Removing and installing the pallet (Mondeo 1 and 2)

Removal

Note: On pre-05/98 models, to perform this procedure with the power unit installed in the vehicle, you will need an assistant and special equipment to raise the vehicle (high enough to remove the oil pan from underneath) and to raise the power unit 50-75 mm above its mounts and support it with the vehicle already raised. The specifics of this procedure will vary depending on the equipment you are using. A typical procedure is outlined below. On 05/98 models after, there is no need to jack up the engine.

1. Apply the parking brake. Raise the front end and place it on stands.

2. Drain the engine oil. Then flush and install the drain plug. Tighten it to the specified torque. It is recommended (although not required) that you also replace the oil filter when changing the oil (chapter 1). Therefore, we advise you to remove and discard the old filter.

Models produced before 10.1996

3. Disconnect the negative battery cable (see Chapter 5, paragraph 1).

4. Drain the cooling system (chapter 1).

5. Disconnect the lower radiator hose from the radiator hose and heater pipe. Remove the mounting bolts and disconnect the coolant line from the pan. Disconnect the coolant hoses from the oil cooler (if equipped) if they interfere with removal of the pan.

6. Remove the two bolts securing the hydraulic steering line to the right side of the subframe.

7. Disconnect the electrical connectors of the oxygen sensor and (if equipped) the oil level sensor.



8. On automatic transmission models, trace the transmission fluid cooling line from the transmission to the radiator and loosen the line lines from their mountings so that they can be mixed as needed.

9. Remove the accessory drive belt cover (chapter 1).

10. Remove the exhaust downpipe from the manifold by loosening the appropriate nuts. Then release all rubber tie-downs and pull the exhaust system assembly out from under the vehicle, or remove just the downpipe/catalytic converter (Chapter 4A).

11. Remove the bolts securing the oil pan to the transmission and also release the lower engine/transmission adapter plate from its mounting.

12. Disconnect the wiring harness connectors, disconnect the vacuum hose (if equipped), and disconnect the crankcase ventilation hose from the cylinder head cover. Then remove the air cleaner assembly together with the air flow meter, resonator, and air duct chamber (Chapter 4A).

13. After this, you need to hang the power unit by the cargo eyes located on the cylinder head. Where necessary, screw in additional cargo eyes (see Fig. 16.13). Remove the front engine/transmission mount completely. Unscrew the central bolt of the rear mount and unscrew the bolts of the left mount from the body. Unscrew the six nuts securing the right mount bracket and remove the bracket.



14. Be careful not to damage the wiring, coolant hoses, radiator lines or transmission linkage and transmission support rods (depending on the version), as well as the electric fan of the radiator of the cooling system. Raise the power unit by 75 mm and securely fix it.



15. Loosen the oil pan mounting bolts one by one. Disconnect the joint by tapping the oil pan with your palm. Then lower the oil pan and pull it out along with the lower adapter plate of the power unit. Note the presence of any adjusting washers between the oil pan and the transmission.

16. Remove and discard the oil pan gasket. It should always be replaced after removal.

Models produced from 10.1998 to 05.1998

17. Remove the engine oil dipstick.

18. On models with a 2.0L engine, release the coolant hose from the fasteners on the exhaust manifold heat shield.

19. Remove the upper and lower bolts and remove the heat shield from the exhaust manifold.

20. Locate the wiring connector coming from the oxygen sensor located on the exhaust manifold and disconnect it.

21. Remove the nuts and detach the catalytic converter from the exhaust manifold. Support it on a support.

22. Use a hoist to lift the engine.

23. Loosen the upper support nut of the right suspension strut by 5 turns, holding the shock absorber rod with an Allen key.

24. Remove the protective shield from under the engine.

25. Remove the flange bolts and disconnect the catalytic converter from the intermediate section of the exhaust system. Release the converter from the rubber stretchers and remove it from under the car.

26. Remove the right drive shaft (Chapter 8).

27. Remove the center bolts from the front and rear engine roll limiters.

28. Remove the bolt and disconnect the coolant pipe bracket from the pan.

29. Mark the position of the right engine mount. Then unscrew the bolts and remove the bracket.



30. Raise the power unit by 75 mm and fix it securely.

31. Loosen the oil pan mounting bolts one by one. Disconnect the joint by tapping the oil pan with your palm. Then lower the oil pan and pull it out along with the lower adapter plate of the power unit. Note the presence of any adjusting washers between the oil pan and the transmission.

32. Remove and discard the oil pan gasket. It should always be replaced after removal.

Models produced since 05.1998

33. When the front of the car is raised, unscrew the mounting bolts of the pan in sequence (see Fig. 16.33). Disconnect the joint by tapping the pan with your palm. Then turn the pan 90°, lower it and pull it out. The pan does not have a gasket.

Installation

34. When installing, thoroughly clean the mating surfaces of the cylinder block/crankcase and sump and remove any grease from them. Then wipe the sump and the inside of the engine with a clean rag.

