Removing and installing the engine (Mondeo 1)

The engine is removed downwards together with the gearbox, which is attached to the engine by means of a flange, so we recommend reading the section "Removing and installing the gearbox", before proceeding to remove the engine. To remove the engine, you will need a crane or a winch. Since the engine together with the gearbox must be removed from under the car, the car must be driven onto a mounting pit or mounting platform. Before working in the engine compartment, the fenders must be covered with rags.

Depending on the year and equipment, electrical wires, possibly vacuum hoses and coolant hoses, may be routed and connected differently in the engine bay. Since it is impossible to choose each option separately, mark the relevant wires with adhesive tape before removing them. The following describes the removal of a gasoline engine with a manual transmission.

Removal

Disconnect the negative (-) cable from the battery.

Warning! This will erase data in electronic memory devices, such as the engine fault memory device or the radio code. Please read the section carefully "Removing and installing the battery", before disconnecting it.

Remove the air filter and air intake pipe, see p. 5.6.



Press the plastic tabs on the fuel supply lines "1" and remove the fuel lines. When removing the fuel line, wrap it with a rag to prevent the fuel flowing out of it from splashing. The fuel lines must be closed with suitable plugs, for example, a clean screw of suitable diameter can be inserted as a plug. To facilitate installation, mark the fuel lines with adhesive tape when removing.

Caution: Remove the fuel lines carefully so that the pressure in the fuel system is released gradually.

Remove clamp "2" and disconnect the gas rod.



Remove the plug "1" of the power steering push switch. Unscrew the bracket for the pressure pipe "2" from the engine.

Unscrew the ground wire from the engine lifting eye.



Remove the vacuum hoses from the fuel pressure regulator "2" and from the suction pipe. The figure also shows: 1 - fuel return hose; 3 - distribution pipe; 4 - valve; 5 - plug for jet; 6 - fuel supply.



Remove the vacuum hoses from the exhaust gas recirculation valve branch pipe "4", "3" at the measurement point "2" of the pipe "1". Remove the engine ventilation hose near the ignition coil.



From the bottom of the vehicle, remove the vacuum hose from the pulse air system control valve "5".

Unbolt the front exhaust pipe from the exhaust manifold. Release the exhaust system from all hangers and remove it, see item 8.



Unscrew the wheel arch trim "1", remove the protective cover of the belt pulley "2".

Remove the V-belt, see paragraph 1.19.

Disconnect the ground wire from the gearbox.

Disconnect the clutch release rod from the gear shift lever.



Disconnect plug "1" and the engine wiring harness multi-pin plug "2".



Pull the power steering receiver "1" up from the holders. Unscrew the ground wire "3". Unscrew the bolt "4", disconnect the plug "2" from the engine control unit.





At bracket "1" on the front wall, disconnect the ignition module wire plug "2" (only in models with automatic transmission), differential pressure converter "3", pulse air supply solenoid valve "4" and vacuum regulator "5". Disconnect the wire bundle from the front wall.

Unscrew the heat shield from the exhaust manifold.

Raise the car onto jack stands.

Drain the oil, see p. 10.6.

Drain the coolant, see p. 3.3.

Loosen the hose clamps and remove the lower coolant hose from the radiator. On vehicles with an oil cooler, also disconnect the coolant hoses from the oil filter flange.

Loosen the hose clamps and remove the coolant hoses from the thermostat, see p. 3.5.

Remove the pressure hose and the expansion tank hose from the power steering pump. Collect the leaking hydraulic fluid in a container. Remove the power steering pump, see item 13.4.

Cars with air conditioning

Warning! The air conditioner coolant circuit must not be opened. The coolant contains components that can cause frostbite if they come into contact with the skin. You can remove the engine without opening the coolant circuit.

Unscrew the mounting bolts (arrows in the figure) of the air conditioner compressor (do not disconnect the hoses) and hang it with a wire so that it does not interfere during dismantling, the hoses should not be stretched. Disconnect the magnetic clutch plug.





Disconnect the brake booster hose from the intake manifold. To do this, lightly press the retaining clip on the intake manifold into the manifold and hold it in this position, carefully pull the vacuum hose out of the spring sleeve.

Remove the left and right propeller shafts, see item 11.8.

Loosen the shift fork rod mounting bolt. Unscrew the shift fork rod and its support from the gearbox.



Unscrew the heat shield of the gearshift lever. Move the gearshift levers back and tie them with wire at the top to the body frame.



Remove the bolts, remove the air conditioner dryer (if any) and tie it with wire to the body frame.





