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303-03A Engine Cooling - 1.25L Duratec-16V (Sigma)-1.3L Duratec-8V (Rocam)-1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma) > < Assembly|Engine

Fiesta 2002.25 (11.2001-)

Engine - 1.6L Duratorq-TDCi (DV) Diesel - Engine Fiesta 2002.25 (11/2001-)
Installation

Special Tool(s)

Lifting Bracket, Engine

303-122

Remover/Installer, Hose Clamp

303-397
General Equipment
Engine hoist
Retaining strap
Workshop table
Materials
Name
Specification
Transmission Fluid
WSD-M2C200-C
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. Install the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Transaxle retaining bolts
See Installation Detail
2
-
Starter motor
See Installation Detail

 
Item
Part Number
Description
3
-
Engine rear mount retaining bolts
See Installation Detail
4
-
Engine front mount retaining bolts
See Installation Detail
5
-
Clutch slave cylinder supply line
See Installation Detail
6
-
Gearshift cables retaining bracket
7
-
Gearshift cables
See Installation Detail
8
-
Gearshift cables cover

 
Item
Part Number
Description
9
-
Engine support insulator
See Installation Detail
10
-
Exhaust flexible pipe
See Installation Detail
11
-
Air conditioning (A/C) compressor
See Installation Detail
12
-
Powertrain control module (PCM) electrical connectors
See Installation Detail

 
Item
Part Number
Description
13
-
Battery junction box (BJB) electrical connector
14
-
Battery tray support bracket
15
-
Thermostat housing coolant hoses
See Installation Detail
16
-
Glow plug relay electrical connector
17
-
Exhaust gas recirculation (EGR) vacuum lines
18
-
Coolant hoses to heater core
19
-
Power steering pump electrical connector

 
Item
Part Number
Description
20
-
Charge air cooler outlet pipe
See Installation Detail
21
-
Turbocharger outlet pipe
22
-
Engine ground cable
23
-
Brake booster vacuum line
24
-
Engine wiring harness electrical connector
25
-
Fuel line quick release coupling
See Installation Detail
26
-
Coolant expansion tank
See Installation Detail
  1. Install the halfshafts. For additional information, refer to: (205-04 Front Drive Halfshafts)
    Front Halfshaft LH (Removal and Installation),
    Front Halfshaft RH (Removal and Installation).

  1. Install the left-hand fender splash shield.
  1. Install the cooling fan motor and shroud.
    For additional information, refer to: Cooling Fan Motor and Shroud (303-03 Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
  1. Install the charge air cooler.
    For additional information, refer to: Charge Air Cooler - 1.6L Duratorq-TDCi (DV) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Install the left-hand headlamp assembly.
    For additional information, refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 1.6L Duratorq-TDCi (DV) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Install the battery tray.
    For additional information, refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Fill and bleed the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).

Installation Details

Item 1 : Transaxle retaining bolts

  1. CAUTION:
    CAUTION:Make sure that the two locating dowels are installed.
    Install the transaxle to the engine

  1. Tighten the transaxle upper retaining bolts.

  1. Tighten the transaxle lower retaining bolts.

Item 2 : Starter motor

  1. Install the starter motor.
    For additional information, refer to: Starter Motor - 1.6L Duratorq-TDCi (DV) Diesel (303-06 Starting System, Removal and Installation).

Item 3 : Engine rear mount retaining bolts

  1. CAUTION:
    CAUTION:Do not support the engine directly on the oil pan.
    NOTE:
    NOTE:Support the engine and transaxle assembly with suitable wooden blocks.
    Using suitable retaining straps, secure the engine and transaxle assembly on the workshop table.

  1. Remove the special tool.
  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:Install new engine rear mount retaining bolts and nuts.
    NOTE:
    NOTE:Do not tighten the engine rear mount retaining bolts and nuts at this stage.
    Install the engine rear mount.

Item 4 : Engine front mount retaining bolts

  1. NOTE:
    NOTE:Install new engine front mount retaining bolts and nuts.
    Tighten the engine front mount retaining bolts and nuts.

  1. Tighten the engine rear mount outer retaining nuts.

  1. Tighten the engine rear mount center retaining nut.
  1. Remove the workshop table.

Item 5 : Clutch slave cylinder supply line
  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 that the spring clip is correctly seated.
    Connect the clutch slave cylinder supply line to the transaxle.
    • Install the spring clip.
    • Attach the clutch slave cylinder supply line to the retaining bracket.

Item 7 : Gearshift cables
  1. Attach the gearshift cables to the bracket and turn the abutment sleeves counterclockwise.

  1. Attach the gearshift cables to the transaxle.
  1. Adjust the gearshift cables.
    For additional information, refer to: Gearshift Cable Adjustment (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).

Item 9 : Engine support insulator
  1. NOTE:
    NOTE:Install a new engine support insulator to transaxle retaining bolt.
    Install the engine support insulator retaining bolts.

Item 10 : Exhaust flexible pipe

  1. Install the exhaust flexible pipe.
    For additional information, refer to: Exhaust Flexible Pipe - 1.4L Duratorq-TDCi (DV) Diesel/1.6L Duratorq-TDCi (DV) Diesel (309-00 Exhaust System, Removal and Installation).

Item 11 : Air conditioning (A/C) compressor
  1. Attach the A/C compressor to the mounting bracket.

  1. Connect the A/C compressor electrical connector.

Item 12 : Powertrain control module (PCM) electrical connectors

  1. Connect the PCM electrical connectors.
    For additional information, refer to: Powertrain Control Module (PCM) - 1.6L Duratorq-TDCi (DV) Diesel (303-14 Electronic Engine Controls, Removal and Installation).

Item 15 : Thermostat housing coolant hoses
  1. Using the special tool, connect the radiator lower coolant hose to the thermostat housing.
  1. Attach the coolant expansion tank to thermostat coolant hose.

Item 20 : Charge air cooler outlet pipe

NOTE:
NOTE:Make sure that the inside of the charge air cooler outlet pipe is clean and free from any oil residue, as this will reduce the installation grip of the pipe to the turbocharger. Failure to follow this instruction may result in damage to the turbocharger.

Item 25 : Fuel line quick release coupling

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

Item 26 : Coolant expansion tank
  1. Using the special tool, install the coolant expansion tank to heat exchanger coolant hose and attach the coolant expansion tank to the wheelhouse panel.

303-03A Engine Cooling - 1.25L Duratec-16V (Sigma)-1.3L Duratec-8V (Rocam)-1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma) > < Assembly|Engine