ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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Engine - Vehicles With: CD4E-4-Speed Automatic Transmission > < Crankshaft Rear Seal

Mondeo 2001 (10.2000-02.2007)

Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) - Engine—Vehicles With: MTX-75/5-Speed Manual Transaxle Mondeo 2001 (10/2000-02/2007)
Removal

Special Tool(s)

Remover, Halfshaft

204-226 (16-092)

Adapter for 204-226

204-226-01 (16-092-01)

Slide Hammer

205-047 (15-011)

Lifting Bracket, Engine

303-122 (21-068A)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)
General Equipment
Workshop Table
Engine Hoist

Removal
  1. 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.
    Detach the positive crankcase ventilation (PCV) hose and the vacuum hose from the engine upper cover.

  1. Remove the engine upper cover.

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

  1. Loosen the strut and spring assembly top mount retaining nuts by four turns on both sides.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  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 from the air cleaner outlet pipe.

  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.

  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.

  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. Detach the gearshift cables from the transaxle.
    1. Pull the locking tabs from the ball and socket and detach the cables from the transaxle selector lever.
    1. Turn the abutment sleeves clockwise and detach the cables from the bracket.

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

  1. Disconnect the reversing lamp switch electrical connector.

  1. Detach the battery ground cables from the transaxle.

  1. Disconnect the vehicle speed (VSS) sensor electrical connector.
  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. 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 tools, detach the left-hand halfshaft from the transaxle and secure it to one side.
    • Discard the snap ring from the stub shaft.
    • Allow the oil to drain into a suitable container.

  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.
    • Allow the oil to drain into a suitable container.

  1. Remove the center bearing bracket.
  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.

  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. 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. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    Disconnect the clutch slave cylinder supply line from the transaxle.
    • Remove the spring clip.
  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 transaxle right-hand retaining bolts.

  1. Remove the transaxle left-hand retaining bolts.
    1. Remove the transaxle side retaining bolts.
    1. Remove the engine side retaining bolt.

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

Engine - Vehicles With: CD4E-4-Speed Automatic Transmission > < Crankshaft Rear Seal