Unscrew the mounting bolts "1" of the steering mechanism on the auxiliary frame.

Unscrew the central bolts "2" on the engine support points. Unscrew the bolts "3" and remove the bracket from the auxiliary frame.

Unscrew the engine mount bracket from the gearbox.



Remove the center bolt on the front engine support bracket.



Support the auxiliary frame with a garage jack. Remove the mounting bolts, lower and remove the auxiliary frame.



Unscrew the tachometer located near the flange of the left drive shaft from the gearbox.

Support the gearbox with a jack, using wooden blocks to prevent possible damage.



Raise the engine slightly with a winch or crane.

Right engine mount

Left engine mount

Unscrew the fastening nuts "arrows" of both engine mounts.



Make sure all wires and hoses coming from the engine are removed.

Lower the block consisting of the engine and gearbox down from the engine compartment.

Installation

Check engine mounts and coolant, oil and fuel hoses for pores and cracks, and replace the relevant parts if necessary.

Only new self-locking nuts may be used on engine mounts.

If the car has a high mileage, the engine and gearbox must be disconnected. Check whether the clutch release bearing rotates easily, check the ease of movement of the clutch release lever, replace them if necessary. Check whether the friction lining on the driven disk of the clutch is thick enough, check the condition of the clutch, replace if necessary, see item 9.

Insert the block consisting of the gearbox and engine from below into the engine compartment, making sure that the engine mounts are seated correctly.

Install the engine mount nuts, but do not tighten them yet.

Install the left and right propeller shafts, see item 11.8.

Engage the brake booster vacuum hose into the snap-on lock on the intake manifold.

Vehicles with air conditioning: Install the air conditioning compressor and tighten the bolts to 30 Nm.

Connect the lower coolant hose to the radiator, secure it with a spring clamp. A screw clamp can be used instead of a spring clamp.

Using the markings made during dismantling, connect the coolant hoses to the coolant pump and thermostat, as well as to the oil radiator, and secure the hoses with clamps.



Using a jack, install the subframe, screw in the bolts, but do not tighten them. Correctly orient the subframe by inserting suitable mandrels into the holes in the subframe and in the underbody of the vehicle. In this position, tighten the four subframe mounting bolts. Tightening torques are 110-150 Nm. Remove the mandrels.

Relieve tension on the engine by rocking it. The engine should move freely in the front mount.

Tighten the right and left engine mount nuts to 90 Nm.

Remove the jack and crane.

Using three bolts, tighten the rear engine mount to the gearbox to a torque of 90 Nm.

Screw the rear engine support to the auxiliary frame, tightening torque of the bolts 50 Nm. Tighten the central bolt of the engine support with a torque of 120 Nm, the engine must not be pressed to the side. The support must not be under tension.

Tighten the steering gear mounting bolts to a torque of 130 Nm.

Tighten the front engine mount center bolt to 120 Nm.

Screw on the air conditioner dryer where applicable.

Screw on the shift levers, install the heat shield for the shift levers. Adjust the shift mechanism, see p. 10.2.

Install the power steering pump, see item 13.4.

Screw on the heat shield for the exhaust manifold. At the same time, screw on the bracket for the coolant pipe and oil level indicator.

Connect the main engine wire harness to the control unit, tighten the mounting bolts. Screw in the ground wire.

Install the power steering fluid reservoir

Completely install the exhaust gas starting system, see p. 8.3.

Lower the car onto its wheels

Install all electrical wires and vacuum hoses according to the markings made during dismantling, tighten their fasteners. Screw the ground wire to the gearbox.

Install the gas rod.

In accordance with the markings made during dismantling, connect the supply and return fuel lines and snap the quick-release coupling into place.

Connect the ventilation hose to the cylinder head.

Install the V-belt, see paragraph 1.19.

Install the belt pulley protective cover.

Connect the clutch rod and adjust the clutch. see p. 9.3.

Install the air filter and air intake pipe, see p. 5.6.

Fill the engine and gearbox with oil, see paragraphs. 10.6, 28.1.1.

Check if the coolant contains antifreeze and add it, see p. 3.3.

Install the lower radiator grille.

Fill the hydraulic power steering reservoir with hydraulic fluid, bleed the hydraulic booster, see paragraph 28.4.5.

Connect the negative (-) wire to the battery. Set the clock and set the anti-theft code for the radio.

Warm up the engine to operating temperature, check fluid levels everywhere, check all connections for leaks.

Adjust the front wheel alignment (work performed in a workshop).

[A copy of the article is available on the website: FordBook.ru]