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Engine - Vehicles With: MMT6-6-Speed Manual Transaxle > < Assembly|Engine

Mondeo 2001 (10.2000-02.2007)

Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel - Engine—Vehicles With: MTX-75/5F31J/5-Speed Automatic Transmission/5-Speed Manual Transaxle Mondeo 2001 (10/2000-02/2007)
Installation

Special Tool(s)

Lifting Bracket, Engine

303-122

Remover/Installer, Hose Clamp

303-397
General Equipment
Engine hoist
Steel straight edge
Workshop table
Transmission jack
Securing straps
Materials
Name
Specification
Grease
WSD-M1C230-A 
Automatic transmission fluid
WSS-M2C922-A1 
High-temperature grease
ESD-M1220-A 

Installation

All vehicles
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 mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. CAUTION:
    CAUTION:Never support the engine under the oil pan.
    Using a suitable engine hoist, position the engine assembly on the workshop table and support the engine assembly with wooden blocks and securing straps.
Vehicles with automatic transaxle
  1. CAUTION:
    CAUTION:The torque converter hub must remain at the correct installation depth throughout the whole installation procedure.
    Check the installation depth of the torque converter.
    1. Lay a steel straight edgeacross the transaxle flange.
    1. Check the installation depth between the steel straight edge and the drive plate stud.
    • Apply a thin layer of high-temperature grease to the centering spigot on the torque converter.

  1. CAUTION:
    CAUTION:The torque converter must remain at the correct installation depth throughout the entire installation procedure.
    NOTE:
    NOTE:The torque converter studs must be aligned with the engine drive plate holes before any transaxle bolts are installed.
    NOTE:
    NOTE:Secure the transaxle with securing straps.
    NOTE:
    NOTE:Use a suitable wooden block to protect the transaxle.
    Using a suitable engine hoist install the transaxle.

  1. Install the transaxle left-hand and lower retaining bolts.

  1. Install the transaxle right-hand retaining bolts.

  1. Install the transaxle right-hand upper retaining bolts.

  1. Install the transaxle left-hand upper retaining bolts.

  1. Connect the transaxle electrical connectors.
Vehicles with manual transaxle
  1. CAUTION:
    CAUTION:Do not tilt the manual transaxle during installation.
    Install the manual transaxle to the engine.
    • Install the transaxle left-hand retaining bolts.

  1. Install the transaxle right-hand retaining bolts.
All vehicles
  1. Install the starter motor.

  1. Install the wiring harness retaining bracket.
    • Attach the wiring harness to the retaining bracket.
  1. CAUTION:
    CAUTION:Never support the engine under the oil pan.
    Using a suitable engine hoist, position the engine assembly on the workshop table and support the engine assembly with wooden blocks and securing straps.
  1. Raise and support the vehicle.
    For additional information, refer to: Jacking (100-02 Jacking and Lifting, Description and Operation) /
    Lifting (100-02 Jacking and Lifting, Description and Operation).

  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 front mount retaining nuts.
    NOTE:
    NOTE:Do not fully tighten the retaining nuts and retaining bolts at this stage.
    Install the engine front mount.

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

  1. Connect the vehicle speed sensor (VSS) electrical connector.
Vehicles with air conditioning
  1. Attach the air conditioning (A/C) compressor to the mounting bracket.
All vehicles
  1. CAUTION:
    CAUTION:The inner constant velocity (CV) joint must not be bent more than 18 degrees. The outer CV joint must not be bent more than 45 degrees.
    NOTE:
    NOTE:Install a new snap-ring
    Attach the left-hand halfshaft to the transmission.
    • Remove the protective sleeve before fully installing the halfshaft.

  1. CAUTION:
    CAUTION:The inner constant velocity (CV) joint must not be bent more than 18 degrees. The outer CV joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft seal.
    Attach the right-hand halfshaft to the transmission together with the intermediate shaft.
    • Remove the protective sleeve before fully installing the halfshaft.

  1. NOTE:
    NOTE:Install new center bearing self-locking nuts.
    Install the intermediate shaft center bearing.
  1. Lower the vehicle.

  1. Tighten the engine rear mount retaining nut.

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

  1. Connect the glow plug cable.

  1. Attach the ground cable to the transaxle.

  1. Connect the ground cable to the battery connection.
Vehicles with manual transaxle
  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paint work, the effected area must be immediately washed down with cold water.
    Connect the clutch slave cylinder supply line to the transaxle.
    • Install the spring clip.

