| Removal and Installation | | 13‐006 Ball joint separator | | | 21‐205 Socket, driveshaft bolts | | | 21‐140 Engine support bar | | | 21‐140‐03 Adapter for 21‐140 | | | 21‐140‐04 Adapter for 21‐140 | | | 21‐140‐05 Adapter for 21‐140 | | | 21‐140‐06 Adapter for 21‐140 | | | 21‐140‐07 Adapter for 21‐140 | | | 24‐003 Removal/installer, radiator hose clamp | | Transmission jack | | | Retaining strap | GV‐2166/3 | | Automatic transmission fluid | N052162VX00 | | Differential fluid (without 4x4) | N052145 VX00 | | Differential/transfer box fluid (with 4x4) | N052145 VX00 | | Coolant | ESD‐M97B49‐A | | Cable ties | | | 2 washers, ∅ 30 mm, 3 mm thick | | Remove | 1. General instructions. The description of the position of the engine mountings is made looking from the automatic transmission towards the engine. If necessary, use Special Tool 24‐003 to remove coolant and ventilation hoses. 2. Standard preparations: • Make a note of the radio keycode. • Make a note of the preset radio stations. • Lay protective covers on the wings. |  | CAUTION: Disconnect the battery. | |  | WARNING: If the engine is warm, wrap a thick cloth around and over the coolant expansion tank cap before opening it, to prevent the risk of scalding. | Open the coolant expansion tank. | | | 3. Loosen the front wheel bolts. 4. Raise the vehicle. 5. Detach the front wheels. | | | 6. Remove the engine undershield (four bolts, two nuts) (right‐hand side shown). | | | | | WARNING: Danger of scalding if the engine is warm. | 7. Drain off the coolant. • Detach the coolant hose. • Lower the vehicle. | | | 8. Remove the upper part of the engine compartment/battery intermediate panel (push fit). 1. Pull off the rubber seal. 2. Remove the upper part. | | | 9. Remove the bulkhead cover. | | | 10. Pull out the headlamp cover. | | | 11. Remove the upper part of the air cleaner housing. 1. Detach the hose leading to the secondary air injection pump. 2. Pull out the plug of the mass air flow sensor (MAF sensor). 3. Undo the clips. 4. Undo the clips. | | | 12. Remove the lower part of the air cleaner housing (push fit). 1. Remove the MAF sensor (one clip). 2. Disconnect the EVAP solenoid multiplug. 3. Pull off the EVAP solenoid with the rubber mounting. Raise the vehicle. | Only on vehicles without 4x4. | | 13. Detach the suspension on both sides (right‐hand side shown). 1. Detach the stabiliser link rod. 2. Release the brake hose and the ABS sensor lead from the bracket. 3. Detach the track rod end. 4. Detach the suspension arm (two bolts). | Only on vehicles with 4x4. | | 14. Detach the suspension on both sides (right‐hand side shown). 1. Release the brake hose and the ABS sensor lead from the bracket. 2. Detach the track rod end. 3. Detach the suspension arm (two bolts). | Only on vehicles with 4x4. | | 15. Detach the stabiliser bar from the front axle crossmember (two bolts) (left‐hand side shown) and tie it up to one side. | Only on vehicles with 4x4. | | | | CAUTION: Mark the position of the driveshaft in relation to the transfer box output flange. | 16. Detach the driveshaft and tie it up to one side. | | | 17. Detach the steering gear from the front axle crossmember and tie it up. Unclip the heated oxygen sensor (HO2S) cable (if necessary). | | | 18. Detach the engine roll restrictor from the transmission. | | | |  | NOTE: Support the front axle crossmember with a transmission jack. | 19. Detach and lower the front axle crossmember. | | | 20. Disconnect the front exhaust pipe from the catalytic converter. 1. Disconnect the HO2S plug and unclip it. 2. Undo the three bolts. | Only on vehicles with 4x4. | | 21. Remove the front exhaust pipe (six nuts). | Only on vehicles with 4x4. | | | | CAUTION: The constant velocity joint on the wheel side must not be bent at more than 50°, the one on the transmission side not more than 20°. | | | NOTE: Screw two wheel bolts into the wheel hub and use a tyre lever to stop the assembly from turning. | 22. Detach the right‐hand front axle driveshaft (six bolts). 1. Slide the heat shield upwards and disconnect the plug of the vehicle speed sensor (VSS). 2. Detach the right‐hand front axle driveshaft and tie it up. | Only on vehicles without 4x4. | | | | CAUTION: The constant velocity joint on the wheel side must not be bent at more than 50°, the one on the transmission side not more than 20°. | | | NOTE: Watch out for escaping oil. Close off the transmission with auxiliary plugs. | 23. Detach the right‐hand front axle driveshaft. 1. Slide the heat shield upwards and disconnect the plug of the vehicle speed sensor (VSS). 