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Ford Mondeo Workshop Service and Auto Repair Manuals

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Engine - Vehicles With: Automatic Transaxle > < In-vehicle Repair|Oil Pan

Mondeo 1997 - Removal of 25L Engine in Vehicles with Manual Transaxle

Engine - 2.5L - Engine—Vehicles With: Manual Transaxle Mondeo 1997 (08/1996-09/2000)
Removal

Special Tool(s)

Lifting bracket, engine

303-12 (21-068A)

Separator, fuel pipe 3/8" (yellow)

310-D004 (23-039)

Separator, fuel pipe 1/2" (green)

310-D005 (23-040)

Adjusting tool, gear shift mechanism - neutral position

308-273 (16-088A)

Radiator hose clamp remover/installer

303-397 (24-003)
General Equipment
Workshop hoist
Drill
4 mm drill bit

Removal

All Vehicles
  1. General
    • The positions of the engine mountings and engine roll restrictors are described looking from the transmission towards the engine.
    • Sub-operations for particular variants which do not apply to all vehicles are marked clearly with a note.
    • Use Special Tool 303-397 as required when disconnecting coolant or ventilation hoses.

  1. Make the auxiliary tool to hold the hood in the open position.

  1. Open the hood and attach the auxiliary tool to the hood.
  1. Standard preparatory measures.
    • Make a note of the radio keycode.
    • Open up the coolant recovery tank.
    • Make a note of the pre-set radio stations.
    • Cut cable ties as necessary.
WARNING:
WARNING:Disconnect the battery and remove.
  1. Unclip the gear lever boot.

  1. Secure the gear lever in neutral using the special tool.

  1. Remove the engine cover.

  1. Remove the air cleaner housing.
    1. Two positive crankcase ventilation (PCV) hoses
    1. Hose clamp at the throttle housing
    1. Idle control valve vacuum hose
    1. MAF multiplug
    1. Intake air temperature (IAT) sensor plug.
    • Pull off the brake booster vacuum line from the upper intake manifold.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Detach the engine undershield (if equipped).
  1. Drain the coolant. For additional information, refer to Section  303-03 Engine Cooling.

  1. Disconnect the coolant hose from the radiator.

  1. Drain off the transmission fluid.
    • Screw the drain plug back in again.
  1. Lower the vehicle.

  1. Detach the accelerator cable (illustration shows vehicle equipped with traction control system).
    1. Turn the cable pulley and unhook the cable.
    1. Pull off the clip and pull the accelerator cable out of the bracket.
    • Unhook the spring.

  1. Detach the cruise control actuation cable from the throttle valve lever.

  1. Disconnect the vacuum hose for the evaporative emission system.

  1. Detach the bracket for the cables.

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

  1. Remove the battery console.

  1. Disconnect the starter motor.

  1. Disconnect the starter motor positive lead.
    • Open the wiring casing and press out the positive cable.

  1. Separate the fuel lines. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.
  1. Drain the brake fluid reservoir using a manual suction pump.

  1. NOTE:
    NOTE:Close off the openings using plugs.
    Disconnect the line from the clutch slave cylinder.

  1. Detach the coolant hoses.

  1. Remove the coolant recovery tank.
    • Disconnect the plug from the coolant level switch (if equipped).

  1. Detach/disconnect the coolant hoses.

  1. Disconnect the coolant hose from the radiator.

  1. Detach the coolant hose for the distribution pipe from the thermostat housing.

  1. NOTE:
    NOTE:The nuts do not need to be renewed
    Undo the left and right-hand suspension strut nuts five turns (right-hand side shown).
Vehicles with air conditioning
  1. Disconnect the plug from the air conditioning collector/dehydrator.
All vehicles
  1. Disconnect the two fan motor plugs.
    • Unclip the plugs and wiring harness.

  1. Detach the fan motor ground cable from the body.

  1. Detach the fan from the radiator.

  1. Detach the fan from the radiator.

  1. Pull off the heater vacuum hoses.

  1. Drain the power steering fluid reservoir using the manual suction pump, pull it out (push fit) and lay it to one side.

  1. CAUTION:
    CAUTION:Do not damage the power steering return line.
    Remove the cover from the powertrain control module (PCM).
    • Drill out the rivets (4 mm).

  1. Detach the connector from the PCM and the ground cable from the body.
    • Disconnect the engine wiring harness from the bulkhead.

  1. CAUTION:
    CAUTION:No hydraulic fluid should come into contact with the drivebelt.
    NOTE:
    NOTE:Collect the hydraulic fluid in a suitable container.
    Detach the power steering line.
    1. Disconnect the plug.
    1. Power steering return line.
    1. Power steering high-pressure line and bracket with ground cable.

  1. Detach the two ground cables from the transmission and detach the main wiring harness connector (one bolt).
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Detach the gearshift cables from the transmission.
    1. Detach the shift cable and the selector cable.
    1. Unscrew the nuts.
    1. Take off the bracket and lay it to one side.

  1. Detach the front exhaust pipe.
    • Remove the gaskets.

  1. Remove the front exhaust pipe and catalytic converter.
    • Unhook the catalytic converter from the rubber loop.
    • Remove the gaskets.

  1. Detach the right-hand lower wheel arch trim panel (shown with the wheel removed).
    • Loosen the upper wheel arch trim panel.

  1. CAUTION:
    CAUTION:Do not damage the boot or the front ABS toothed sensor wheel.
    Detach the lower suspension arm on both sides (right-hand side shown).

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 18 degrees, the outer joint not more than 45 degrees.
    NOTE:
    NOTE:Tie up the front driveshaft.
    Remove the right-hand front driveshaft.
    • Pull the spindle carrier outwards and pull the front driveshaft off the intermediate shaft.

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 18 degrees, the outer joint not more than 45 degrees.
    NOTE:
    NOTE:Tie up the front driveshaft.
    Remove the left-hand front driveshaft.
    • Pull the spindle carrier outwards and pull the front driveshaft out of the transmission.
Vehicles with air conditioning
  1. Detach the air conditioning condenser from the radiator.
    • One bolt on each side (right-hand side shown).
    • Tie up the condenser.
All vehicles
  1. Remove the radiator.
Vehicles with air conditioning
  1. Disconnect the plug from the air conditioning compressor.
All vehicles
  1. Take out the fan.

  1. Disconnect the plug for the left-hand heated oxygen sensor (HO2S).

  1. Detach the thermostat housing distribution pipe.
  1. Remove the drivebelt. For additional information, refer to Section  303-05 Accessory Drive.
Vehicles with air conditioning
  1. Remove the heat shield from the air conditioning compressor.
Vehicles with air conditioning
  1. Detach the air conditioning compressor and tie it up.
All vehicles
  1. Remove the left-hand engine roll restrictor.

  1. Remove the right-hand engine roll restrictor.
    1. Center bolt
    1. Three bolts.
    1. Engine roll restrictor

  1. Detach the bracket for the right-hand engine roll restrictor.
  1. Lower the vehicle.

  1. Hook the engine and manual transmission assembly into the workshop hoist and secure it.

  1. Detach the front engine mounting.

  1. Detach the rear engine mounting.
  1. Lift out the engine and manual transmission assembly.

Engine - Vehicles With: Automatic Transaxle > < In-vehicle Repair|Oil Pan