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Engine - Vehicles With: Automatic Transaxle > < Engine - Vehicles With: Manual Transaxle

C-MAX 2003.75 (06.2003-)

Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) - Engine—Vehicles With: Automatic Transmission (CFT23) C-MAX 2003.75 (06/2003-)
Installation

Special Tool(s)

Engine Lifting Bracket

303-122

Remover/Installer, Coolant Hose Clamp

303-397
General Equipment
Retaining straps
Workshop table

1. Install the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Transmission
See Installation Detail
2
-
Transmission ground lead
3
-
Transmission flange upper bolts
4
-
Starter motor
See Installation Detail
5
-
Starter motor wiring harness bracket
6
-
Starter motor connectors
See Installation Detail

 
Item
Part Number
Description
7
-
Transmission flange lower bolts
See Installation Detail

 
Item
Part Number
Description
8
-
Rear engine mounting bolt
See Installation Detail
9
-
Front engine mounting
See Installation Detail
10
-
Selector lever cable
See Installation Detail
11
-
Transmission fluid feed and return lines
See Installation Detail
12
-
Automatic transmission central connector
See Installation Detail

 
Item
Part Number
Description
13
-
Catalytic converter
See Installation Detail
14
-
Catalytic converter retaining nuts
See Installation Detail
15
-
Catalytic converter support bracket retaining bolts
16
-
Catalytic converter heat shield
17
-
Catalytic converter heat shield bolts

 
Item
Part Number
Description
18
-
Engine roll restrictor rubber mounting

 
Item
Part Number
Description
19
-
A/C compressor
See Installation Detail
20
-
A/C compressor bolt
21
-
A/C compressor heat shield
22
-
A/C compressor heat shield bolt
23
-
A/C compressor bolts
24
-
A/C clutch connector
All vehicles
  1. Install the left-hand halfshaft.
    For additional information, refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
  1. Install the right-hand halfshaft.
    For additional information, refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).

  1. Connect the fuel supply line.

  1. Tighten the bolt of the rear engine mounting.

  1. Tighten the front engine mounting nuts and bolts.

  1. Attach the brake booster vacuum line to the intake manifold.

  1. Install the coolant expansion tank.

  1. Connect the coolant hose to the coolant expansion tank using the special tool.

  1. Connect the coolant hoses to the heater core.

  1. Using the special tool, connect the coolant hose to the coolant outlet connector.
  1. Install the fluid cooler.
    For additional information, refer to: Radiator (303-03C Engine Cooling - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Removal and Installation).

  1. Connect the catalyst monitor sensor electrical connector.

  1. Connect the heated oxygen (HO2S) sensor electrical connector.

  1. Connect the engine wiring harness electrical connector.

  1. Remove the central junction box (CJB) cover.

  1. Attach the ground cables to the wheel housing.

  1. Connect the battery positive lead to the battery positive cable terminal clamp.
  1. Install the battery tray.
    For additional information, refer to: Battery Tray - 1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Install the air cleaner.
    For additional information, refer to: Luftfilter - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (303-12, Removal and Installation).
Vehicles with global closing
  1. Initialize the window winder motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).
All vehicles
  1. Install the engine cover.

  1. Install the oil filler pipe.
    • Rotate the oil filler pipe approximately 90 degrees clockwise until the securing clip snaps into position.
  1. Install the air cowl grille.
    For additional information, refer to: Cowl Panel Grille - Vehicles Built Up To: 03/2007 (501-02 Front End Body Panels, Removal and Installation).

Installation Details

Item 1 : Transmission

  1. CAUTION:
    CAUTION:The torque converter must remain at the correct installation depth throughout the whole installation procedure.
    CAUTION:
    CAUTION:Make sure that the two locating dowels are installed.
    NOTE:
    NOTE:Before installing the bolts in the transmission, the torque converter studs must be aligned with the holes in the drive plate.
    Install the torque converter.

  1. CAUTION:
    CAUTION:The torque converter hub must engage fully in the oil pump drive gear.
    Check the installation depth of the torque converter.
    1. Position the steel straightedge on the transmission flange.
    1. Measure the correct installation depth between the automatic transmission flange and the torque converter guide collar.

Item 4 : Starter motor
  1. CAUTION:
    CAUTION:Make sure that the torque converter nuts do not fall into the torque converter housing.
    NOTE:
    NOTE:Install new torque converter nuts.
    Install the torque converter nuts.
    • Turn the engine to gain access to the fastening points of the three nuts.

Item 6 : Starter motor connectors
  1. Connect the ignition switch and battery to starter motor solenoid cables.

Item 7 : Transmission flange lower bolts

  1. NOTE:
    NOTE:Support the engine and transaxle assembly on wooden blocks.
    Secure the engine and transmission on the workshop table using suitable retaining straps.

  1. Remove the special tool.

Item 8 : Rear engine mounting bolt
  1. Position the workshop table under the vehicle and carefully lower the vehicle until the engine and transmission assembly is in the correct position to install the engine mountings.

  1. NOTE:
    NOTE:Do not tighten the bolt of the rear engine mounting for the moment.
    Screw in the bolt on the rear engine mounting.

Item 9 : Front engine mounting

  1. Install the front engine mounting.

  1. Install the front engine mounting stud.

  1. NOTE:
    NOTE:Do not tighten the front engine mounting nuts and bolts yet.
    NOTE:
    NOTE:Install new front engine mounting nuts.
    Install the front engine mounting nuts and bolts.

  1. Install the A/C line retaining bracket.
  1. Remove the retaining straps.

Item 10 : Selector lever cable
  1. CAUTION:
    CAUTION:Do not kink the selector lever cable.
    Attach the selector lever cable to the transmission.
    1. Press the locking pins together and attach the selector lever cable to the abutment, press down the locking tab.
    1. Attach the selector lever cable to the selector mechanism.

Item 11 : Transmission fluid feed and return lines
  1. Attach the transmission fluid cooler feed and return lines to the automatic transmission.

  1. Clip in the transmission fluid cooler feed and return lines at the fluid line bracket.

Item 12 : Automatic transmission central connector
  1. CAUTION:
    CAUTION:The automatic transmission contains components and assemblies which are sensitive to electrostatic charging.
    Attach the automatic transmission central connector.
    • Attach the central connector by turning the catch clockwise and lock.

Item 13 : Catalytic converter

NOTE:
NOTE:Install a new exhaust manifold gasket.

Item 14 : Catalytic converter retaining nuts

CAUTION:
CAUTION:Never use jointing compound forward of the catalytic converter.
NOTE:
NOTE:Coat the studs with anti-seize grease meeting Ford specification.
NOTE:
NOTE:Install new exhaust manifold assembly retaining nuts.

Item 19 : A/C compressor
  1. Attach the air conditioning line bracket.

Engine - Vehicles With: Automatic Transaxle > < Engine - Vehicles With: Manual Transaxle