ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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Engine - Vehicles With: 5F31J-5-Speed Automatic Transmission > < Engine - Vehicles With: MTX-75-5-Speed Manual Transaxle

Mondeo 2001 (10.2000-02.2007)

Engine - 2.5L Duratec-VE (VE6) - Engine—Vehicles With: MMT6/6-Speed Manual Transaxle Mondeo 2001 (10/2000-02/2007)
Installation

Special Tool(s)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)
General Equipment
Workshop table
Lifting Bracket, Engine
Securing 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:Do not support the engine directly underneath the oil pan. Secure the engine to the workshop table using suitable retaining straps.
    Attach the transmission to the engine.
    • Support the engine with wooden blocks.

  1. Install the transmission upper retaining bolts.

  1. Install the transmission left-hand retaining bolts.

  1. Install the transmission right-hand retaining bolts.
  1. Support the engine and transmission with suitable wooden blocks.
  1. Detach the engine lifting tackle.

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

  1. NOTE:
    NOTE:Renew the rear engine mount nut.
    NOTE:
    NOTE:Do not fully tighten the nut at this stage.
    Screw on the rear engine mount nut.

  1. NOTE:
    NOTE:Renew the front engine mount nuts.
    NOTE:
    NOTE:Do not fully tighten the front engine mount nuts at this stage.
    Unscrew the front engine mount nuts.
  1. Remove the securing straps.

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

  1. Attach the reversing lamp switch connector.

  1. CAUTION:
    CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay.
    Attach the clutch slave cylinder pipe to the clutch slave cylinder.
    • Install the spring clip.
    • Attach the clutch slave cylinder pipe to the bracket.

  1. Attach the ground lead to the transmission.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

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

  1. Attach the battery positive lead and the starter motor solenoid cable to the starter motor.

  1. Attach the generator wiring harness.
    • Attach the generator connector.
    • Attach the generator wiring.

  1. CAUTION:
    CAUTION:Secure the halfshaft to prevent damage to the constant velocity joints. 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.
    CAUTION:
    CAUTION:Ensure that the snap ring is correctly located in the groove.
    NOTE:
    NOTE:Install a new snap-ring.
    Attach the left-hand halfshaft to the transmission.
    • Remove the protective sleeve before fully installing the halfshaft.

  1. CAUTION:
    CAUTION:Secure the halfshaft to prevent damage to the constant velocity joints. 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.
    Attach the right-hand halfshaft to the transmission together with the intermediate shaft.
    • Remove the protective sleeve before fully installing the halfshaft.

  1. NOTE:
    NOTE:Install new intermediate shaft center bearing self-locking nuts.
    Install the intermediate shaft center bearing self-locking nuts.

  1. Attach the vehicle speed sensor (VSS) 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 bracket nuts.

  1. Attach the HT lead bracket to the front engine mount.

  1. Attach the power steering fluid reservoir.

  1. Attach the power steering line.
    • Install the clip.

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

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

  1. Attach the engine wiring harness connector.

  1. Attach the wiring harness to the right-hand cylinder head cover.

  1. Attach the heated oxygen sensor (HO2S) connector.

  1. Attach the ignition coil to the right-hand cylinder head cover.
    1. Install the condenser bolt.
    1. Install the ground cable bolt.

  1. Attach the compressor connector.

  1. Attach the ignition coil connector.

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

  1. Using the special tool, connect the coolant hoses to the coolant connection fittings.

  1. Attach the starter motor positive lead to the battery.

  1. Attach the throttle cable.
    • Attach the clips and throttle cable to the bracket.

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

  1. Connect the brake servo vacuum line to the intake manifold.
  1. Install the auxiliary 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 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. Install the air cleaner.
    1. Attach the hose clamp.
    1. Attach the PCV hoses.
    1. Attach the mass air flow (MAF) sensor connector.

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

  1. Install the strut mount reinforcement 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 window winder motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

Engine - Vehicles With: 5F31J-5-Speed Automatic Transmission > < Engine - Vehicles With: MTX-75-5-Speed Manual Transaxle