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303-01F Engine - 1.6L Duratorq-TDCi (DV) Diesel|Engine > < Engine - Vehicles With: Manual Transaxle

Focus 2004.75 (07.2004-)

Engine - 1.6L Duratorq-TDCi (DV) Diesel - Engine—Vehicles With: Automatic Transaxle Focus 2004.75 (07/2004-)
Installation

Special Tool(s)

Lifting Bracket, Engine

303-122

Remover/Installer, Hose Clamp

303-397
General Equipment
Engine hoist
Workshop table
Steel straightedge
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. Install the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Automatic transaxle
See Installation Detail
2
-
Torque converter retaining nuts
See Installation Detail
3
-
Starter motor
See Installation Detail

 
Item
Part Number
Description
4
-
Engine front mount
See Installation Detail
5
-
Engine rear mount
See Installation Detail
6
-
Transmission fluid cooler feed and return lines
See Installation Detail
7
-
Radiator to thermostat housing coolant hose
See Installation Detail
8
-
Thermostat housing degas hose
See Installation Detail
9
-
Selector lever cable
See Installation Detail
10
-
Brake booster vacuum hose

 
Item
Part Number
Description
11
-
Engine support insulator
See Installation Detail
12
-
Exhaust flexible pipe
See Installation Detail
13
-
Air conditioning (A/C) compressor
See Installation Detail
14
-
Powertrain control module (PCM) electrical connectors
See Installation Detail

 
Item
Part Number
Description
15
-
Charge air cooler outlet pipe
16
-
Heater core coolant hose
17
-
Engine ground cables
18
-
Battery junction box (BJB) electrical connector
See Installation Detail
19
-
Fuel supply lines
See Installation Detail
20
-
Coolant expansion tank to heat exchanger coolant hose
See Installation Detail
21
-
Turbocharger outlet pipe
See Installation Detail
All vehicles
  1. Install the right-hand halfshaft.
    For additional information, refer to: 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 left-hand fender splash shield.
  1. Install the cooling fan motor and shroud.
    For additional information, refer to: Cooling Fan Motor and Shroud (303-03E Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 1.8L Duratorq-TDCi (Lynx) Diesel (303-12A Intake Air Distribution and Filtering, Removal and Installation).
  1. Install the battery tray.
    For additional information, refer to: Battery Tray - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Fill the transaxle with automatic transmission fluid.
    For additional information, refer to: Transmission Fluid Drain and Refill (307-01B Automatic Transmission/Transaxle - Vehicles With: Automatic Transmission (CFT23), General Procedures).
  1. Adjust the selector lever cable.
    For additional information, refer to: Selector Lever Cable Adjustment (307-05B Automatic Transmission/Transaxle External Controls - Vehicles With: 6DCT450/CFT23, General Procedures).
  1. Install the cowl panel grille.
    For additional information, refer to: Cowl Panel Grille (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 (303-03E Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).

  1. Install the crashbox (if equipped).
    1. M10 x 16 bolt.
    1. M10 x 25 bolts.

  1. Install the engine undershield.
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).

Installation Details

Item 1 : Automatic transaxle
  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 a steel straightedge on the transaxle flange.
    1. Measure the installation depth between the transaxle flange and the torque converter guide collar.
  1. CAUTION:
    CAUTION:Make sure that the two locating dowels are installed.
    CAUTION:
    CAUTION:The torque converter must remain at the correct installation depth during the entire installation.
    NOTE:
    NOTE:Using suitable securing straps and wooden blocks, secure the transaxle to the workshop table.
    Install the transaxle to the engine.

  1. Install the transaxle upper retaining bolts.
    • Attach the ground cable to the transaxle.

  1. CAUTION:
    CAUTION:Perform this and the following operation simultaneously.
    Install the lower bolt with the catalytic converter bracket.

  1. Install the transaxle lower retaining bolts.
    • Attach the catalytic converter bracket to the transaxle.
    • Install the catalytic converter bracket bolts.

  1. Install the transaxle left-hand retaining bolts.

  1. Install the catalytic converter bracket bolt.

  1. Install the transaxle right-hand retaining bolt.
    • Install the vacuum reservoir bracket.

  1. Install the transaxle right-hand retaining bolt.

  1. Install the torque converter housing cover.
  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.

Item 2 : Torque converter retaining nuts
  1. CAUTION:
    CAUTION:Make sure that the torque converter retaining nuts do not fall into the torque converter housing.
    NOTE:
    NOTE:Install new torque converter retaining nuts.
    Install the torque converter retaining nuts.
    • Turn the crankshaft to gain access to the torque converter studs.

