Engine Removal Ford Tempo I

1.9L (114") Removal

1. Mark hinges for reinstallation and remove hood. Remove air cleaner, hot air tube, alternator air tube, and airflow sensor (if equipped). Disconnect negative battery cable at both ends. Remove secondary wire from ignition coil. Drain cooling system.
2. Remove all drive belts. Remove alternator mounting bolts and position alternator aside. Disconnect thermactor pump hoses and remove pump (if equipped). Disconnect upper and lower radiator hoses at engine. Disconnect transaxle oil cooler lines at radiator (if equipped).
3. Disconnect heater return hose at engine. Disconnect all electrical wiring and vacuum hoses at engine. Disconnect fuel lines at pump or intake manifold. Remove fan motor and shroud assembly.
4. On automatic transaxles, remove transaxle cooler line routing clip. On all models, remove radiator. Disconnect heater hose at steel tube. Remove power steering pump filter tube and plug pump opening (if equipped).
5. Disconnect throttle kickdown linkage (if equipped), accelerator cable and bracket at engine. Disconnect vacuum hose from thermactor valve. Disconnect accelerator cable and remove cable routing bracket screws. Disconnect vapor hose at carbon canister tube.
6. Raise vehicle on hoist. Remove clamp from heater supply and return tubes. Disconnect battery cable from starter motor. Remove brace at front of starter motor. On manual transaxles, remove roll restrictor.
7. On all models, remove starter motor, and brace rear section. Disconnect exhaust pipe at manifold. Remove converter/flywheel cover and brackets.
8. On all models, remove crankshaft pulley. On manual transaxles, remove lower timing belt cover bolts. Remove lower clutch housing bolts. On automatic transaxles, remove torque converter-to-drive plate nuts. Remove lower converter/flywheel housing bolts.
9. On all models, remove coolant by-pass hose at intake manifold. Remove lower right side engine mount bolt and nut. Lower vehicle. Attach engine lift to brackets. Remove right side engine mount through-bolt and remove engine mount.
10. On manual transaxles, remove timing belt cover. Remove insulator attaching bracket from engine. Position floor jack under transaxle and support transaxle. Remove upper converter/flywheel housing attaching bolts. Remove engine, making sure converter studs clear drive plate.

Installation

1. To install, reverse removal procedure. Ensure half-shaft alignment is proper by adjusting following clearances. Crankshaft damper-to-frame rail should be .63" (16.0 mm).
2. Manual transaxle case-to-frame rail should be .98" (25.0 mm). On automatic transaxle models, transaxle oil pump housing-to-frame rail should be .98" (25.0 mm). Check fluid levels. Start engine and check for leaks.

2.3L (141") OHC Removal

1. Raise hood and secure in vertical position. Disconnect ground cable. Drain cooling system. Drain crankcase. Remove air cleaner or turbocharger.
2. Remove upper and lower radiator hoses. Disconnect transmission oil cooler lines (if equipped). Remove radiator and fan. On vehicles equipped with an electric cooling fan, disconnect power lead to fan motor, then remove fan and shroud assembly.
3. Disconnect heater hose from water pump and carburetor choke fitting. Disconnect all wiring, vacuum hoses and linkages from engine. Remove A/C compressor from mounting bracket (if equipped). Position compressor aside with lines connected.
4. Disconnect flexible fuel line at fuel pump or at fuel rail (EFI) and plug. Remove starter. Raise vehicle on hoist. Remove upper bellhousing bolts. Disconnect exhaust pipe from exhaust manifold or turbocharger outlet.
5. Disconnect right and left motor mounts at crossmember pedestal. Remove bellhousing cover. On automatic transmission equipped vehicles, remove bolts attaching converter to flex plate.
6. Disconnect oil cooler lines from engine. On all models, Remove remaining bolts attaching bellhousing to engine. Lower vehicle. Support transmission with a jack. Attach engine hoist and remove engine.

To install, reverse removal procedure. Check fluid levels. Start engine and check for leaks.

Note. Engine/transaxle is removed as an assembly.

