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Disassembly and Assembly of Subassemblies > < Engine - Vehicles With: MMT6-6-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 Mondeo 2001 (10/2000-02/2007)
Disassembly

Special Tool(s)

Universal Flange Holding Wrench

205-072

Adapter for 205-072

205-072-01

Remover/Installer, Hose Clamp

303-397

Separator, Oil Pan

303-428

Mounting Stand

303-435

Mounting Bracket for 303-435

303-435-06

Mounting Plate for 303-435-06

303-435-14A

Locking Tool, Fuel Injection Pump Sprocket

303-681

Adapter for 303-681

303-681-01
General Equipment
Three new 6 mm Drill Bits
Spatula
Engine vacuum cleaner
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.
WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. 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 is observed when working with these components. Always install blanking plugs to any open orifices or lines.
CAUTION:
CAUTION:Do not disassemble or clean inside the fuel pump, even with an ultrasonic cleaner. Always install a new fuel pump when required.
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
  1. Mount the engine on the mounting stand.
Vehicles with manual transaxle
  1. CAUTION:
    CAUTION:Loosen the clutch pressure plate retaining bolts by two turns at a time in the sequence shown.
    Remove the clutch disc and pressure plate.

  1. Remove the flywheel.
    • Discard the bolts.
Vehicles with automatic transaxle
  1. NOTE:
    NOTE:Make a note of position and numbers of the dowels at the engine flange to aid installation.
    Remove the flexplate.
    • Discard the bolts.
All vehicles
  1. Remove the crankshaft rear oil seal carrier.
    • Discard the carrier.
  1. Drain the engine oil.
    • Allow the oil to drain into a suitable container.

  1. NOTE:
    NOTE:Inspect the oil pan drain plug seal for damage. Install a new oil pan drain plug and seal if required.
    Install the drain plug.

  1. Disconnect the generator electrical connectors.
    • Detach the wiring harness from the retaining clip.

  1. Remove the generator.
    • Remove the wiring harness support bracket from the generator upper retaining bolt.

  1. Remove the accessory drive belt tensioner bracket.

  1. Remove the starter motor wiring harness retaining bracket.

  1. Disconnect the starter motor ground cable.
    • Detach the starter motor wiring harness from the retaining clips.

  1. Remove the starter motor.
    • Discard the gasket.

  1. Remove the turbocharger heat shield.

  1. Remove the air cleaner outlet pipe from the turbocharger.

  1. Remove the thermostat housing.
    • Disconnect the coolant hoses from the thermostat housing.
    • Discard the gasket.

  1. Remove the coolant hose bracket retaining bolt.

  1. Disconnect the intake manifold air intake pipe.

  1. Disconnect the exhaust gas recirculation (EGR) valve outlet tube from the EGR valve.
    • Discard the gasket.

  1. Remove the EGR valve outlet tube retaining bolts and remove the EGR valve outlet tube.

  1. Disconnect the EGR cooler coolant hose.

  1. Disconnect the EGR coolant hose.
    • Detach the coolant hose support bracket.

  1. Remove the EGR cooler bracket retaining bolts.

  1. Disconnect the EGR cooler from the exhaust manifold.
    • Discard the gasket.

  1. Disconnect the oil supply and oil return tube from the turbocharger.
    • Remove the oil return tube bracket retaining bolt and remove the oil return tube.
    • Discard the return tube gasket, the O-ring seal and the supply tube sealing washer.

  1. Remove the catalytic converter support bracket.

  1. Remove the turbocharger and exhaust manifold assembly.
    • Discard the bolts and nuts.

  1. Remove the exhaust manifold studs.
    • Discard the studs.

  1. Disconnect the crankshaft position (CKP) sensor electrical connector.
Vehicles with common rail fuel injection
  1. Remove the CKP sensor.
    • Discard the CKP sensor.
Vehicles without common rail fuel injection
  1. Remove the CKP sensor.
All vehicles
  1. Disconnect the oil pressure switch electrical connector.

  1. Remove the oil pressure switch.

  1. Remove the oil cooler assembly.

  1. Remove the intermediate driveshaft and bracket.
    • Discard the bearing cap and the bearing cap retaining nuts.
Vehicles with variable vane turbocharger
  1. Disconnect the exhaust gas recirculation (EGR) control solenoids electrical connectors.

