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In-vehicle Repair|Disassembly > < Crankshaft Rear Seal

Cougar 1999 (08.1998-01.2001)

Engine - 2.0L - Engine Cougar 1999 (08/1998-01/2001)
Removal

Special Tool(s)

Remover, front axle driveshaft

308-192 (16057)

Adjusting tool, gearshift mechanism neutral position

308-273 (16088)

Remover, fuel pipe 3/8" (yellow)

310-D004 (23039)

Remover, fuel pipe 1/2" (green)

310-D005 (23040)

Lifting equipment, engine

303-122 (21068A)
General Equipment
Assembly plugs
Assembly table
Retaining strap
Workshop hoist
Materials
Name
Specification
Cable ties
 

Removal

All vehicles
  1. General
    • Make a note of the radio keycode.
    • Make a note of the pre-programmed radio stations.
      CAUTION:
      CAUTION:Disconnect the battery ground cable.
    • Remove the battery.
    • The position markings for the engine mountings and engine roll restrictors are described looking from the transmission towards the engine.
    • Due to special model variants, some job steps do not apply to all vehicles. These are clearly marked in the text.
    • Cable ties : cut if necessary and renew them on installation.

  1. Fabricate an auxiliary tool to fix the hood in open position.

  1. Lock the gearshift lever inside the vehicle using the special tool.
    • Shift the gearshift mechanism to "neutral".
    • Unclip and pull up the boot and bellows.

  1. Open the hood and attach the auxiliary tool to the hood.

  1. NOTE:
    NOTE:Prevent the assembly from turning
    Slacken the suspension strut retaining nuts on the right and left sides by five turns.
  1. WARNING:
    WARNING:To prevent the risk of scalding, place a thick cloth over the filler cap before opening the cooling circuit.
    Release the coolant circuit pressure.
    • Carefully open the filler cap.

  1. Loosen the wheel nuts for both front wheels.
  1. Raise the vehicle.For additional information, refer to Section  100-02 Jacking and Lifting.
  1. Remove both front wheels.

  1. Detach the lower radiator cover (nine bolts) and the bumper braces (left side shown).

  1. WARNING:
    WARNING:Danger of scalding if the engine is hot.
    Drain the coolant.
    • Retighten the drain plug.
  1. Lower the vehicle.

  1. Remove the intake pipe with air cleaner housing.
    1. Disconnect the mass air flow (MAF) sensor plug.
    1. Disconnect the intake air temperature (IAT) sensor multiplug.
    1. Remove one bolt and two nuts.

  1. Remove the intake pipe with air cleaner housing (continued).
    1. Detach the positive crankcase ventilation (PCV) hose.
    1. Detach the intake hose.
    • Remove the air cleaner housing from the rubber bushes.

  1. Detach the cable and disconnect the plug.
    1. Battery positive cable
    1. Disconnect the plug.
    1. Ground cable

  1. Detach the central junction box (CJB) and lay it to one side.

  1. Remove the battery tray.

  1. Remove the battery tray (continued).

  1. Detach the main harness from the Powertrain Control Module (PCM).
    1. Remove the power steering fluid reservoir (plugged in) and lay it to one side.
    1. Open the cable fastener.
    1. Detach the ground leads (2 off).
    1. Detach the main harness connector from the PCM.

  1. Detach the ground lead from the engine lifting eye and pull out the power steering pressure connector.

  1. Detach the leads.
    1. Engine wiring harness connector
    1. Automatic transmission ground lead
    1. Cable tie

  1. Detach the speed control cable (if present).
    1. Detach the cable from the throttle plate.
    1. Carefully move the cable up and down and pull it out of the clip.
    1. Remove the clip.

  1. Detach the accelerator cable.
    1. Pull out the clip.
    1. Unhook the accelerator cable.

  1. Detach the vacuum hoses from the inlet manifold.

  1. Remove the heat shield.
    1. Remove the upper bolts.
    • Remove the brackets for the coolant hoses and remove the oil dipstick.
    1. Remove the lower bolt.
    1. Remove the coolant pipe bracket.

  1. Remove the coolant pipe.
    1. Remove the coolant pipe.
    1. Detach the coolant hose from the coolant pipe.
    1. Detach the coolant hose from the coolant pump.

  1. Detach the catalytic converter from the exhaust manifold.
Vehicles with air conditioning
  1. Disconnect the plug for the A/C compressor (shown with drive belt removed).
All vehicles
  1. Disconnect the engine coolant temperature sensor (ECT sensor) plug.

  1. Disconnect the plug and detach the upper coolant hoses.
    1. Unclip the cable.
    1. Detach the coolant hoses.
    1. Disconnect the fan motor plug.

