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

Maverick 2001 (12.2000-07.2004)

Engine - 2.0L Zetec-E (Zetec) - Engine—Vehicles With: Manual Transaxle Maverick 2001 (12/2000-07/2004)
Removal

Special Tool(s)

Remover Fuel Pipe 1/2 In (green)

310-D005 (D87L-9280-B) or equivalent

Heavy Duty Floor Crane

014-00072 or equivalent

Engine Stand

014-00232 or equivalent

Flywheel Holding Tool

303-103 (T74P-6375-A)

Spreader Bar

303-D089 (D93P-6001-A3)
WARNING:
WARNING:Clutches and brakes contain asbestos fibers. Avoid breathing dust. Breathing asbestos dust may cause asbestosis and cancer.
WARNING:
WARNING:Dust and dirt present on wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing.
WARNING:
WARNING:Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum 164-R3600. Dust and dirt from vacuum should be disposed of in a manner that prevents dust exposure such as sealed bags. The bag must be labeled as per OSHA instructions and the trash hauler notified as to the bag's contents. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:Grinding or sanding on brake linings, pads, rotors, drums or clutch facings should be done only while using correctly exhaust-ventilated equipment. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians concerned with carrying out brake or clutch repair should be present in the area. Failure to follow these instructions may result in personal injury.
  1. Remove the hood. For additional information, refer toSection 501-02 Front End Body Panels.
  1. Relieve the fuel system pressure. For additional information, refer toSection 310-00 Fuel System - General Information.
  1. Remove the battery tray. For additional information, refer toSection 414-01 Battery, Mounting and Cables.
  1. Remove the air cleaner assembly. For additional information, refer toSection 303-12 Intake Air Distribution and Filtering.
  1. Drain the engine coolant. For additional information, refer toSection 303-03 Engine Cooling.
  1. Recover the A/C system refrigerant. For additional information, refer toSection 412-03 Air Conditioning.

  1. Using the special tool, disconnect the fuel line.

  1. Disconnect the throttle cables and the speed control cable (if equipped).

  1. Disconnect the exhaust gas recirculation (EGR) vacuum regulator valve.
    • Disconnect the electrical connector.
    • Disconnect the vacuum hoses.

  1. Disconnect the brake booster vacuum supply hose.

  1. Disconnect the powertrain control module (PCM) wire harness and ground.

  1. Disconnect the ground wire.

  1. Disconnect the wire harness connector.

  1. Disconnect the power distribution box electrical connectors.

  1. Disconnect the vacuum lines at the evaporative emission (EVAP) canister.

  1. Disconnect the upper radiator hose.

  1. Remove the power steering line bracket bolt.

  1. Remove the power steering line bracket bolt.

  1. Remove the upper power steering pump bolts.

  1. Disconnect the coolant hose.

  1. Disconnect the heater hoses.

  1. Remove the speed control unit (if equipped) and position aside.
  1. Remove the catalytic converter. For additional information, refer toSection 309-00 Exhaust System.

  1. Disconnect the coolant hose.
  1. Remove the A/C compressor. For additional information, refer toSection 412-03 Air Conditioning.
  1. Remove the halfshafts. For additional information, refer toSection 205-04 Front Drive Halfshafts.

  1. Disconnect the shifter linkages.

  1. Disconnect the block heater electrical connector.

  1. Remove the front transaxle mount through bolt.

  1. Remove the engine to transaxle bolts.

  1. Disconnect the lower radiator hose.

  1. Remove the lower power steering pump bolts and position the pump aside.
  1. Lower the vehicle.

  1. Disconnect the power steering line brackets and position the lines out of the way.

  1. Remove the clutch slave cylinder bolts.

  1. Remove the clutch slave cylinder line from the bracket and position the clutch slave cylinder aside.
  1. Support the engine using a suitable lifting device.

  1. Remove the rear transaxle mount.

  1. Remove the LH transaxle mount.

  1. Disconnect the ground cable.

  1. Remove the engine mount upper bracket.

  1. Install the special tool and suitable lifting device and remove the engine and transaxle as an assembly.

  1. Disconnect the generator electrical connectors.

  1. Disconnect the electrical connectors.
    • Disconnect the knock sensor electrical connector.
    • Disconnect the oil pressure sender electrical connector.
    • Disconnect the starter electrical connector.

  1. Disconnect the vehicle speed sensor (VSS) electrical connector.

  1. Disconnect the park neutral position (PNP) switch electrical connector and ground wire.

  1. Disconnect the fuel charging wiring harness electrical connector.

  1. Disconnect the PCM wire harness from the bracket.

  1. Disconnect the ground wire.

  1. Disconnect the reversing lamp switch electrical connector.

  1. Remove the wire harness.
    1. Disconnect the differential pressure feedback EGR sensor.
    1. Remove the wire harness from the brackets and remove from the engine/transaxle assembly.

  1. Remove the starter.

  1. Remove the engine to transaxle bolts.

  1. Remove the engine to transaxle bolts and remove the transaxle.

  1. Using the special tool, lock the flywheel to the engine.

  1. WARNING:
    WARNING:The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury.
    CAUTION:
    CAUTION:Loosen the bolts evenly to prevent pressure plate damage.
    Remove the bolts, clutch pressure plate and clutch disc.

  1. Remove the flywheel.

  1. Remove rear cover plates and dowels.
  1. Mount the engine on a suitable engine stand.

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