Ford Workshop Service and Repair Manuals

Engine lifting bracket

303-122 (21-068A)

Remover/installer, coolant hose clip

303-397 (24-003)

1. General note.
   • Renew all circlips, self-locking nuts and split pins.
   • If necessary when installing coolant and ventilation hoses, use removal tool 303-3973.

2. 

   CAUTION:Make sure that the two locating tubes are installed.
   Position the transaxle to the engine.
   • Install the adapter plate over the flywheel.

3. Install the upper flange bolts.
   • Attach the cable guide.

4. Install the right-hand flange bolts.
   • Attach the catalytic converter bracket.
   • Install the cover of the CKP sensor.

5. Install the left-hand flange bolts.

6. Install the starter motor bolt.

7. Install the starter motor.
   • Insert the retaining plate and install the bolt.

8. Attach the front engine mounting bracket.

9. Install the rear engine mounting bracket.

10. 

    NOTE:Wait 10 seconds between the two tightening stages.
    Install the catalytic converter on the exhaust manifold and tighten in two stages, working diagonally.
    • First stage: 25 Nm.
    • Second stage: 40 Nm.

11. Install the heat shield.

12. Install the catalytic converter.

13. Lift the engine and transmission assembly onto the assembly stand.
    • Position an assembly stand with wooden blocks under the engine and transmission assembly.

14. Secure the engine to the assembly stand with a retaining strap.

15. Detach the special tool.

16. Detach the left-hand engine lifting eye.
    • Unscrew the lower nut from the exhaust manifold (cylinder no. 4).

17. 

    NOTE:Renew the nut.
    Install the exhaust manifold nut.

18. Detach the right-hand engine lifting eye.

19. Move the engine and transmission into position under the vehicle.

20. Lower the vehicle slowly and position the engine and transmission assembly in the engine compartment.

21. 

    NOTE:Do not tighten the nuts yet.
    

    NOTE:Use new nuts.
    Insert the studs for the rear engine mounting bracket and do the nuts up five turns.

22. 

    NOTE:Do not tighten the nuts yet.
    

    NOTE:Use new nuts.
    Install the front engine mounting bracket.

23. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

24. 

    CAUTION:The inner joint must not be bent at more than 18 degrees and the outer joint must not be bent at more than 45 degrees.
    

    CAUTION:When installing the intermediate shaft, use the locating sleeve (supplied with every new oil seal) to protect the oil seal.
    Install the right-hand front drive halfshaft with the intermediate shaft in the transmission.

25. 

    CAUTION:The inner joint must not be bent at more than 18 degrees and the outer joint must not be bent at more than 45 degrees.
    

    CAUTION:When inserting the front axle drive halfshafts always use the installation sleeve (supplied with every new oil seal) to protect the oil seal.
    

    NOTE:Make sure the circlip engages correctly.
    Install the right-hand front drive halfshaft with a new circlip and the intermediate shaft in the transmission.

26. 

    CAUTION:The inner joint must not be bent at more than 18 degrees and the outer joint must not be bent at more than 45 degrees.
    Tighten the front drive halfshaft center bearing.

27. 

    CAUTION:The inner joint must not be bent at more than 18 degrees and the outer joint must not be bent at more than 45 degrees.
    

    CAUTION:When inserting the front axle drive halfshafts always use the installation sleeve (supplied with every new oil seal) to protect the oil seal.
    

    NOTE:Make sure the circlip engages correctly.
    Install the left-hand front drive halfshaft in the transmission with a new circlip.

28. Fill the transmission with transmission fluid to 10-15 mm below the lower edge of the level check bore.

29. Install the engine roll restrictor.

30. Install the suspension lower arm and the left-hand track rod.

31. 

    NOTE:Do not tighten the bolt on the shift rod.
    

    NOTE:Washer
    Attach the shift rod and gearshift stabilizer to the transmission.
    1. Shift rod stabilizer.
    2. Shift rod.

32. Connect the exhaust system.

33. Connect the starter motor wiring.

34. Connect the fuel lines. For additional information, refer to Section  310-00 Fuel System - General Information.

35. Install the air conditioning compressor.
    • Connect the compressor electromagnetic clutch plug.

36. 