  1. Detach the wiring clamp from the fender apron panel and the coolant hoses.

  1. Remove the upper drive belt cover.

  1. WARNING:
    WARNING:Brake fluid will escape. Observe the safety regulations for working with brake fluid.
    CAUTION:
    CAUTION:Close off the openings.
    Disconnect the clutch slave cylinder.
    1. Pull out the clip and detach the pipe.
    1. Detach the slave cylinder pipe from the transmission and tie it up.
    • Disconnect the ground lead from the transmission.
  1. Raise the vehicle.For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the lower wheel housing trim panels (right side shown).

  1. Slacken and remove the drive belt.

  1. Detach the brake booster vacuum pipe from the intake manifold.
    • Release the quick-release coupling and pull out the pipe.

  1. Disconnect the heated oxygen sensor (HO2S) plug.
    • Cut the cable tie.

  1. Disconnect and unhook the front exhaust pipe.
    • Remove the gasket.

  1. CAUTION:
    CAUTION:Do not damage the boots and the ABS sensor ring.
    Detach the lower suspension arm ball joint on both sides.
    • Detach the ABS sensor cable bracket from the suspension strut.

  1. CAUTION:
    CAUTION:The inner joint must not be bent by more than 18°; the outer joint must not be bent by more than 45°.
    Detach the right front axle driveshaft centre bearing.
    • Pull the right front axle driveshaft out of the transmission and tie up with the intermediate shaft.

  1. CAUTION:
    CAUTION:The inner joint must not be bent by more than 18°; the outer joint must not be bent by more than 45°.
    Detach the left front axle driveshaft from the transmission and tie it up.

  1. Remove the right engine roll restrictor.
    1. Unscrew the centre bolt.
    1. Remove the bolts.

  1. Detach the bracket for the right engine roll restrictor from the transmission.

  1. NOTE:
    NOTE:If necessary, raise the transmission slightly.
    Remove the left engine roll restrictor and the catalytic converter.
    1. Unscrew the nuts.
    1. Unscrew the centre bolt.
    1. Loosen the catalytic converter bracket.
    • Remove the catalytic converter.
Vehicles with air conditioning
  1. Detach the air-conditioning system dehydrator and tie it up.
All vehicles
  1. Detach the lower coolant hoses.

  1. Detach the heater hose.
Vehicles with air conditioning
  1. Detach the air conditioning compressor and tie it up.
All vehicles
  1. Detach the shift cables from the transmission.
    1. Detach the shift cable from the gearshift lever.
    1. Tension the abutment bracket by twisting it anti-clockwise, and remove the cable from the bracket.
    1. Detach the shift cable from the gearshift lever.
    1. Tension the abutment bracket by twisting it anti-clockwise, and remove the cable from the bracket.
    1. Release the adjustment mechanism by pressing it in.
  1. Lower the vehicle.

  1. Separate the fuel pipes.For additional information, refer to Section  310-00 Fuel System - General Information.

  1. Detach the coolant expansion tank and lay it to one side.
    • Detach the speed control cable (if present) from the coolant expansion tank.

  1. Attach the special tool and raise the engine slightly using a workshop hoist .

  1. NOTE:
    NOTE:Mark the installation position.
    Remove the front engine mounting.
    1. Unscrew the nuts.
    1. Slacken the bolts by two turns.

  1. NOTE:
    NOTE:Mark the installation position.
    Remove the rear engine mounting.
    1. Unscrew the nuts.
    1. Remove the bolts.

  1. CAUTION:
    CAUTION:Do not subject the hoses and pipes to tension.
    NOTE:
    NOTE:Raise the engine and transmission assembly until the power steering pump is accessible.
    Detach the power steering pump and tie it up using cable ties .

  1. CAUTION:
    CAUTION:Do not subject to tension or damage the air conditioning system pipes or hoses.
    Remove the engine and transmission assembly.
  1. Lift the engine and transmission onto the assembly table and secure using a retaining strap .

  1. Disconnect the plug for the reversing lamp switch and the vehicle speed sensor (VSS).

  1. Disconnect the starter motor.

  1. Unscrew the upper flange bolts.
    • Upper starter motor bolts.
    • Two flange bolts.
    • Disconnect the ground lead from the transmission.

  1. Remove the flange bolts on the right side of the transmission and the lower starter motor bolt.
    • Remove the starter motor with the wiring harness.

  1. Remove the flange bolts on the left side of the transmission.
  1. Separate the transmission from the engine.

In-vehicle Repair|Disassembly > < Crankshaft Rear Seal