With MTX-75/Manual Transaxle
NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.
Special Tools:
Special Tools
Removal
1. General remarks.
^ The positions of the engine mounting and the engine roll restrictor are described looking from the transmission towards the engine.
^ If necessary, use Special Tool 412-108 to remove coolant and ventilation hoses.
^ Owing to special model variants, some job steps do not apply to all vehicles. These are clearly marked in the text.
^ If necessary, separate the cable ties and renew on installation.
2. Release the fuel pressure.
3. WARNING: To prevent the risk of scalding, place a thick cloth over the filler cap before opening the cooling circuit. Failure to do so can result in injury.
Open the coolant expansion tank.
4. CAUTION: Disconnect the battery positive and negative cables. Remove the battery.
Remove the battery tray and detach the ground cable.
1. Unclip and separate the connector.
2. Unclip the wiring harness.
3. Unscrew the bolts.
4. Detach the positive and negative cables.
5. Remove the air cleaner housing.
1. Pull off the plug of the mass air flow (MAP) sensor.
2. Detach the PCV hose.
3. Detach the intake hose.
^ Remove the air cleaner housing from the rubber bushing.
6. Detach the ground cable.
7. NOTE: The resonator is a push fit in the bracket.
Remove the air cleaner intake with resonator.
8. WARNING: Danger of scalding if the engine is warm.
Drain the coolant (shown from below).
^ Screw the drain plug back in after draining.
9. NOTE: Stop from turning using an Allen key.
Slacken the suspension strut nuts by five turns on both sides.
10. Loosen the wheel nuts of the left and right-hand front wheels.
11. Lock the driver's gear shift lever using the special tool.
^ Move the shift lever to neutral.
^ Detach the shift lever cover and insert the special tool.
12. Detach the accelerator cable and the speed control cable (if equipped).
13. Pull off the connectors of the EI coil and the radio interference filter.
14. Separate the heated oxygen sensor (HO2S) connector.
15. Disconnect the radiator fan plug.
^ Separate the cable ties.
16. Disconnect the fuel injector wiring.
17. Pull off the generator connector
18. WARNING: Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or eyes. If brake fluid should come into contact with your skin or eyes, rinse the affected area immediately with water.
CAUTION: If any brake fluid gets on the paint work wash it off immediately with water.
Detach the high-pressure pipe from the clutch slave cylinder.
^ Pull out the clip.
^ Pull out the high-pressure pipe and tie it up with cable ties
19. Separate the harness connector.
20. Disconnect the plug of the vehicle speed sensor (VSS)
21. Disconnect the plug for the reversing lamp switch and the crankshaft position sensor.
^ Unclip the wiring loom from the engine.
22. Remove the air deflector and the radiator fan.
^ Undo the clips on both sides (left side shown).
^ Unhook the air deflector upwards and remove it downwards.
23. Pull off the low pressure hoses.
24. Detach the brake servo vacuum hose.
25. WARNING: Escaping fuel. Observe the safety regulations for working with fuel.
Detach the fuel pipes.
^ Detach the ground cable.
26. Detach the coolant hoses.
27. Detach the shift cable and selector cable from the transmission.
1. Detach the shift cable from the gear lever.
2. Pretension the abutment collars by turning them in an anti-clockwise direction and remove the cable assembly from the bracket.
3. Detach the selector cable from the selector lever.
4. Pretension the abutment collars by turning them in an anti-clockwise direction and remove the cable assembly from the bracket.
5. Undo the adjustment mechanism by pressing it in.
28. Raise the vehicle.
29. Remove the drive belt cover.
30. Disconnect the power steering pressure switch (PSPS), slacken the drive belt and remove it (vehicle without air conditioning shown).
^ Turn the belt tensioner clockwise.
Vehicles with air conditioning
31. Detach the air conditioning compressor and tie it up on the radiator crossmember.
All vehicles
32. Detach the coolant hose and remove the bolts of the power steering pump.
33. Lower the vehicle.
34. Detach the coolant expansion tank and lay it to one side.
35. Remove the PAS reservoir and lay it to one side.
36. Detach the bracket of the power steering high-pressure pipe.
37. Detach the power steering pump and tie it up with cable ties.
38. Raise the vehicle.
39. Remove the flexible exhaust pipe.
40. Remove the engine roll restrictor.
41. Detach both suspension arms (left-hand side shown).
1. Remove the bolt.
2. Detach the lower arm ball joint.
42. Detach both front wheels.
43. CAUTION: The inner joint must not He bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
Detach the right-hand front drive halfshaft with intermediate shaft.
^ Detach the intermediate shaft bearing cap.
^ Discard the nuts and bearing cap.
^ Pull the intermediate shaft with front drive halfshaft from the transmission and tie up with cable ties.
^ Close off the transmission with auxiliary plugs.
44. CAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
Detach the left-hand front drive halfshaft from the transmission using the special tool.
^ Pull out the front drive halfshaft and tie up with cable ties.
^ Close off the transmission with auxiliary plugs.
45. Put the assembly table with wooden blocks on it under the vehicle.
46. Carefully lower the vehicle until the engine and transmission assembly is on the assembly stand.
47. Secure the engine and transmission assembly on the assembly stand with a retaining strap.
48. Remove the rear engine mounting.
49. Remove the front engine mounting.
50. Carefully raise the vehicle.
^ Pull forwards the assembly stand with the engine and transmission assembly.
51. Hook the engine and transmission assembly into the crane.
52. Remove the starter motor and ground cable.
53. Remove the flange bolts.
54. Remove the flange bolts (continued).