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303-01C Engine - 2.3L DOHC-16V|Specifications > < Assembly|Engine

Transit 2000.5 (01.2000-05.2006)

Engine - 2.3L DOHC-16V - Engine Transit 2000.5 (01/2000-05/2006)
Installation

Special Tool(s)

Remover/Installer, Hose Clamp

303-397 (24-003)
General Equipment
Engine hoist
Trolley jack
Axle stands

Installation

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.
All vehicles
  1. Install a new pilot bearing.
    For additional information, refer to: Pilot Bearing (308-01A Clutch - Vehicles With: MT-75, Removal and Installation).
  1. CAUTION:
    CAUTION:Do not tilt the transmission during installation. This may cause damage to the pilot bearing.
    CAUTION:
    CAUTION:Make sure that the two locating tubes are installed.
    Install the transmission to the engine.

  1. Install the transmission left-hand retaining bolts.

  1. Install the transmission right-hand retaining bolts.
  1. Remove the M10 x 60 mm locating studs.

  1. Install the two remaining transmission retaining bolts.

  1. Install the starter motor and connect the starter motor ground cable.

  1. Connect the jump start point to starter motor solenoid cable and the ignition switch to starter motor solenoid cable to the starter motor.

  1. Install the engine support insulator retaining nuts.
  1. Using a suitable engine hoist, with the aid of another technician lift the engine and transmission over the towing eye and push the vehicle forwards.
  1. Lower the engine hoist and support the engine crossmember and transmission on suitable axle stands.

  1. Using a suitable trolley jack under the engine crossmember, raise the engine.

  1. Install the engine crossmember support brackets.

  1. Install the engine crossmember retaining bolts.

  1. Attach the engine wiring harness to the engine crossmember.
Vehicles with air conditioning
  1. Attach the air conditioning (A/C) compressor.

  1. Attach the refrigerant line support bracket to the A/C compressor.

  1. Install the A/C compressor retaining bolts.

  1. Connect the high-pressure cutoff switch electrical connector.

  1. Attach the A/C compressor wiring harness to the A/C compressor.

  1. Connect the A/C compressor clutch electrical connector.
Vehicles built up to 10/2001
  1. NOTE:
    NOTE:Align the mark on the driveshaft flange with the mark on the transmission output shaft flange.
    NOTE:
    NOTE:Use new driveshaft to transmission output shaft flange bolts.
    Attach the driveshaft to the transmission output shaft flange.
Vehicles built 10/2001 onwards
  1. NOTE:
    NOTE:Align the mark on the driveshaft flange with the mark on the transmission output shaft flange.
    NOTE:
    NOTE:Use new driveshaft to transmission output shaft flange bolts.
    Attach the driveshaft to the transmission output shaft flange.
All vehicles
  1. Install the new driveshaft front center bearing retaining bolts.

  1. Install the transmission support insulator to front axle crossmember bolts.

  1. NOTE:
    NOTE:Make sure that the clutch slave cylinder actuating rod correctly engages with the clutch release lever.
    Attach the clutch slave cylinder to the transmission.
  1. Install the catalytic converter.
    For additional information, refer to: Catalytic Converter - 2.3L DOHC-16V (309-00 Exhaust System, Removal and Installation).
  1. Lower the vehicle.

  1. Connect the exhaust gas recirculation (EGR) vacuum regulator solenoid vacuum lines.

  1. Connect the evaporative emission canister purge valve electrical connector.

  1. Connect the positive crankcase ventilation (PCV) hose.

  1. Connect the vapor line to the evaporative emission canister.

  1. Connect the vapor line to the intake manifold.

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

  1. Attach the accelerator cable bracket to the throttle body.

  1. Attach the accelerator cable to the throttle body.

  1. Connect the engine ground cable to the cylinder head.

  1. Connect the engine ground cable to the side member.

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

  1. Connect the battery to starter motor solenoid cable to the jump start point.

  1. Install the jump start point cover.
Vehicles with LPG fuel system
  1. Attach the engine wiring harness electrical connector to the retaining bracket.

  1. Connect the engine wiring harness electrical connector.
All except vehicles with LPG fuel system
  1. Attach the engine wiring harness electrical connector to the retaining bracket.

  1. Connect the engine wiring harness electrical connector.
All vehicles
  1. Connect the lower coolant hose to the heater core.

  1. Connect the power steering pressure (PSP) switch electrical connector.

  1. Attach the power steering pump to the mounting bracket.

  1. Install the power steering pump rear retaining bolts.

  1. Install the power steering pump pulley.
    • Use an 9 mm Allen key to prevent the power steering pump pulley from rotating.

  1. Install the air cleaner outlet pipe.
Vehicles with LPG fuel system
  1. Install the fuel distributor.

  1. Connect the LPG fuel injection supply manifold hoses.
All vehicles
  1. Install the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 2.3L DOHC-16V (303-05 Accessory Drive, Removal and Installation).
  1. Install the radiator.
    For additional information, refer to: Radiator - 2.3L DOHC-16V (303-03 Engine Cooling, Removal and Installation).
Vehicles with air conditioning
  1. Attach the condenser core.
All vehicles
  1. Using the special tool, connect the coolant hose to the water pump.

  1. Using the special tool, connect the coolant hoses to the thermostat housing.

  1. Install the stub lever.

  1. NOTE:
    NOTE:The rough surface of the insulation pad must face upwards.
    Install the gearshift lever insulation pad.

  1. Install the gearshift lever.
    1. Install the insulator.
    1. Install gearshift lever until the plunger locks.
    1. Install the boot.
  1. Install the radiator grille opening panel.
    For additional information, refer to: Radiator Grille Opening Panel (501-02 Front End Body Panels, Removal and Installation).
  1. Fill and bleed the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures).

303-01C Engine - 2.3L DOHC-16V|Specifications > < Assembly|Engine