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303-01C Engine - 1.8L Endura-DE (Kent) Diesel > < Assembly|Engine

Ikon 1999 (01.2000-)

Engine - 1.3L Duratec-8V (Rocam)/1.6L Duratec-8V (Rocam) - Engine Ikon 1999 (01/2000-)
Installation

Special Tool(s)

Remover/Installer, Hose Clamp

303-397 (24-003)
General Equipment
Retaining strap
Workshop table

Installation

All vehicles
  1. Install the transaxle.

  1. Install the transaxle upper flange bolt.

  1. Install the transaxle lower flange bolts.

  1. Install the transaxle right-hand flange bolts.

  1. Install the bolts.
    1. Transaxle left-hand flange bolt.
    1. Starter motor bolts.

  1. Connect the engine wiring harness electrical connectors.
    1. Connect the generator electrical connectors.
    1. Connect the oil pressure switch electrical connectors.
    1. Connect the crankshaft position (CKP) sensor electrical connector.

  1. Connect the knock sensor (KS) electrical connector.
  1. Raise and support the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

  1. Secure the engine and transmission assembly with a retaining strap to the workshop table and position for installation underneath the vehicle.
  1. Lower the vehicle.

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

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

  1. CAUTION:
    CAUTION:Brake fluid will escape. Observe the safety regulations for the use of brake fluid.
    Connect the clutch slave cylinder hydraulic line.
  1. Remove the retaining strap from the engine.
  1. Raise and support the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

  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:Do not damage the halfshaft seal.
    Attach the left-hand halfshaft to the transaxle.

  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:Do not damage the halfshaft seal.
    Attach the right-hand halfshaft to the transaxle.

  1. Install the coolant return hose.

  1. Install the engine support insulator.

  1. Connect the lower arms to the wheel knuckles on both sides (left-hand side shown).

  1. Install the shift rod and gear shift stabilizer.
    1. Install the shift rod.
    1. Install the gearshift stabilizer.

  1. Install the exhaust lower heat shield.

  1. NOTE:
    NOTE:Install a new catalytic converter gasket.
    Connect the catalytic converter to the exhaust manifold.
    1. Install the nuts.
    1. Attach the exhaust hanger insulator.

  1. Using the special tool, connect the coolant hose.
Vehicles with air conditioning
  1. Install the air conditioning (A/C) compressor.
All vehicles
  1. Install the accessory drive belt cover.
  1. Lower the vehicle.
Vehicles with power steering
  1. Attach the power steering pump to the retaining bracket.
    For additional information, refer to: Power Steering Pump - 1.3L Duratec-8V (Rocam)/1.6L Duratec-8V (Rocam) (211-02 Power Steering, Removal and Installation).
All Vehicles
  1. Install the accessory drive belt.
    • Turn the belt tensioner clockwise and slip the belt onto all the pulleys.

  1. NOTE:
    NOTE:Use an Allen key to stop the piston rod turning.
    Tighten the suspension strut retaining nut on both sides (right-hand side shown).

  1. Install the cooling fan.

  1. Connect the cooling fan electrical connectors.

  1. Connect the speedometer drive cable to the transaxle.

  1. Connect the reversing lamp switch electrical connector.

  1. Remove the engine lifting eye.

  1. Tighten the engine front mount retaining nuts.

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

  1. Connect the heated oxygen (HO2S) sensor, powertrain control module (PCM), electronic ignition (EI) coil and vehicle speed sensor (VSS) electrical connectors.
    1. HO2S sensor
    1. PCM
    1. EI coil
    1. VSS sensor

  1. Install the ground cable, the electrical connectors and the transmission breather.
    1. Ground cable
    1. Generator electrical connector
    1. Starter motor electrical connector
    1. Transmission breather

  1. Install the left-hand coolant hose bracket.

  1. Install the right-hand coolant hose bracket.

  1. Using the special tool, connect the coolant hoses to the coolant flow control housing.

  1. Install the accelerator cable.
    1. Hook in the inner cable.
    1. Install the cable into the bracket, adjust and secure using the clip.

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

  1. Install the hoses and the vacuum lines.
    1. EVAP solenoid valve vacuum hose.
    1. Positive crankcase ventilation hose.
    1. Brake booster vacuum hose.

  1. Install the air cleaner intake pipe.

  1. Install the battery tray.
    1. Install new cable ties.
    1. Install the bolts.
  1. Fill the engine with engine oil.
    For additional information, refer to: Specifications (303-01B Engine - 1.3L Duratec-8V (Rocam)/1.6L Duratec-8V (Rocam), Specifications).
  1. Install the battery.
    For additional information, refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Fill and bleed the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures).
  1. Adjust the gearshift linkage.
    For additional information, refer to: Gearshift Linkage 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. Using WDS, erase the power train control module (PCM) memory.

303-01C Engine - 1.8L Endura-DE (Kent) Diesel > < Assembly|Engine