2.3L (141") High Swirl Combustion (HSC) & High Swirl Output (HSO) Removal

1. Mark hinges for reinstallation. Remove hood. Disconnect ground cable. Remove air cleaner assembly. Drain cooling system. Remove upper and lower radiator hoses. Disconnect transaxle cooler lines at hoses below radiator (if equipped).
2. Remove coil assembly. Disconnect cooling fan. Remove radiator shroud and fan as assembly. Remove radiator. Discharge A/C system and disconnect hoses at compressor (if equipped). Disconnect all electrical and vacuum lines.
3. On automatic transaxle, disconnect TV linkage. Disconnect clutch cable on manual transaxle. Disconnect accelerator linkage, fuel lines at engine, and thermactor discharge hose at pump.
4. Disconnect power steering hoses at pump (if equipped). Remove hose bracket at cylinder head. Attach engine support tool to lifting eye. Raise vehicle.
5. Remove starter cable, hose from catalytic converter, exhaust pipe bracket bolt at oil pan, and exhaust pipe-to-manifold nuts. Remove exhaust system from grommets and set aside. Disconnect speedometer cable at transaxle.
6. Disconnect heater hoses at engine. Remove water pump inlet tube and clamps. Disconnect control arms at body. Remove stabilizer bar brackets. Remove half-shaft assemblies and install alignment plugs in differential side gears. See FWD AXLE SHAFTS article in DRIVE AXLE section.
7. On manual transaxle, remove roll restrictor, shift stabilizer bar-to-transaxle bolts, and shift mechanism-to-shift shaft bolt. On automatic transaxle, disconnect manual shift cable clip and remove manual shift linkage bracket.
8. Remove left rear insulator mount bracket. Remove left front insulator-to-transaxle mount bolts. Lower vehicle. Attach engine hoist to lifting eyes. Remove engine support tool. CAUTION: Do not allow front wheels to touch floor.
9. Remove right-hand insulator intermediate bracket from engine bracket and insulator. Lower engine/transaxle assembly to floor.

To install, reverse removal procedure. Check fluid levels. Start engine and check for leaks.

2.5L (153") Removal

1. Relieve fuel system pressure by disconnecting electrical connector at inertia switch, then cranking engine for 15 seconds. On ATX automatic transaxle equipped models, remove timing window cover at transaxle and rotate engine until flywheel timing marker is aligned with timing pointer. Mark crankshaft pulley at 12 o'clock position (TDC). Rotate crankshaft pulley mark to 6 o'clock position.
2. On all models, disconnect battery negative cable. Mark hood hinge position and remove hood. Remove air cleaner assembly. Drain cooling system. Remove upper radiator hose at engine. Remove all wiring and vacuum lines as necessary.
3. Disconnect crankcase ventilation hose at valve cover and intake manifold. Remove fuel lines at throttle body. Disconnect ground wire at engine. Remove accelerator cable and throttle valve control cable at throttle body. Discharge air conditioning system and remove pressure and suction lines from compressor (if equipped).
4. On manual transaxle equipped models, remove engine damper brace. On all models, remove drive belt, water pump pulley, and air cleaner-to-canister hose. Raise and support vehicle. Drain engine oil and remove oil filter. Disconnect starter cable and remove starter motor.
5. On automatic transaxle equipped models only, remove converter nuts and position mark previously made on crankshaft pulley as close to 6 o'clock position (BDC) as possible with converter stud visible. NOTE: Flywheel timing marker must be in 6 o'clock (BDC) position for proper engine removal.
6. Remove engine insulator nuts. Disconnect exhaust pipe from manifold. Remove cansiter bracket and halfshaft bracket from engine. Remove lower engine-to-transmission attaching bolts. Remove engine from vehicle.

To install, reverse removal procedure. Check fluid levels. Start engine and check for leaks.

