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In-vehicle Repair|Disassembly > < Crankshaft Rear Seal

Mondeo 2001 (10.2000-02.2007)

Engine - 1.8L Duratec-SCi (MI4) - Engine—Vehicles With: MMT6/6-Speed Manual Transaxle Mondeo 2001 (10/2000-02/2007)
Removal

Special Tool(s)

Lifting Bracket, Engine

303-122 (21-068 A)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)

Remover, Halfshaft

308-192 (16-057)
General Equipment
Workshop table
Engine lifting bracket
Retaining straps

Removal

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to observe this instruction can lead to injury.
  1. Remove the engine cover.

  1. Install the suspension strut mount reinforcement cover on both sides.

  1. Loosen the strut mount nuts by four turns on both sides.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Drain the cooling system. For additional information, refer to Section  303-03 Engine Cooling.

  1. Remove the air cleaner housing.
    1. Detach the clamp from the air cleaner/engine intake hose.
    1. Detach the positive crankcase ventilation (PCV) hose from the air cleaner/engine intake hose.

  1. Detach the intake manifold wiring harness connector.
    • Unclip the wiring harness.

  1. Disconnect the ignition coil connectors.

  1. Disconnect the camshaft position sensor (CMP sensor) connector.

  1. Disconnect the fuel metering valve connector.

  1. Disconnect the exhaust gas recirculation (EGR) valve connector.

  1. Disconnect the engine coolant temperature sensor (ECT sensor) connector.

  1. Disconnect the throttle plate servo motor connector.

  1. Disconnect the swirl plate servo motor connector.

  1. Disconnect the swirl plate position sensor connector.
    • Unclip the wiring harness.

  1. Detach the ground cable from the fuel supply line cover.

  1. Detach the brake servo vacuum line from the intake manifold.

  1. Disconnect the intake manifold wiring harness connector.
    • Unclip the wiring harness.

  1. Disconnect the connector from the power steering pressure (PSP) switch.

  1. Remove the engine cover bracket.

  1. Remove the engine wiring harness bracket.

  1. Using the special tool, disconnect the coolant hoses from the coolant distribution pipe.

  1. Using the special tool, disconnect the coolant hose from the EGR valve.

  1. Detach the canister purge solenoid valve from the intake manifold.

  1. Unclip the wiring harness.

  1. Disconnect the manifold absolute pressure (MAP) sensor connector.

  1. Disconnect the knock sensor (KS) connector for cylinders 3 and 4.

  1. Using the special tool, disconnect the power steering hose from the power steering reservoir.
    • Allow the fluid to drain into a suitable container.

  1. NOTE:
    NOTE:A filter is built into the power steering reservoir. If the fluid is contaminated, the power steering reservoir must be replaced.
    Remove the power steering reservoir.
    1. Remove the rear stud.
    1. Remove the front bolts.
    • Discard the O-rings.

  1. Detach the power steering pipe bracket from the power steering pump.
  1. Remove the power steering pump pulley. For additional information, refer to Section  211-02 Power Steering.

  1. Remove the power steering pump to steering gear pipe from the power steering pump.

  1. Disconnect the KS connector for cylinders 1 and 2.

  1. Disconnect the thermostat connector.

  1. Disconnect the generator connector.

  1. Disconnect the A/C compressor connector.

  1. Disconnect the reversing lamp switch connector.

  1. CAUTION:
    CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay.
    CAUTION:
    CAUTION:Close off the clutch slave cylinder pressure pipe to prevent fluid loss or dirt ingress.
    Detach the clutch slave cylinder pressure pipe from the clutch slave cylinder.

  1. Detach the gearshift cables from the transmission.
    1. Detach the gearshift and selector cables from the selector mechanism.
    1. Press the locking pins together and detach the gearshift cables from the abutment.
  1. Remove the subframe. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.

  1. Detach the heated oxygen sensor (HO2S) connector.

  1. Disconnect the oil pressure switch connector.

  1. Disconnect the starter motor connector.

  1. Detach the ground cable from the transmission.

  1. CAUTION:
    CAUTION:Support the A/C compressor before removing the retaining bolts and secure it to prevent load being placed on the refrigerant lines.
    Detach the AC compressor from the A/C compressor bracket and secure it to one side.

  1. Using the special tool, detach the coolant hose from the radiator.

  1. CAUTION:
    CAUTION:Secure the halfshaft to prevent damage to the constant velocity joints. The inner constant velocity joint must not be bent by more than 18 degrees. The outer constant velocity joint must not be bent by more than 45 degrees.
    CAUTION:
    CAUTION:Ensure that the halfshaft oil seal is not damaged.
    CAUTION:
    CAUTION:Close off the transmission openings to prevent fluid loss or dirt ingress.
    Detach the right-hand halfshaft together with the intermediate shaft from the transmission and secure it to one side.
    • Discard the self-locking nuts.
    • Allow the transmission fluid to drain into a suitable container.

  1. CAUTION:
    CAUTION:Secure the halfshaft to prevent damage to the constant velocity joints. The inner constant velocity joint must not be bent by more than 18 degrees. The outer constant velocity joint must not be bent by more than 45 degrees.
    CAUTION:
    CAUTION:Ensure that the halfshaft oil seal is not damaged.
    CAUTION:
    CAUTION:Close off the transmission openings to prevent fluid loss or dirt ingress.
    Detach the left-hand halfshaft from the transmission using the special tool and secure it to one side.
    • Discard the snap ring.
    • Allow the transmission fluid to drain into a suitable container.

  1. Disconnect the fuel lines. For additional information, refer to Section  310-00 Fuel System - General Information.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Position the workshop table under the vehicle and lower the vehicle carefully until the engine mounts can be removed.

  1. NOTE:
    NOTE:Secure the engine / transmission assembly to the workshop table using suitable retaining straps.
    Support the engine / transmission assembly with suitable wooden blocks.

  1. Remove the front engine mount.

  1. Remove the rear engine mount nut.
    • Discard the nut.
  1. Raise the vehicle. Remove the engine and transmission. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Raise the engine / transmission assembly slightly using the special tools and remove the retaining straps.

  1. Remove the engine wiring harness bracket.

  1. Remove the starter motor.
    • Detach the wiring harness from the bracket.

  1. Remove the transmission lower bolts.

  1. Remove the right-hand transmission bolts.

  1. Remove the left-hand transmission bolts.
  1. Detach the transmission from the engine.

In-vehicle Repair|Disassembly > < Crankshaft Rear Seal