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303-01A Engine - 1.8L Duratec-DOHC (Zetec)|Specifications > < Assembly|Engine

Transit.Tourneo Connect 2002.5 (06.2002-)

Engine - 1.8L Duratec-DOHC (Zetec) - Engine Transit/Tourneo Connect 2002.5 (06/2002-)
Installation

Special Tool(s)

Lifting Bracket, Engine

303-122 (21-068A)

Remover/Installer, Hose Clamp

303-397 (24-003)
General Equipment
Workshop table
Retaining straps
Engine hoist
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 follow these instructions may result in personal injury.
  1. WARNING:
    WARNING:Support the engine and transaxle assembly on wooden blocks and secure it with suitable retaining straps. Failure to follow these instructions may result in personal injury.
    Using the special tool and the engine hoist, position the engine and transaxle assembly on the workshop table.

  1. Install the transaxle left-hand retaining bolts.

  1. Install the transaxle right-hand retaining bolts.

  1. Install the starter motor and the ground cable.
  1. Remove the engine hoist.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Position the engine and transaxle assembly in the engine compartment.
    • Carefully lower the vehicle until the engine and transaxle assembly is supported by the workshop table.

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

  1. NOTE:
    NOTE:Install a new rear mount center retaining nut.
    NOTE:
    NOTE:Do not tighten the engine rear mount center retaining nut at this stage.
    Install the engine rear mount center retaining nut.
  1. Raise the vehicle and remove the workshop table.

  1. Attach the gearshift cables to the transaxle.
    • Attach the gearshift cables to the bracket and turn the abutment sleeves counterclockwise.

  1. Connect the crankshaft position (CKP) sensor electrical connector.

  1. Connect the vehicle speed sensor (VSS) electrical connector.

  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.
    NOTE:
    NOTE:Install a new center bearing cap and locknuts.
    Attach the right-hand halfshaft and the intermediate shaft to the transaxle.
    • Install the center bearing cap and locknuts.

  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.
    Attach the left-hand halfshaft to the transaxle.

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

  1. Connect the power steering pressure (PSP) switch electrical connector.

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

  1. NOTE:
    NOTE:Install new flexible exhaust pipe gaskets.
    Install the flexible exhaust pipe.
  1. Install the crossmember. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.
  1. Install the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.
  1. Lower the vehicle.

  1. Tighten the engine front mount retaining nuts.

  1. Tighten the engine rear mount center retaining nut.

  1. Using the special tool, connect the coolant hoses to the thermostat housing.

  1. Using the special tool, connect the coolant hose to the coolant distribution pipe.

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

  1. Connect the catalyst monitor sensor electrical connector.

  1. Connect the reversing lamp switch electrical connector.

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    NOTE:
    NOTE:Make sure the spring clip is correctly seated.
    Connect the clutch slave cylinder supply hydraulic fluid line to the transaxle and install the spring clip.

  1. Connect the transaxle ventilation hose to the transaxle.

  1. Connect the power steering hose to the power steering fluid reservoir.

  1. Connect the vacuum hose to the throttle body.

  1. Connect the brake booster vacuum pipe to the brake booster.

  1. Connect the generator electrical connector.

  1. Connect the powertrain control module (PCM) electrical connector.

  1. Connect the ground cable to the engine front lifting eye.

  1. Connect the fuel supply line and fuel return line to the fuel rail.

  1. Connect the transaxle wiring harness electrical connector.

  1. Connect the ignition coil electrical connector.

  1. Attach the accelerator cable to the throttle body.
    1. Attach the accelerator outer cable to the accelerator cable bracket.
    1. Attach the accelerator inner cable to the throttle body lever.

  1. Connect the ground cable to body.

  1. Tighten the strut and spring assembly top mount nuts on both sides.
  1. Check the transaxle fluid level and top up with manual transmission fluid, if necessary. For additional information, refer to Section  308-03 Manual Transmission/Transaxle.
  1. Fill and bleed the power steering system. For additional information, refer to Section  211-00 Steering System - General Information.
  1. Bleed the hydraulic clutch system. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.
  1. Adjust the gearshift cables. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.
  1. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Install the air cleaner. For additional information, refer to Section  303-12 Intake Air Distribution and Filtering.
  1. Fill and bleed the cooling system. For additional information, refer to Section  303-03 Engine Cooling.

303-01A Engine - 1.8L Duratec-DOHC (Zetec)|Specifications > < Assembly|Engine