ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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Engine - Vehicles With: 5F31J-5-Speed Automatic Transmission > < Engine - Vehicles With: MTX-75-5-Speed Manual Transaxle

Mondeo 2001 (10.2000-02.2007)

Engine - 2.5L Duratec-VE (VE6) - Engine—Vehicles With: MMT6/6-Speed Manual Transaxle Mondeo 2001 (10/2000-02/2007)
Removal

Special Tool(s)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)

Remover, Halfshaft

308-192 (16-057)
General Equipment
Mounting Stand
Vehicle hoist

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. Disconnect the battery ground lead.For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Detach the starter motor positive lead from the battery.

  1. Remove the strut mount reinforcement cover on both sides.

  1. Loosen the strut top mount nuts by four turns on both sides.

  1. Remove the air cleaner housing.
    1. Disconnect the PCV hoses.
    1. Detach the mass air flow (MAF) sensor connector.
    1. Detach the air cleaner intake hose to the engine.

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

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

  1. Remove the fuel supply line. For additional information, refer to Section  310-00 Fuel System - General Information.
  1. Remove the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.
  1. Drain the cooling system. For additional information, refer to Section  303-03 Engine Cooling.
  1. Lower the vehicle.

  1. Detach the throttle cable.
    • Detach the clips and throttle cable from the bracket.

  1. Using the special tool, remove the coolant hoses from the coolant connection fittings.

  1. Using the special tool, detach the coolant hose from the coolant expansion tank.

  1. Disconnect the ignition coil connector.

  1. Detach the condenser connector.

  1. Detach the ignition coil from the cylinder head cover.
    1. Remove the condenser bolt.
    1. Remove the ground cable bolt.

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

  1. Detach the engine wiring harness connector from the right-hand cylinder head cover.

  1. Detach the engine wiring harness connector.

  1. Detach the power steering line bracket from the front engine mount.

  1. Detach the power steering line.
    • Remove the clip.
    • Allow the fluid to drain into a suitable container.

  1. Using the special tool, disconnect the power steering hose from the power steering reservoir.

  1. Detach the power steering reservoir and lay it to one side.

  1. Detach 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 line to prevent fluid loss or dirt ingress.
    Detach the clutch slave cylinder line 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 bracket.

  1. Detach the ground lead from the transmission.
  1. Remove the subframe. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.

  1. Detach the battery positive lead and the ignition switch cable from the starter motor.

  1. Detach the vehicle speed sensor (VSS) connector.

  1. Remove the generator wiring harness.

  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. 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 bracket and secure it to one side.
  1. Position theworkshop table under the vehicle and lower the vehicle carefully until the engine mounts can be removed.

  1. CAUTION:
    CAUTION:Do not support the oil sump.
    NOTE:
    NOTE:Secure the engine and transmission to the workshop table using suitable retaining straps.
    Support the engine and transmission with suitable wooden blocks.

  1. Detach the HT lead bracket from the front engine mount.

  1. Unscrew and remove the front engine mount nuts.
    • Discard the nuts.

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

  1. Remove the transmission right-hand retaining bolts.

  1. Remove the transmission left-hand retaining bolts.

  1. Remove the transmission upper retaining bolts.
  1. Remove the transmission from the engine.

Engine - Vehicles With: 5F31J-5-Speed Automatic Transmission > < Engine - Vehicles With: MTX-75-5-Speed Manual Transaxle