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303-01D Engine - 3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6) > < Engine - Vehicles With: MMT6-6-Speed Manual Transaxle

Mondeo 2001 (10.2000-02.2007)

Engine - 2.5L Duratec-VE (VE6) - Engine—Vehicles With: 5F31J/5-Speed Automatic Transmission Mondeo 2001 (10/2000-02/2007)
Installation

Special Tool(s)

Remover/Installer, Hose Clamp

303-397 (24-003)
General Equipment
Workshop table
Securing straps
Engine hoist
Steel straight edge
Materials
Name
Specification
Grease
WSD-M1C230-A

Installation

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 stud.
    • Apply a thin layer of grease to the centering spigot on the torque converter.
  1. NOTE:
    NOTE:Do not support directly on the oil pan. Using suitable securing straps, secure the engine to the workshop table.
    Install the transaxle to the engine.

  1. Install the transaxle upper retaining bolts.

  1. Install the transaxle left-hand retaining bolts.

  1. Install the transaxle right-hand retaining bolts.

  1. Install the transaxle lower retaining bolts.

  1. Install the starter motor.
  1. Using wooden blocks and a securing strap, support the engine and transaxle assembly on the workshop table.
  1. Remove the engine hoist.

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

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

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

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

  1. Connect the A/C compressor electrical connector.

  1. Connect the transaxle electrical connectors.
Vehicles built up to 03/2003
  1. Connect the fluid cooler pipes to the transaxle.
Vehicles built 03/2003 onwards
  1. Connect the fluid cooler pipes.
All vehicles
  1. Using the special tool, connect the lower coolant hose to the radiator.

  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.
    NOTE:
    NOTE:Install a new O-ring seal.
    Attach the left-hand halfshaft to the transaxle.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent at more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft seal.
    NOTE:
    NOTE:Install new retaining locknuts.
    NOTE:
    NOTE:Install a new O-ring seal.
    Attach the right-hand halfshaft and the intermediate shaft to the transaxle.
  1. Install the subframe. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.

  1. NOTE:
    NOTE:Make sure the transaxle selector lever is in "D" (Drive) position.
    Connect the selector lever cable to the selector shaft lever.
    1. Attach the selector lever cable to the selector lever cable bracket.
    1. Attach the selector lever cable to the selector shaft lever pin.

  1. Open the yellow locking clip on the selector lever cable adjustment mechanism.
  1. Adjust the selector lever cable. For additional information, refer to Section  307-05A Automatic Transmission/Transaxle External Controls / 307-05B Automatic Transmission/Transaxle External Controls.
  1. Lower the vehicle.

  1. Tighten the engine rear mount retaining nuts.

  1. Tighten the engine front mount bracket retaining nuts and bolt.

  1. Attach the spark plug cable retaining bracket to the engine front mount.

  1. Attach the power steering reservoir to the radiator grille opening panel.

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

  1. Connect the power steering pipe.
    • Install the clip.

  1. Attach the power steering line support bracket to the engine front mount.

  1. Connect the starter motor electrical connectors.

  1. Connect the ground cable to the transaxle.

  1. Connect the engine wiring harness electrical connectors.

  1. Attach the engine wiring harness to the right-hand valve cover.

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

  1. Install the electronic ignition (EI) coil to the right-hand valve cover.

  1. Connect the EI electrical connectors.

  1. Attach the evaporative emissions (EVAP) solenoid valve to the intake manifold.

  1. Using the special tool, connect the coolant hose to the coolant expansion tank.

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

  1. Attach the accelerator cable.
    • Attach the clips and the accelerator cable to the bracket.
  1. Install the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. Connect the fuel supply line. For additional information, refer to Section  310-00 Fuel System - General Information.
  1. Adjust the selector lever cable. For additional information, refer to Section  307-05A Automatic Transmission/Transaxle External Controls / 307-05B Automatic Transmission/Transaxle External Controls.

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

  1. Install the air cleaner.
    1. Attach the air cleaner outlet hose clamp.
    1. Connect the positive crankcase ventilation (PCV) hoses.
    1. Connect the mass air flow (MAF) sensor electrical connector.

  1. Install the engine upper cover.

  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. 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. Initialize the door window motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

303-01D Engine - 3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6) > < Engine - Vehicles With: MMT6-6-Speed Manual Transaxle