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In-vehicle Repair|Disassembly > < Engine - Vehicles With: MTX-75-5-Speed Manual Transaxle

Mondeo 2001 (10.2000-02.2007)

Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) - Engine—Vehicles With: CD4E/4-Speed Automatic Transmission Mondeo 2001 (10/2000-02/2007)
Removal

Special Tool(s)

Lifting Bracket, Engine

303-122 (21-068A)

Remover/Installer, Hose Clamp

303-397 (24-003)

Remover, Transmission Fluid Cooler

307-242 (17-049)

Remover, Halfshaft

308-256 (16-089)
General Equipment
Workshop Table
Engine Hoist

Removal

All vehicles
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 mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. Detach the positive crankcase ventilation (PCV) hose and the vacuum hose from the engine cover.

  1. Remove the engine cover.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Remove the strut and spring assembly top mount brace cover on both sides.

  1. Loosen the strut and spring assembly top mount nuts by four turns on both sides.
  1. Drain the cooling system. For additional information, refer to Section  303-03 Engine Cooling.

  1. Remove the air cleaner housing.
    1. Detach the hose clamp from the air cleaner outlet pipe.
    1. Disconnect the PCV hose.

  1. Detach the accelerator cable from the retaining bracket and position it to one side.
    1. Detach the inner cable from the throttle body.
    1. Turn the cable out of the bracket.
Vehicles with speed control
  1. Detach the speed control cable from the retaining bracket and position it to one side.
    1. Detach the speed control cable retaining bracket from the throttle body.
    1. Detach the inner cable from the throttle body.
All vehicles
  1. Disconnect the wiring harness electrical connectors.

  1. Disconnect the engine wiring harness.
    • Remove the clip.

  1. Disconnect the generator electrical connectors.

  1. Detach the power steering line bracket from the valve cover.

  1. Using the special tool, disconnect the coolant hoses.

  1. Using the special tool, disconnect the coolant hose from the expansion tank.
    • Remove the clip.

  1. Detach the coolant expansion tank from the wheel housing and position it to one side.

  1. Disconnect the fuel supply line. For additional information, refer to Section  310-00 Fuel System - General Information.

  1. Disconnect the vacuum hoses.

  1. Remove the cooling fan motor and shroud.
    1. Disconnect the electrical connectors.
    1. Remove the nut on both sides (left-hand side shown).

  1. Disconnect the transmission range (TR) sensor electrical connector.

  1. Disconnect the automatic transmission control electrical connector.
    • Remove the wiring harness retaining clip.
    • Remove the cable ties.

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

  1. Disconnect the ground cable from the transaxle.
  1. Remove the subframe. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.

  1. Disconnect the wiring harness electrical connectors.

  1. Disconnect the output shaft speed (OSS) sensor electrical connector.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    NOTE:
    NOTE:Plug the transaxle to prevent oil loss or dirt ingress.
    Using the special tool, detach the left-hand halfshaft from the transaxle and secure it to one side.
    • Discard the snap ring.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    NOTE:
    NOTE:Plug the transaxle to prevent oil loss or dirt ingress.
    Detach the right-hand halfshaft and the intermediate shaft from the transaxle and secure it to one side.
    • Remove and discard the center bearing cap and locknuts.
  1. Remove the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. Disconnect the crankshaft position (CKP) sensor electrical connector.
Vehicles built up to 03/2003
  1. CAUTION:
    CAUTION:Prevent the fluid pipe adapter from turning using an open-ended wrench, do not remove it from the transaxle housing.
    NOTE:
    NOTE:Cap the fluid cooler openings to prevent oil loss and dirt ingress.
    Detach the fluid cooler pipe from the transaxle.
    • Detach the fluid pipe bracket from the transaxle.

  1. CAUTION:
    CAUTION:Prevent the fluid pipe adapter from turning using an open-ended wrench, do not remove it from the transaxle housing.
    NOTE:
    NOTE:Cap the fluid cooler openings to prevent oil loss and dirt ingress.
    Detach the fluid cooler return pipe from the transaxle.
Vehicles built 03/2003 onwards
  1. NOTE:
    NOTE:Plug the fluid cooler openings to prevent oil loss or dirt ingress.
    Using the special tool, disconnect the fluid cooler pipes.
    1. Insert the special tool into the quick release coupling.
    1. Slide the special tool along the pipe to release the locking tangs.
    • Allow the fluid to drain into a suitable container.
All vehicles
  1. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
    • Remove the cable retaining clip.

  1. CAUTION:
    CAUTION:Support the air conditioning (A/C) compressor before removing the retaining bolts and secure it to prevent load being placed on the refrigerant lines.
    Detach the A/C compressor from the mounting bracket and secure it to one side.

  1. Using the special tool, disconnect the coolant hose from the radiator.

  1. Disconnect the wiring harness.
  1. Lower the vehicle.

  1. Remove the engine wiring harness support bracket.

  1. Disconnect the power steering hose from the power steering fluid reservoir.
    • Allow the fluid to drain into a suitable container.

  1. NOTE:
    NOTE:The power steering fluid reservoir contains a filter. If the power steering fluid is contaminated a new power steering fluid reservoir must be installed.
    Remove the power steering fluid reservoir.
    1. Remove the rear retaining stud.
    1. Remove the front retaining bolts.
    • Discard the O-ring seals.

  1. Remove the power steering line support retaining nut.
  1. Remove the power steering pump pulley. For additional information, refer to Section  211-02 Power Steering.

  1. Disconnect the power steering line from the power steering pump.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Position the workshop table under the vehicle and carefully lower the vehicle, until the engine and transaxle assembly is in the correct position to remove the engine mounts.

  1. CAUTION:
    CAUTION:Do not support the oil pan.
    NOTE:
    NOTE:Using suitable securing straps, secure the engine and the transaxle on a workshop table.
    Using suitable wooden blocks, support the engine and transaxle assembly.

  1. Remove the engine front mount.

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

  1. Using a suitable engine hoist support the engine and transaxle assembly and remove the securing straps.

  1. Remove the wiring harness retaining bracket.

  1. Remove the starter motor.
    • Detach the wiring harness from the retaining bracket.

  1. Remove the rubber cover and the four torque converter retaining nuts.
    • Rotate the engine to gain access to the nuts.
    • Discard the nuts.

  1. Remove the transaxle upper retaining bolts.

  1. Remove the transaxle lower retaining bolts.

  1. Remove the transaxle right-hand retaining bolts.

  1. Remove the transaxle left-hand retaining bolts.
  1. CAUTION:
    CAUTION:Make sure that the torque converter remains in the transaxle.
    Remove the transaxle from the engine.

In-vehicle Repair|Disassembly > < Engine - Vehicles With: MTX-75-5-Speed Manual Transaxle