  1. Detach the EGR control solenoids bracket and position it to one side.

  1. Disconnect the EGR valve electrical connector.
Vehicles with common rail fuel injection
  1. Disconnect the fuel pressure sensor electrical connector.
Vehicles built up to 07/2002
  1. Remove the intake manifold.
Vehicles built 07/2002 onwards
  1. Detach the throttle body from the EGR valve.

  1. Remove the intake manifold.
All vehicles
  1. Remove the oil level indicator and tube.

  1. Remove the brake vacuum pump retaining bolts.
    • Remove the power steering pump belt cover.

  1. Remove the power steering pump belt.
    • Rotate the tensioner clockwise.

  1. Using the special tool, remove the power steering pump drive pulley.

  1. Remove the power steering pump belt tensioner.

  1. Remove the power steering pump.

  1. Using the special tool, disconnect the coolant hoses from the water pump.

  1. Remove the water pump retaining bolts.

  1. Disconnect the coolant hose and remove the water pump.
    • Discard the gasket.

  1. Remove the idler pulley.

  1. Remove the engine front mount bracket.

  1. Remove the crankshaft pulley
Vehicles built 06/2000 onwards
  1. Remove the engine front cover nuts and bolts.
    • 2 nuts.
    • 20 bolts.
All vehicles
  1. NOTE:
    NOTE:Lubricate the spatula with clean engine oil.
    NOTE:
    NOTE:The engine front cover can be distorted during removal.
    Using the special tool and a spatula, separate the engine front cover from the engine.
    • Insert the special tool between the front cover and the engine, slide the special tool in anticlockwise direction, make enough room for the spatula and return the special tool to original position.
    • Slide the spatula in anticlockwise direction around the cover, cutting the silicone gasket.
    • Remove and discard the engine front cover.

  1. Detension and lock the timing chain tensioner.
    1. Retract the pawl.
    1. Push the lock in.
    1. Insert a pin.

  1. Remove the timing chain tensioner and the timing chain guides.

  1. Remove the fuel injection pump sprocket.

  1. Remove the camshaft sprockets and the timing chain.
Vehicles with common rail fuel injection
  1. Clean the fuel injectors, fuel injection supply manifold, high-pressure fuel supply lines and surrounding area.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, General Procedures).

  1. NOTE:
    NOTE:Protect the fuel injector electrical connectors with lint free cloth to prevent contamination from the cleaning fluid.
    Disconnect the fuel injector electrical connectors from the fuel injectors.

  1. Disconnect the fuel injector return line from the fuel injectors.
    • Position the fuel injector fuel return lines to one side.
    • Discard the fuel return line O-ring seals.

  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    CAUTION:
    CAUTION:Make sure the tool used to loosen the high-pressure fuel supply line unions is used at the top of the unions as this is where there is most material. Failure to follow this instruction may result in damage to the unions.
    CAUTION:
    CAUTION:Make sure that the fuel injector does not move when loosening the high-pressure fuel supply lines. Failure to follow this instruction will result in damage to the fuel injector and the fuel injector sealing washer.
    Detach the high-pressure fuel supply lines from the fuel injection supply manifold.
  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Using the engine vacuum cleaner, vacuum foreign material from the high-pressure fuel supply line, the fuel injectors and the fuel injection supply manifold.

  1. Remove the high-pressure fuel supply lines.
    • Install blanking caps to the open threaded ports on the fuel injectors and fuel supply manifold.
    • Discard the lines.

  1. NOTE:
    NOTE:The blanking cap will have to be removed from the fuel injector for the fuel return line retaining collar to be removed. Once this is done re-install the blanking cap to the fuel injector.
    Remove the fuel return line retaining collar.

  1. Remove the valve cover fuel injector seal.

  1. NOTE:
    NOTE:Protect the fuel metering valve and fuel temperature sensor electrical connectors with lint free cloth to prevent contamination from the cleaning fluid.
    Disconnect the fuel metering valve and fuel temperature sensor electrical connectors.

  1. Remove the high-pressure fuel supply line clamp.
  1. Clean the fuel pump, high-pressure fuel supply line and surrounding areas.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, General Procedures).

  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel pump and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    CAUTION:
    CAUTION:Make sure the tool used to loosen the high-pressure fuel supply line union is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.
    CAUTION:
    CAUTION:Maintain pressure on the high-pressure fuel supply line to keep the olive in contact with the fuel pump cone while unscrewing the union. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Loosen the high-pressure supply fuel line at the fuel pump.
  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel pump and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Using the engine vacuum cleaner, vacuum foreign material from the high-pressure fuel supply line and the fuel pump.

