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303-01E Engine - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel|Engine > < Engine - Vehicles With: MTX-75-5F31J-5-Speed Automatic Transmission-5-Speed Manual Transaxle

Mondeo 2001 (10.2000-02.2007)

Engine - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel - Engine—Vehicles With: MMT6/6-Speed Manual Transaxle Mondeo 2001 (10/2000-02/2007)
Installation

Special Tool(s)

Lifting Bracket, Engine

303-122

Remover/Installer, Hose Clamp

303-397
General Equipment
Engine hoist
Workshop table
Securing straps

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.
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness be observed when working with these components. Always fit blanking plugs to any open orifices or lines.
  1. CAUTION:
    CAUTION:Make sure that the two locating dowels are installed.
    CAUTION:
    CAUTION:Do not tilt the transaxle during installation.
    Install the transaxle.

  1. Install the transaxle left-hand and lower retaining bolts.

  1. Attach the coolant pipe bracket to the transmission.

  1. Install the transaxle right-hand retaining bolts.

  1. Install the transaxle upper retaining bolts.

  1. NOTE:
    NOTE:Install a new starter motor gasket.
    Install the starter motor.

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

  1. CAUTION:
    CAUTION:Never support the engine under the oil pan.
    Using a suitable engine hoist, position the engine assembly on the workshop table and support the engine assembly with wooden blocks and securing straps.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  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 front mount retaining nuts.
    NOTE:
    NOTE:Do not fully tighten the retaining nuts and retaining bolts at this stage.
    Install the engine front mount.

  1. NOTE:
    NOTE:Install a new engine rear mount retaining nut.
    NOTE:
    NOTE:Do not fully tighten the retaining nut at this stage.
    Install the engine rear mount retaining nut.
  1. Remove the securing straps.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
Vehicles with air conditioning
  1. Attach the air conditioning (A/C) compressor to the mounting bracket.
All vehicles
  1. CAUTION:
    CAUTION:The inner constant velocity (CV) joint must not be bent more than 18 degrees. The outer CV joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft seal.
    CAUTION:
    CAUTION:Make sure 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:The inner constant velocity (CV) joint must not be bent more than 18 degrees. The outer CV joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft seal.
    Attach the right-hand halfshaft to the transaxle together with the intermediate shaft.
    • Remove the protective sleeve before fully installing the halfshaft.

  1. NOTE:
    NOTE:Install a new intermediate shaft center bearing cap and self-locking nuts.
    Install the intermediate shaft center bearing.
  1. Lower the vehicle.

  1. Tighten the engine rear mount retaining nut.

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

  1. Connect the glow plug cable.

  1. Attach the ground cable to the transaxle.

  1. Connect the ground cable to the battery connection.

  1. Attach the gearshift cables to the transaxle.
    1. Attach the gearshift cables to the bracket.
    1. Attach the gearshift and selector cables to the gearshift mechanism.

  1. Attach the reversing lamp switch connector.
Right-hand drive vehicles
  1. Attach the clutch slave cylinder supply line to the bracket.

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paint work, the effected area must be immediately washed down with cold water.
    NOTE:
    NOTE:Make sure the spring clip is slid back into the installation position before connecting the supply line.
    NOTE:
    NOTE:Make sure the supply line does not come into contact with other components or the vehicle body.
    Connect the clutch slave cylinder supply line to the clutch master cylinder.
Left-hand drive vehicles
  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paint work, the effected area must be immediately washed down with cold water.
    NOTE:
    NOTE:Make sure the spring clip is slid back into the installation position before connecting the supply line.
    NOTE:
    NOTE:Make sure the supply line does not come into contact with other components or the vehicle body.
    Connect the clutch slave cylinder supply line to the transaxle.
    • Attach the clutch slave cylinder supply line to the bracket.
All vehicles
  1. Connect the fuel supply and return lines.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Connect the fuel injector return line.
    For additional information, refer to: Spring Lock Couplings (310-00 Fuel System - General Information, General Procedures).
  1. Install the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel (303-05 Accessory Drive, Removal and Installation).
  1. Install the subframe.
    For additional information, refer to: Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).

  1. Attach the intercooler outlet pipe to the turbocharger intake hose.

  1. Using the special tool, connect the heater hoses to the heater core and to the additional heater.

  1. Connect the coolant hose to the oil cooler.

  1. Connect the air hoses to the charge air cooler.
  1. Install the cooling fan motor and shroud.
    For additional information, refer to: Cooling Fan Motor and Shroud - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Vehicles With: 6-Speed Manual Transmission (MMT6)/5-Speed Automatic Transmission (5F31J) (303-03 Engine Cooling, Removal and Installation).

  1. Using the special tool, connect the coolant hose to the coolant pump.

  1. Install the brake vacuum hose bracket retaining bolt.
Vehicles with common rail fuel injection
  1. Connect the exhaust gas recirculation (EGR) vacuum regulator vacuum hose.

  1. Install the vacuum regulator solenoid valve assembly.
    1. Install the retaining bolts.
    1. Attach the vacuum hoses.
    1. Connect the electrical connector.
All vehicles
  1. NOTE:
    NOTE:Install a new O-ring seal.
    Connect the power steering line to the power steering pump.

  1. Connect the power steering hose to the power steering pump.

  1. Install the power steering line support brackets retaining bolts.

  1. Connect the engine wiring harness electrical connector.
Vehicles with 130 PS diesel engine
  1. Connect the brake vacuum hose to the brake vacuum pump.
    • Install a new cable tie.

  1. Connect the EGR valve vacuum hose.

  1. Connect the engine wiring harness central connector.
Vehicles with 90 PS or 115 PS diesel engine
  1. Connect the brake vacuum hose to the brake vacuum pump.

  1. Connect the EGR valve vacuum hose and the electrical connector.
All vehicles
  1. Connect the coolant hoses to the thermostat housing.
    1. Connect the thermostat to radiator hose.
    1. Connect the thermostat to coolant reservoir hose.

        2. 1. Attach the coolant reservoir hose, to the retaining clips.

  1. Install the air cleaner.
    1. Connect the air cleaner intake pipe to the front fender.
    1. Connect the positive crankcase ventilation (PCV) hose to the valve cover.
    1. Connect the turbocharger air intake pipe to the turbocharger.
    1. Connect the vacuum hose to the air cleaner.

  1. Connect the mass air flow (MAF) sensor electrical connector.

  1. Tighten the strut and spring assembly top mount retaining nuts

  1. Install the strut and spring assembly top mount brace cover.
  1. Fill and bleed the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel (303-03 Engine Cooling, General Procedures).

  1. Install the battery tray.
  1. Install the battery.
    For additional information, refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Fill and bleed the power steering system.
    For additional information, refer to: Power Steering System Bleeding (211-00 Steering System - General Information, General Procedures).
  1. Adjust the gearshift cables.
    For additional information, refer to: Gearshift Cable Adjustment - Vehicles With: MMT6/6-Speed Manual Transaxle (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  1. Bleed the hydraulic clutch system.
    For additional information, refer to: Clutch System Bleeding (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).

  1. Install the engine cover.
    • Install the oil level indicator and oil filler cap.
  1. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

303-01E Engine - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.2L Duratorq-TDCi (Puma) Diesel|Engine > < Engine - Vehicles With: MTX-75-5F31J-5-Speed Automatic Transmission-5-Speed Manual Transaxle