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In-vehicle Repair|Disassembly > < Oil Pump

Mondeo 1997 (08.1996-09.2000)

Engine - 1.8L Diesel - Engine Mondeo 1997 (08/1996-09/2000)
Removal

Special Tool(s)

Separator, Ball Joint

211-020 (13-006)

Lifting Bracket, Engine

303-122 (21-068A)

Remover, Halfshaft

308-192 (16-057)
General Equipment
Jib crane
Assembly plugs
Assembly table GV2166

Removal

  1. Standard preparatory measures
    • Make a note of the radio keycode.
    • Make a note of the pre-set radio stations.
    • Open the coolant expansion tank.
      CAUTION:
      CAUTION:Disconnect the battery ground lead.
    • If necessary undo the cable ties.

  1. Lock the gearshift mechanism.
    • Remove the boot from the gear lever.
    • Put the transmission into neutral.
    • Pull the reverse gear lock up and put the adjusting tool in place.
      NOTE:
      NOTE:Make sure that the adjusting tool is correctly located.
    • Release the reverse gear lock.

  1. Make help tool to fix hood in open position.

  1. Open the hood and attach the help tool to the hood.

  1. Undo the left and right-hand suspension strut nuts five turns (right-hand side shown).
  1. Remove the battery.

  1. Remove the fuse box.
    • Pull out from battery tray.

  1. Unclip cable on battery tray.

  1. Remove battery tray.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the engine undershield (nine bolts).

  1. Detach the lower radiator cover.
    1. Unscrew the bolts.
    1. Unhook the radiator cover from the radiator crossmember.

  1. CAUTION:
    CAUTION:Risk of scalding when engine is at operating temperature.
    Drain the coolant.
    • Detach the coolant hose from the radiator.
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Close off the opening to the turbocharger using a lint-free cloth.
    Detach the intercooler.
    1. Take out the two bolts on each side.
    1. Detach the hose.
    1. Unclip the low pressure hose.

  1. Remove the air cleaner.
    1. Pull off the connector on the mass air flow (MAF) sensor.
    1. Disconnect the low pressure hose.
    1. Undo the retaining clips.

  1. Detach coolant hoses on coolant expansion tank.

  1. Remove coolant expansion tank.
    • Pull off connector.

  1. WARNING:
    WARNING:Risk of scalding if the engine is hot.
    Drain the coolant from the lower coolant hose connection pipe and detach the lower coolant hose from the connection pipe.

  1. Detach coolant hose from coolant pump.

  1. CAUTION:
    CAUTION:Over bending of the flexible pipe may cause damage resulting in failure.
    Support the flexible pipe with a support wrap or suitable splint assembly.
  1. Lower the vehicle.

  1. Separate fuel lines.
    1. Separate fuel line.
    1. Detach vacuum line.
    1. Detach coolant hose.

  1. Detach accelerator cable and cold starting system cable.
    1. Pull off accelerator cable.
    1. Pull off the clip.
    1. Pull the accelerator pedal out of the bracket and lay it to one side.
    1. Detach the cold starting system cable.

  1. Pull off the exhaust gas recirculation (EGR) valve.

  1. Detach the glow plug power supply.

  1. Separate the main engine wiring harness connector.
    • Undo the cable ties and lay the engine main wiring harness to one side.
    • Unclip speedometer lever (VSS) and clutch slave cylinder hydraulic line from selector cable bracket.

  1. Detach ground lead on transmission.
  1. Drain power steering reservoir.

  1. Detach the pipes from the power steering pump.
    1. Low pressure hose
    1. High pressure pipe

  1. Detach the power steering pipe bracket from the generator.

  1. Detach the heater coolant hoses.

  1. Detach the catalytic converter from the exhaust manifold.

  1. Undo the wheel nuts.
  1. Remove the front wheels.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the catalytic converter.

  1. Remove the catalytic converter.
    • Detach bracket.

  1. Disconnect the starter motor.

  1. Detach front right wheel housing covers.

  1. Detach rear left wheel housing cover (right-hand side shown).

  1. Remove the air conditioning compressor drive belt.
    • Undo the lockscrew.
    1. Release the tensioning bolt.
    1. Remove the drive belt.
  1. Detach the alternator drive belt. For additional information, refer to Section  414-02 Generator and Regulator.

  1. Remove the crankshaft pulley/vibration damper.
  1. Remove the air-conditioning compressor. For additional information, refer to Section  412-03 Air Conditioning.

  1. Detach the air conditioning compressor from the bracket.
    1. Pull off the electromagnetic clutch connector.
    1. Unscrew the bolts.
    • Tie up the compressor.

  1. Remove the air-conditioning compressor bracket.

  1. Detach the coolant line bracket.

  1. Remove the right-hand transverse link from the spindle carrier (left-hand side shown).

  1. Detach the left-hand transverse link.
    1. Detach the stabiliser bar connecting link.
    1. Detach the track rod end.
    1. Remove the transverse link from the spindle carrier.

  1. NOTE:
    NOTE:Lower nut with coolant line bracket.
    Detach the front driveshaft center bearing from the bracket, pull out the right-hand front driveshaft from the transmission and tie it up.
    • Refit the coolant line bracket loose on the sump.

  1. CAUTION:
    CAUTION:The inner tripod joint must not be bent more than 18 degrees, the outer joint not more than 45 degrees.
    Remove the left-hand front driveshaft.
    • Free the front driveshaft from its seat.
    • Pull the front driveshaft out of the transmission and tie it up.
    • Close off both holes in the transmission using assembly plugs.

  1. Remove the left-hand engine roll restrictor.
    • Unscrew and remove the centre bolt from the left-hand engine roll restrictor.

  1. Detach the left-hand engine roll restrictor bracket from the transmission.

  1. Remove the right-hand engine roll restrictor.
    1. Unscrew the center bolt.
    1. Remove the bolts.

  1. Detach the right-hand engine roll restrictor bracket from the transmission (three bolts).

  1. Detach the gearshift cables from the transmission.
    1. Unclip the shift and selector cable.
    1. Remove the nuts.
    1. Remove the bracket and lay to one side.

  1. NOTE:
    NOTE:Close off the openings using plugs.
    Detach the hydraulic pipe from the clutch slave cylinder.
    1. Pull out the safety clip and pull off the hydraulic pipe.
    1. Unclip the hydraulic pipe upwards out of the bracket.

  1. Attach engine and transmission to jib crane using special tool.
  1. Lower the vehicle.

  1. Remove the rear engine mounting.
    1. Remove the air cleaner bracket.
    1. Remove the rear engine mounting.

  1. Loosen the front engine mounting.
  1. Remove the engine and transmission by lifting upwards.
  1. Lift the engine and transmission onto assembly table and secure using retaining strap.
  1. Separate engine from transmission.

In-vehicle Repair|Disassembly > < Oil Pump