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In-vehicle Repair|Disassembly > < Intake Manifold

Fusion 2002.75 (06.2002-)

Engine - 1.4L Duratorq-TDCi (DV) Diesel - Engine Fusion 2002.75 (06/2002-)
Removal

Special Tool(s)

Wrench, Hydraulic Line Union Nut

211-269 (13-027)

Lifting Bracket, Engine

303-122 (21-068A)

Remover/Installer, Hose Clamp

303-397 (24-003)

Remover, Halfshaft

308-256 (16-089)
General Equipment
Retaining straps
Workshop table
Engine hoist
Worldwide diagnostic system (WDS)
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. Using the datalogger in worldwide diagnostic system (WDS), check that the fuel pressure has dropped to zero and that the fuel temperature is below 30°C.
  1. Drain 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. Remove the battery tray.
    For additional information, refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
Vehicles without exhaust gas recirculation (EGR) cooler
  1. Disconnect the EGR control valve electrical connector.

  1. Detach the EGR control valve from the battery tray bracket and position it to one side.
All vehicles
  1. Detach the ground cable from the inner fender.

  1. Disconnect the battery junction box electrical connectors.

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

  1. Disconnect the glow plug relay electrical connector.

  1. Detach the glow plug relay power supply cables.

  1. Remove the battery tray bracket.

  1. Loosen the strut and spring assembly top mount retaining nuts by three turns on both sides.

  1. Disconnect the coolant degas hose from the coolant expansion tank.

  1. Using the special tool, disconnect the coolant hose from the coolant expansion tank.

  1. Remove the coolant expansion tank.
  1. Remove 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. Disconnect the coolant degas hose from the thermostat housing.

  1. Using the special tool, disconnect the rear coolant hose from the thermostat housing.

  1. Using the special tool, disconnect the lower front coolant hose from the thermostat housing.

  1. Drain the power steering fluid from the power steering fluid reservoir.

  1. Detach the power steering fluid reservoir from the radiator grille opening panel.

  1. Remove the power steering fluid reservoir.
    • Disconnect the power steering line from the power steering fluid reservoir.

  1. Detach the power steering line support bracket from the power steering pump.

  1. CAUTION:
    CAUTION:Cover the generator with a suitable cloth to prevent the ingress of power steering fluid.
    CAUTION:
    CAUTION:Do not disconnect the power steering pump pressure adapter from the power steering pump.
    CAUTION:
    CAUTION:Cap the power steering line to prevent fluid loss or dirt ingress.
    CAUTION:
    CAUTION:Cap the power steering pump pressure adapter to prevent fluid loss or dirt ingress.
    Using the special tool, disconnect the power steering line from the power steering pump.
    • Using a suitable wrench, hold the power steering pump pressure adapter.
    • Allow the fluid to drain into a suitable container.
    • Discard the O-ring seal.

  1. Detach the engine wiring harness from the engine wiring harness bracket.

  1. Detach the engine wiring harness from the engine wiring harness bracket.

  1. Disconnect the vacuum hose from the brake vacuum pump.
Vehicles without EGR cooler
  1. Disconnect the EGR valve vacuum hose.
Vehicles with EGR cooler
  1. Disconnect the EGR valve electrical connector.
All vehicles
  1. Using the special tool, disconnect the heater core return hose.

  1. Disconnect the electric booster heater electrical connector.
Vehicles with air conditioning

  1. Detach the air conditioning (A/C) pressure pipe bracket from the transaxle housing.

  1. Disconnect the A/C dryer pressure switch electrical connector (headlamp shown removed for clarity).
All vehicles
  1. Disconnect the fuel pump to fuel tank return line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Remove the fuel filter shield.
  1. Clean the area around the fuel filter connections and fuel lines.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).

  1. Disconnect the fuel supply line from the fuel filter.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Disconnect the power steering pressure switch electrical connector.

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

  1. Detach the exhaust flexible pipe from the catalytic converter.
    • Discard the gasket and nuts.

  1. Detach the exhaust front pipe from the exhaust hanger insulator.
  1. Remove 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).
Vehicles with air conditioning

  1. Disconnect the A/C compressor electrical connector.

  1. Detach the A/C compressor from the mounting bracket and secure it to one side.
All vehicles
  1. Disconnect the cooling fan motor and cooling fan resistor electrical connectors.

  1. Remove the cooling fan motor and shroud.
  1. Lower the vehicle.

  1. Remove the gear shift cables cover.

  1. Detach the gearshift cables from the transaxle.
    1. Detach the gearshift cable and the selector cable from the selector levers.
    1. Turn the abutment sleeves clockwise and detach the cables from the bracket.

  1. Remove the engine support insulator.

  1. CAUTION:
    CAUTION:Protect the ball joint seal, using a soft cloth to prevent damage.
    Detach the lower arm ball joint from the wheel knuckle on both sides.
    • Remove the heat shield.

  1. CAUTION:
    CAUTION:Secure the halfshaft to prevent damage to the constant velocity (CV) joints. 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 damaged.
    CAUTION:
    CAUTION:Cap the transaxle to prevent oil loss and dirt ingress.
    Detach the right-hand halfshaft together with the intermediate shaft from the transaxle and secure it to one side.
    • Remove and discard the center bearing cap and locknuts.
    • Allow the fluid to drain into a suitable container.

  1. CAUTION:
    CAUTION:Secure the halfshaft to prevent damage to the CV joints. 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 damaged.
    CAUTION:
    CAUTION:Cap the transaxle to prevent oil loss and dirt ingress.
    Using the special tool, detach the left-hand halfshaft from the transaxle and secure it to one side.
    • Discard the snap ring.
    • Allow the fluid to drain into a suitable container.

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    Disconnect the clutch slave cylinder supply line.
    • Remove the spring clip.
  1. Position a workshop table under the engine and transaxle assembly.

  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.
    Lower the vehicle until the engine and transaxle assembly is supported by the workshop table.

  1. Remove the engine rear mount.
    • Discard the nuts.

  1. Detach the engine front mount from the engine front mount bracket.
    • Discard the nuts.

  1. Remove the engine front mount.
    • Discard the nuts.
  1. Remove the engine and transaxle assembly.

  1. Using the special tool, attach the engine and transaxle assembly to the engine hoist.

  1. Disconnect the starter motor electrical connectors.

  1. Remove the starter motor lower retaining bolt.

  1. Remove the starter motor.

  1. Remove the transaxle upper retaining bolts.
    • Detach the engine wiring harness bracket from the transaxle.

  1. Remove the transaxle right-hand retaining bolts.

  1. Remove the transaxle left-hand retaining bolts.
  1. CAUTION:
    CAUTION:Make sure that the fuel pressure sensor electrical connector is not damaged while moving the transaxle.
    Detach the transaxle from the engine.

In-vehicle Repair|Disassembly > < Intake Manifold