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303-01A Engine - 1.8L Duratec-SCi (MI4)|Engine > < Assembly|Engine

Mondeo 2001 (10.2000-02.2007)

Engine - 1.8L Duratec-SCi (MI4) - Engine—Vehicles With: MMT6/6-Speed Manual Transaxle Mondeo 2001 (10/2000-02/2007)
Installation

Special Tool(s)

Expander, Teflon Seal

211-188 (13-015)

Lifting Bracket, Engine

303-122 (21-068A)

Remover/Installer, Cooling Hose Clamp

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

Installation

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 observe this instruction can lead to injury.
  1. NOTE:
    NOTE:Secure the engine to the workshop table using suitable retaining straps.
    Support the engine with wooden blocks.
  1. Attach the transmission to the engine.

  1. Remove the special tool.

  1. Install the left-hand transmission bolts.

  1. Install the right-hand transmission bolts.

  1. Install the transmission lower bolts.

  1. Install the starter motor.

  1. Install the engine wiring harness bracket.
    • Attach the wiring harness to the bracket.

  1. Position the workshop table under the vehicle and lower the vehicle carefully until the engine mounts can be installed.

  1. NOTE:
    NOTE:Install new rear engine mount retaining nuts.
    NOTE:
    NOTE:Do not tighten the rear engine mount nuts for the moment.
    Screw on the rear engine mount nut.

  1. NOTE:
    NOTE:Install new front engine mount nuts.
    NOTE:
    NOTE:Do not tighten the bolts and nuts for the moment.
    Install the front engine mount.
  1. Remove the retaining straps from the transmission.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. CAUTION:
    CAUTION:The inner constant velocity joint must not be bent by more than 18 degrees. The outer constant velocity joint must not be bent by more than 45 degrees.
    CAUTION:
    CAUTION:Ensure that the halfshaft oil seal is not damaged.
    NOTE:
    NOTE:Install a new halfshaft center bearing cap and new self-locking nuts.
    Attach the right-hand halfshaft to the transmission together with the intermediate shaft.

  1. CAUTION:
    CAUTION:The inner constant velocity joint must not be bent by more than 18 degrees. The outer constant velocity joint must not be bent by more than 45 degrees.
    CAUTION:
    CAUTION:Ensure that the halfshaft oil seal is not damaged.
    NOTE:
    NOTE:Install a new snap-ring.
    Attach the left-hand halfshaft to the transmission.

  1. Using the special tool, attach the coolant hose to the radiator.

  1. Attach the A/C compressor to the A/C compressor bracket.

  1. Attach the ground cable to the transmission.

  1. Connect the starter motor connector.

  1. Connect the oil pressure switch connector.

  1. Connect the heated oxygen sensor (HO2S) connector.
  1. Install the subframe. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.

  1. Tighten the rear engine mount nut.

  1. Tighten the front engine mount bolts and nuts.

  1. Attach the gearshift cables to the transmission.
    1. Attach the gearshift cables to the abutment.
    1. Attach the gearshift and selector cables to the selector mechanism.

  1. CAUTION:
    CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay.
    Connect the clutch slave cylinder pressure pipe to the clutch slave cylinder.

  1. Attach the reversing lamp switch connector.

  1. Connect the A/C compressor connector.

  1. Connect the generator connector.

  1. Connect the thermostat connector.

  1. Connect the knock sensor (KS) connector for cylinders 1 and 2.

  1. NOTE:
    NOTE:Install a new O-ring.
    Using the special tool, attach the O-ring to the power steering line connection.
    1. Push the O-ring onto the special tool.
    1. Position the special tool onto the connection and install the O-ring.

  1. Attach the power steering pump to steering gear pipe to the power steering pump.
  1. Install the power steering pump pulley. For additional information, refer to Section  211-02 Power Steering.

  1. Attach the power steering pipe bracket to the power steering pump.

  1. NOTE:
    NOTE:Install new O-rings.
    Install the O-rings.

  1. Install the power steering fluid reservoir.
    1. Install the front bolts.
    1. Screw in the stud.

  1. Using the special tool, connect the power steering hose to the power steering reservoir.

  1. Connect the KS connector for cylinders 3 and 4.

  1. Connect the manifold absolute pressure (MAP) sensor connector.

  1. Clip the wiring harness in place.

  1. Attach the canister purge solenoid valve to the intake manifold.

  1. Using the special tool, attach the coolant hose to the exhaust gas recirculation (EGR) valve.

  1. Using the special tool, attach the coolant hoses to the coolant distribution pipe.

  1. Install the engine wiring harness bracket.

  1. Install the engine cover bracket.

  1. Connect the power steering pressure (PSP) switch connector.

  1. Connect the fuel lines. For additional information, refer to Section  310-00 Fuel System - General Information.

  1. Attach the brake booster vacuum line to the intake manifold.

  1. Attach the ground cable to the fuel supply line cover.

  1. Connect the swirl plate position sensor connector.
    • Clip the wiring harness in place.

  1. Connect the swirl plate servo motor connector.

  1. Connect the throttle flap servo motor connector.

  1. Connect the engine coolant temperature (ECT) sensor connector.

  1. Connect the EGR valve connector.

  1. Connect the fuel metering valve connector.

  1. Connect the camshaft position (CMP) sensor connector.

  1. Connect the ignition coil connectors.

  1. Disconnect the intake manifold wiring harness connector.
    • Unclip the wiring harness.

  1. Install the air cleaner housing.
    1. Connect the positive crankcase ventilation (PCV) hose.
    1. Attach the air cleaner to engine intake hose clamp.
  1. Adjust the gearshift cables. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.
  1. Bleed the hydraulic clutch system. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.
  1. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Fill the cooling system. For additional information, refer to Section  303-03 Engine Cooling.
  1. Fill and bleed the power steering system. For additional information, refer to Section  211-00 Steering System - General Information.

  1. Tighten the suspension strut top mount nuts on both sides.

  1. Install the suspension strut mount reinforcement cap on both sides.

  1. Install the engine cover.
  1. Initialize the window winder motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

303-01A Engine - 1.8L Duratec-SCi (MI4)|Engine > < Assembly|Engine