  1. Connect the reversing lamp switch electrical connector.

  1. Attach the gearshift cables to the transaxle.
    1. Install the gearshift cables to the retaining bracket, turning the abutment sleeves.
    1. Attach the gearshift cables to the transaxle linkage, press the tabs into the ball and socket.
Vehicles with automatic transaxle
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. NOTE:
    NOTE:Install new torque converter retaining nuts.
    Install the torque converter retaining nuts.
    • Rotate the engine to gain access to the nuts.
    • Install the cover.
  1. NOTE:
    NOTE:Make sure the transaxle selector lever is in the ”P” (PARK) position.
    Attach the selector lever cable to the transaxle.
    1. Attach the selector lever cable to the transaxle.
    1. Attach the selector lever cable to the selector shaft.

  1. Install the selector lever cable cover.
  1. Lower the vehicle.

  1. Connect the crankshaft position (CKP) sensor electrical connector.
All vehicles
  1. Connect the fuel supply and return lines.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Connect the fuel injector return line.
    For additional information, refer to: Spring Lock Couplings (310-00 Fuel System - General Information, General Procedures).
  1. Install the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel (303-05 Accessory Drive, Removal and Installation).
  1. Install the subframe.
    For additional information, refer to: Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).

  1. Connect the heater hoses to the heater core and to the additional heater.

  1. Connect the coolant hose to the oil cooler.

  1. Connect the air hoses to the charge air cooler.
  1. Install the cooling fan motor and shroud.
    For additional information, refer to: Cooling Fan Motor and Shroud - 2.0L Diesel, Vehicles With: 5-Speed Manual Transaxle (MTX-75)/6-Speed Manual Transaxle (MMT6) (303-03, Removal and Installation) /
    Cooling Fan Motor and Shroud - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Vehicles With: 6-Speed Manual Transmission (MMT6)/5-Speed Automatic Transmission (5F31J) (303-03 Engine Cooling, Removal and Installation).

  1. Connect the coolant hose to the water pump.

  1. Install the brake vacuum hose bracket retaining bolt.
Vehicles with common rail fuel injection
  1. Connect the exhaust gas recirculation (EGR) vacuum regulator vacuum hose.

  1. Install the vacuum regulator solenoid valve assembly.
    1. Install the retaining bolts.
    1. Attach the vacuum hoses.
    1. Connect the electrical connector.
All vehicles
  1. Connect the power steering line to the power steering pump.

  1. Connect the power steering hose to the power steering pump.

  1. Install the power steering line support brackets retaining bolts.

  1. Connect the engine wiring harness electrical connector.
Vehicles with 90 PS or 115 PS engine
  1. Connect the brake vacuum hose to the brake vacuum pump.

  1. Connect the EGR valve vacuum hose and the electrical connector.
Vehicles with 130 PS diesel engine
  1. Connect the brake vacuum hose to the brake vacuum pump.
    • Install a new cable tie.

  1. Connect the EGR valve vacuum hose.
All vehicles
  1. Connect the coolant hoses to the thermostat housing.
    1. Connect the thermostat to radiator hose.
    1. Connect the thermostat to coolant reservoir hose.

        2. 1. Clip the coolant reservoir hose.

  1. Install the air cleaner.
    1. Connect the air cleaner intake pipe to the front fender.
    1. Connect the positive crankcase ventilation (PCV) hose to the valve cover.
    1. Connect the turbocharger air intake pipe to the turbocharger.
    1. Connect the vacuum hose to the air cleaner.

  1. Connect the mass air flow (MAF) sensor electrical connector.

  1. Install the battery tray.
    • Install the clip.

  1. Tighten the strut and spring assembly top mount retaining nuts

  1. Install the strut and spring assembly top mount brace cover.
  1. Fill the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel (303-03 Engine Cooling, General Procedures).
  1. Install the battery.
    For additional information, refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Fill and bleed the power steering system.
    For additional information, refer to: Power Steering System Filling (211-00 Steering System - General Information, General Procedures) /
    Power Steering System Bleeding (211-00 Steering System - General Information, General Procedures).
Vehicles with manual transaxle
  1. Adjust the gearshift cables.
    For additional information, refer to: Gearshift Cable Adjustment - Vehicles With: MTX-75/5-Speed Manual Transaxle (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).
Vehicles with automatic transaxle
  1. Check the selector lever cable adjustment.
    For additional information, refer to: Selector Lever Cable Adjustment (307-05B Automatic Transmission/Transaxle External Controls - Vehicles With: 5-Speed Automatic Transmission (5F31J), General Procedures).
All vehicles
  1. Install the engine upper cover.
    • Install the oil level indicator.
  1. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

Engine - Vehicles With: MMT6-6-Speed Manual Transaxle > < Assembly|Engine