ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Disassembly and Assembly of Subassemblies > < Engine - Vehicles With: Automatic Transaxle

Mondeo 1997 (08.1996-09.2000)

Engine - 2.5L - Engine Mondeo 1997 (08/1996-09/2000)
Disassembly

Special Tool(s)

Universal Flange Holding Wrench

205-072 (15-030 A)

Remover, Seal

303-112 (21-051)

Remover, Crankshaft Seal

303-293 (21-143)

Remover, Crankshaft Vibration Damper

303-338 (21-153 B)

Adapter for 303-338

303-338-02 (21-153 A02)

Remover/Installer, Hose Clamp

303-397 (24-003)

Mounting Bracket for 303-435

303-435-06 (21-031 B)

Mounting Plate for 303-435-06

303-435-11A (21-146 C)

Socket, Spark Plug

303-499 (21-202)
General Equipment
Lengths of rubber hosing

Disassembly

All vehicles
  1. Drain off the engine.

  1. Disconnect the exhaust gas recirculation (EGR) pipe from the EGR valve.
    1. Detach the hoses.
    1. Unscrew the pipe.

  1. NOTE:
    NOTE:Loosening sequence.
    Remove the right-hand exhaust manifold.
    • Discard the gasket.

  1. Remove the intermediate driveshaft bracket.

  1. Attach the special tool to the engine.

  1. Install the mounting bracket to the mounting plate.
  1. Mount the engine on the mounting stand.

  1. Disconnect off the plugs and detach the wiring harness.
    1. Generator cable.
    1. Differential pressure feedback EGR (DPFE) plug.
    1. Electronic vacuum regulator.
    1. ECT sensor on coolant distribution pipe.
    1. Detach the wiring rail.

  1. Disconnect the intake manifold runner control (IMRC) cable.
    • Unhook from the bracket.
    • Detach from the IMRC.

  1. Remove the IMRC actuator.
    1. Disconnect the IMRC multiplug.
    1. Unscrew the bolts.
  1. Disconnect the spark plug connectors.

  1. Detach the EI coil with the high tension leads and the spark plug connectors.
    1. Disconnect the EI ignition coil multiplug.
    1. Detach the ground cable.
    1. Detach the condenser.
    1. Remove the remaining bolts and the EI coil.

  1. Disconnect the vacuum hoses.
    1. From the upper intake manifold.
    1. From the electronic vacuum regulator.
    1. From the fuel pressure regulator.
    1. From the DPFE.
    1. From the EGR valve.

  1. Pull off the hoses and the electrical plugs.
    1. Throttle position (TP) sensor plug.
    1. Positive crankcase ventilation hose.
    1. Idle air control valve (IAC valve) plug.

  1. NOTE:
    NOTE:Loosening sequence
    Remove the upper intake manifold.
    • Discard the gaskets.
  1. Disconnect the heated oxygen sensor (H02S) plug.

  1. Disconnect the plugs.
    1. Oil pressure switch.
    1. Crankshaft position (CKP) sensor.
    1. Camshaft position (CMP) sensor.
    • Unclip the wiring harness.

  1. Detach the fuel injection system wiring harness.
    1. Pull off the engine coolant temperature sensor (ECT sensor) plug.
    1. Pull off the EGR back pressure transducer plug.
    1. Pull off the fuel injector plugs.

  1. NOTE:
    NOTE:Loosening sequence
    Remove the lower intake manifold.
    • Discard the gaskets.

  1. Using the special tool, remove the thermostat housing with the coolant hoses.

  1. Detach the coolant distribution pipe, the engine lifting eye and the oil dipstick.
    1. Unscrew the nuts.
    1. Detach the left-hand engine lifting eye.
    1. Withdraw the engine oil dipstick.

  1. Remove the coolant pump drivebelt.
    • Rotate the belt tensioner clockwise to relieve tension on the drivebelt.

  1. Remove the hose and the positive crankcase ventilation valve.
    1. Unscrew the nut.
    1. Detach the hose and the positive crankcase ventilation valve.

  1. Remove the coolant connecting pipe.

  1. Remove the coolant pump.
    1. Unscrew the bolts.
    1. Disconnect the coolant hose.
    1. Detach the coolant hose from the oil cooler.
Vehicles with manual transaxle
  1. Remove the clutch disc and pressure plate. For additional information, refer to Section  308-01 Clutch.

