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303-01D Engine - 2.0L Duratec-HE (MI4)|Engine > < Assembly|Engine

Fiesta 2002.25 (11.2001-)

Engine - 2.0L Duratec-HE (MI4) - Engine Fiesta 2002.25 (11/2001-)
Installation

Special Tool(s)

Protector, Halfshaft Seal

205-775

Expander, Teflon Seal

211-188

Remover/Installer, Hose Clamp

303-397

Installer, Camshaft Pulley

303-458
General Equipment
Workshop table
Securing straps
Engine hoist
WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. NOTE:
    NOTE:Using suitable retaining straps, secure the engine on the workshop table.
    Support the engine with wooden blocks.
  1. Install the transaxle.

  1. Install the transaxle upper retaining bolts.

  1. Install the transaxle left-hand retaining bolts.

  1. Install the transaxle right-hand retaining bolts.

  1. Install the transaxle lower retaining bolts.

  1. Install the starter motor.

  1. Install the wiring harness retaining bracket.
    • Attach the wiring harness to the retaining bracket.

  1. Position the workshop table under the vehicle and carefully lower the vehicle until the engine and transaxle assembly is in the correct position to install the engine mounts.

  1. NOTE:
    NOTE:Do not tighten the engine rear mount retaining nuts at this stage.
    Install the engine rear mount retaining nuts.

  1. NOTE:
    NOTE:Install new engine front mount retaining nuts.
    NOTE:
    NOTE:Do not tighten the engine front mount retaining nuts and bolts at this stage.
    Install the engine front mount retaining nuts and bolts.
  1. Remove the securing straps.
  1. Raise and support the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

  1. Install the engine support insulator.

  1. Attach the air conditioning (A/C) compressor to the cylinder block.

  1. Connect the A/C high pressure switch electrical connector.

  1. Attach the gearshift cables to the bracket and turn the abutment sleeves counterclockwise.

  1. Attach the gearshift cables to the selector levers.

  1. CAUTION:
    CAUTION:The inner CV joint must not be bent more than 23 degrees. The outer CV joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Make sure that the halfshaft seal is not damaged.
    CAUTION:
    CAUTION:Make sure the snap ring is correctly seated.
    NOTE:
    NOTE:Install a new snap ring.
    Using the special tool, attach the left-hand halfshaft to the transaxle.
    • Remove the special tool before fully installing the halfshaft.

  1. CAUTION:
    CAUTION:The inner CV joint must not be bent more than 23 degrees. The outer CV joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Make sure the halfshaft seal is not damaged.
    Using the special tool, attach the right-hand halfshaft and intermediate shaft assembly to the transaxle.
    • Remove the special tool before fully installing the halfshaft.

  1. NOTE:
    NOTE:Install a new intermediate shaft center bearing cap and retaining nuts.
    NOTE:
    NOTE:Make sure that the intermediate shaft center bearing is correctly positioned in the intermediate shaft center bearing retaining bracket.
    Install the intermediate shaft center bearing cap.
    • Position the center bearing cap.
    • Position the intermediate shaft center bearing heat shield (if equipped).
    • Tighten the center bearing cap retaining nuts.

  1. CAUTION:
    CAUTION:Make sure that the lower arm ball joint heat shield is installed to prevent damage to the ball joint.
    Install the lower arm ball joint heat shield.

  1. CAUTION:
    CAUTION:The lower arm pinch bolt must be installed from the rear of the wheel knuckle.
    Attach the lower arm ball joint to the wheel knuckle.

  1. Attach the powertrain control module (PCM) support bracket to the side member.

  1. Install the air cleaner resonator support bracket.
  1. Lower the vehicle.

  1. Tighten the engine rear mount outer retaining nuts.

  1. Tighten the engine rear mount center retaining nut.

  1. Tighten the engine front mount retaining nuts and retaining bolts.

  1. Connect the fuel supply line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Attach the power steering pump to steering gear pressure line to the intake manifold.

  1. CAUTION:
    CAUTION:Care must be taken to prevent dirt ingress.
    Using the special tool, install a new O-ring seal onto the power steering pump to steering gear pressure line union.
    1. Push the O-ring seal onto the special tool.
    1. Locate the special tool onto the power steering pump to steering gear pressure line union and install the O-ring seal.

  1. Attach the power steering pump to steering gear pressure line from the power steering pump.

  1. NOTE:
    NOTE:Install a new power steering pump pulley.
    Using the special tool, install the power steering pump pulley.

  1. Install new power steering fluid reservoir O-ring seals.

  1. Install the power steering fluid reservoir.

  1. Using the special tool, connect the steering gear to power steering fluid reservoir return line to the power steering fluid reservoir.

  1. Attach the steering gear to power steering fluid reservoir return line support bracket to the generator.

  1. Connect the A/C low pressure switch connector.

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    NOTE:
    NOTE:Make sure the spring clip is correctly seated.
    Connect the clutch slave cylinder supply line.
    • Install the spring clip.

  1. Connect the reversing lamp switch electrical connector.
  1. Lower the vehicle.

  1. Install the coolant expansion tank.

  1. Attach the power steering high-pressure line retaining bracket to the transaxle.

  1. Install the engine wiring harness bracket.

  1. Connect the engine wiring harness electrical connector.

  1. Connect the catalyst monitor sensor electrical connector.

  1. Connect the power steering pump switch electrical connector.

  1. Install the battery tray support bracket.

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

  1. Attach the evaporative emission (EVAP) valve from EVAP valve support bracket.
    1. Connect the EVAP valve electrical connector.
    1. Connect the low pressure line to the EVAP valve.
    1. Push the EVAP valve onto the support bracket.

  1. Using the special tool, connect the coolant hose to the coolant outlet connector.

  1. Tighten the strut and spring assembly top mount nuts.
  1. Install the right-hand headlamp assembly.
    For additional information, refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
  1. Attach the exhaust flexible pipe to the exhaust manifold.
    For additional information, refer to: Exhaust Flexible Pipe - 2.0L Duratec-HE (MI4) (309-00 Exhaust System, Removal and Installation).

  1. Install the cooling fan motor and shroud.

  1. Connect the cooling fan motor and cooling fan resistor electrical connectors.
  1. Install the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 2.0L Duratec-HE (MI4) (303-05 Accessory Drive, Removal and Installation).
  1. Adjust the gearshift cables.
    For additional information, refer to: Gearshift Cable Adjustment (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  1. Bleed the hydraulic clutch system.
    For additional information, refer to: Clutch System Bleeding (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  1. Install the battery tray.
    For additional information, refer to: Battery Tray - 2.0L Duratec-HE (MI4) (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 2.0L Duratec-HE (MI4) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Fill and bleed the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03C Engine Cooling - 2.0L Duratec-HE (MI4), General Procedures).

303-01D Engine - 2.0L Duratec-HE (MI4)|Engine > < Assembly|Engine