Engine - Manual Transaxle
Engine - Manual Transaxle
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Release the fuel system pressure.
3. Remove the Air Cleaner (ACL) and ACL (Air Cleaner) outlet pipe.
4. Disconnect the crankcase vent tube from the valve cover.
- Detach the 2 crankcase vent tube retainers and remove the tube.
5. Remove the positive battery cable cover.
6. Remove the battery.
7. Remove the nut and cable from the positive battery cable terminal.
8. Remove the bolt and the PCM cover.
9. Disconnect the 3 PCM electrical connectors.
10. Remove the 3 bolts and the battery tray.
11. Detach the 2 positive battery cable wire harness retainers from battery tray bracket.
12. Remove the 3 battery tray nuts and the battery tray bracket.
- Detach the 2 wiring harness retainers from the battery tray bracket.
13. Disconnect the engine harness electrical connector.
14. Disconnect the brake booster vacuum hose.
15. Disconnect the fuel tube spring lock couplings from the fuel rail.
16. Detach the fuel tube from the coolant outlet bracket retainer.
17. Remove the generator.
18. Drain the cooling system.
19. Remove the degas bottle.
20. Release the 7 retainers (2 shown) and remove the gearshift cable cover.
21. Remove the gearshift cables.
1. Using a suitable tool, lightly pry the gearshift cables off the transaxle shift control levers.
2. Remove the gearshift cable by pulling the lower part of abutment down and removing from the brackets.
22. Remove the cooling fan motor and shroud.
23. Disconnect the 2 coolant hoses from the engine oil cooler.
- Detach the oil cooler hose retainer from the upper radiator hose.
24. Remove the Heated Oxygen Sensor (HO2S).
25. Disconnect the lower heater hose from the heater core.
26. Detach the coolant hose retainer from the coolant outlet bracket.
27. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling near the bulk head.
28. Disconnect the upper radiator hose from the engine.
29. Disconnect the lower radiator hose and coolant hose from the thermostat housing.
30. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.
Remove the clip and disconnect the clutch hydraulic hose.
31. Detach the clutch hydraulic hose from the transaxle retainer.
32. Remove the bolt and position the engine ground wire aside.
33. Remove the RH and LH halfshafts.
34. Remove the 3 bolts and the halfshaft bracket.
Vehicles with A/C
35. Disconnect the A/C compressor electrical connector.
36. Remove the nut and position the A/C line bracket aside.
37. Disconnect the A/C pressure transducer electrical connector.
- Detach the wiring harness retainer.
38. Detach the wiring harness retainer from the lower A/C compressor bracket.
39. Remove the 2 bolts, stud bolt and position the A/C compressor aside and support with a length of mechanic's wire.
Vehicles without A/C
40. Remove the 3 bolts and the accessory drive belt idler pulley bracket.
All vehicles
41. Remove the Catalyst Monitor Sensor (CMS).
42. Remove the 2 catalytic converter-to-muffler nuts and separate.
- Discard the gasket.
43. NOTICE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.
Support the exhaust flexible pipe with a support wrap or suitable splint.
44. Remove the 4 bolts and the lower catalytic converter bracket.
45. Remove the 4 bolts and the catalytic converter heat shield.
46. Remove the 4 catalytic converter nuts and bolt.
- Discard the bolt and 4 nuts.
47. Position the catalytic converter back and secure with mechanic wire.
- Discard the catalytic converter gasket.
48. Clean and inspect the catalytic converter flange.
49. If equipped, disconnect the block heater electrical connector.
50. Drain the engine oil.
- Install the drain plug and tighten to 28 Nm (21 lb-ft).
51. Remove and discard the engine oil filter.
52. Using the Powertrain Lift and Adjustable Grip Arms, secure the engine to the lift table.
53. Remove the bolt for the transaxle roll restrictor.
54. NOTICE: The engine mount studs must be held while removing the engine mount nuts or damage to the powertrain may occur.
NOTE: Do not loosen the engine mount center bolt or the engine may become improperly positioned.
Use the holding feature to prevent the engine mount studs from turning, remove the 2 engine mount nuts.
55. Remove the 3 bolts and the engine mount.
56. Remove the 2 bolt, 2 nuts and the transaxle support insulator.
57. Lower the engine and transaxle assembly from the vehicle.
58. Remove the 4 catalytic converter studs and discard.
59. Detach the 2 wiring harness retainers from the coolant outlet bracket.
60. Disconnect the ignition coil and Engine Coolant Temperature (ECT) sensor electrical connectors.
61. Detach the HO2S (Heated Oxygen Sensor) sensor electrical connector pin-type retainer from the bracket.
62. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors.
63. Detach and disconnect the LH Knock Sensor (KS) electrical connector.
64. Disconnect the Variable Camshaft Timing (VCT) oil control solenoid electrical connectors.
- Detach the 2 wiring harness retainers.
65. Disconnect the 4 fuel injector electrical connectors.
- Detach the wiring harness retainers from the valve cover stud bolts.
66. Disconnect the EVAP (Evaporative Emission) canister purge valve electrical connector.
67. Disconnect the Throttle Body (TB) electrical connector.
- Detach the 2 wiring harness retainers from the TB (Throttle Body).
68. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
69. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
- Detach the wiring harness retainer from the engine block.
70. Disconnect the RH KS (Knock Sensor) electrical connector.
- Detach the 2 wiring harness retainers from the intake manifold.
71. Remove the 2 nuts and disconnect the starter motor electrical terminals.
72. Remove the 3 bolts (2 shown) and the starter motor.
73. Detach the wiring harness pin-type retainer and remove the 2 upper bellhousing-to-engine bolts and bracket.
74. NOTE: Lower the engine to within a few inches of the floor.
Using the Floor Crane and Spreader Bar, remove the engine and transaxle assembly from the lift table.
75. Remove the 6 clutch housing-to-engine bolts and separate the engine and transaxle.
