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303-01B Engine - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel|Specifications > < Assembly|Engine

Transit 2000.5 (01.2000-05.2006)

Engine - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel - Engine Transit 2000.5 (01/2000-05/2006)
Installation

Special Tool(s)

Remover/Installer, Hose Clamp

303-397 (24-003)
General Equipment
Workshop table
Securing straps

Installation

All vehicles
  1. 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.
    Install the transaxle to the engine.

  1. Install the transaxle left-hand retaining bolts.

  1. Install the transaxle right-hand retaining bolts.
  1. WARNING:
    WARNING:Support the engine and transaxle assembly on wooden blocks and secure it with suitable securing straps.
    Position the engine and transaxle assembly on a suitable workshop table .

  1. Position the engine in the engine compartment.
Vehicles built up to 07/2003
  1. CAUTION:
    CAUTION:Visibly inspect that the mount is parallel to the body side bracket. If the mount is not parallel loosen the bolts and move the engine.
    NOTE:
    NOTE:Install new engine front mount to engine bracket bolts.
    Install the engine front mount.
    • Tighten the engine front mount to side member bolts in two stages.
    • Finger tighten the bolts.
    • Tighten the bolts to final torque.

  1. CAUTION:
    CAUTION:Visibly inspect that the mount is parallel to the body side bracket. If the mount is not parallel loosen the bolts and move the engine.
    Install the engine rear mount.
Vehicles built 07/2003 onwards
  1. CAUTION:
    CAUTION:Visibly inspect that the mount is parallel to the body side bracket. If the mount is not parallel loosen the bolts and move the engine.
    NOTE:
    NOTE:Install new engine front mount to engine bracket bolts.
    Install the engine front mount.
    • Tighten the engine front mount to side member bolts in two stages.
    • Finger tighten the bolts.
    • Tighten the bolts to final torque.

  1. CAUTION:
    CAUTION:Visibly inspect that the mount is parallel to the body side bracket. If the mount is not parallel loosen the bolts and move the engine.
    Install the engine rear mount.
All vehicles
  1. Remove the securing straps.

  1. WARNING:
    WARNING:Make sure the engine rear lifting eye is removed as it may come into contact with the brake pipe. Failure to follow this instruction may result in personal injury.
    Remove the engine rear lifting eye (if equipped).
    • Store the engine lifting eye in the workshop for future use.
  1. Raise and support the vehicle.
    For additional information, refer to: Jacking (100-02 Jacking and Lifting, Description and Operation) /
    Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. NOTE:
    NOTE:Install a new engine support insulator to transaxle housing bolt.
    Install the engine support insulator.

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 21 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    CAUTION:
    CAUTION:Make sure the snap ring is correctly seated.
    Attach the left-hand halfshaft to the transaxle.
    • Install a new snap ring.

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 21 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    NOTE:
    NOTE:Install a new halfshaft center bearing cap and locknuts.
    Attach the right-hand halfshaft to the transaxle.

  1. WARNING:
    WARNING:Install a new tie-rod end retaining nut. Failure to follow this instruction may result in personal injury.
    Attach the left-hand tie-rod end to the wheel knuckle.

  1. WARNING:
    WARNING:Install a new lower arm ball joint retaining nut. Failure to follow this instruction may result in personal injury.
    CAUTION:
    CAUTION:Make sure the heat shield is installed to prevent damage to the ball joint.
    Attach the lower arms to the wheel knuckles.

  1. Install the radiator support bracket and the radiator.
    • Install the radiator support bracket left-hand retaining bolts.

  1. Install the radiator support bracket right-hand retaining bolts.

  1. Install the radiator support bracket lower bolt.

  1. Connect the horn electrical connector.

  1. Connect the temperature and manifold absolute pressure (T-MAP) sensor electrical connector.

  1. Connect the charge air cooler outlet pipe to the charge air cooler.

  1. Connect the charge air cooler intake pipe to the charge air cooler.
Vehicles with air conditioning
  1. NOTE:
    NOTE:Only install M8 X 107 mm retaining bolts.
    Attach the air conditioning (A/C) compressor to the mounting bracket.

  1. Connect the A/C compressor clutch electrical connector.
All vehicles
  1. Install the catalytic converter.
    For additional information, refer to: Catalytic Converter - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System, Removal and Installation).

  1. Connect the reversing lamp switch electrical connector.

  1. NOTE:
    NOTE:Install a new power steering pump O-ring seal.
    Connect the power steering line to the power steering pump.

  1. Connect the clutch slave cylinder supply line to the transaxle.

  1. Attach the gearshift cables to the transaxle.
    1. Pull the locking pins and attach the abutment sleeves.
    1. Press the tabs together to lock the locks.
Vehicles with auxiliary heating
  1. Using the special tool, connect the heater hoses to the auxiliary heater core housing.

  1. Connect the heater control valve electrical connector.
All vehicles
  1. Connect the coolant hoses and the vacuum hoses to the heater core.
  1. Connect the fuel supply and return line quick release couplings.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).

  1. Connect the battery to starter motor solenoid cable to the jump start point.

  1. Install the jump start point cover.

  1. Connect the engine wiring harness electrical connector.

  1. Using the special tool, connect the coolant expansion tank hose and the radiator lower hose.

  1. Using the special tool, connect the radiator upper hose.
  1. Install the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 2.4L Duratorq-Di (Puma) Diesel (303-05 Accessory Drive, Removal and Installation).

  1. Connect the coolant hoses to the thermostat housing.
    • Connect the degas hose.

  1. Using the special tool, connect the coolant hoses to the water pump.
Vehicles with common rail fuel injection
  1. Connect the injection control unit (ICU) electrical connector.

  1. Connect the vacuum hoses to the control unit.

  1. Install the engine upper cover.
All vehicles
  1. Install the cooling fan motor and shroud.
    For additional information, refer to: Cooling Fan Motor and Shroud - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel, Vehicles With: Air Conditioning (303-03 Engine Cooling, Removal and Installation) /
    Cooling Fan Shroud - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel, Vehicles Without: Air Conditioning (303-03 Engine Cooling, Removal and Installation).

  1. Install the air cleaner outlet pipe and intake air resonator assembly.

  1. Install the intake air resonator retaining bolts.

  1. Install the engine oil filler pipe.
  1. Fill and bleed the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures).
Vehicles with air conditioning
  1. Fill the air conditioning system.
    For additional information, refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).
All vehicles
  1. Install the radiator grille opening panel.
    For additional information, refer to: Radiator Grille Opening Panel (501-02 Front End Body Panels, Removal and Installation).
  1. Install the front wheels and tires.
    For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
  1. Bleed the clutch system.
    For additional information, refer to: Clutch System Bleeding - Vehicles With: MT-75 (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).

303-01B Engine - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel|Specifications > < Assembly|Engine