• (2) plastic shopping bags
• Catch basin for coolant (or wet dry vac)
• Catch basin for oil
• Diagonal cutters
• Standard screwdriver
• Philips scewdriver
• 13mm combo wrench
• Ratchet
• Extension(s)
• 17mm socket
• 13mm socket
• 10mm socket
• 8mm socket
• Pliers or spring clamp removal tool
• 8mm allen or triple square(for CV bolts heads, varies by van) bit/socket
• Paint marker

ENGINE REMOVAL

Using Bentley as your guide perform the following steps:

Raise Rear of Van and support on ramps or jackstands. The van must be at least 12 to 15

inches in the air so that the Intake System and the Alternator can clear.  Be sure to chock

the front wheels to prevent rolling. 

Disconnect Battery Ground Strap.

Remove Air Cleaner/Air Box Assembly and Elbow along with all hoses.

Disconnect Alternator Harness at Alternator.

Disconnect Injector Connection Cyl #1 – 4.

Disconnect Connectors at Throttle Valve Switch.

Disconnect Plug at Auxillary Air Valve.

Disconnect Hose at Top of Charcoal Filter Valve.

Disconnect Hose at Bottom of Charcoal Filter Valve.

Disconnect & Plug Incoming Fuel Hose at Pressure Regulator.

Disconnect & Plug Return Fuel Hose at Tee just under Air Plenum.

Disconnect Accelerator Cable.

Disconnect Oxygen Sensor Plug.

Disconnect Ignition Harness at Distributor & Ground on Alternator.

Disconnect & Remove Coil Wire at both Coil and Distributor – LABEL FOR ZETEC

Disconnect Oil Pressure Harness Plug (Top of Engine) .

Disconnect Water Temp Sensor Plug – LABEL FOR ZETEC

Disconnect ECU Temp Sensor Plug .

Disconnect Expansion Tank Sensor Plug – LABEL FOR ZETEC

Disconnect Ground Wires and Strap from Ground Tree on Engine Case
.
Disconnect Plug at Vacuum Switch at Front Right Side of Access Hole.

*If equipped with A/C:
Disconnect AC Compressor Wire Plug
Keeping the AC lines connected, remove the Compressor and Bracket off of the engine and

using something like wire and a support to keep the unit clear of the engine (hanging there)

OR
If your AC system is trashed and you don't want to reuse it:
Disconnect AC Compressor Hoses
Remove AC Compressor and Mounting Bracket Completely

Remove Muffler and Catalytic Converter from Left Collector Pipe.   You can leave the

Collector Pipe attached to the Front/Rear Header Pipes.

Disconnect & drain Coolant Hoses from Block and Water Pump. Keep a drain pan handy, there

will be coolant all over the place if you don't.

Disconnect & drain Heater Supply & Return Hoses at Front Right Side of Engine compartment.

Disconnect Brake Servo Vacuum Hose at One-Way Valve – LABEL FOR ZETEC

Disconnect & Remove Coolant Bypass Hose (8mm) from Heater Return Pipe & Coolant Bleeder

Connector.

Disconnect & Remove Heater Return Hose from Crosspipe and Expansion Tank Connector Piece

Disconnect & Remove Coolant Hose Between Block and Expansion Tank Connector

Remove Coolant Expansion Tank

Remove drive axles at inner CV joints (on transaxle drive flanges).  Put bags over the CV

joints to keep them clean and then tie them up out of the way.

Syncro only – remove drive shaft, transaxle vent tube & decoupler lines.

Remove reverse light wires from switch on transaxle.

Remove transaxle ground strap.

Remove shift linkage from transaxle.  Tie up out of the way.

Disconnect Starter Wires – LABEL FOR ZETEC

Place floor jack pad on bottom of transaxle just forward of  the location of the axle

flanges.  Protect the trans with a scrap of wood.  Lift the jack until it just touches, but

does not lift the engine/trans.

Attach engine crane or straps to engine lifting points.  Lift until snug, but do not pull

upward on the engine.

Remove Outer Engine Heatshield Tins on each side of engine mounted on the Body/Frame

Remove Bolts from Rear Engine Heatshield Tin (no need to remove the tin itself)

Remove Engine Carrier Bolts on each end of the carrier where it meets the vehicle frame.

Remove Thru-Bolt and Nut on Front Transmission Mount.

Lower engine and trans as evenly as possible.   Be sure that Oil Filler clears when lowering

and watch for pinched wires or any other obstructions.

Using the combination of the engine hoist and floor jack, slowly and carefully lower the

engine / transaxle assembly to the ground and then slide it out the back from under the van.