| Installation Special Tool(s) | | Lifting Bracket, Engine 303-122 | | | Remover/Installer, Hose Clamp 303-397 | General Equipment Retaining strap Workshop table Engine hoist Materials Name Specification Transmission Fluid
WSD-M2C200-C 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). 2 - Transaxle right-hand retaining bolts 3 - Transaxle lower retaining bolts 4 - Transaxle left-hand retaining bolts 6 - Starter motor retaining bolts 7 - Starter motor power supply 8 - Starter motor electrical connector retaining nuts 10 - Transaxle ground cable retaining bolt 15 - Engine roll restrictor retaining bolts 16 - Charge air cooler intake pipe 17 - Charge air cooler intake pipe retaining bolts 18 - Air conditioning (A/C) compressor 19 - A/C compressor retaining bolt 20 - A/C compressor electrical connector 27 - Brake booster vacuum hose 28 - Powertrain control module (PCM) cover 33 - Engine ground cable retaining bolts 34 - Coolant regulator valve electrical connector 35 - Engine wiring harness electrical connector 36 - Battery junction box (BJB) cover All vehicles | | -
Install the catalytic converter.
For additional information, refer to: Catalytic Converter - 2.0L Duratorq-TDCi (DW) Diesel (309-00 Exhaust System, Removal and Installation).
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Install the radiator.
For additional information, refer to: Radiator (303-03F Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).
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Install the charge air cooler.
For additional information, refer to: Charge Air Cooler - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
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Install the intake air cleaner.
For additional information, refer to: Air Cleaner - 1.8L Duratorq-TDCi (Lynx) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
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Install the battery tray.
For additional information, refer to: Battery Tray - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (414-01 Battery, Mounting and Cables, Removal and Installation).
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Install the fender splash shield. | | | -
Install the front drive halfshafts. For additional information, refer to: (205-04 Front Drive Halfshafts) Halfshaft LH (Removal and Installation), Halfshaft RH - 3-Door (Removal and Installation). | | | -
Fill and bleed the cooling system.
For additional information, refer to: Cooling System Draining, Filling and Bleeding - 2.0L (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures).
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Adjust the gearshift cables.
For additional information, refer to: Gearshift Cable Adjustment - Vehicles With: 6-Speed Manual Transaxle (MMT6) (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
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Fill and bleed the clutch system.
For additional information, refer to: Clutch System Bleeding - Vehicles With: MMT6/6-Speed Manual Transaxle.
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Apply soap solution to the ball clip mountings in the engine upper cover. - Soap solution (maximum concentration of soap in water 1:200).
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CAUTION:Contact of the engine upper cover with the cowl panel may cause damage (scratches) on the engine upper cover. Failure to follow this instruction may cause the engine upper cover to be damaged. Put the engine cover into installation position and clip it in place by pressing at the places shown. - Make sure that the engine upper cover is fully engaged in the area of the fuel filter, if necessary apply more pressure in the areas shown.
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Install the cowl panel grille.
For additional information, refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
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With the vehicle on a level surface fill the transaxle with transmission oil until the level is just below the filler hole. | Vehicles with global closing | | -
Initialize the door window motors.
For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).
| Installation Details Item 1 : Transaxle | | -
WARNING:Make sure that the two locating dowels are installed. Install the transaxle. | Item 11 : Engine rear mount | | -
WARNING:Support the engine and transaxle assembly on wooden blocks and secure it with a suitable retaining strap. Position the engine and transaxle assembly on the workshop table. | | | -
Detach the special tool from the engine hoist and the engine and transaxle assembly. | | | -
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. | | | -
NOTE:Install new engine rear mount retaining nuts. Install the engine rear mount. | Item 12 : Engine front mount | | -
NOTE:Install new engine front mount retaining nuts. Install the engine front mount. | | | -
Detach the engine and transaxle assembly from the workshop table. - Remove the retaining strap.
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Raise the vehicle and remove the workshop table. | Item 21 : Accessory drive belt | | -
Install the accessory drive belt.
For additional information, refer to: Accessory Drive Belt - 2.0L Duratorq-TDCi (DW) Diesel (303-05 Accessory Drive, Removal and Installation).
| Item 22 : Gearshift cables | | -
Attach the gearshift cables to the transaxle. - Attach the gearshift cable and selector cable to the bracket.
- Attach the gearshift cable and selector cable to the selector levers.
| Item 23 : Clutch slave cylinder supply line | | -
CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water. Attach the clutch slave cylinder supply line to the clutch slave cylinder. - Attach the clutch slave cylinder supply line to the bracket.
| Item 24 : Thermostat housing lower coolant hose | | -
Using the special tool, install the thermostat housing lower coolant hose. | | | -
Using the special tool, attach the thermostat housing lower coolant hose to the thermostat housing. | Item 25 : Thermostat housing upper coolant hose | | -
Using the special tool, install the thermostat housing upper coolant hose. | | | -
Using the special tool, attach the thermostat housing upper coolant hose to the thermostat housing. | Item 29 : PCM electrical connectors | | -
Connect the powertrain control module (PCM) electrical connectors. | Item 30 : PCM security bracket (if equipped) | | -
Install a new PCM security bracket and security bracket sheer bolt (if equipped). - Tighten the security bracket sheer bolt until the head of the sheer bolt is sheered off.
| Item 38 : Fuel supply line and fuel return line | | -
Connect the fuel supply line and the fuel return line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| Item 40 : Coolant expansion tank hoses | | -
Using the special tool, install the coolant expansion tank hoses. | |
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