Ford Mondeo (petrol engines). Manual - part 84

safely and with relative ease, and which may
have to be hired or borrowed, includes (in
addition to the engine hoist) a heavy-duty trolley
jack, a strong pair of axle stands, some wooden
blocks, and an engine dolly (a low, wheeled
platform capable of taking the weight of the
engine/transmission, so that it can be moved
easily when on the ground). A complete set of
spanners and sockets (as described in the front
of this manual) will obviously be needed,
together with plenty of rags and cleaning
solvent for mopping-up spilled oil, coolant and
fuel. If the hoist is to be hired, make sure that
you arrange for it in advance, and perform all of
the operations possible without it beforehand.
This will save you money and time.

Plan for the vehicle to be out of use for

quite a while. A machine shop will be required
to perform some of the work which the do-it-
yourselfer can’t accomplish without special
equipment. These establishments often have
a busy schedule, so it would be a good idea
to consult them before removing the engine,
to accurately estimate the amount of time
required to rebuild or repair components that
may need work.

Always be extremely careful when removing

and installing the engine/transmission.
Serious injury can result from careless
actions. By planning ahead and taking your
time, the job (although a major task) can be
accomplished successfully.

Warning: Petrol is extremely
flammable, so take extra
precautions when disconnecting
any part of the fuel system. Don’t

smoke, or allow naked flames or bare light
bulbs in or near the work area, and don’t
work in a garage where a natural gas
appliance (such as a clothes dryer or water
heater) is installed. If you spill petrol on
your skin, rinse it off immediately. Have a
fire extinguisher rated for petrol fires
handy, and know how to use it.

Note: Read through the entire Section, as well
as reading the advice in the preceding Section,
before beginning this procedure. The engine
and transmission are removed as a unit,
lowered to the ground and removed from
underneath, then separated outside the vehicle.

Removal

1 Park the vehicle on firm, level ground, apply
the handbrake firmly, and slacken the nuts
securing both front roadwheels.
2 Relieve the fuel system pressure (see
Chapter 4).
3 Disconnect the battery negative (earth) lead
- see Chapter 5, Section 1. For better access
the battery may be removed completely (see
Chapter 5).
4 Place protective covers on the wings and
engine compartment front crossmember, then
remove the bonnet (see Chapter 11).
5 Whenever you disconnect any vacuum
lines, coolant and emissions hoses, wiring
loom connectors, earth straps and fuel lines
as part of the following procedure, always
label them clearly, so that they can be
correctly reassembled.
6 Unplug the two electrical connectors,

disconnect the vacuum hose (where fitted)
and disconnect the crankcase breather hose
from the cylinder head cover, then remove the
complete air cleaner assembly, with the air
mass meter, the resonator and the plenum
chamber (see Chapter 4).
7 Equalise the pressure in the fuel tank by
removing the filler cap, then undo the fuel
feed and return lines connecting the engine to
the chassis (see Chapter 4). Plug or cap all
open fittings (see illustration).
8 Disconnect the accelerator cable from the
throttle linkage as described in Chapter 4 -
where fitted, also disconnect the cruise
control actuator cable (see Chapter 12).
Secure the cable(s) clear of the
engine/transmission.
9 Releasing its wire clip, unplug the power
steering pressure switch electrical connector,
then unbolt the power steering high-pressure
pipe and the earth lead from the cylinder head
rear support plate/engine lifting eye (see
illustrations).
10 Marking or labelling all components as
they are disconnected (see paragraph 5
above), disconnect the vacuum hoses as
follows:

4 Engine/transmission - 

removal and refitting

2B•4 Engine removal and general engine overhaul procedures

4.7  Note colour-coding of unions when

disconnecting fuel feed and return lines

4.9A  Unplug the power steering pressure

switch electrical connector . . .

4.9B  . . . unbolt the power steering high-

pressure pipe . . .

Whenever any wiring is disconnected,

. . . vacuum hoses and pipes should 

mark or label it as shown, to ensure

be similarly marked

correct reconnection . . .