Item 3 : Starter motor

  1. Install the starter motor. For additional information, refer to: (303-06 Starting System)
    Starter Motor - 1.6L Duratorq-TDCi (DV) Diesel, Vehicles With: Automatic Transaxle (Removal and Installation),
    Starter Motor - 1.6L Duratorq-TDCi (DV) Diesel, Vehicles With: Automatic Transaxle (Removal and Installation).

  1. Install the vacuum reservoir (if equipped) (starter motor cable shown removed for clarity).
    • Install the vacuum reservoir bolt.
    • Connect the vacuum lines.

Item 4 : Engine front mount
  1. CAUTION:
    CAUTION:Do not support the engine directly on the oil pan.
    NOTE:
    NOTE:Support the engine and transaxle assembly with suitable wooden blocks.
    Using suitable retaining straps, secure the engine and transaxle assembly on the workshop table.

  1. Remove the special tool.

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

Item 5 : Engine rear mount
  1. NOTE:
    NOTE:Install a new engine rear mount retaining bolt.
    Install the engine rear mount retaining bolt.

  1. Tighten the engine front mount.
  1. Remove the workshop table.

Item 6 : Transmission fluid cooler feed and return lines
  1. Connect the transmission fluid cooler feed and return lines to the automatic transaxle.

  1. Clip in the transmission fluid cooler feed and return lines to the retaining bracket.

  1. CAUTION:
    CAUTION:The automatic transaxle contains components and assemblies which are sensitive to electrostatic charging.
    Connect the automatic transaxle central electrical connector.
    • Turn the automatic transaxle central electrical connector clockwise.

Item 7 : Radiator to thermostat housing coolant hose
  1. Using the special tool, connect the radiator to thermostat housing coolant hose.

Item 8 : Thermostat housing degas hose
  1. Connect the degas hose to the thermostat housing.

Item 9 : Selector lever cable
  1. CAUTION:
    CAUTION:Do not kink the selector lever cable.
    Attach the selector lever cable to the transaxle.
    1. Press the locking pins together and attach the selector lever cable to the bracket, press down the locking tab.
    1. Attach the selector lever cable to the selector mechanism.

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

Item 11 : Engine support insulator
  1. NOTE:
    NOTE:Install a new engine support insulator to transaxle bolt.
    Install the engine support insulator retaining bolts.

Item 12 : Exhaust flexible pipe
  1. NOTE:
    NOTE: Coat the exhaust flexible pipe to rear muffler flange studs with grease.
    NOTE:
    NOTE:Install new exhaust flexible pipe gaskets and nuts.
    Tighten the exhaust flexible pipe to catalytic converter retaining nuts.

  1. Install the floor panel brace.

  1. CAUTION:
    CAUTION:Over bending of the exhaust flexible pipe may cause damage resulting in failure.
    Remove the exhaust flexible pipe support wrap or splint.

Item 13 : Air conditioning (A/C) compressor
  1. Attach the A/C compressor to the A/C compressor bracket.

  1. Connect the A/C compressor electrical connector.

Item 14 : Powertrain control module (PCM) electrical connectors
  1. Connect the PCM electrical connectors.
  1. Install a new PCM security bracket and security bracket sheer bolt.
    • Tighten the security bracket sheer bolt until the head is sheered off.

Item 18 : Battery junction box (BJB) electrical connector

  1. CAUTION:
    CAUTION:Do not bent the BJB electrical connector.
    Connect the BJB electrical connector.

Item 19 : Fuel supply lines

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

Item 20 : Coolant expansion tank to heat exchanger coolant hose
  1. Using the special tool, install the coolant expansion tank to heat exchanger coolant hose and attach the coolant expansion tank to the wheelhouse panel.

Item 21 : Turbocharger outlet pipe
  1. Attach the charge air cooler intake pipe to the transaxle and connect the charge air cooler intake hose.

  1. Attach the turbocharger outlet pipe to the transaxle and connect the turbocharger outlet hose.

303-01F Engine - 1.6L Duratorq-TDCi (DV) Diesel|Engine > < Engine - Vehicles With: Manual Transaxle