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303-01C Engine - 1.3L Duratec-8V (Rocam) > < Assembly|Engine

Fiesta 2002.25 (11.2001-)

Engine - 1.4L Duratorq-TDCi (DV) Diesel - Engine Fiesta 2002.25 (11/2001-)
Installation

Special Tool(s)

Protector, Halfshaft Seal

205-755

Expander, Teflon Seal

211-188

Wrench, Hydraulic Line Union Nut

211-269

Lifting Bracket, Engine

303-122

Remover/Installer, Hose Clamp

303-397
General Equipment
Workshop table
Engine hoist
Retaining straps
Materials
Name
Specification
Manual transmission fluid
WSD-M2C200-C 
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:Make sure that the fuel pressure sensor electrical connector is not damaged while moving the transaxle.
    CAUTION:
    CAUTION:Make sure that the two locating dowels are installed.
    Attach the transaxle to the engine.

  1. Install the transaxle left-hand retaining bolts.

  1. Install the transaxle right-hand retaining bolts.

  1. Install the transaxle upper retaining bolts.
    • Attach the engine wiring harness bracket to the transaxle.

  1. Install the starter motor.

  1. Install the starter motor lower retaining bolt.

  1. Connect the starter motor electrical connectors.

  1. WARNING:
    WARNING:Support the engine and transaxle assembly on wooden blocks and secure it with suitable retaining straps. Failure to follow these instructions may result in personal injury.
    CAUTION:
    CAUTION:Do not support the engine directly on the oil pan.
    Position the engine and transaxle assembly on the workshop table.

  1. Remove the special tool.
  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 tighten the engine front mount retaining bolts and nuts at this stage.
    Install the engine front mount.

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

  1. Detach the engine and transaxle assembly from the workshop table.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
  1. Remove the workshop table.

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    NOTE:
    NOTE:Make sure the spring clip is correctly seated.
    Connect the clutch slave cylinder supply line.
    • Install the spring clip.

  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:Make sure that the halfshaft seal is not damage.
    CAUTION:
    CAUTION:Make sure the snap ring is correctly seated.
    NOTE:
    NOTE:Install a new snap ring.
    Using the special tool, attach the left-hand halfshaft to the transaxle.
    • Remove the protective sleeve before fully installing the halfshaft.

  1. CAUTION:
    CAUTION:The inner 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 seal is not damage.
    Using the special tool, attach the right-hand halfshaft together with the intermediate shaft to the transaxle.
    • Remove the protective sleeve before fully installing the halfshaft.

  1. NOTE:
    NOTE:Install a new intermediate shaft bearing cap and locknuts.
    Install the intermediate shaft center bearing cap.

  1. CAUTION:
    CAUTION:Make sure the heat shield is installed to prevent damage to the ball joint.
    Attach the lower arm ball joint to the wheel knuckle on both sides.

  1. Install the engine support insulator.

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

  1. Tighten the engine rear mount outer retaining nuts.

  1. Tighten the engine rear mount center retaining nut.

  1. Attach the gearshift cables to the bracket and turn the abutment sleeves counterclockwise.

  1. Attach the gearshift cables to the transaxle.
Vehicles with air conditioning

  1. Attach the air conditioning (A/C) compressor to the A/C compressor bracket.

  1. Connect the A/C compressor electrical connector.
All vehicles
  1. Install the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 1.4L Duratorq-TDCi (DV) Diesel (303-05 Accessory Drive, Removal and Installation).

  1. NOTE:
    NOTE:Install new exhaust flange nuts and a new exhaust flange gasket.
    Attach the exhaust flexible pipe to the catalytic converter.

  1. Attach the exhaust front pipe to the exhaust hanger insulator.

  1. Remove the exhaust flexible pipe support.

  1. Connect the power steering pressure switch electrical connector.

  1. Install the cooling fan motor and shroud.

  1. Connect the cooling fan motor and cooling fan resistor electrical connectors.
  1. Lower the vehicle.

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

  1. Install the fuel filter shield.

  1. Connect the fuel pump to fuel tank return line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
Vehicles with air conditioning

  1. Connect the A/C dryer pressure switch electrical connector (headlamp shown removed for clarity).

  1. Attach the A/C pressure pipe bracket to the transaxle housing.
All vehicles
  1. Connect the electric booster heater electrical connector.

  1. Using the special tool, connect the heater core return hose.
Vehicles without exhaust gas recirculation (EGR) cooler
  1. Connect the EGR valve vacuum hose.
Vehicles with EGR cooler
  1. Connect the EGR valve electrical connector.
All vehicles
  1. Connect the vacuum hose to the brake vacuum pump.

  1. Attach the engine wiring harness to the engine wiring harness bracket.

  1. Attach the engine wiring harness to the engine wiring harness bracket.

  1. NOTE:
    NOTE:Install a new power steering pump O-ring seal.
    Using the special tool, attach the O-ring seal to the power steering pump union.
    1. Slide the O-ring seal onto the special tool.
    1. Position the special tool onto the power steering pump union, install the new O-ring seal.

  1. CAUTION:
    CAUTION:Cover the generator with a suitable cloth to prevent the ingress of power steering fluid.
    Using the special tool, connect the power steering line to the power steering pump.

  1. Attach the power steering line support bracket to the power steering pump.

  1. Connect the power steering line to the power steering fluid reservoir.

  1. Attach the power steering fluid reservoir to the radiator grille opening panel.

  1. Using the special tool, connect the lower front coolant hose to the thermostat housing.

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

  1. Connect the coolant degas hose to the thermostat housing.
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 1.4L Duratorq-TDCi (DV) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).

  1. Install the coolant expansion tank.

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

  1. Connect the coolant degas hose to the coolant expansion tank.

  1. Tighten the strut and spring assembly top mount nuts on both sides.

  1. Install the battery tray support bracket.

  1. Attach the glow plug relay power supply cables.

  1. Connect the glow plug relay electrical connector.

  1. Connect the powertrain control module (PCM) electrical connectors.

  1. Connect the battery junction box electrical connectors.

  1. Attach the ground cable to the inner fender.
Vehicles without EGR cooler
  1. Attach the EGR control valve to the battery tray bracket.

  1. Connect the EGR control valve electrical connector.
All vehicles
  1. Install the battery tray.
    For additional information, refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Adjust the gearshift cables.
    For additional information, refer to: Gearshift Cable Adjustment (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  1. Fill and bleed the clutch system.
    For additional information, refer to: Clutch System Bleeding (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  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).
  1. Fill and bleed the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03B Engine Cooling - 1.4L Duratorq-TDCi (DV) Diesel, General Procedures).
  1. With the vehicle on a level surface, fill the transaxle withmanual transmission fluid until the level is just below the filler hole.

303-01C Engine - 1.3L Duratec-8V (Rocam) > < Assembly|Engine