  1. Remove the flywheel.
    1. Remove the flywheel retaining bolts.
    1. Remove the adapter plate.
Vehicles with automatic transaxle
  1. Remove the flexplate.
    1. Remove the flexplate retaining bolts.
    1. Remove the adapter plate.
All vehicles
  1. CAUTION:
    CAUTION:Do not scratch or damage the seal sealing surfaces on the crankshaft and cylinder block. Use a 0,25 mm brass or copper shim to protect the sealing surface.
    CAUTION:
    CAUTION:Only insert the special tool by hand.
    Remove the crankshaft rear seal.

  1. Remove the generator.
    1. Remove the bracket bolt.
    1. Remove the generator bolts.

  1. Remove the generator bracket.

  1. Remove the oil filter.

  1. NOTE:
    NOTE:Loosening sequence.
    Remove the left-hand exhaust manifold.
    • Discard the gasket.

  1. Remove the oil cooler and the oil pressure switch.
    1. Unscrew the bolt and remove the oil cooler.
    1. Remove the oil pressure switch.

  1. Remove the studs and take off the oil pan heat shields.

  1. NOTE:
    NOTE:Loosening sequence
    Remove the oil pan.
    • Discard the gasket.
    • Check the oil pan and the cylinder block for damage.

  1. Remove the wiring harness retaining plate.
    1. Unscrew the bolts.
    1. Take off the retaining plate.

  1. Detach the right-hand engine lifting eye.
    1. Remove the bolt.
    1. Take off the engine lifting eye.

  1. NOTE:
    NOTE:Slackening sequence.
    Remove the valve covers.
    • Discard the gaskets.

  1. Remove the camshaft pulley.

  1. CAUTION:
    CAUTION:Only insert the special tool by hand.
    Using the special tool, remove the camshaft seal.

  1. CAUTION:
    CAUTION:Protect the camshaft when removing the seal carrier.
    Remove the camshaft seal carrier.
    • Discard the seal.

  1. Remove the power steering pump pulley (four bolts).

  1. Remove the power steering pump and bracket.

  1. Using the special tool, remove the crankshaft pulley retaining bolt.

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

  1. Remove the sensors and wiring brackets.
    1. CKP sensor.
    1. CMP sensor.
    1. Wiring bracket.
    1. Wiring bracket.

  1. NOTE:
    NOTE:Loosening sequence.
    Remove the timing chain cover.
    • Discard the gaskets.

  1. CAUTION:
    CAUTION:Protect the surface of the crankshaft while removing the seal.
    Using the special tool, remove the crankshaft front seal (engine shown installed).

  1. Position the crankshaft.
    1. Remove the CKP sensor pulse ring.
    1. Screw in the crankshaft pulley/vibration damper bolt and turn the crankshaft clockwise until the Woodruff key is in the 3 o'clock position. Undo the bolt.

  1. Install the crankshaft pulley retaining bolt and washer.

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

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

  1. 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.

  1. 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.

  1. NOTE:
    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.
    1. Remove the timing chain tensioner.
    1. Remove the timing chain tensioner arm.

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

  1. CAUTION:
    CAUTION:The cylinder head and the camshaft bearing caps are numbered and marked for left-hand and right-hand cylinder heads.
    CAUTION:
    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:
    NOTE:Camshaft bearing caps are dowelled to the cylinder head. If necessary, use a plastic mallet to loosen the caps.
    NOTE:
    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:
    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.

  1. CAUTION:
    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.

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

  1. Remove the crankshaft pulley retaining bolt and washer.

  1. NOTE:
    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.
    1. Remove the timing chain tensioner.
    1. Remove the timing chain tensioner arm.

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

  1. CAUTION:
    CAUTION:The cylinder head and the camshaft bearing caps are numbered and marked for left-hand and right-hand cylinder heads.
    CAUTION:
    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:
    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:
    NOTE:Camshaft bearing caps are dowelled to the cylinder head. If necessary, use a plastic mallet to loosen the caps.
    NOTE:
    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.

  1. CAUTION:
    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.

  1. Remove the bracket for the power steering pump.

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

  1. Remove the oil intake pipe.

  1. Remove the oil pan baffle.

  1. NOTE:
    NOTE:Loosening sequence.
    Remove the oil pump.

Disassembly and Assembly of Subassemblies > < Engine - Vehicles With: Automatic Transaxle