Masking tape and/or a touch-up paint applicator work well for marking items. Take
instant photos, or sketch the locations of components and brackets.

(a) One from the rear of the throttle housing

(only the one hose - there is no need to
disconnect the second hose running to
the fuel pressure regulator) (see
illustration).

(b) One from the union on the inlet manifold’s

left-hand end (see illustration).

(c) The braking system vacuum servo unit

hose - from the inlet manifold (see
Chapter 9 for details).

(d) Also disconnect the vacuum hoses from

the Exhaust Gas Recirculation system
components - one from the EGR valve,
two from the EGR pipe (note that these
last two are of different sizes, as are their
pipe stubs, so that they can only be
connected the correct way round).

(e) While you are there, trace the vacuum line

from the pulse-air filter housing over the
top of the transmission, and disconnect it
by pulling the plastic pipe out of the
rubber hose just beneath the bulkhead-
mounted pulse-air solenoid valve (see
illustration).

(f)

Secure all these hoses so that they won’t
get damaged as the engine/transmission
is removed.

11 Unbolt the engine/transmission-to-body
earth lead from the transmission’s top surface
(see illustration). Disconnect the speed-
ometer drive cable (see Chapter 12) and
secure it clear of the engine/transmission.
12 Where the vehicle is fitted with manual
transmission, disconnect the clutch cable (see

Chapter 8). Where automatic transmission is
fitted, disconnect the selector cable (see
Chapter 7, Part B). Secure the cable clear of
the engine/transmission.
13 Marking or labelling all components as
they are disconnected (see paragraph 5
above), disconnect the engine wiring loom
from the body as follows:
(a) Starting at the left-hand side of the engine

compartment, release and unplug the
three large electrical connectors clipped
to the suspension mounting - note the
wire clips fitted to some connectors (see
illustration).

(b) Disconnect and/or release the battery-to-

starter motor wiring, noting the single
connector which must be unplugged.

(c) Unplug the electrical connector(s) to

disconnect the vehicle speed sensor,
oxygen sensor and, where fitted, the oil
level sensor wiring - unclip the connectors
to release the wiring where necessary.

(d) Work along the loom to the bulkhead,

unclipping the loom and unplugging the
various bulkhead-mounted components
connected into it, until you reach the
right-hand side of the engine
compartment (see illustration).

(e) Carefully prise the power steering fluid

reservoir upwards out of its clip on the
suspension mounting, then unscrew the
ECU connector’s retaining bolt and
unplug the connector (see illustration).

(f)

Unbolt the earth lead from the right-hand

Engine removal and general engine overhaul procedures  2B•5

2B

4.13A  Unplug three large electrical

connectors (arrowed) . . .

4.13B  . . . unplug engine wiring loom from

battery wiring and bulkhead components

(arrowed) . . .

4.13C  . . . and disconnect ECU wiring and

earth lead (arrowed) to release engine

wiring loom from vehicle body

4.9C  . . . and the earth lead from the

cylinder head rear support plate/engine

lifting eye

4.10A  Disconnect vacuum hose shown

from rear of throttle housing . . .

4.10B  . . . vacuum hose (arrowed) from

union on left-hand end on inlet manifold . . .

4.10C  . . . also brake servo hose (A), EGR

valve hose (B), EGR pipe hoses (C) - noting

their different sizes - and pulse-air filter

vacuum line (D)

4.11  Unbolt the engine/transmission-to-

body earth lead - hidden behind wiring

loom guide - from location (arrowed) on

the transmission’s top surface

inner wing panel, release the engine
wiring loom and refit the power steering
fluid reservoir.

(g) Secure the engine wiring loom neatly to

the engine/transmission so that it cannot
be damaged as the unit is removed from
the vehicle.

