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Ford Workshop Service and Repair Manuals

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303-01B Engine - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)|Engine > < Engine - Vehicles With: MTX-75-5-Speed Manual Transaxle

Mondeo 2001 (10.2000-02.2007)

Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) - Engine—Vehicles With: CD4E/4-Speed Automatic Transmission 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, Hose Clamp

303-397 (24-003)
General Equipment
Workshop Table
Engine Hoist
Materials
Name
Specification
High Temperature Grease
ESD-M1C220-A 
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. CAUTION:
    CAUTION:The torque converter hub must engage fully in the oil pump drive gear.
    Check the installation depth of the torque converter.
    1. Lay a steel straightedge across the automatic transaxle flange.
    1. Check the installation depth between the steel straight edge and the drive plate..
    • Apply a thin layer of grease to the centering spigot on the torque converter.
  1. NOTE:
    NOTE:Do not support the oil pan. Using suitable securing straps, secure the engine on the workshop table.
    Using wooden blocks, support the engine.
  1. CAUTION:
    CAUTION:The torque converter studs must be aligned with the engine drive plate holes before any transaxle bolts are installed.
    Install the transaxle.

  1. Install the transaxle upper retaining bolts.

  1. Install the transaxle lower retaining bolts.

  1. Install the transaxle right-hand retaining bolts.

  1. NOTE:
    NOTE:Install new torque converter retaining nuts.
    Install the torque converter retaining nuts (four nuts).
    • Rotate the engine to gain access to the nuts.
    • Install the cover.

  1. Install the starter motor.

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

  1. Install the transaxle left-hand retaining bolts.

  1. 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.

  1. NOTE:
    NOTE:Install a new engine rear mount retaining nut.
    NOTE:
    NOTE:Do not tighten the engine rear mount retaining nut at this stage.
    Install the engine rear mount retaining nut.

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

  1. Connect the wiring harness electrical connectors.

  1. Attach the air conditioning (A/C) compressor to the mounting bracket.

  1. Connect the crankshaft position (CKP) sensor electrical connector.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft seal.
    CAUTION:
    CAUTION:Make sure the snap ring is correctly seated.
    NOTE:
    NOTE:Install a new snap ring.
    Attach the left-hand halfshaft to the transaxle.
    • Before fully engaging the halfshaft in the transaxle remove the halfshaft seal protection sleeve.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft seal.
    NOTE:
    NOTE:Install a new center bearing cap and new retaining nuts.
    Attach the right-hand halfshaft and the intermediate shaft to the transaxle.

  1. Connect the wiring harness electrical connectors.

  1. Connect the turbine shaft speed (TSS) sensor electrical connector.
    • Install the wiring retaining clip.
Vehicles built up to 03/2003
  1. CAUTION:
    CAUTION:Use an open-ended wrench on the fluid line adapter to prevent it from rotating.
    Attach the fluid cooler return pipe to the transaxle.

  1. CAUTION:
    CAUTION:Use an open-ended wrench on the fluid line adaptor to prevent it from turning.
    Attach the fluid cooler pipe to the transaxle.
    • Attach the fluid pipe bracket to the transaxle.
Vehicles built 03/2003 onwards
  1. Connect the fluid cooler pipes.
All vehicles
  1. Connect the output shaft speed (OSS) sensor electrical connector.
  1. Install the subframe. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.
  1. Lower the vehicle.

  1. Tighten the engine rear mount retaining nut.

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

  1. Using the special tool, install a new O-ring seal onto the power steering line to power steering pump union.
    1. Push the O-ring seal onto the special tool.
    1. Locate the special tool onto the union and install the O-ring seal.

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

  1. Install the power steering line support retaining nut.

  1. Install new O-ring seals.

  1. Install the power steering fluid reservoir.
    1. Install the front retaining bolts.
    1. Install the retaining stud.

  1. Connect the power steering hose to the power steering fluid reservoir.

  1. Install the engine wiring harness bracket.

  1. Attach the battery ground lead to the transaxle.

  1. Connect the automatic transmission control electrical connector.
    • Install the cable ties.
    • Attach the wiring harness retaining clip to the retaining bracket.

  1. Connect the transmission range (TR) sensor electrical connector.

  1. Connect the heated oxygen (HO2S) sensor electrical connector.

  1. Attach the selector lever cable to the transaxle.
    1. Attach the selector lever cable to the transaxle.
    1. Install the selector lever cable bracket.

  1. Install the cooling fan motor and shroud.
    1. Connect the electrical connector.
    1. Install the nuts on both sides (left-hand side shown).

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

  1. Connect the vacuum hoses to the intake manifold.

  1. Attach the coolant expansion tank to the wheel housing.

  1. Using the special tool, install the coolant hose.

  1. Using the special tool, connect the coolant hoses to the coolant connecting pipe.

  1. Connect the generator electrical connectors.

  1. Attach the power steering line retaining bracket to the valve cover.

  1. Connect the engine wiring harness electrical connectors.
    • Install a new clip.

  1. Connect the wiring harness electrical connectors.
Vehicles with speed control
  1. Attach the speed control cable to the retaining bracket.
    1. Attach the inner cable to the throttle body.
    1. Attach the speed control cable retaining bracket to the throttle body.
All vehicles
  1. Attach the accelerator cable to the retaining bracket.
    1. Turn the cable into the bracket.
    1. Attach the inner cable to the throttle body.

  1. Install the air cleaner housing.
    1. Connect the positive crankcase ventilation (PCV) hose.
    1. Attach the hose clamp to the intake air cleaner outlet pipe.
  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. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Tighten the strut and spring assembly top mount nuts on both sides.

  1. Install the strut and spring assembly top mount brace cover on both sides.

  1. Install the engine cover.

  1. Attach the PCV hose and the vacuum hose to the engine cover.
  1. Initialize the door window motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

303-01B Engine - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)|Engine > < Engine - Vehicles With: MTX-75-5-Speed Manual Transaxle