Ford Mondeo Workshop Service and Auto Repair Manuals

Universal Flange Holding Wrench

205-072 (15-030A)

Remover, Seal

303-112 (21-051)

Remover, Crankshaft Seal

303-293 (21-143)

Remover, Crankshaft Vibration Damper

303-338 (21-153B)

Adapter for 303-338

303-338-02 (21-153A-02)

Remover/Installer, Hose Clamp

303-397 (24-003)

Mounting Bracket for 303-435

303-435-06 (21-031B)

Mounting Plate for 303-435-06

303-435-11 (21-146C)

Socket, Spark Plug

303-499 (21-202)

1. Drain the engine oil.
   • Allow the oil to drain into a suitable container.

2. 

   NOTE:Inspect the oil pan drain plug seal for damage. Install a new drain plug and seal if required.
   Install the drain plug.

3. 

   CAUTION:Remove the right-hand exhaust manifold retaining nuts in the sequence shown.
   Remove the right-hand exhaust manifold.
   • Discard the gasket and the retaining nuts.

4. Remove the intermediate drive shaft bracket.

5. Install the mounting plate to the engine.

6. Install the mounting bracket to the mounting plate.

7. Mount the engine on the mounting stand.

8. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
   • Detach the wiring harness.

9. Detach the intake manifold runner control (IMRC) cable from the throttle body.

10. Remove the IMRC actuator and mounting bracket.
    1. Cut the cable tie.
    2. Disconnect the IMRC electrical connector.
    3. Remove the retaining bolts.

11. Disconnect the right-hand spark plug electrical connectors.
    • Detach the bracket.

12. Disconnect the left-hand spark plug electrical connectors.
    • Detach the bracket.

13. Disconnect the differential pressure feedback EGR electrical connector.

14. Disconnect the electronic vacuum regulator (EVR) solenoid valve electrical connector.

15. Disconnect the EGR tube from the EGR valve.
    1. Disconnect the hoses.
    2. Detach the tube fitting.

16. Disconnect the vacuum hoses from the upper intake manifold, the EGR valve and the fuel pressure regulator.

17. Disconnect the electronic vacuum regulator (EVR) hoses.
    • Remove the vacuum hose harness.

18. Disconnect the positive crankcase ventilation (PCV) hose from the throttle body.

19. Disconnect the throttle position (TP) sensor electrical connector.

20. Disconnect the idle air control (IAC) valve electrical connector.

21. 

    CAUTION:Remove the upper intake manifold retaining bolts in the sequence shown.
    Remove the upper intake manifold.
    • Discard the gaskets.

22. Disconnect the heated oxygen sensor (HO2S) electrical connector.

23. Disconnect the oil pressure switch electrical connector.

24. Disconnect the crankshaft position (CKP) sensor electrical connector.
    • Detach the wiring harness from the retaining stud.

25. Disconnect the camshaft position (CMP) sensor electrical connector.
    • Detach the wiring harness from the stud.

26. Detach the wiring harness in-line electrical connectors from the mounting bracket.

27. Detach the wiring harness bracket from the right-hand valve cover (two nuts).

28. Remove the electronic ignition (EI) coil.

29. Disconnect the fuel injector electrical connectors.
    • Detach the wiring harness.

30. 

    CAUTION:Remove the lower intake manifold retaining bolts in the sequence shown.
    Remove the lower intake manifold.
    • Discard the gaskets.

31. Remove the coolant distribution tube.

32. Remove the oil level indicator and tube.

33. Remove the coolant pump belt.
    • Rotate the belt tensioner clockwise to release the tension from the coolant pump belt.

34. Using a suitable knife, cut the coolant pump belt.
    • Discard the coolant pump belt.

35. Remove the PCV valve and hoses.
    1. Remove the retaining nut.
    2. Remove the PCV and hoses.

36. Remove the coolant bypass assembly.

37. Using the special tool, disconnect the coolant hoses from the coolant pump.

38. Remove the coolant pump.
    • Discard the gasket.

39. Remove the clutch disc and pressure plate.
    For additional information, refer to: Clutch Disc and Pressure Plate (308-01A Clutch - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal and Installation).
    

40. Remove the flywheel.
    1. Remove the flywheel retaining bolts.
    2. Remove the adapter plate.

41. Remove the flexplate.
    1. Remove the flexplate retaining bolts.
    2. Remove the adapter plate.

42. Using the special tool, remove the crankshaft rear seal.
    • Discard the seal.

43. Remove the generator.

44. Remove the generator mount bracket.

45. Remove the oil filter.

46. 

    CAUTION:Remove the left-hand exhaust manifold retaining nuts in the sequence shown.
    Remove the left-hand exhaust manifold.
    • Discard the gasket and the retaining nuts.

47. Remove the oil pressure switch.

48. 

    NOTE:Remove the oil pan retaining bolts and studs in the sequence shown.
    Remove the oil pan.
    • Discard the gasket.

49. Remove the engine wiring harness bracket from the right-hand valve cover.

50. 

    CAUTION:Remove the valve cover retaining bolts and nuts in the sequence shown.
    Remove the valve covers.
    • Discard the gaskets.

