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303-01D Engine - 1.6L Duratorq-TDCi (DV) Diesel > < Engine - Vehicles With: Automatic Transmission (CFT23)

C-MAX 2003.75 (06.2003-)

Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) - Engine—Vehicles With: Automatic Transaxle C-MAX 2003.75 (06/2003-)
Installation

Special Tool(s)

Remover/Installer, Hose Clamp

303-397
General Equipment
Workshop table
Retaining straps
Engine hoist

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 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. CAUTION:
    CAUTION:The torque converter hub must engage fully with the oil pump drive gear.
    Check the installation depth of the torque converter.
    1. Position the steel straightedge on the transmission flange.
    1. Measure the correct installation depth between the automatic transmission flange and the torque converter guide collar.
  1. CAUTION:
    CAUTION:The torque converter must remain at the correct installation depth during the entire installation.
    Install the transaxle.

  1. Install the transaxle upper retaining bolts.

  1. Install the transaxle left-hand retaining bolt.

  1. Install the transaxle right-hand retaining bolts.

  1. Install the transaxle lower retaining bolts.

  1. NOTE:
    NOTE:Install new torque converter nuts.
    Install the torque converter nuts (4 nuts).

  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 bolt at this stage.
    Install the engine rear mount retaining bolt.
  1. Install the engine front mount.

  1. Install the engine front mount retaining studs.

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

  1. Attach the air conditioning (A/C) compressor line retaining bracket to the engine front mount.
  1. Remove the retaining straps from the transaxle.

  1. Connect the fuel supply line.

  1. Connect the evaporative emission (EVAP) valve vacuum line.
  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 right-hand halfshaft.
    For additional information, refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).
  1. Install the left-hand halfshaft.
    For additional information, refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).

  1. Install the engine support insulator.

  1. Attach the A/C compressor to the oil pan.

  1. Connect the A/C compressor electrical connector.
  1. Install the A/C compressor belt.
    For additional information, refer to: Air Conditioning (A/C) Compressor Belt - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (303-05 Accessory Drive, Removal and Installation).

  1. Install the A/C compressor cover.

  1. Install the A/C line retaining bracket.

  1. Connect the output shaft speed (OSS) sensor electrical connector.

  1. Attach the selector lever cable to the transmission.
    1. Press the locking pins together and attach the selector lever cable to the abutment
    1. Attach the selector lever cable to the selector mechanism.

  1. Connect the transmission range (TR) sensor electrical connector.

  1. Install the exhaust manifold lower retaining nuts (engine shown removed for clarity).
  1. Lower the vehicle.

  1. Tighten the engine rear mount retaining bolt.

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

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket.
    Tighten the exhaust manifold retaining nuts (engine shown removed for clarity).

  1. Install the exhaust manifold heat shield (engine shown removed for clarity).

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

  1. Install the coolant expansion tank.

  1. Using the special tool, connect the coolant hose to the coolant expansion tank.

  1. Connect the coolant hose.

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

  1. Connect the automatic transaxle electrical connector.

  1. NOTE:
    NOTE:The transmission fluid cooler feed and return lines connectors are color coded.
    Attach the transmission fluid cooler feed and return lines to the automatic transaxle.

  1. Connect the turbine shaft speed (TSS) sensor electrical connector.

  1. Connect the catalyst monitor sensor electrical connector.

  1. Connect the heated oxygen (HO2S) sensor electrical connectors.

  1. Connect the engine wiring harness electrical connector.

  1. Install the central junction box (CJB) cover.

  1. Attach the ground cables to the wheel housing.
  1. Adjust the selector lever cable.
    For additional information, refer to: Selector Lever Cable Adjustment (307-05B Automatic Transmission/Transaxle External Controls - Vehicles With: 4-Speed Automatic Transmission (4F27E), General Procedures).
  1. Install the battery tray.
    For additional information, refer to: Battery Tray - 1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (414-01 Battery, Mounting and Cables, Removal and Installation).

  1. Connect the battery positive lead to the battery positive cable terminal clamp.
  1. Connect the battery.
    For additional information, refer to: Battery - 1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/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 - 1.8L Duratec-HE (MI4)/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 - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), General Procedures).

  1. Install the engine cover.

  1. Install the oil filler pipe.
    • Rotate the oil filler pipe approximately 90 degrees clockwise until the securing clip snaps into position.
  1. Install the cowl panel grille.
    For additional information, refer to: Cowl Panel Grille - Vehicles Built Up To: 03/2007 (501-02 Front End Body Panels, Removal and Installation).
Vehicles with global closing
  1. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

303-01D Engine - 1.6L Duratorq-TDCi (DV) Diesel > < Engine - Vehicles With: Automatic Transmission (CFT23)