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In-vehicle Repair|Disassembly > < Engine - Vehicles With: MTX-75-5F31J-5-Speed Automatic Transmission-5-Speed Manual Transaxle

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: MMT6/6-Speed Manual Transaxle Mondeo 2001 (10/2000-02/2007)
Removal

Special Tool(s)

Remover/Installer, Hose Clamp

303-397

Remover, Halfshaft

308-192
General Equipment
Workshop table
Securing straps
Assembly stand
Worldwide diagnostic system (WDS)

Removal

All vehicles
WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:Do not carry out any repairs to the fuel injection system without checking that the fuel pressure has dropped to zero and that the fuel temperature is below 30°C. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system is approximately 1600 bar. Failure to follow these instructions may result in personal injury.
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.
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness be observed when working with these components. Always fit blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to fuel injection system components to prevent foreign material entering the components.
  1. Clean the engine and fuel system components.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, General Procedures).
Vehicles with common rail fuel injection
  1. Using datalogger in worldwide diagnostic system (WDS), check that the fuel pressure has dropped to zero and that the fuel temperature is below 30°C.
All vehicles
  1. Drain 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. Remove the engine cover.
    • Remove the oil level indicator and oil filler cap.
  1. Remove the battery.
    For additional information, refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

  1. Remove the battery tray.
    • Remove the clips.

  1. Remove the strut and spring assembly top mount brace cover on both sides.
    • Release the clips.

  1. Loosen the strut and spring assembly top mount retaining nuts by four turns on both sides.

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

  1. Remove the air cleaner.
    1. Disconnect the air cleaner intake pipe from the front fender.
    1. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover.
    1. Disconnect the turbocharger air intake pipe from the turbocharger.
    1. Disconnect the vacuum hose from the air cleaner.

  1. Disconnect the coolant hoses from the thermostat housing.
    1. Disconnect the thermostat to radiator hose.
    1. Disconnect the thermostat to coolant reservoir hose.
    • Detach the coolant reservoir hose from the retaining clips.
Vehicles with 90 PS or 115 PS diesel engine
  1. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose and the electrical connector.

  1. Disconnect the brake vacuum hose from the brake vacuum pump.
Vehicles with 130 PS diesel engine
  1. Disconnect the brake vacuum hose from the brake vacuum pump.
    • Cut the cable tie.

  1. Disconnect the EGR valve vacuum hose.

  1. Disconnect the engine wiring harness central connector.
    • Position the engine wiring harness to one side.
All vehicles
  1. Disconnect the engine wiring harness electrical connector.

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

  1. Disconnect the power steering line from the power steering pump.
    • Allow the fluid to drain into a suitable container.
    • Discard the O-ring seal.

  1. Disconnect the power steering hose from the power steering pump.
    • Allow the fluid to drain into a suitable container.

  1. Remove the brake vacuum hose bracket retaining bolt.

  1. Using the special tool, disconnect the coolant hose from the coolant pump.
Vehicles without common rail fuel injection
  1. Disconnect the EGR regulator vacuum hose.

  1. Remove the vacuum regulator solenoid valve assembly.
    1. Disconnect the electrical connectors.
    1. Detach the vacuum hoses.
    1. Remove the retaining bolts.
All vehicles
  1. Disconnect the reversing lamp switch electrical connector.
Right-hand drive vehicles
  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    CAUTION:
    CAUTION:Cap the clutch slave cylinder supply line to prevent fluid loss or dirt ingress.
    NOTE:
    NOTE:Slide the spring clip back into the installation position before connecting the supply line.
    Pull the spring clip, disconnect the clutch slave cylinder supply line from the clutch master cylinder.

  1. Detach the clutch slave cylinder supply line from the bracket.
Left-hand drive vehicles
  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    CAUTION:
    CAUTION:Cap the clutch slave cylinder supply line to prevent fluid loss or dirt ingress.
    NOTE:
    NOTE:Slide the spring clip back into the installation position before connecting the supply line.
    Pull the spring clip, disconnect the clutch slave cylinder supply line from the clutch master cylinder.
    • Detach the clutch slave cylinder supply line from the bracket.
All vehicles
  1. Detach the gearshift cables from the transaxle.
    1. Detach the shift cable and the selector cable from the gearshift mechanism.
    1. Press the locking pins together and detach the gearshift cables from the bracket.
  1. Remove the cooling fan motor and shroud.
    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. Disconnect the air hoses from the charge air cooler.

  1. Disconnect the coolant hose from the oil cooler.

  1. Using the special tool, disconnect the heater hoses from the heater core and from the additional heater.

  1. Detach the intercooler outlet line from the turbocharger intake hose.
  1. Remove 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. Remove the subframe.
    For additional information, refer to: Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).

  1. Disconnect the fuel injector return line.
    For additional information, refer to: Spring Lock Couplings (310-00 Fuel System - General Information, General Procedures).

  1. Disconnect the fuel supply and return lines.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
All vehicles
  1. Disconnect the ground cable from the battery connection.

  1. Detach the ground cable from the transaxle.

  1. Disconnect the glow plug cable.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. CAUTION:
    CAUTION:Support the halfshaft. 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:Make sure that the halfshaft oil seal is not damaged.
    CAUTION:
    CAUTION:Cap the transaxle to prevent oil loss and dirt ingress.
    Detach the right-hand halfshaft together with the intermediate shaft from the transmission and secure it to one side.
    • Discard the intermediate shaft bearing cap and the self-locking nuts.
    • Allow the transmission fluid to drain into a suitable container.

  1. CAUTION:
    CAUTION:Support the halfshaft. 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:Make sure that the halfshaft oil seal is not damaged.
    CAUTION:
    CAUTION:Cap the transaxle to prevent oil loss and dirt ingress.
    Using the special tools, detach the left-hand halfshaft from the transmission and secure it to one side.
    • Discard the snap ring.
    • Allow the transmission fluid to drain into a suitable container.
Vehicles with air conditioning
  1. CAUTION:
    CAUTION:Support the air conditioning (A/C) compressor before removing the retaining bolts and secure it to prevent load being placed on the refrigerant lines.
    Detach the A/C compressor from the mounting bracket and secure it to one side.
All vehicles
  1. CAUTION:
    CAUTION:Never support the engine under the oil pan.
    NOTE:
    NOTE:Support the engine and transaxle with wooden blocks.
    Using a workshop table support the engine and transaxle assembly.
    • Carefully lower the vehicle, until the engine and transaxle assembly is in the correct position to remove the engine mounts.

  1. Remove the engine rear mount retaining nut.
    • Discard the nut.

  1. Remove the engine front mount.
    • Discard the nuts.
  1. Raise and support the vehicle and remove the engine and transaxle assembly.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Remove the wiring harness retaining bracket.

  1. Remove the starter motor.
    • Detach the wiring harness from the retaining bracket.
    • Discard the gasket.

  1. Remove the transaxle upper retaining bolts.

  1. Remove the transaxle right-hand retaining bolts.

  1. Using a suitable engine hoist, support the engine and transaxle assembly and remove the retaining straps.

  1. Detach the coolant line bracket from the transaxle.

  1. Remove the transaxle left-hand and lower retaining bolts.
  1. CAUTION:
    CAUTION:Do not tilt the transaxle during removal.
    Remove the transaxle from the engine.

In-vehicle Repair|Disassembly > < Engine - Vehicles With: MTX-75-5F31J-5-Speed Automatic Transmission-5-Speed Manual Transaxle