14 Unbolt both parts of the exhaust manifold
heat shield; unclip the coolant hose to allow
the upper part to be withdrawn.
15 Remove the auxiliary drivebelt (see
Chapter 1).
16 Unbolt the power steering pump (see
Chapter 10); secure it as far as possible
(without disconnecting the system’s hoses)
clear of the engine/transmission.
17 Raise the vehicle and support it securely
on axle stands, then remove the front
roadwheels. Drain the cooling system and (if
the engine is to be dismantled) drain the
engine oil and remove the oil filter (see
Chapter 1). Also drain the transmission as
described in the relevant Part of Chapter 7.
18 Withdraw the lower part of the exhaust
manifold heat shield.
19 Unscrew the nuts to disconnect the
exhaust system front downpipe from the
manifold, then unhook all the system’s rubber
mountings and withdraw the complete
exhaust system from under the vehicle (see
Chapter 4 for details).
20 Where the vehicle is fitted with manual
transmission, mark their positions, then
disconnect the gearchange linkage and
transmission support rods from the rear of the
transmission. Unscrew the retaining nuts, and
withdraw the gear linkage heat shield from the
underbody. Unbolt the rear end of the linkage
from the underbody, swivel the linkage around
to the rear, and tie it to the underbody (see
Chapter 7, Part A, for details).
21 Disconnect both anti-roll bar links from
their respective suspension strut - note the
flexible brake hose bracket attached to each
link stud - and both track rod ends from their
steering knuckles. Unfasten the clamp bolt
securing each front suspension lower arm
balljoint to its steering knuckle (see Chap-
ter 10 for details). Check that both balljoints
can be released from the knuckle assemblies
when required, but leave them in place for the

time being, secured by the clamp bolts if
necessary.
22 Where the vehicle is fitted with air
conditioning, unbolt the accumulator/
dehydrator from the subframe; secure it as far
as possible (without disconnecting the
system’s hoses) clear of the engine/
transmission. 

Warning: Do not disconnect the
refrigerant hoses.

23 Unbolt the steering gear from the
subframe; if the bolts are not accessible from
above, a Ford service tool will be required to
reach them from underneath the vehicle (see
Chapter 10 for details).
24 Unscrew the two bolts securing the power
steering system pipes to the right-hand side
of the subframe.
25 Hold the radiator in its raised position, by
inserting split pins through the holes in the
rear of the engine compartment front
crossmember and into the radiator’s upper
mounting extensions. Unbolt the radiator
mounting brackets from the subframe; note
that they are handed, and are marked to
ensure correct refitting (see illustrations).
Collect and store the bottom mounting
rubbers for safekeeping, noting which way up
they are fitted.
26 Unbolt the engine/transmission rear
mounting from the subframe - where the
vehicle is fitted with automatic transmission, a
separate damper may be fitted beneath the
subframe, which must be unbolted to reach
the mounting’s fasteners. Where the vehicle is
fitted with manual transmission, also unscrew
the mounting centre bolt, and unbolt the
mounting bracket from the transmission.
27 Unscrew the engine/transmission front
mounting centre bolt, and unbolt the
mounting from the subframe, noting the
location of the wiring connector bracket.
28 Use white paint or similar (do not use a
sharp-pointed scriber, which might break the
underbody protective coating and cause
rusting) to mark the exact relationship of the
subframe to the underbody. Unscrew the four
mounting bolts from the subframe (note their
different-sized washers - see also illus-

tration 4.47A) and allow the subframe to hang
down on the suspension lower arm balljoints.
Disconnect the balljoints one at a time from
the steering knuckle assemblies (see Chap-
ter 10) and lower the subframe to the ground;
withdraw the subframe from under the
vehicle.
29 Marking or labelling all components as
they are disconnected (see paragraph 5
above) and catching as much as possible of
the escaping coolant in the drain tray,
disconnect the cooling system hoses and
pipes as follows - refer to Chapter 3 for further
details, if required:
(a) Remove the radiator top hose.
(b) Remove the (heater) hose running from

the thermostat to the engine
compartment bulkhead union.

(c) Disconnect from the thermostat the hose

running to the expansion tank - secure the
hose clear of the working area.

(d) Disconnect from the thermostat the

coolant hose/pipe which runs to the
radiator bottom hose.

