Removing the Duratec 8V 1.6L engine

Special tool

	Engine lift bracket 303-122 (21-068A)
	Clamp removal/installation tool 303-397 (24-003)
	Axle puller 308-237 (16-087)

General equipment:

• Workbench
• Fixing clamps
• Engine lifting crane

All cars

WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.

1. Relieve fuel system pressure. Refer to Section 310-00 for additional information.

2. Disconnect the battery. For additional information, refer to Section 414-01.

3. Remove the air cleaner. For additional information, refer to Section 303-12.

4. Loosen the upper strut support nut with the spring assembly by five turns (on both sides).



5. Disconnect the fuel supply and return line quick release couplings. Refer to Section 310-00 for additional information.




6. Drain the coolant from the cooling system. Refer to Section 303-03 for additional information.

7. Using the special tool, disconnect the coolant hoses from the coolant circulation control unit.



8. Disconnect the brake booster vacuum line from the intake manifold.



9. Disconnect the plug connector of the electronic ignition (EI) unit.




10. Disconnect the accelerator cable from the throttle body and place it aside.

• 1. Disconnect the outer casing of the accelerator cable from the throttle body bracket.
• 2. Disconnect the inner accelerator cable from the throttle body lever.

11. Disconnect the engine wiring harness plug connector.



12. Disconnect the vacuum hose from the EVAP canister purge valve.




13. Disconnect the ground cable from the cylinder head.



14. Disconnect the plug connector of the transmission wiring harness in the block with the drive axle.



15. Disconnect the power steering pressure (PSP) switch connector.



16. Disconnect the power steering line bracket and ground cable from the transaxle.




17. Using the special tool, disconnect the coolant hose.



18. Remove the accessory drive belt. For additional information, refer to Section 303-05.

19. Disconnect the power steering pump from its bracket and secure it to the side.



20. Raise and support the vehicle. Refer to Section 100-02 for additional information.

21. Disconnect the starter electrical connections.



22. Using the special tool, disconnect the coolant hose.



23. Remove the gear shift cable cover.



24. Disconnect the gear shift cables from the transaxle.

• 1. Disconnect the gear shift cables and gear selector cable from the gear selector levers.
• 2. Turn the support sleeve clockwise and disconnect the cables from the bracket.

25. Disconnect the flexible exhaust pipe from the exhaust manifold. Discard the gasket as it is no longer needed.



Cars with air conditioning system

26. Disconnect the A/C compressor from its bracket and secure it to the side (shown with engine removed for clarity).



All cars

27. Remove the engine support mount.



28. Disconnect the lower arm from the steering knuckle (on both sides).



29.

CAUTION: Secure the axle shaft to prevent damage to the constant velocity joints. The inner joint should not be deflected more than 18 degrees. The outer joint should not be deflected more than 45 degrees.

CAUTION: Do not damage the axle shaft seal.

NOTE: Shut off the transaxle to prevent oil leakage and dirt ingress.

Disconnect the axle shaft together with the intermediate shaft from the gearbox in the block with the driving axle and secure it to the side.

• Remove the intermediate shaft bearing cap.
• Discard the bearing cover and locknuts as they are no longer needed.
• Allow the oil to drain into a suitable container.

30.

CAUTION: Secure the axle shaft to prevent damage to the constant velocity joints. The inner joint should not be deflected more than 18 degrees. The outer joint should not be deflected more than 45 degrees.

CAUTION: Do not damage the axle shaft seal.

NOTE: Shut off the transaxle to prevent oil leakage and dirt ingress.

Using the special tool, disconnect the left axle shaft from the transaxle and secure it to the side.

• Allow the oil to drain into a suitable container.
• Discard the snap ring as it is no longer needed.

31. Place the workbench under the engine assembly with the gearbox in the block with the drive axle.

32.

WARNING: Support the engine/transaxle assembly with wood blocks and secure it with appropriate clamps. Failure to follow this instruction may result in personal injury.

Carefully lower the vehicle so that the engine and gearbox assembly in the block with the drive axle stands on the workbench.



33.

CAUTION: If brake fluid comes into contact with the paintwork, the affected area must be immediately washed with cold water.

Disconnect the clutch slave cylinder feed line. Remove the spring-loaded clamp.



34. Remove the rear engine mount mounting nuts. Discard the nuts as they are no longer needed.



35. Remove the front engine mount mounting nuts. Discard the nuts as they are no longer needed.



36. Raise the vehicle and remove the engine assembly with the gearbox in the block with the drive axle.

37. Using the special tool, connect the engine assembly with the gearbox in the block with the drive axle to the crane to lift the engine.



38. Unscrew the left bolt securing the gearbox in the block with the drive axle.



39. Remove the starter.



40. Unscrew the right gearbox mounting bolts in the block with the drive axle.



41. Unscrew the lower bolts securing the gearbox in the block with the drive axle.



42. Unscrew the upper bolts securing the gearbox in the block with the drive axle.



43. Remove the gearbox in block with the drive axle.