Removal 3.0L (183")

1. Disconnect battery cables. Mark hinges for reinstallation and remove hood. Drain cooling system and discharge A/C (if equipped). Remove air cleaner assembly, battery and tray, integrated relay controller, cooling fan, radiator and shroud. Remove bounce damper bracket on shock tower.
2. Disconnect evaporative emission line, upper radiator hose, starter brace, lower radiator hose, and exhaust manifold at pipe. Remove power steering pump lines, fuel lines, vacuum lines, ground strap, and heater hoses. Disconnect accelerator cable linkage, throttle valve linkage, and speed control cable.
3. Disconnect following connections: alternator, A/C compressor, EGO sensor, ignition coil, radio frequency suppressor, cooling fan voltage resistor, coolant temperature sensor, and TFI module.
4. Remove following components of injector wiring harness: 6 injectors, ACT sensor, ISC, and throttle position sensor. Remove oil pressure sending switch, ground wire, block heater (if equipped), knock sensor, EGR sensor and oil level sensor. Install engine lifting bolts and chains.
5. Remove lower damper bolt from right side of engine. Raise and support vehicle. Place jack and wood block under engine block. Remove nuts attaching right front and right rear insulators to frame. Raise engine with jack. Remove 2 through bolts and remove insulator from engine bracket.
6. Remove left tire and wheel. With jack and wood block still under engine, remove nut and bolt attaching hydraulic engine damper to transmission support assembly. Push damper shaft up out of way. Remove 2 nuts attaching insulator to support assembly.
7. Remove 2 through bolts attaching insulator to frame. Raise transmission with jack. Remove bolts attaching support assembly to transmission. Remove the insulator and/or transmission support assembly.
8. Remove bolt attaching lower end of right engine damper to engine bracket. Remove bolts attaching upper damper bracket to shock tower bracket. Remove engine damper. Remove speed control servo and bracket assembly.
9. Remove bolt and nut attaching lower end of left engine damper to engine mount attaching bracket. Remove bolts attaching upper d amper bracket to side rail bracket. Remove left engine damper. Remove engine.

To install, reverse removal procedure. Check fluid levels. Start engine and check for leaks.

Note. Information for Continental not available from manufacturer. Also see TSB NUMBER 91-5B-9 for information on revised engine mount replacement procedures.

Removal 3.8L (232") (All Except Continental)

1. Drain cooling system. Disconnect negative battery cable. Disconnect under hood wiring connector retaining engine compartment light. Mark hinges for reinstallation and remove hood.
2. Remove air cleaner assembly, air intake duct and heat tube. Remove oil level indicator tube and fan shroud attaching screws. Remove fan/clutch assembly and shroud. Loosen accessory drive belt idler. Remove drive belt. Remove water pump pulley.
3. Disconnect upper and lower radiator hoses at radiator. Disconnect thermactor hose from downstream air tube check valve. Remove downstream air tube bracket bolt from rear of right cylinder head.
4. Remove coil secondary wire from coil. Remove power steering pump attaching bolts (if equipped). Place pump aside with hoses connected.
5. Remove A/C compressor attaching bolts (if equipped). Position compressor aside leaving refrigerant lines connected. Disconnect and remove alternator. Disconnect heater hoses from heater tube and water pump.
6. Remove cruise control servo and bracket (if equipped). Disconnect all vacuum hoses, electrical wiring and linkages from engine. Disconnect engine ground strap at dash panel. Disconnect transmission linkage at fuel charging assembly.
7. Remove crankshaft pulley assembly. Disconnect fuel lines connecting engine to vehicle body. Plug the hoses to prevent leakage.
8. Raise vehicle. Drain crankcase. Remove dust shield from converter housing. Remove flex plate-to-torque converter bolts. Disconnect battery cable from starter motor. Remove starter motor.
9. Remove transmission oil cooler line routing clip. Remove exhaust inlet pipe at exhaust manifold. Disconnect exhaust heat control valve vacuum line (if equipped). Remove valve from exhaust manifold studs.
10. Remove transmission-to-engine lower attaching bolts. Remove engine mount bolts. Lower vehicle. Support transmission with a jack.
11. Remove remaining bolts connecting transmission to engine. Slightly raise engine. Carefully pull engine away from transmission. Remove engine from engine compartment.

To install, reverse removal procedure. Check fluid levels. Start engine and check for leaks.

