the retainers and position wiring harness aside.
Ford Fusion. Engine. Removal
  1. NOTE: Discard the O-ring seals and gasket seals.

    Remove the nuts and position the A/C lines aside.
Ford Fusion. Engine. Removal
  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)
Ford Fusion. Engine. Removal
  1. Remove and discard the engine oil filter.
    Use the General Equipment: Strap Wrench
Ford Fusion. Engine. Removal
  1. Remove the bolts and the cross support.
Ford Fusion. Engine. Removal
  1. Remove the nuts and position the muffler inlet pipe aside. Discard the nuts.
Ford Fusion. Engine. Removal
  1. Remove and discard the muffler inlet pipe gasket.
Ford Fusion. Engine. Removal
  1. Mark on subframe before removal.
Ford Fusion. Engine. Removal
  1. Mark on subframe before removal.
Ford Fusion. Engine. Removal
  1. Remove the bolts and position the auxiliary water pump aside.
Ford Fusion. Engine. Removal
  1. NOTE: One of these bolts will be used to mount the Adjustable Mounting Arm to the powertrain.

    Remove the engine to transmission bolts.
Ford Fusion. Engine. Removal
  1. Remove the nuts and the catalytic converter grommet.
Ford Fusion. Engine. Removal
  1. Remove the bolt position the wheel speed sensor aside.
Ford Fusion. Engine. Removal
  1. Remove the bolt position the wheel speed sensor aside.
Ford Fusion. Engine. Removal
  1. Remove the nut and position the LH stabilizer bar link aside.
Ford Fusion. Engine. Removal
  1. Remove the nut and position the RH stabilizer bar link aside.
Ford Fusion. Engine. Removal
  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
Ford Fusion. Engine. Removal
  1. Install Special Service Tool: 300-OTC1585AE  Powertrain Lift.
    Use the General Equipment: Wooden Block
Ford Fusion. Engine. Removal
  1. Install the adjustable mounting arm.
    Use the General Equipment: Adjustable Mounting Arm
Ford Fusion. Engine. Removal
  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.
Ford Fusion. Engine. Removal
  1. Remove the nuts, bolts and the position the RH wheel knuckle assembly aside.
Ford Fusion. Engine. Removal
  1. Remove the transmission support insulator nut.
Ford Fusion. Engine. Removal
    • Remove the nuts, bolts and the engine mount.
    • Discard the nuts and bolts.
Ford Fusion. Engine. Removal
    1. Remove and discard the subframe rear mounting bolts.
    1. Remove the bolts and the subframe support bracket.
Ford Fusion. Engine. Removal
  1. Remove and discard the subframe front mounting bolts.
Ford Fusion. Engine. Removal
  1. Using the powertrain lift, lower the powertrain and subframe as an assembly.
Ford Fusion. Engine. Removal
  1. Detach the retainer and disconnect the electrical connectors.
Ford Fusion. Engine. Removal
  1. Remove the muffler inlet pipe isolator bracket bolts.
Ford Fusion. Engine. Removal
  1. Remove and discard the catalytic converter bolt.
Ford Fusion. Engine. Removal
  1. Remove the bolts and the catalytic converter. Discard the bolts.
Ford Fusion. Engine. Removal
  1. Remove and discard the catalytic converter gasket.
Ford Fusion. Engine. Removal
  1. Detach the wiring harness retainers and disconnect the electrical connectors.
Ford Fusion. Engine. Removal

Vehicles with automatic start-stop

  1. Disconnect the coolant hoses.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Removal

All vehicles

  1. Remove the nuts and position the starter motor cable aside.
Ford Fusion. Engine. Removal
    • Detach the wiring harness retainers, disconnect the electrical connector.
    • Slide the generator insulator up, remove the nut and position the wiring harness aside.
Ford Fusion. Engine. Removal
  1. Remove the nut and position the wiring harness aside.
Ford Fusion. Engine. Removal
  1. Remove the bolts, stud bolt and the starter motor.
Ford Fusion. Engine. Removal
  1. Remove the starter motor insulator.
Ford Fusion. Engine. Removal
  1. NOTE: Only rotate the crankshaft in a clockwise direction.

    Index-mark the torque converter nuts. Remove and discard the torque converter nuts.
Ford Fusion. Engine. Removal
    • Detach the wiring harness retainer.
    • Disconnect and remove the crankcase vent hose.
      Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Removal
    • 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.
Ford Fusion. Engine. Removal
  1. Loosen the clamp, remove the bolts and the TC inlet pipe.
Ford Fusion. Engine. Removal
  1. Remove the bolts and position the halfshaft support bracket aside.
Ford Fusion. Engine. Removal
  1. Remove the bolts and the bracket.
Ford Fusion. Engine. Removal
  1. Install Special Service Tool: 303-1502  Lifting Device Engine.
Ford Fusion. Engine. Removal
  1. Install Special Service Tool: 300-OTC1819E  2,200# Floor Crane, Fold Away.
Ford Fusion. Engine. Removal
  1. Remove the bolts and the adjustable mounting arm.
    Use the General Equipment: Adjustable Mounting Arm
Ford Fusion. Engine. Removal
  1. Remove the engine to transmission bolts.
Ford Fusion. Engine. Removal
  1. Remove the engine to transmission bolts.
Ford Fusion. Engine. Removal
  1. Remove the bolt and separate the engine from transmission.
Ford Fusion. Engine. Removal

    Variable Camshaft Timing (VCT) Unit. Removal and Installation

    S..

    Engine. Disassembly

    Special Tool(s) / General Equipment 100-001 (T50T-100-A) Slide Hammer 300-OTC1819E2,200# Floor Crane, Fold Away 303-1097Locking Tool, Variable Camshaft Timing Oil Control UnitTKIT-2010B-FLMTKIT-2010B-ROW 303-1502Lifting Device EngineTKIT-2012A-FLTKIT-2012A-ROW 303-409 (T92C-6700-CH) Remover, Crankshaft SealTKIT-1992-FH/FMH/FLMHTKIT-1993-LMH/MH 303-748L..

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    Ford Fusion 2013–2020 Service Manual: Horn - Component Location. Description and Operation


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