51. Using the special tools, remove the camshaft pulley.

52. 

    CAUTION:Do not damage the camshaft seal surface.
    Using the special tool, remove the camshaft seal.
    • Discard the seal.

53. 

    CAUTION:Protect the camshaft surface when removing the seal retainer.
    Remove the camshaft seal retainer.
    • Discard the gasket.

54. Remove the power steering pump pulley.

55. Remove the power steering pump and bracket (five bolts and six nuts).

56. Using the special tool, remove the crankshaft pulley retaining bolt.
    • Discard the crankshaft pulley retaining bolt.

57. Using the special tool, remove the crankshaft pulley.

58. Remove the CMP and CKP position sensors.

59. Using the special tool, remove the crankshaft front seal.
    • Discard the seal.

60. 

    NOTE:Remove the engine front cover retaining bolts and nuts in the sequence shown.
    Remove the engine front cover.
    • Discard the gaskets.

61. Remove the ignition pulse wheel.

62. 

    NOTE:Do not tighten the bolt at this stage.
    Install the crankshaft pulley retaining bolt and washer.

63. Using the special tool, remove the right-hand spark plugs.

64. Using the special tool, remove the left-hand spark plugs.

65. Rotate the crankshaft in a clockwise direction to position number one cylinder at top dead center (TDC) with the crankshaft keyway at the 11 o'clock position.
    • If the camshafts are not positioned as shown, rotate the crankshaft one complete revolution.

66. Rotate the crankshaft in a clockwise direction to position the crankshaft keyway at the 3 o'clock position.
    • The right-hand camshafts will be in the neutral position.

67. 

    NOTE:Mark the position of all timing chain tensioner components to make sure they are assembled in their original positions.
    Remove the right-hand timing chain tensioner and timing chain tensioner arm.
    1. Remove the bolts.
    2. Remove the timing chain tensioner.
    3. Remove the timing chain tensioner arm.

68. Remove the right-hand timing chain.
    1. Remove the right-hand timing chain guide.
    2. Remove the right-hand timing chain.

69. 

    CAUTION:The cylinder head and the camshaft bearing caps are numbered and marked for left-hand and right-hand cylinder heads.
    

    CAUTION:Remove camshaft bearing thrust caps No. 1R and 5R first. Do not loosen any other retaining bolts until the thrust caps are removed.
    

    NOTE:Camshaft bearing caps are dowelled to the cylinder head. If necessary, use a plastic mallet to loosen the caps.
    

    NOTE:Loosen the retaining bolts and bearing caps in the indicated sequence in several passes to allow the camshafts to gradually rise from the cylinder head.
    

    NOTE:If the cam followers and valve tappets are to be re-used, mark their position to make sure they are assembled in the original location.
    Remove the right-hand cylinder head camshafts.
    • Remove the cam followers.
    • Remove the valve tappets.

70. 

    CAUTION:Remove the right-hand cylinder head bolts in the sequence shown in several passes.
    Remove the right-hand cylinder head.
    • Discard the cylinder head bolts, washers and gasket.

71. Rotate the crankshaft in a clockwise direction approximately 600 degrees and position the crankshaft keyway at the 11 o'clock position.

72. Remove the crankshaft pulley retaining bolt and washer.

73. 

    NOTE:Mark the position of all timing chain tensioner components to make sure they are assembled in their original positions.
    Remove the left-hand timing chain tensioner and timing chain tensioner arm.
    1. Remove the bolts.
    2. Remove the timing chain tensioner.
    3. Remove the timing chain tensioner arm.

74. Remove the left-hand timing chain.
    1. Remove the left-hand timing chain guide.
    2. Remove the left-hand timing chain.

75. 

    CAUTION:The cylinder head and the camshaft bearing caps are numbered and marked for left-hand and right-hand cylinder heads.
    

    CAUTION:Remove camshaft bearing thrust caps No. 1L and 5L first. Do not loosen any other retaining bolts until the thrust caps are removed.
    

    NOTE:Loosen the retaining bolts and bearing caps in the sequence shown in several passes to allow the camshafts to gradually rise from the cylinder head.
    

    NOTE:Camshaft bearing caps are dowelled to the cylinder head. If necessary, use a plastic mallet to loosen the caps.
    

    NOTE:If the cam followers and valve tappets are to be re-used, mark their position to make sure they are assembled in the original location.
    Remove the left-hand camshafts.
    • Remove the cam followers.
    • Remove the valve tappets.

76. 

    CAUTION:Remove the left-hand cylinder head bolts in the sequence shown in several passes.
    Remove the left-hand cylinder head.
    • Discard the cylinder head bolts, washers and gasket.

77. Remove the power steering pump bracket.

78. Remove the oil separator.
    • Discard the gasket.

79. Remove the oil pick-up pipe.
    1. Remove the retaining nut.
    2. Remove the retaining bolts.
    3. Remove the oil pick-up pipe.

80. Remove the oil pan baffle.

81. 

    CAUTION:Remove the oil pump retaining bolts in the sequence shown.
    Remove the oil pump.