Ford Fusion: Starting System - 1.5L EcoBoost (118kW/160PS) – I4 / Starter Motor. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

  WARNING: Always disconnect the battery ground cable at the battery before disconnecting the starter motor battery terminal lead. If a tool is shorted at the starter motor battery terminal, the tool can quickly heat enough to cause a skin burn. Failure to follow this instruction may result in serious personal injury.

NOTE: Removal steps in this procedure may contain installation details.

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

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).
   

1. Remove the battery tray.
   Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
   

1. Remove the engine appearance cover.
   

1. 1. Disconnect the selector lever cable from the transmission controller arm.
      
   2. Remove the selector lever cable bracket bolt and position the selector lever cable aside.
      Torque: 62 lb.in (7 Nm)

1. Remove the upper starter motor retaining bolt.
   Torque: 35 lb.ft (48 Nm)

1. Remove the retainers and the underbody shield.
   

1. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.

   Remove and discard the engine oil filter.
   Use the General Equipment: Oil Drain Equipment
   Use the General Equipment: Strap Wrench
   Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)
   Torque: 133 lb.in (15 Nm)

1. NOTICE: If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may cause engine failure.

   
   
   • To diagnose mechanical concerns,
     Refer to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
     Use the General Equipment: Oil Drain Equipment
   • Remove the engine oil cooler bolt and position the engine oil cooler aside.
     Torque: 41 lb.ft (55 Nm)

1. Inspect the engine oil cooler gasket and replace as needed.
   

1. Disconnect the A/C pressure transducer electrical connector.
   

1. 1. Remove the starter motor control wire retaining nut and disconnect the starter motor control wire at the starter motor.
      Torque: 53 lb.in (6 Nm)
   2. Remove the battery positive cable retaining nut and disconnect the battery positive cable at the starter motor.
      Torque: 106 lb.in (12 Nm)

1. 1. Detach the retainer from the studbolt.
      
   2. Remove the ground cable bolt and position the ground cable aside.
      Torque: 35 lb.ft (48 Nm)

1. Remove the nuts from the bracket and position the cabin heater coolant pump and bracket aside.
   Torque: 71 lb.in (8 Nm)

1. Remove the starter motor retaining bolts, bracket and the starter motor.
   Torque: 35 lb.ft (48 Nm)

1. Inspect the starter motor drive gear and ring gear.
   Refer to: Starter Motor Drive Gear and Flywheel Ring Gear Inspection (303-06A Starting System - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
   

Installation

1. To install, reverse the removal procedure.
   

1. Check and top off the engine oil level.
   Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)