Manual Transaxle

Engine - Manual Transaxle





All vehicles

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. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering [1][2]Diagrams.

4. Disconnect the crankcase vent tube from the valve cover.
- Detach the 2 crankcase vent tube retainers and remove the tube.





5. Remove the positive battery cable cover.





6. Remove the battery. For additional information, refer to Battery, Mounting and Cables Battery And Battery Tray - Exploded View.

7. Remove the nut and cable from the positive battery cable terminal.





8. Remove the bolt and the PCM cover.





9. Disconnect the 3 PCM electrical connectors.





10. Remove the 3 bolts and the battery tray.





11. Detach the 2 positive battery cable wire harness retainers from battery tray bracket.





12. Remove the 3 battery tray nuts and the battery tray bracket.
- Detach the 2 wiring harness retainers from the battery tray bracket.





13. Disconnect the engine harness electrical connector.





14. Disconnect the brake booster vacuum hose.





15. Disconnect the fuel tube spring lock couplings from the fuel rail. For additional information, refer to Fuel System - General Information Spring Lock Couplings.





16. Detach the fuel tube from the coolant outlet bracket retainer.





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

18. Remove the 2 bolts and the accessory drive belt splash shield.





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

20. Remove the degas bottle. For additional Information, refer to Engine Cooling Service and Repair.

21. Release the 7 retainers (2 shown) and remove the gearshift cable cover.





22. Remove the gearshift cables.

1. Using a suitable tool, lightly pry the gearshift cables off the transaxle shift control levers.

2. Remove the gearshift cable by pulling the lower part of abutment down and removing from the brackets.





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

24. Remove the Heated Oxygen Sensor (HO2S).

25. Disconnect the lower heater hose from the heater core.





26. Detach the coolant hose retainer from the coolant outlet bracket.





27. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling near the bulk head. For additional information, refer to Fuel System - General Information Quick Connect Coupling.





28. Disconnect the 2 coolant hoses from the engine oil cooler.
- Detach the oil cooler hose retainer from the upper radiator hose.





29. Disconnect the upper radiator hose from the engine.





30. Disconnect the lower radiator hose and coolant hose from the thermostat housing.





31. 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 and disconnect the clutch hydraulic hose.





32. Detach the clutch hydraulic hose from the transaxle retainer.





33. Remove the bolt and position the engine ground wire aside.





34. Remove the RH and LH halfshafts. For additional information, refer to Front Drive Halfshafts Removal and Replacement.

35. Remove the 3 bolts and the halfshaft bracket.





Vehicles with A/C

36. Disconnect the A/C compressor electrical connector.





37. Remove the nut and position the A/C line bracket aside.





38. Disconnect the A/C pressure transducer electrical connector.
- Detach the wiring harness retainer.





39. Detach the wiring harness retainer from the lower A/C compressor bracket.





40. Remove the 2 bolts, stud bolt and position the A/C compressor aside and support with a length of mechanic's wire.





Vehicles without A/C

41. Remove the 3 bolts and the accessory drive belt idler pulley bracket.





All vehicles

42. Remove the Catalyst Monitor Sensor (CMS).

43. Remove the 2 catalytic converter-to-muffler nuts and separate.
- Discard the gasket.





44. NOTICE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.

Support the exhaust flexible pipe with a support wrap or suitable splint.





45. Remove the 4 bolts and the lower catalytic converter bracket.





46. Remove the 4 bolts and the catalytic converter heat shield.





47. Remove the 4 catalytic converter nuts and bolt.
- Discard the bolt and 4 nuts.





48. Position the catalytic converter back and secure with mechanic wire.
- Discard the catalytic converter gasket.

49. If equipped, disconnect the block heater electrical connector.

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





51. Remove and discard the engine oil filter.





52. Using the Powertrain Lift and Universal Adapter Brackets, secure the engine to the lift table.





53. Remove the bolt for the transaxle roll restrictor.





54. NOTICE: The engine mount studs must be held while removing the engine mount nuts or damage to the powertrain may occur.

NOTE: Do not loosen the engine mount center bolt or the engine may become improperly positioned.

Use the holding feature to prevent the engine mount studs from turning, remove the 2 engine mount nuts.





55. Remove the 3 bolts and the engine mount.





56. Remove the 2 bolt, 2 nuts and the transaxle support insulator.





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

58. Remove the 4 catalytic converter studs and discard.





59. Detach the 2 wiring harness retainers from the coolant outlet bracket.





60. Disconnect the ignition coil and Engine Coolant Temperature (ECT) sensor electrical connectors.





61. Detach the HO2S sensor electrical connector pin-type retainer from the bracket.





62. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors.





63. Detach and disconnect the LH Knock Sensor (KS) electrical connector.





64. Disconnect the Variable Camshaft Timing (VCT) oil control solenoid electrical connectors.
- Detach the 2 wiring harness retainers.





65. Disconnect the 4 fuel injector electrical connectors.
- Detach the wiring harness retainers from the valve cover stud bolts.





66. Disconnect the EVAP canister purge valve electrical connector.





67. Disconnect the Throttle Body (TB) electrical connector.
- Detach the 2 wiring harness retainers from the TB.





68. Disconnect the Crankshaft Position (CKP) sensor electrical connector.





69. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
- Detach the wiring harness retainer from the engine block.





70. Disconnect the RH KS electrical connector.
- Detach the 2 wiring harness retainers from the intake manifold.





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





72. Remove the 3 bolts (2 shown) and the starter motor.





73. Detach the wiring harness pin-type retainer and remove the 2 upper bellhousing-to-engine bolts and bracket.





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

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





75. Remove the 6 clutch housing-to-engine bolts and separate the engine and transaxle.