(e) Disconnect the radiator bottom hose from

the radiator union, from the (sump) heater
coolant pipe and from the water pump
union - secure the hose clear of the
working area.

(f)

Unbolt the (heater) coolant pipe from the
sump, trace the pipe/hose round to the
engine compartment bulkhead union,
disconnecting (where fitted) the oil cooler
hoses from the cooler unions, then
remove it.

(g) Unless the vehicle has air conditioning

fitted, secure the radiator as far forwards
as possible while it is in its raised position;
if air conditioning is fitted, remove the
radiator completely (see Chapter 3).

30 Where the vehicle is fitted with air
conditioning, unplug the compressor’s
electrical connector, and unbolt the
compressor from the engine (see
illustration). Secure it as far as possible
(without disconnecting the system’s hoses)
clear of the engine/transmission. 

Warning: Do not disconnect the
refrigerant hoses.

2B•6 Engine removal and general engine overhaul procedures

4.25A  Use split pins as shown to secure

radiator in its raised position . . .

4.25B  . . . while you unbolt the bottom

mountings (arrowed) - note that the

mountings are handed, and do not lose the

mounting rubbers

4.30  Unscrew bolts (arrowed) to release

air conditioning compressor from engine

31 Where the vehicle is fitted with manual
transmission, disconnect the driveshafts from
the transmission as follows, referring to
Chapter 8 for further details when required:
(a) Unscrew the nuts securing the right-hand

driveshaft support bearing, and withdraw
the heat shield.

(b) Pull the right-hand driveshaft out of the

transmission; be prepared to catch any
spilt oil.

(c) Secure the driveshaft clear of the

engine/transmission - remember that the
unit is to be lowered out of the vehicle -
and ensure that the inner joint is not
turned through more than 18°.

(d) Prise the left-hand driveshaft out of the

transmission - again, be prepared for oil
spillage. Secure the driveshaft clear of the
engine/transmission, and ensure that its
inner joint is not turned through more than
18°.

32 Where the vehicle is fitted with automatic
transmission, proceed as follows, referring to
Chapter 7, Part B and to Chapter 8 for further
details when required:
(a) Unscrew its centre bolt, then unbolt the

engine/transmission rear mounting
bracket from the transmission.

(b) Disconnect the fluid cooler pipe from the

rear of the transmission, and secure it
clear of the unit.

(c) Prise the left-hand driveshaft out of the

transmission; be prepared to catch any
spilt oil.

(d) Secure the driveshaft clear of the

engine/transmission - remember that the
unit is to be lowered out of the vehicle -
and ensure that the inner joint is not
turned through more than 18°.

(e) Unscrew the nuts securing the right-hand

driveshaft support bearing, and withdraw
the heat shield.

(f)

Pull the right-hand driveshaft out of the
transmission - again, be prepared for oil
spillage. Secure the driveshaft clear of the
engine/transmission, and ensure that its
inner joint is not turned through more than
18°.

(g) Disconnect the fluid cooler pipe from the

front of the transmission, and secure it
clear of the unit.

33 The engine/transmission unit should now
be hanging on the right- and left-hand
mountings only, with all components which
connect it to the rest of the vehicle
disconnected or removed and secured well
clear of the unit. Make a final check that this is
the case, then ensure that the body is
securely supported, high enough to permit the
withdrawal of the engine/transmission unit
from underneath; allow for the height of the
engine dolly, if used.
34 Take the weight of the engine/
transmission unit, using the lifting eyes
provided on the cylinder head. Unscrew the
six nuts securing the right-hand mounting
bracket, then the three nuts securing the left-
hand bracket. 

