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Engine - Vehicles With: 6-Speed Manual Transmission (MMT6) > < Assembly|Engine

Mondeo 2007.5 (02.2007-)

Engine - 1.8L Duratorq-TDCi (Lynx) Diesel - Engine—Vehicles With: 5-Speed Manual Transmission (MTX-75) Mondeo 2007.5 (02/2007-)

Installation

General Equipment
Cable ties
Vehicle/axle stands
WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation).
  1. Install the transaxle to the engine.

  1. Torque: 48 Nm

  1. Torque: 48 Nm

  1. Torque: 48 Nm

  1. Torque: 48 Nm

  1. Torque: 48 Nm

  1. Torque: 24 Nm

  1. Torque: 25 Nm
  1. Refer to: Starter Motor (303-06D Starting System - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1. WARNING:
    WARNING:Make sure that the engine and transmission assembly is on wooden blocks and secured with suitable retaining straps.
    Secure the engine and transaxle assembly on a suitable workshop table and position it under the vehicle.
    General Equipment: Vehicle/axle stands
    General Equipment: Cable ties

  1. Loosen: 2 turn(s)

  1. Torque: 133 Nm

  1.  
    1. Torque: 12 Nm
    1. Torque: 80 Nm
    1. NOTE:
      NOTE:Only tighten the bolts finger tight at this stage.
  1. Raise the vehicle and remove the Vehicle/axle stands.
    General Equipment: Vehicle/axle stands

  1. Torque: 80 Nm

  1. Torque: 90 Nm

  1. Connect the fuel supply line and fuel return line quick release couplings.
    Refer to: Fuel Filter - 1.8L Duratorq-TDCi (Lynx) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
  1. Connect the PCM electrical connectors.
    Refer to: Powertrain Control Module (PCM) (303-14B Electronic Engine Controls - 2.0L Duratec-HE (MI4), Removal and Installation).

  1. Torque: 25 Nm

  1. Torque: 23 Nm
  1. Refer to: Accessory Drive Belt (303-05D Accessory Drive - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

  1. CAUTION:
    CAUTION:Make sure that the exhaust flexible pipe is not forcibly bent.
    Tighten all retaining nuts in the sequence shown.
    Torque:
    1-5: 25 Nm
    6: 51 Nm
  1. Remove the front subframe.
    Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
  1. Refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
  1. Refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).
  1. Install both front wheels.
    Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

  1. Torque: 23 Nm

  1. Torque: 24 Nm

  1. CAUTION:
    CAUTION:If the fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.
    Refer to: Clutch System Bleeding (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).

  1. CAUTION:
    CAUTION:Gearshift cables must not be kinked or bent.
  1. Refer to: Gearshift Cable Adjustment - Vehicles With: 5-Speed Manual Transmission (MTX-75) (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).

  1. Torque: 12 Nm
  1. Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Fill and bleed the cooling system.
    Refer to: Cooling System Draining, Filling and Bleeding (303-03D Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel, General Procedures).
  1. Install the air cleaner.
    Refer to: Air Cleaner (303-12D Intake Air Distribution and Filtering - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).

Engine - Vehicles With: 6-Speed Manual Transmission (MMT6) > < Assembly|Engine