With Manual Transaxle

Engine - Manual Transaxle





1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. Release the fuel system pressure. For additional information, refer to Fuel System - General Information Service and Repair.

3. Recover the A/C system. For additional information, refer to Climate Control System - General Information and Diagnostics Air Conditioning (A/C) System Recovery, Evacuation and Charging.

4. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering Air Cleaner and Air Cleaner Outlet Pipe.

5. Disconnect the crankcase vent tube from the valve cover.





6. Remove the battery tray. For additional information, refer to Battery, Mounting and Cables Battery Tray.

7. Disconnect the positive battery cable nut.





8. Detach the 2 positive battery cable wire harness retainer.





9. Remove the bolt and the negative battery cable ground.





10. Disconnect the fuel tube quick connect coupling from the fuel rail and position the fuel tube aside. For additional information, refer to Fuel System - General Information Service and Repair.





11. Disconnect the Evaporative Emission (EVAP) tube and position aside. For additional information, refer to Fuel System - General Information Service and Repair.





12. Disconnect the power brake booster vacuum tube.
- Depress the quick connect locking ring.

- Pull the vacuum tube out of the quick connect fitting.





13. Detach the brake booster vacuum hose retainer.





14. Detach and disconnect the 2 engine harness electrical connectors.





15. Detach the engine harness from the coolant outlet bracket harness retainer.





16. Disconnect the 3 PCM electrical connectors.





17. Disconnect the starter wire harness electrical connector.





18. Disconnect the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) connectors and detach the wire harness retainer.





19. Pressing the locking tab, disconnect the gearshift cables from the transaxle.

1. Disconnect the shift cable from the shift mass.

2. Disconnect the selector cable from the selector lever.





20. Remove the gearshift levers from the bracket.

1. Disconnect the shift cable from the retaining bracket by pulling the abutment sleeves rearward.

2. Disconnect the selector cable from the retaining bracket by pulling the abutment sleeve rearward.





21. 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, then disconnect the clutch hydraulic line.





22. Disconnect the hydraulic clutch line and grommet from the retaining bracket.





23. Remove the engine oil level indicator.





24. Remove the bolt and the radio capacitor ground cable.





25. Remove the 2 front wheels and tires. For additional information, refer to Wheels and Tires Removal and Replacement.

26. Remove the retainers and the splash shield.





27. Remove the accessory drive belt and tensioner. For additional information, refer to Accessory Drive Accessory Drive Belt and Accessory Drive Belt Tensioner.

28. Remove the generator. For additional information, refer to Charging System Service and Repair.

29. Detach the 4 B+ battery cable wire harness retainers (2 shown) and position aside.





30. Remove the 2 A/C tube nuts.





31. Remove the nut and the A/C tube bracket from the A/C compressor stud bolt.





32. Disconnect the A/C tubes from the compressor.
- Discard the 2 O-ring seals.





33. Drain the engine cooling system. For additional information, refer to Engine Cooling Cooling System Draining, Filling and Bleeding.

34. Remove the cooling fan motor and shroud. For additional information, refer to Engine Cooling Service and Repair.

35. Disconnect the lower radiator hose from the radiator.





36. Drain the engine oil.
- Install the drain plug and tighten to 28 Nm (21 lb-ft).





37. Remove the engine oil filter and discard.





38. Remove the LH halfshaft. For additional information, refer to Front Drive Halfshafts Removal and Replacement.

39. Remove the bolt and the power steering tube clip.





40. Remove the bolt and the power steering tubes from the steering gear.
- Discard the 2 power steering tube O-ring seals.





41. Remove the 2 nuts and disconnect the flexpipe from the catalytic converter.
- Remove and discard the nuts and gasket.





42. Remove the 2 catalytic converter support bracket-to-engine bolts.





43. Remove the 2 bolts and the catalytic converter support bracket.





44. NOTE: Mark the location of bolts for installation.

Remove the 6 bolts and the catalytic converter heat shield.





45. Remove and discard the 7 catalytic converter-to-engine nuts.





46. Position aside the catalytic converter and support with mechanic's wire.
- Remove and discard the catalytic converter gasket.

47. Remove the power steering pump. For additional information, refer to Power Steering Service and Repair.

48. Disconnect the upper radiator hose and the heater hose from the coolant bypass.





49. Disconnect the heater hose from the coolant tube.





50. Disconnect the throttle control electrical connector.





51. NOTE: The bolts are different lengths, mark the bolts for installation.

Remove the 2 bolts and the transaxle roll restrictor.





52. Remove the 2 lower bellhousing-to-oil pan bolts.





53. Remove the 2 oil pan-to-bellhousing bolts.





54. Using the Powertrain Lift and Universal Adapter Brackets, fasten the engine to the lift table.





55. Remove the 2 engine mount nuts.





56. Remove the 2 bolts, stud bolt and the engine mount.





57. Remove the 5 transaxle mount nuts and the transaxle mount plate.





58. Lower the engine and transaxle assembly from the vehicle.

59. Remove the nut for the HO2S and CMS wire connector bracket.





60. Remove the nut and position the HO2S and CMS wire connector bracket aside.





61. Disconnect the Vehicle Speed Sensor (VSS) electrical connector.





62. Disconnect the reversing lamp switch electrical connector.





63. Disconnect the A/C compressor electrical connector.





64. Disconnect the Power Steering Pressure (PSP) switch electrical connector.





65. Detach the 2 Crankshaft Position (CKP) sensor wire harness retainers.





66. Disconnect the CKP sensor electrical connector.





67. Remove the 2 nuts and disconnect the starter motor electrical terminals.





68. Detach the starter wire harness retainer from the starter motor stud bolt.





69. Remove the nut from the starter motor stud bolt and remove the power steering tube bracket.





70. Remove the bolt and the engine ground wire.





71. Remove the 2 power steering tubes and the wiring harness as an assembly.





72. Remove the bolt, stud bolt and the starter.





73. Remove the starter isolator.





74. Remove and discard the 7 catalytic converter manifold studs.





75. NOTE: Lower the engine to within a few inches of the floor.

Using the Heavy Duty Floor Crane, Engine Lifting Bracket and Spreader Bar, remove the engine and transaxle assembly from the lift table.





76. NOTE: Mark the bolts and stud bolts location for installation.

Remove the 3 bellhousing-to-engine bolts, 2 stud bolts and separate the engine and transmission.