Warning: Do not put any part of
your body under the vehicle, or
under the engine/transmission

unit, when they are supported only by a
hoist or other lifting equipment.
35 Lower the engine/transmission to the
ground, and withdraw it from under the
vehicle (see illustration).
36 Referring to the relevant part of Chapter 7,
separate the transmission from the engine.
37 While the engine/transmission is removed,
check the mountings; renew them if they are
worn or damaged. Similarly, check the
condition of all coolant and vacuum hoses
and pipes (see Chapter 1); components that
are normally hidden can now be checked
properly, and should be renewed if there is
any doubt at all about their condition. Where
the vehicle is fitted with manual transmission,
take the opportunity to overhaul the clutch
components (see Chapter 8). It is regarded by
many as good working practice to renew the
clutch assembly as a matter of course,
whenever major engine overhaul work is
carried out. Check also the condition of all
components (such as the transmission oil
seals) disturbed on removal, and renew any
that are damaged or worn.

Refitting

38 Refitting is the reverse of the removal
procedure, noting the following points.
Tighten all fasteners to the torque wrench
settings given; where settings are not quoted
in the Specifications Sections of the two Parts
of this Chapter, refer to the Specifications
Section of the relevant Chapter of this manual.
39 In addition to the points noted in
paragraph 37 above, always renew any
circlips and self-locking nuts disturbed on
removal.
40 Where wiring, etc, was secured by cable
ties which had to be cut on removal, ensure
that it is secured with new ties on refitting.
41 With all overhaul operations completed,
refit the transmission to the engine as
described in Chapter 7.
42 Manoeuvre the engine/transmission unit
under the vehicle, attach the hoist, and lift the
unit into position until the right- and left-hand
mountings can be reassembled; tighten the
(new) nuts only lightly at this stage. Do not yet
release the hoist; the weight of the
engine/transmission unit must not be taken by
the mountings until all are correctly aligned.
43 Using new circlips, and ensuring that the
inner joints are not twisted through too great
an angle (see Chapter 8), refit the driveshafts.
Where the vehicle is fitted with manual
transmission, the procedure is the reverse of
that outlined in paragraph 31 above. Where
the vehicle is fitted with automatic
transmission, proceed as follows, referring to
Chapter 7, Part B and to Chapter 8 for further
details when required:
(a) Refit the left-hand driveshaft.
(b) Using the clips provided to ensure that

they are correctly routed, and tightening

the couplings to the specified torque
wrench setting where possible, reconnect
the fluid cooler pipes, first to the rear,
then to the front, of the transmission.

(c) Refit the right-hand driveshaft to the

transmission, refit the heat shield, and
tighten the support bearing nuts to the
specified torque wrench setting.

(d) Refit the engine/transmission rear

mounting bracket to the transmission,
tightening the bolts to the torque wrench
setting specified, then refit the mounting,
tightening the centre bolt only lightly at
this stage.

44 Where the vehicle is fitted with air
conditioning, do not forget to refit the
compressor; tighten the bolts to the specified
torque wrench setting, and plug in its
electrical connector.
45 Using the marks and notes made on
removal, refit the cooling system hoses.
Where they are left disconnected or unclipped
for the time being, do not forget to secure
them at the appropriate moment during the
reassembly procedure. Refit the radiator (if
removed), using split pins to secure it in the
raised position.
46 Offer up the subframe one side at a time,
and hold it by securing the suspension lower
arm balljoints to the steering knuckle
assemblies. Refit the subframe bolts, ensuring
that the washers are refitted correctly, and
tightening the bolts only lightly at this stage.
47 The subframe must now be aligned on the
underbody. Ford specify the use of service
tool 15-097, which is a pair of tapered guides,
with attachments to hold them in the
subframe as it is refitted. However, since the
working diameter of these tools is 20.4 mm,
and since the corresponding aligning holes in
the subframe and underbody are respectively
21 mm and 22 mm in diameter, there is a
significant in-built tolerance possible in the
subframe’s alignment, even if the correct tools
are used. If these tools are not available, you
can align the subframe by eye, centring the
subframe aligning holes on those of the
underbody, and using the marks made on
removal for assistance. Alternatively, you can
align the subframe using a tapered drift (such
as a clutch-aligning tool), or even a deep

Engine removal and general engine overhaul procedures  2B•7

2B

4.35  Lowering the engine/transmission

unit out of the vehicle