    NOTE:Screw the ground lead to the left-hand side of the radiator crossmember.
    Install the air guide with the fan motor (push-fit at the top and bottom).
    • Attach the radiator crossmember on the bottom left-hand side.

37. Install the radiator shroud.

38. Attach the coolant hose to the coolant pump.

39. Clip the coolant hose into the bracket.

40. Attach the lower drive belt cover.

41. Lower the vehicle.

42. 

    CAUTION:Always tighten the front engine mounting bracket before the rear engine mounting bracket so that the studs can locate in the elongated holes in the rear engine mounting.
    Tighten the nuts for the front engine mounting bracket.

43. Tighten the nuts for the rear engine mounting bracket.
    • Install the transmission breather.

44. 

    NOTE:Renew the O-ring.
    Install the clutch hydraulic pipe.
    1. Pull out the clip, push on the pipe and press the clip back in.
    2. Press it into the guide.

45. Connect the feed hose and pressure pipe to the power steering pump.

46. 

    NOTE:Make sure the drive belt is seated correctly.
    Install the drive belt.
    • Slacken the tensioning pulley with a 15 mm ring spanner and put the drive belt in place.

47. 

    NOTE:Attach the pressure pipe bracket.
    Attach the upper drive belt cover.

48. Connect the VSS plug.

49. Attach the speedometer drive cable.

50. Connect the ground lead to the transmission.

51. Connect the starter motor plug.
    1. Plug.
    2. Clip the wire in place.

52. 

    NOTE:To connect the hose, first detach the oil filler cap, then reinstall it afterwards.
    Connect the hose to the oil filler cap.

53. Connect the ECT sensor plug.

54. Connect the plugs and attach the vacuum lines.
    1. Two plugs (engine wiring loom)
    2. Vacuum line - brake servo
    3. Vacuum line - EVAP
    • Clip the wiring brackets in place.

55. Join the connectors and vacuum lines.
    1. Engine wiring loom plug.
    2. Vacuum line - fuel pressure control.
    3. Evaporative emission control valve (EVAP) vacuum line.
    4. Vacuum line - brake servo.
    5. T-MAP sensor connector.

56. Connect the coolant hose to the top right of the radiator.

57. Connect the coolant hose to the heat exchanger.

58. Connect the generator plug.

59. Connect the upper coolant hose to the thermostat housing.
    • Install the clips and clip the wiring loom in place.

60. Attach the throttle cable.
    1. Hook the accelerator cable into the throttle plate lever.
    2. Attach the clip.
    3. Clip the accelerator cable in place.

61. Connect the HO2S plug.

62. Install the battery box.

63. Install the battery.
    1. Attach the retaining strap.
    2. Clip the wiring bracket in place.

64. Connect the intake pipe to the air cleaner.

65. Connect the intake pipe to the throttle body.

66. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

67. Remove the heat shield.

68. 

    NOTE:Ensure that the shift rod can move freely on the selector shaft and that fourth gear is engaged in the transmission.
    

    NOTE:Wrap the flutes of the drill bit with adhesive tape.
    

    NOTE:Use a new twist drill.
    Adjust the gearshift mechanism.
    • Shift the transmission into fourth gear.
    • Insert a 9 mm drill shank into the selector mechanism housing and lock the selector.

69. Adjust the gearshift mechanism.
    • The detailed illustration shows the shank of the drill bit inserted.

70. Tighten the shift rod bolt.
    • Remove the twist drill from the selector mechanism housing.

71. 

    NOTE:Use new nuts.
    Install the heat shield.

72. Connect the plug of the fan thermostatic switch.

73. Lower the vehicle.

74. Bleed the hydraulic clutch system. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.

75. Fill the power steering fluid reservoir. For additional information, refer to Section  211-00 Steering System - General Information.

76. Standard finishing operations.
    • Fill up with coolant.
    • Check the fluid levels and correct as necessary.
    • Check the cooling system for leaks.
    • Check the operation of the gearshift mechanism.
    • Check the routing of cables and hoses and fix them with cable ties.
    • Connect the battery. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
    • Start the engine, bring it up to operating temperature and check for leaks (visual check).