Removal 5.0L (302")

1. Mark hinges for reinstallation and remove hood. Drain crankcase and cooling system. Disconnect battery and alternator ground cables from engine. Remove air cleaner and intake duct assembly.
2. Disconnect upper and lower radiator hoses. Disconnect transmission oil cooler lines from radiator. Remove bolts attaching fan shroud to radiator. Remove radiator.
3. Remove fan, spacer, belt, pulley and shroud. Remove alternator bolts and position alternator aside. Disconnect oil pressure sending unit wire from sending unit.
4. Disconnect flexible fuel line at fuel tank line. On EFI equipped vehicles, relieve pressure in fuel lines before disconnecting. Plug fuel tank line. Disconnect accelerator cable from carburetor. Disconnect speed control cable (if equipped).
5. Disconnect throttle valve vacuum line from intake manifold (if equipped). Disconnect transmission filler tube bracket from engine block. On vehicles equipped with A/C, remove A/C compressor and set aside.
6. If power steering equipped, disconnect power steering pump bracket from cylinder head. Remove drive belt. Position pump aside. If power brake equipped, disconnect brake vacuum line from intake manifold.
7. Disconnect heater hoses from water pump and intake manifold. Disconnect coolant temperature sending unit wire from sending unit. Remove flywheel/converter housing-to-engine upper bolts.
8. Disconnect primary wiring connector from ignition coil. Remove wire harness and position aside. Disconnect ground strap from block.
9. Raise front of vehicle. Disconnect starter cable from starter. Remove starter. Disconnect exhaust pipes from exhaust manifolds. Disconnect engine support insulators.
10. On automatic transmission equipped models, disconnect transmission cooler lines from retainer and remove converter housing inspection cover. Disconnect converter from flex plate. Secure converter assembly in housing. On all models, remove remaining converter housing-to-engine bolts.
11. Lower vehicle and support transmission. Attach engine hoist and carefully separate engine from transmission. Remove engine.

To install, reverse removal procedure. Check fluid levels. Start engine and check for leaks.

Removal 5.8L (351")

1. Drain cooling system and crankcase. Mark hinges for reinstallation and remove hood. Disconnect battery cables from engine block. Remove air cleaner and intake duct assembly. Remove upper and lower radiator hoses.
2. Disconnect transmission oil cooler lines from radiator. Remove fan shroud attaching bolts. Remove radiator, fan, spacer, belt pulley and shroud. Remove alternator bolts and position out of way.
3. Disconnect oil pressure sending unit wire from sending unit. Disconnect low oil level sensor wire (if equipped). Remove flexible fuel line at fuel tank and plug fuel tank line. Disconnect accelerator cable from carburetor. Disconnect TV rod on automatic overdrive transmissions. Disconnect speed control cable (if equipped).
4. Remove throttle valve vacuum line from intake manifold (if equipped). Disconnect transmission filler tube bracket from cylinder block. On air conditioning equipped vehicles, remove compressor. On power steering equipped models, remove power steering pump bracket from cylinder head. Remove drive belt. Position power steering pump out of way.
5. On all models, disconnect brake vacuum line from intake manifold. Remove heater hoses from water pump and intake manifold. Remove coolant temperature sending unit. Remove bolts connecting bellhousing to upper engine.
6. Disconnect primary wiring connector from ignition coil. Disconnect wiring-to-solenoid on left rocker arm cover. Remove wire harness from left rocker arm cover and position wires out of way. Remove ground strap from block.
7. Raise front of vehicle. Disconnect starter cable from starter. Remove starter. Remove exhaust pipes from exhaust manifolds. Disconnect engine support insulators from chassis. Disconnect downstream thermactor tubing and check valve from right exhaust manifold stud (if equipped).
8. On automatic transmission equipped models, remove transmission cooler lines from retainer and remove converter housing inspection cover. Disconnect flex plate from converter. Secure converter assembly in housing. On all models, remove remaining bolts connecting bellhousing to engine.
9. Lower vehicle and support transmission. Attach engine lift sling to lifting brackets on intake manifold. Raise engine slightly and pull from transmission. Remove engine.

To install, reverse removal procedure. Check fluid levels. Start engine and check for leaks.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS