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303-01E Engine - 1.8L Endura-DI (Lynx) Diesel|Specifications > < Assembly|Engine

Fiesta 1996 (08.1995-02.2002)

Engine - 1.8L Endura-DI (Lynx) Diesel - Engine Fiesta 1996 (08/1995-02/2002)
Installation

Special Tool(s)

Boot clamp tightening tool

204-169 (14-044)

Engine lifting bracket

303-122 (21-068A)

Remover/installer, coolant hose clip

303-397 (24-003)
General Equipment
Assembly stand with retaining straps, GV 2166
Workshop hoist
New 9 mm twist drill bit
Materials
Name
Specification
Motorcraft Super-Plus 4 coolant concentrate
ESDM97B49-A 
High-pressure transmission fluid
SQM-2C9008-A 
Power steering hydraulic fluid
ESPM-2C-166-H 
Ford DOT 4 brake fluid for hydraulic clutch system
SAM 6C9103A 
High temperature grease for transmission input shaft, guide sleeve - clutch release bearing, pilot bearing - crankshaft and clutch splines
ESD-M1C220-A 
  1. NOTE:
    NOTE:Renew all circlips and self-locking nuts.
    Preparatory measures.
    • Clean the inner splines of the clutch disc, the transmission input shaft splines and the clutch release bearing guide sleeve.
    • Apply high-temperature grease thinly to the transmission input shaft, the clutch release bearing guide sleeve and the clutch splines.

  1. NOTE:
    NOTE:Make sure that the two locating dowels are installed.
    Align the intermediate plate on both guide sleeves with the cylinder block.

  1. NOTE:
    NOTE:The transmission is centered with two locating dowels on the engine.
    Move the transmission into position and tighten the flange rear bolts.

  1. Tighten the flange upper bolts.

  1. Tighten the flange front bolts.
  1. Lower the engine/transmission onto the assembly stand and use retaining straps to secure it.

  1. NOTE:
    NOTE:Install a new intermediate shaft bracket and nuts.
    NOTE:
    NOTE:Do not damage the oil seal when inserting the intermediate shaft.
    Install the right-hand intermediate halfshaft.

  1. Install the coolant hose.

  1. Install the bracket and coolant pipe.

  1. Install the starter motor.

  1. Unhook the jib crane and detach the special tool.
  1. Locate the engine and transmission assembly in position under the vehicle.
  1. Slowly lower the vehicle and guide the engine and transmission assembly into the engine compartment.

  1. NOTE:
    NOTE:Do not tighten the nuts and bolts yet.
    Install the engine rear mount.
    1. Install the transmission breather.
    1. Tighten the nuts finger tight.

  1. NOTE:
    NOTE:Do not tighten the nuts yet.
    Install the engine front mount.
    • Remove the tensioning straps.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Install the engine roll restrictor.

  1. NOTE:
    NOTE:Do not tighten the selector shaft bolt yet.
    NOTE:
    NOTE:Stabiliser washer
    Install the stabiliser and selector shaft.
    1. Gearshift stabilizer
    1. Shift rod
  1. Install the splash shield.
  1. Lower the vehicle.

  1. CAUTION:
    CAUTION:Always tighten the front engine mounting bracket before the rear engine mounting bracket so that the studs can be seated in the slots in the rear engine mounting bracket.
    Tighten the bolts and nuts of the engine front mounting bracket.

  1. Tighten the bolts and nuts of the engine rear mounting bracket.
  1. Put the transmission into 4th gear.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. CAUTION:
    CAUTION:The outer joint must not be bent at more than 45 degrees.
    Guide the left-hand and right-hand front halfshafts into the tripode bells (right-hand side shown).

  1. Make a clamp head for Special Tool 204-169.
    • Material: aluminium or steel plate

  1. Put the tripode joint gaiter in position and secure it with clamping straps.
    • Put on the special tool so that the clamp head is at a perpendicular to the clamping strap head.
    • Tighten the clamping strap using the special tool.

  1. Attach the power steering pump.

  1. Attach the auxiliary drive belt cover.

  1. Attach the vibration damper.

  1. Attach the coolant hose to the oil cooler (shown on removed engine for clarity).
    • Install a new oil filter.

  1. Attach the left and right suspension arms (left-hand side shown).

  1. NOTE:
    NOTE:Renew the gasket.
    Attach the rear of the exhaust pipe to the flexible pipe.
    • Remove the support sleeve from the flexible pipe.

  1. Adjust the gearshift mechanism.
    • Lock the gearshift mechanism in the 4th gear position using the shaft of a new 9 mm twist drill bit.

  1. Adjust the gearshift mechanism.
    • The illustration shows the shaft of the drill bit inserted.

  1. Tighten the shift rod bolt.
    • Withdraw the drill bit from the gearshift mechanism housing.

  1. Connect the plug to the reversing lamp switch.
  1. Put the radiator together with the air guide and radiator crossmember into position.

  1. NOTE:
    NOTE:The radiator is a push fit at the top.
    Install the radiator (two bolts on each side, left-hand side shown).
    • Connect the ground lead.

  1. Connect and clip in the plug.

  1. Connect the starter motor.

  1. Connect the coolant hoses.

  1. Attach the splash shield.
  1. Lower the vehicle.

  1. WARNING:
    WARNING:Watch out for escaping brake fluid. For additional information, refer to Section  100-00 General Information.
    NOTE:
    NOTE:Renew the O-rings.
    Install the clutch hydraulic line.
    • Attach the transmission ground cable.

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

  1. Install the connectors and hoses.
    1. EGR valve vacuum hose.
    1. Intake air temperature sensor (IAT) sensor electrical connector.
    1. EGR valve electrical connector.
    1. Brake booster vacuum line.

  1. Connect the generator electrical connector.

  1. Connect the plug and attach the wiring.
    1. Injection pump connector.
    1. Glow plug wiring.
    1. Brake booster vacuum line.

  1. Fit the coolant hose.

  1. Install the heater coolant hoses.

  1. NOTE:
    NOTE:Markings.
    Attach the coolant hoses to the thermostat housing.

  1. Install the battery tray.

  1. Install the battery.
    1. Cable ties.
    1. Retaining clip.

  1. Install the intake air tube.

  1. NOTE:
    NOTE:When tightening the nuts, counterhold with an Allen key to prevent from turning.
    Tighten the nuts on both suspension struts (left-hand side shown).

  1. Bleed the hydraulic clutch system For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.
    • If necessary, top up the brake fluid reservoir with brake fluid .
  1. Standard finishing operations.
    • Fill up with coolant.
    • Check the transmission fluid level and correct as necessary.
    • Check the routing of the vacuum hoses and cables and secure them with cable ties .
    • Connect the battery.
    • Enter the radio keycode.
    • Reprogram the preset radio stations.
    • Set the clock.
    • Road test the vehicle to collect data for the PCM.
    • Check the engine and cooling system for leaks (visual inspection).
    • Check the fluid levels and correct as necessary.

303-01E Engine - 1.8L Endura-DI (Lynx) Diesel|Specifications > < Assembly|Engine