2. Remove the centre bearing bracket from the cylinder block. • Pull out the right‐hand front axle driveshaft and tie it to one side. • Remove the circlip. | | | | | NOTE: Screw two wheel bolts into the wheel hub and use a tyre lever to stop the assembly from turning. | 24. Detach the left‐hand front axle driveshaft (six bolts) and tie it up to one side. | | | 25. Remove the secondary air injection pump. 1. Disconnect the plug. 2. Disconnect the hose. 3. Undo the four bolts (one of them also holds the bracket). Lower the vehicle. | | | | | CAUTION: Working carelessly can cause damage to the hood paintwork. | 26. Detach the bump stops (right‐hand side shown). Open the hood as far as the stop. | | | 27. Take out the rear engine mounting inner bolts. | | | | CAUTION: Do not damage the wing paintwork. | 28. Attach the engine support bar. 1. Attach both engine support bar adapters using the available bodywork bolts. | | NOTE: Push the adapters outwards before tightening the engine support bar in place. | 2. Fit the engine support bar and support it with washers (∅ 30 mm/3 mm thick) on the battery tray. | | NOTE: Hang the chains vertically. | | | CAUTION: The engine support bar chains must be tight. | 3. Attach the spring shackles and chains to the engine lifting eyes and lift the engine slightly. • Disconnect the vacuum hose leading from the inlet manifold to the brake servo. • Disconnect the plug of the intake air temperature sensor (IAT sensor). | | | 29. Remove the front engine mounting bracket. | | | 30. Take out the rear engine mounting outer bolts. 31. Lower the engine/transmission assembly with the engine support bar. Carefully raise the vehicle. | | | 32. Detach the selector cable. 1. Unclip it from the ball joint. 2. Unclip it from the bracket. | | | 33. Disconnect the multiplugs from the transmission. 1. Multiplug ‐ large sungear sensor. 2. Solenoid valve control multiplug. 3. Transmission output speed sensor multiplug. 4. Transmission range sensor (TR sensor) multiplug. | | 34. Detach the ground lead from the flange bolt. 35. Pull out the plug and disconnect the wiring. 36. Detach the starter motor/transmission bracket. | | | 37. Detach the coolant hoses from the transmission oil cooler. | | | 38. Detach the torque converter cover. | | | 39. Remove the torque converter (three nuts). • Turn the crankshaft by turning the crankshaft pulley/vibration damper. • Support the transmission with a transmission jack. | | | 40. Undo the flange bolts on the left‐hand side of the engine. | | | 41. Undo the flange bolt on the right‐hand side of the engine. | | | | | CAUTION: Do not let the torque converter drop out of the transmission. | | | CAUTION: Support the transmission with wooden blocks and secure it to the transmission jack with a retaining strap. | 42. Separate the transmission from the engine and lower it. | | 43. General remarks. If necessary, use Special Tool 24‐003 to install coolant and ventilation hoses. | Install | | | | CAUTION: Do not let the torque converter drop out of the transmission. | | | CAUTION: Support the transmission with wooden blocks and secure it to the transmission jack with a retaining strap. | 44. Bring the transmission into position using the transmission jack. | | | 45. Check the installation depth of the torque converter in the transmission housing. 46. Insert the torque converter studs into the flywheel. | | | 47. Tighten the flange bolts on the left‐hand side of the engine. | | | 48. Tighten the flange bolt on the right‐hand side of the engine. | | | 49. Fit the torque converter (three nuts). Turn the crankshaft by turning the crankshaft pulley/vibration damper. | | | 50. Fit the torque converter cover. | | | 51. Attach the coolant hoses to the transmission oil cooler. | | 52. Attach the bracket to the starter motor/transmission. 53. Connect the plug and wiring. 54. Attach the ground lead to the flange bolt. | | | 55. Connect the multiplugs to the transmission. 1. Multiplug on the large sungear sensor. 2. Solenoid valve control multiplug. 3. Transmission output speed sensor multiplug. 4. TR sensor multiplug | | | 56. Attach the selector cable. Lower the vehicle. 1. Clip it in place in the bracket. 2. Clip it in place in the ball joint. | | | 57. Raise the engine/transmission assembly with the engine support bar. | | NOTE: Do not tighten the bolts yet. | 58. Screw in the rear engine mounting outer bolts. | | | | | NOTE: Do not tighten the nuts/bolts. | 59. Install the front engine mounting bracket. | | | | CAUTION: Do not damage the wing paintwork. | 60. Detach the engine support bar. Screw the body bolts back into the wing. | | | 61. Insert the inner bolts of the rear engine mounting and tighten all the bolts. | | | 62. Tighten the bolts and nuts of the front engine mounting bracket. 1. Two nuts. 2. Three bolts. | | | 63. Fit the bump stops (right‐hand side shown). | | | 64. Fit the secondary air injection pump. 1. Tighten the four bolts (one holds the bracket). 