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303-01D Engine - Vehicles Built From: 05-1998 1.6L-1.8L-2.0L > < Assembly|Engine

Mondeo 1997 (08.1996-09.2000)

Engine - 1.8L Diesel - Engine Mondeo 1997 (08/1996-09/2000)
Installation

Special Tool(s)

Lifting Bracket, Engine

303-122 (21-068A)

Alignment, Powertrain

502-003 (21-172)
General Equipment
Assembly stand GV2166
Jib crane
Retaining strap
Materials
Name
Specification
High-temperature grease
ESDM-1C220-A 
Brake fluid
ESDM-6C57-A 
Coolant
ESDM-97B49-A 

Installation

All Vehicles
  1. Coat the transmission input shaft splines with high temperature grease .
  1. Lift engine and transmission off assembly table using jib crane.

  1. Position engine and transmission in the engine compartment using jib crane.

  1. CAUTION:
    CAUTION:Use new self-locking nuts. Do not distort or twist the engine mounting.
    Install front engine mounting.
    • Tighten the new nuts on the front engine mounting.

  1. CAUTION:
    CAUTION:Use new self-locking nuts. Do not distort or twist the engine mounting.
    Install the rear engine mounting.
    1. Fit new nuts on the rear engine mounting.
    1. Tighten the air cleaner bracket.

  1. Connect the hydraulic pipe to the clutch slave cylinder.
    1. Clip the hydraulic pipe into the bracket.
  1. Detach engine and transmission from the jib crane.

  1. NOTE:
    NOTE:The adjustment mechanisms must be released by pressing them in.
    NOTE:
    NOTE:The abutment brackets tension themselves automatically after releasing them.
    Attach the gearshift cables to the transmission and adjust them.
    1. Attach the cables to the lever.
    1. Insert the cables to the lever.
    1. Lock the abutment bracket by turning it clockwise.

  1. Fit the right-hand engine roll restrictor bracket on the transmission.

  1. CAUTION:
    CAUTION:Do not skew the engine roll restrictor.
    Fit the right-hand engine roll restrictor and insert the centre bolt.
    1. Tighten the bolts.
    1. Tighten the center bolt.

  1. Fit the left-hand engine roll restrictor bracket on the transmission.

  1. Align the powertrain.
    1. Install the special tool.
    1. Tighten the bolt finger tight.

  1. CAUTION:
    CAUTION:Do not skew the engine roll restrictor.
    Fit the left-hand engine roll restrictor.
    • Insert the bolts.
    1. Tighten the two bolts.
    1. Tighten the center bolt.
  1. Remove the special tool.

  1. CAUTION:
    CAUTION:The inner tripod joint must not be bent more than 18 degrees, the outer joint not more than 45 degrees.
    Install the left-hand front driveshaft.
      NOTE:
      NOTE:Use a new snap-ring. Clip the snap-ring into place.
    • Insert the front driveshaft into the transmission using a new snap-ring.

  1. CAUTION:
    CAUTION:The inner tripod joint must not be bent more than 18 degrees, the outer joint not more than 45 degrees.
    NOTE:
    NOTE:The lower bolt also holds the bracket for the refrigerant line in place.
    Insert the right-hand front driveshaft into the transmission and attach the center bearing to the bracket.

  1. Fit the coolant line bracket.

  1. Fit the left-hand transverse link.
    1. Fit the transverse link on the spindle carrier.
    1. Fit the track rod end.
    1. Fit the stabiliser bar connecting link.

  1. Fit the right-hand transverse link on the spindle carrier (left-hand side shown).
Vehicles with air conditioning
  1. Fit the air-conditioning compressor bracket.

  1. Fit the crankshaft pulley/vibration damper.
  1. Install the alternator drive belt. For additional information, refer to Section  414-02 Generator and Regulator.

  1. Attach the air conditioning compressor to its bracket.

  1. Install the air-conditioning compressor drive belt.
    1. Fit the drive belt.
    1. Tighten the tensioning bolt.
    • Tighten the lockscrew.
All vehicles
  1. Fit the rear left wheel housing cover (right-hand side shown).

  1. Fit the front right wheel housing cover.

  1. Connect the starter motor.

  1. Install the catalytic converter bracket.

  1. Install the catalytic converter.
  1. Lower the vehicle.

  1. Fit the catalytic converter on the exhaust manifold.

  1. Fit the heater coolant hoses.

  1. Fit the power steering line bracket on the alternator.

  1. Attach the pipes for the power steering pump.

  1. Fit the ground lead on the transmission.

  1. Connect the main engine wiring harness connector.
    • Clip the VSS cable and the clutch slave cylinder hydraulic line into the selector cable bracket.
    • Secure the main engine wiring harness using cable tie.

  1. Fit the glow plug power supply.

  1. Attach the EGR valve hose.

  1. Fit the accelerator cable and cold starting system cable.
    1. Attach the cold starting system cable.
    1. Fit the accelerator cable in the bracket.
    1. Push on the clip.
    1. Attach the accelerator cable.

  1. Connect the pipes.
    1. Connect the fuel line.
    1. Attach the coolant hose to the thermostat housing.
    1. Connect the vacuum pipe to the vacuum pump.

  1. Attach the coolant hose to the coolant pump.

  1. Install the coolant expansion tank.
    • Fit the connector.

  1. Attach the coolant hoses to the coolant expansion tank.

  1. Install the intercooler.
    1. Clip in the vacuum line.
    1. Connect the hose.
    1. Tighten two bolts each on the left and right-hand side.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Attach the coolant hose to the radiator.

  1. Fit the lower radiator cover.
    • Hook the radiator cover in place.
    1. Tighten the bolts.
  1. Remove the support wrap from the flexible pipe.
  1. Attach the front wheels and lower the vehicle.

  1. Install the battery tray.

  1. Clip the cable into the battery tray.

  1. Install the fuse box.

  1. Fit the air cleaner.
    1. Fit the connector on the MAF.
    1. Fit the vacuum hose.
    1. Tighten the retaining clips.

  1. Tighten the suspension strut nut on the right and left-hand side.

  1. Tighten the suspension strut nut on the right and left-hand side.
  1. Install the battery.

  1. Tighten the wheel nuts.

  1. Detach the help tool from the hood.
  1. Standard finishing operations.
    • Check the cooling system for leaks.
    • Connect the battery ground lead.
    • Check the routing of the hoses and wiring and secure them with cable ties where necessary.
    • Enter the radio keycode.
    • Reprogram the pre-set radio stations.
    • Carry out a road test to enable the PCM (EEC V) to collect data.
    • Check the fluid levels and correct as necessary.

  1. Fit the engine undershield.
  1. Lower the vehicle.

303-01D Engine - Vehicles Built From: 05-1998 1.6L-1.8L-2.0L > < Assembly|Engine