With Manual Transmission
NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.
Special Tools:
Materials:
Removal
NOTE: The locations of engine mountings and engine support insulators are given looking from the transaxle to the engine.
1. Disconnect the battery ground cable.
2. Put the gearshift lever into neutral.
3. Using the special tool, lock the gearshift lever in neutral.
^ Unclip the boot from the gearshift lever and insert the special tool.
4. Remove the hood.
^ Disconnect the hose and remove the bolts (right hand side shown).
5. NOTE: Use an Allen Key to stop the piston rod from turning.
Loosen the suspension strut locknut five turns on both sides (right hand side shown).
6. WARNING: When releasing the system pressure, cover the expansion tank cap with a thick cloth to prevent the possibility of coolant scalding. Failure to follow these instructions will result in personal injury.
Relieve the cooling system pressure.
^ Unscrew the cap slowly.
7. Raise and support the vehicle.
8. Remove the both front wheels.
9. Remove the radiator splash shield (nine bolts) and remove the brackets on both sides (left-hand side shown).
10. WARNING: When the engine is hot there is a risk of scalding. Failure to follow these instructions may result in personal injury.
Drain the coolant.
^ Tighten the drain plug back up again.
11. Lower the vehicle.
12. Remove the air intake tube.
1 Disconnect the mass air flow (MAF) electrical connector.
2 Disconnect the intake air temperature (IAT) sensor electrical connector.
3 Remove one bolt, two nuts.
4 Disconnect two clips.
^ Remove the air intake tube (push fit).
13. Remove the air cleaner (ACL).
1 Remove the crankcase ventilation hose.
2 Remove the air hose.
3 Unhook the rubber ring.
^ Pull the ACL out upwards (push fit).
14. Remove the battery.
15. Disconnect the cables and the electrical connector.
1 Battery cable
2 Electrical connector
3 Ground cable
16. Loosen the Central Junction Box (CJB) and position it to one side.
17. Remove the four battery bracket bolts and remove the two ground cables.
18. Remove the battery bracket.
19. Disconnect the main wiring harness from the Powertrain Control Module (PCM).
1 Take out the power steering reservoir (push fit) and position it to one side.
2 Open the wiring bracket.
3 Disconnect the two ground cables.
4 Disconnect the main wiring harness electrical connector from the PCM.
20. Remove the ground cable from the engine lifting eye and disconnect the power steering pressure (PSP) switch.
21. Disconnect the wiring.
1 Engine wiring harness electrical connector
2 Transaxle ground cable
3 Remove the cable tie.
22. Disconnect the speed control cable.
1 Disconnect the cable from throttle valve.
2 Gently move the cable up and down and pull it out off the retaining bush.
3 Press the retaining bush out of the bracket.
23. Disconnect the throttle cable.
^ Unhook the cable.
^ Pull off the plastic clip and lay the throttle cable to one side.
24. Disconnect the vacuum hoses from the intake manifold.
25. Remove the heat shield.
1 Remove the upper bolts.
^ Remove the coolant hose brackets, and pull out the engine oil level indicator tube.
2 Remove the bolt.
3 Remove the bracket for the coolant tube.
26. Disconnect the coolant hoses and remove the coolant pipe.
1 Remove the coolant pipe.
2 Remove the coolant hose from the coolant pipe.
3 Remove the coolant hose from the water pump.
27. Remove the Three-Way Catalytic Converter (TWC) from the exhaust manifold.
Vehicles with air conditioning
28. Disconnect the compressor electrical connector (without accessory drive belt shown).
All Vehicles
29. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
30. Disconnect the electrical connector and the upper coolant hoses.
1 Unclip the wiring harnesses.
2 Disconnect the coolant hoses.
3 Disconnect fan motor electrical connector.
31. Remove the clamp from the fender apron panel and remove the coolant hoses.
32. Remove the upper accessory drive belt cover.
CAUTION: Block off the hose connections to prevent fluid loss or dirt contamination.
33. WARNING: Brake fluid may leak out. Observe the safety procedures for handling brake fluid. Failure to follow these instructions may result in personal injury.
Disconnect the clutch slave cylinder.
1 Pull out the clip and pull off the pipe.
2 Disconnect the slave cylinder pipe from the transaxle and tie it UP.
^ Disconnect the ground cable from the transaxle.