2. Connect the hose. 3. Connect the plugs. | | | 65. Install the coolant hose. | | | | | CAUTION: The constant velocity joint on the wheel side must not be bent at more than 50°, the one on the transmission side not more than 20°. | | | NOTE: Use a tyre lever on the wheel hub to stop the assembly from turning. | 66. Install the left‐hand front axle driveshaft. • Remove the wheel bolts from the wheel hub. | Only on vehicles with 4x4. | | | | CAUTION: The constant velocity joint on the wheel side must not be bent at more than 50°, the one on the transmission side not more than 20°. | | | NOTE: Use a tyre lever on the wheel hub to stop the assembly from turning. | 67. Fit the right‐hand front axle driveshaft. 1. Connect the plug of the vehicle speed sensor (VSS) and fit the heat shield. 2. Fit the front axle driveshaft. • Remove the wheel bolts from the wheel hub. | Only on vehicles without 4x4. | | | | CAUTION: The constant velocity joint on the wheel side must not be bent at more than 50°, the one on the transmission side not more than 20°. | | | CAUTION: Do not damage the oil seal when inserting the front axle driveshaft. | | | NOTE: Renew the circlip. | 68. Install the right‐hand front axle driveshaft and circlip. Install the right‐hand front axle driveshaft. 1. Bolt the centre bearing bracket onto the cylinder block. 2. Attach the multiplugs for the VSS and overheat protection. | Only on vehicles with 4x4. | | 69. Connect the front exhaust pipe to the exhaust manifold (six nuts). | | | 70. Connect the front exhaust pipe to the catalytic converter. 1. Tighten the three bolts. 2. Connect the HO2S plug and clip it in place. | | | | | NOTE: Move the front axle crossmember into installation position using a transmission jack. | 71. Install the front axle crossmember. 1. Short bolts. 2. Long bolts. | Only on vehicles with 4x4. | | | | NOTE: The installation position is marked. | 72. Locate the driveshaft in position on the transfer box output flange. | | | | | NOTE: Tightening torques, engine roll restrictor to transmission. Engine roll restrictor made of steel = 98 Nm, engine roll restrictor made of aluminium = 70 Nm. | 73. Secure the engine roll restrictor to the transmission. | Vehicles with 4x4 only | | | | NOTE: Always use the same length bolts as were removed. | | | NOTE: When installing a new engine roll restrictor, also renew bolt X. | 74. Secure the engine roll restrictor to the transmission (continued). Torques • 78 mm = 70 Nm • 88 mm = 60 Nm + 90° Always renew the 88 mm long bolts. | Only on vehicles with 4x4. | | | | NOTE: The installation position is marked. | 75. Attach the driveshaft. | | | 76. Attach the steering gear to the front axle crossmember. Clip the HO2S cable in place (if necessary). | Only on vehicles with 4x4. | | 77. Attach the stabiliser bar to the front axle crossmember (two bolts) (left‐hand side shown). | Only on vehicles without 4x4. | | 78. Install the suspension on the left‐ and right‐hand sides (right‐hand side shown) 1. Attach the suspension arm (two bolts). 2. Attach the track rod end. 3. Attach the stabiliser link rod. 4. Clip the brake hose and the ABS wheel sensor cable into the bracket. | Only on vehicles with 4x4. | | 79. Install the suspension on the left‐ and right‐hand sides (right‐hand side shown) 1. Attach the suspension arm (two bolts). 2. Attach the track rod end. 3. Clip the brake hose and the ABS wheel sensor cable into the bracket. | | | | | WARNING: On 16 inch aluminium wheels tighten the wheel bolts to 170 Nm. | 80. Fit the front wheels. • Lower the vehicle. • Tighten the wheel bolts. | | | 81. Fit the lower part of the air cleaner housing (push fit). Push it into the three guides. | | | 82. Fit the lower part of the air cleaner housing (cont.). 1. Push on the EVAP solenoid with its rubber mounting. 2. Push on the EVAP solenoid multiplug. 3. Install the MAF. | | | 83. Fit the upper part of the air cleaner housing. 1. Close the three clips. 2. Close the two clips. 3. Push on the MAF connector. 4. Fit the secondary air injection pump hose. | | | 84. Fit the headlamp cover. | | | 85. Fit the upper part of the engine compartment/battery intermediate panel (push fit). 1. Fit the upper part. 2. Slide on the rubber seal. | | | 86. Install the bulkhead cover. 87. Fit the battery and connect it. | | | 88. Finishing operations. • Fill up with coolant. • Check the engine oil level and correct as necessary. • Secure the wiring and hoses with cable ties. • Check the engine and cooling system for leaks. • Check the level of the automatic transmission fluid and top up as necessary as described in Operation No. 17 112 0. | | NOTE: Fill up to the bottom of the filler hole. | 89. Check the level of the automatic transmission fluid in the differential and correct it as necessary (Ford specification N052145 VX00). Fit and tighten the filler plug. | | | 90. Fit the engine undershield (four bolts, two nuts) (right‐hand side shown. 91. Standard finishing operations (continued). • Remove the protective covers. • Enter in the radio keycode. • Reprogramme the preset radio stations. • Set the clock. • Carry out a road test to enable the PCM to collect data. | |