  1. CAUTION:
    CAUTION:Make sure the tool used to loosen the high-pressure fuel supply line union is used at the top of the union as this is where there is most material. Failure to follow this instruction may result in damage to the union.
    CAUTION:
    CAUTION:Maintain pressure on the high-pressure fuel supply line to keep the olive in contact with the fuel injection supply manifold cone while unscrewing the union. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    CAUTION:
    CAUTION:While maintaining the pressure on the high-pressure fuel supply line, clean and vacuum foreign material from the line and union.
    Remove and discard the high-pressure fuel supply line.
  1. Using the engine vacuum cleaner, vacuum foreign material from the fuel pump and the fuel injection supply manifold.
  1. Install blanking caps to the open threaded ports on the fuel pump and the fuel injection supply manifold.

  1. Disconnect the fuel injector to fuel pump fuel return line and detach the line from the retaining clip.
    • Install blanking plugs to the fuel injector to fuel pump fuel return line male and female connectors.

  1. Disconnect the fuel pump fuel supply and fuel return lines.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
    • Install blanking plugs to the fuel pump fuel supply and fuel return line male and female connectors.

  1. Detach the fuel pump fuel supply and fuel return lines retaining bracket from the cylinder head.
    1. Loosen the retaining bolt.
    1. Remove the retaining nut.
    1. Slide the fuel pump fuel supply and fuel return lines retaining bracket up and position it to one side.

  1. Remove the fuel injection pump.
    • Discard the gasket.

  1. Remove the fuel pump support bracket to cylinder block retaining bolts and remove the fuel pump.
    • Discard the fuel pump gasket.

  1. Remove the fuel pump support bracket from the fuel pump.

  1. Remove the fuel pump shield from the fuel pump.

  1. Remove the fuel return line venturi from the fuel pump.

  1. Remove the fuel pump fuel supply line from the fuel pump.

  1. Remove the fuel injection supply manifold retaining bolts.

  1. Remove the fuel injection supply manifold support brackets.

  1. Remove the fuel injection supply manifold.
Vehicles without common rail fuel injection
  1. Disconnect the high-pressure fuel supply lines from the fuel injectors.

  1. Disconnect the fuel injection pump control unit electrical connector.
    • Slide out the locking tang.

  1. Disconnect the high-pressure fuel supply lines from the fuel injection pump.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Remove the high-pressure fuel supply line support bracket.

  1. Remove the high-pressure fuel supply lines.
    • Discard the lines.

  1. Disconnect the fuel injector return line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Remove the fuel injector return line.
    • Discard the line and the sealing washers.

  1. Detach the fuel injection pump bracket from the engine.

  1. Remove the fuel injection pump fuel supply and fuel return lines retaining bracket bolts.

  1. Remove the fuel injection pump.
    • Discard the gasket.
All vehicles
  1. Remove the valve cover.
    • Discard the valve cover gasket and valve cover fuel injector seals.

  1. Remove the rocker shafts.
    • Discard the bolts.

  1. CAUTION:
    CAUTION:Remove the camshaft carrier bolts in the sequence shown.
    Remove the camshaft carrier.
  1. Remove the camshafts.

  1. CAUTION:
    CAUTION:Remove the cylinder head bolts in the sequence shown.
    Remove the cylinder head.
    • Discard the gasket and the bolts.

  1. Remove the oil pan retaining bolts.

  1. CAUTION:
    CAUTION:Do not distort the oil pan.
    Using a suitable spatula, remove the oil pan.
    • Slide the spatula around the profile of the oil pan.

  1. Remove the oil pump chain tensioner.
    1. Detension the chain.
    1. Lock the tensioner by inserting a pin.
    1. Remove the bolts.

  1. Remove the oil pump pickup tube.

  1. Remove the oil pump.
    • Remove the chain from the crankshaft sprocket.

  1. CAUTION:
    CAUTION:Remove the ladder frame bolts in the sequence shown.
    Remove the ladder frame.
    • Discard the gasket.

  1. CAUTION:
    CAUTION:Keep the connecting rod bearing caps in order for installation.
    Remove the connecting rod bearing caps.
  1. Remove the pistons.

  1. CAUTION:
    CAUTION:Keep the crankshaft main bearing caps in order for installation.
    Remove the crankshaft main bearing caps.
  1. Remove the crankshaft.

Disassembly and Assembly of Subassemblies > < Engine - Vehicles With: MMT6-6-Speed Manual Transaxle