| Installation Special Tool(s) | | Lifting Bracket, Engine 303-122 | | | Remover/Installer, Hose Clamp 303-397 | General Equipment Engine hoist Retaining strap Workshop table 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). 8 - Brake booster vacuum hose 9 - Reversing lamp switch electrical connector 14 - Intake air shutoff throttle intake pipe 15 - Heater core coolant hose 20 - Turbocharger outlet pipe All vehicles | | -
Install the engine cover. | | | -
Install the left-hand fender splash shield. | | | -
Install the front drive halfshafts.
For additional information, refer to: Halfshaft LH (205-04, Removal and Installation) /
Halfshaft RH (205-04, Removal and Installation).
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Install the cooling fan motor and shroud.
For additional information, refer to: Cooling Fan Motor and Shroud (303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
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Install the air cleaner.
For additional information, refer to: Air Cleaner - 1.6L Duratorq-TDCi (DV) 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 cowl panel grille.
For additional information, refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
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Fill and bleed the cooling system.
For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).
| 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 retaining bolts | | -
CAUTION:Make sure that the two locating dowels are installed. Install the transaxle to the engine | | | -
Tighten the transaxle upper retaining bolts. | | | -
Tighten the transaxle lower retaining bolts. | Item 2 : Starter motor | | -
Install the starter motor.
For additional information, refer to: Starter Motor - 1.6L Duratorq-TDCi (DV) Diesel (303-06 Starting System, Removal and Installation) /
Starter Motor - 1.6L Duratorq-TDCi (DV) Diesel, Vehicles With: Automatic Transaxle (303-06 Starting System, Removal and Installation).
| Item 3 : Engine front mount | | -
CAUTION:Do not support the engine directly on the oil pan. 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. | | | -
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 front mount retaining nuts. NOTE:Do not tighten the engine front mount retaining bolts and nuts at this stage. Install the engine front mount. | Item 4 : Engine rear mount | | -
NOTE:Install new engine rear mount retaining nuts. Install the engine rear mount. | | | -
Tighten the engine front mount. | | | -
Remove the workshop table. | Item 5 : Thermostat housing degas hose | | -
Connect the degas hose to the thermostat housing. | Item 6 : Radiator to thermostat housing coolant hose | | -
Using the special tool, connect the radiator to thermostat housing coolant hose. | Item 7 : Gearshift cables | | -
Attach the gearshift cables to the abutment. - Attach the gearshift cable to the abutment and secure by turning the catches clockwise.
- Attach the selector cable to the abutment and secure by turning the catches clockwise.
| | | -
Install the gearshift cables on the shift mechanism. - Press the gearshift cable catch and attach the gearshift cable to the gear lever.
- Press the selector cable catch and attach the selector cable to the selector lever.
| Item 10 : Engine support insulator | | -
NOTE:Install a new engine support insulator to transaxle bolt. Install the engine support insulator retaining bolts. | Item 11 : Exhaust flexible pipe | | -
Install the exhaust flexible pipe.
For additional information, refer to: Exhaust Flexible Pipe (309-00 Exhaust System, Removal and Installation).
| Item 12 : Air conditioning (A/C) compressor | | -
Attach the A/C compressor to the A/C compressor bracket. | | | -
Connect the A/C compressor electrical connector. | Item 13 : Powertrain control module (PCM) electrical connectors | | -
Connect the PCM electrical connectors. | | | -
Install a new PCM security bracket and security bracket sheer bolt. - Tighten the security bracket sheer bolt until the head is sheered off.
| Item 17 : Battery junction box (BJB) electrical connector | | -
CAUTION:Do not bent the BJB electrical connector. Connect the BJB electrical connector. | Item 18 : Fuel supply line | | -
Connect the fuel supply line.
For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
| Item 19 : Coolant hose | | -
Using the special tool, install the coolant hose and attach the coolant expansion tank to the wheelhouse panel. | |
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