Models produced before 10.1996

35. Place a new gasket into the groove of the pan (see Fig. 16.35).



36. If you are installing the oil pan while the engine and transmission are connected and installed in the vehicle, follow these instructions:

• a) Make sure that the mating surfaces of the oil pan, cylinder block/crankcase and transmission are smooth and perfectly clean. If the oil pan was removed together with the adjusting washers, they must be installed in their places.
• b) Apply a thin layer of sealant (Ford recommends HYLOSIL102) to the joints of the cylinder block/crankcase with the oil pump and the cylinder block/crankcase with the left crankshaft oil seal housing. The oil pan bolts must be fully tightened within 10-20 minutes after applying the sealant. Raise the oil pan and the lower adapter plate of the power unit, install the bolts and tighten them slightly (see Fig. 16.36).
• c) After ensuring that the lower power unit adapter plate is installed correctly, press the oil pan against the transmission and tighten the oil pan to transmission mounting bolts to the specified torque.
• d) Without disturbing the position of the pallet, tighten the pallet bolts to the required torque in a cross sequence, starting from the middle to the edges.
• d) Follow the instructions in paragraph 38.

37. If you are installing the oil pan while the engine and transmission are separated (inside or outside the vehicle), follow these instructions:

• a) Apply a thin layer of sealant (Ford recommends HYLOSIL 102) to the joints of the cylinder block/crankcase with the oil pump and the cylinder block/crankcase with the left crankshaft oil seal housing. The oil pan bolts must be fully tightened within 10-20 minutes after applying the sealant. Raise the oil pan, install the bolts and tighten them slightly (see Fig. 16.37.a).
• b) Using a ruler (see Fig. 16.37.6) installed on the machined surfaces of the cylinder block and sump, align the left end of the sump (together with the washers, if you removed them together with the sump) flush with the left end of the cylinder block/crankcase. If the sump is not aligned, tighten its bolts to the required torque in a cross sequence, from the center to the edges.
• c) Check again that the exposed ends have not shifted. If necessary, unscrew the pan bolts again, clean the mating surfaces and repeat the entire procedure to ensure correct installation.
• d) If it is not possible to accurately adjust the tray, then to achieve the required position, place adjusting washers 0.25 mm thick (yellow) or 0.50 mm thick (black) (see Fig. 16.37, c).

38. Perform the remaining installation operations in the reverse order of removal, taking into account the following:

• a) Tighten all fasteners to the specified torque.
• b) Self-locking nuts removed during removal must always be replaced.
• c) Lower the power unit into place and restore the rear, left and right supports. The weight of the power unit should not be transferred to the supports, but should be supported by the lifting device until all supports are correctly aligned.
• d) Install the Ford special tool in place of the front support, tighten the fasteners of the power unit supports to the required torque in the specified sequence (Chapter 2B).
• d) Fill the cooling system (chapter 1).
• e) Fill the engine with oil and do not forget to install a new oil filter (chapter 1).
• g) Immediately after starting and warming up the engine to normal operating temperature, check for oil or coolant leaks.

Models produced from 10.1996 to 05.1998

39. Apply a thin layer of sealant to the joints on the cylinder block under the oil pump and the rear cuff housing, as well as the corresponding places on these components.

40. Place a new gasket on the pan and position the pan against the cylinder block. Insert the pan-to-block bolts and tighten them to the specified torque to stage 1.

41. Install the adapter plate. Then press the pan onto the clutch housing. Insert the pan-to-transmission mounting bolts and tighten them to the specified torque.

42. Tighten the oil pan to cylinder block mounting bolts to the specified torque in step 2.

43. Lower the engine and install its right support in the position marked during removal. Tighten the bolts and nuts to the specified torque.



44. Install the coolant pipe bracket and tighten the bolt.

45. Install and tighten the engine tilt limiter bolts. If necessary, check their position and adjust them (paragraph 23).

46. Install the right drive shaft (Chapter 8).

47. Install the catalytic converter (Chapter 4A).

48. Install the protective shield.

49. Tighten the right suspension strut upper support nut to the specified torque (Chapter 10).

50. Remove the lift.

51. Connect the oxygen sensor wiring connector.

52. Install the exhaust manifold heat shield and tighten its bolts.

53. On models with 2.0L engines, route the coolant hose to the support areas on the heat shield.

54. Install the oil level dipstick. Lower the vehicle to the ground and fill the engine with oil (Chapter 1).

Models produced since 05.1998

55. Apply a 3mm thick bead of sealant to the tray flange at a distance of about 5mm from its outer edge. The sealant should also surround the bolt holes. Install the tray within 10 minutes of applying the sealant.

56. Insert the bolts and tighten them sequentially to the required torque (see Fig. 16.56).



57. Lower the car to the ground and fill the engine with oil (chapter 1).