34. Raise and support the vehicle.
35. Remove the fender splash shields (right-hand side shown).
36. Loosen and remove the accessory drive belt.
37. Disconnect the brake booster vacuum line from the intake manifold.
^ Disconnect the quick-release coupling and pull out the line.
38. Remove the radiator brackets and disconnect both Heated Oxygen Sensor (H02S) electrical connectors.
^ Cut the cable ties.
39. Disconnect the front exhaust tube and unhook it.
^ Discard the gasket.
40. CAUTION: Do not damage boot and ABS sensor ring.
Disconnect the lower suspension arm ball joints from the wheel knuckles.
^ Disconnect the ABS wiring harness bracket from the suspension strut.
CAUTION: To avoid to damage the halfshaft joints and boots, do not bend the inner halfshaft joint by more than 18 degrees, the outer one by not more than 45 degrees.
NOTE: Collect escaping oil. Close off the transaxle opening with plug.
41. Using the special tools, release the left-hand drive halfshaft.
42. Withdraw the drive halfshaft and tie it up.
43. Using the special tool, remove the right-hand halfshaft.
^ Secure the Tight-hand halfshaft out of the way with mechanics wire.
44. Remove the right-hand engine support insulator.
1 Remove the center bolt.
2 Remove the bracket bolts.
45. Remove the bracket for the right-hand engine support insulator from the transaxle.
46. NOTE: If necessary raise the transaxle slightly with a transmission Jack.
Remove the left-hand engine support insulator and the Three-Way Catalytic Converter (TWC).
1 Remove the nuts.
2 Remove the center bolt.
3 Loosen the TWC bracket.
^ Remove the TWC.
Vehicles with air conditioning
47. Remove the suction accumulator bracket bolts.
All Vehicles
48. Disconnect the lower coolant hose.
49. Disconnect the heater coolant hoses.
Vehicles with air conditioning
50. Remove the compressor bolts and position the compressor with mechanics wire to one side.
All Vehicles
51. NOTE: Press the adjustment mechanism in until it clicks in place.
Disconnect the shift. cables from the transaxle.
1 Disconnect the shift cable from the gear shift lever.
2 Release the abutment bracket by turning it counter-clockwise and remove the cable from the bracket.
3 Disconnect the shift cable from the gear selector lever.
4 Release the abutment bracket by turning it counter-clockwise and remove the cable from the bracket.
5 Release the adjustment mechanism by pressing it in.
52. Lower the vehicle.
53. Relieve the fuel pressure.
54. Using the special tools, disconnect the fuel lines.
^ Take off the retaining clips.
55. Disconnect the coolant expansion tank and position it to one side.
^ Disconnect the speed control cable (if equipped) from the coolant expansion tank.
56. Remove the TWC bracket.
57. Install the special tools 303-050 and 303-D089. Using the special tools, engine lifting eyes and a Suitable Floor Crane, raise the engine/transaxle assembly slightly to remove the pressure from the support insulator.
58. Remove the front engine support insulator.
1 Remove the nuts.
2 Loosen the bolts two turns.
59. NOTE: Mark up the position.
Remove the rear transaxle support insulator.
1 Remove the nuts.
2 Remove the bolts.
CAUTION: Make sure, that the pipes and hoses are not in stress.
60. Raise the engine/transaxle assembly, until the power steering pump is accessible. Remove the power steering pump bolts and position the pump with mechanics wire to one side.
CAUTION: The engine/transaxle assembly has to be in a diagonal position to pull it out below the tube/hose (A/C). Make sure, that the tube/hose (A/C) is not in stress.
61. Remove the engine/transaxle assembly.
62. Using the special tools and a Suitable Floor Crane, move the engine/transaxle assembly and secure the transaxle with Securing Straps to the powertrain lift (automatic transaxle shown).
63. Disconnect the reversing lamp switch and the Vehicle Speed Sensor (VSS) electrical connector.
64. Disconnect the starter motor electrical connections.
65. Remove the upper transaxle flange bolts.
^ Remove the upper starter motor bolts.
^ Remove two flange bolts.
^ Disconnect the ground cable from the transaxle.
66. Remove the transaxle flange bolts on the right-hand side of the transaxle and the lower starter motor bolt.
^ Take out the starter motor and the wiring harness.
67. Remove the transaxle flange bolts on the left-hand side of the transaxle.
68. Separate the transaxle from the engine.