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Engine - Vehicles With: Manual Transaxle > < Assembly|Engine

Fiesta 1996 (08.1995-02.2002)

Engine - 1.25L/1.4L Zetec-SE (Sigma)/1.6L - Engine—Vehicles With: Automatic Transaxle Fiesta 1996 (08/1995-02/2002)
Installation

Special Tool(s)

Separator, ball joint

211-020 (13-006)

Remover/installer, coolant hose clip

303-397 (24-003)
Materials
Name
Specification
Cable ties
 
Coolant
ESDM-97B49-A 
Automatic transmission fluid (ATF)
ESP-M2C166-H 
Automatic transmission fluid (Tutela)
A92CT-7000-EM /FC 

Installation

All Vehicles
  1. General note.
    • Always renew all circlips and self-:locking nuts.
    • If necessary when installing coolant and ventilation hoses. Use Special Tool 303-397. For additional information, refer to Section  303-03 Engine Cooling.
  1. Lower the vehicle and guide the engine and transmission assembly into the engine compartment.

  1. NOTE:
    NOTE:Do not tighten the nuts.
    Install the front engine mounting bracket.

  1. NOTE:
    NOTE:Do not tighten the nuts and bolts.
    Install the rear engine mounting bracket.
    • Remove the retaining strap from the engine.
  1. Connect the fuel lines. For additional information, refer to Section  310-00 Fuel System - General Information.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Install the engine roll restrictor.

  1. NOTE:
    NOTE:Use a new gasket.
    Connect the exhaust.
  1. Remove the gaiter from the flexible pipe.
Only vehicles from build month 01/1997 for the European market
  1. CAUTION:
    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:
    CAUTION:When installing the intermediate shaft, use the locating sleeve (supplied with each new oil seal) to protect the oil seal.
    Install the right-hand front drive halfshaft and the intermediate shaft in the transmission.
Only vehicles up to build month 12/1996 and vehicles for markets outside Europe
  1. CAUTION:
    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:
    CAUTION:When inserting the front drive halfshafts always use the installation sleeve (supplied with every new oil seal) to protect the oil seal.
    NOTE:
    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.

  1. CAUTION:
    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 centre bearing

  1. CAUTION:
    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:
    CAUTION:When inserting the front drive halfshafts always use the installation sleeve (supplied with every new oil seal) to protect the oil seal.
    NOTE:
    NOTE:Make sure the circlip engages correctly.
    Install the left-hand front drive halfshaft with a new circlip in the transmission.

  1. Connect the transmission immobiliser plug.

  1. NOTE:
    NOTE:Left-hand side only: attach the brake pipe bracket to the suspension strut.
    Attach the suspension arm on the left and right (right-hand side shown).

  1. Attach the speedometer drive cable.

  1. Guide the gearshift cable into the bracket and clip it in place.

  1. NOTE:
    NOTE:One bolt also holds the power steering pipe bracket.
    Attach the power steering pump and bracket to the cylinder block.

  1. Install and tension the drive belt.

  1. Connect the starter motor wiring.
    1. Solenoid switch cable
    1. Battery cable

  1. Locate the radiator crossmember in the installation position and install it (left-hand side shown).

  1. Attach the coolant hoses at bottom left.
    1. To the coolant pump.
    1. To the coolant pump
    1. To the radiator

  1. Connect the oil pipes to the transmission.

  1. Install the radiator shroud.

  1. Connect/push on radiator plugs.
    • Clip the wiring in place on the radiator.
  1. Lower the vehicle.

  1. CAUTION:
    CAUTION:Always tighten the front engine mounting bracket before the rear engine mounting bracket so that the stud bolts can locate in the slots of the rear engine mounting bracket.
    Tighten the nuts on the front engine mounting.

  1. Tighten the rear engine mounting bracket nuts and bolts.

  1. Connect the coolant hose to the radiator.

  1. Connect the coolant hoses and the ground cable.
    1. Ground lead
    1. From the coolant outlet housing
    1. Joining hose to the coolant expansion tank.
    1. Heater hose

  1. Attach the vacuum hoses.
    • To the brake servo
    • To the EVAP canister
    • To the fuel pressure regulator

  1. Push the hoses onto the EGR valve (if present).

  1. Join the connectors.
    1. CMP sensor
    1. HO2S
    1. Injectors
    1. IAC valve
    1. Connect the wiring to the alternator.

  1. Join the connectors.
    1. TP sensor
    1. EI ignition coil
    1. ECT sensor
    1. Engine wiring loom plug
    1. VSS plug.

  1. NOTE:
    NOTE:Use new nuts.
    Tighten the right and left-hand suspension strut nuts (right-hand side shown).

  1. NOTE:
    NOTE:To put on the cover, unscrew the oil filler cap and screw it back on again afterwards.
    Attach the cover plate for the cylinder head cover.

  1. Push on the positive crankcase ventilation hose.
    1. Hook the accelerator cable in place.
    1. Push the breather hose onto the cylinder head and close the flap.

  1. Install the intake hose.

  1. Install the battery box.
    1. Attach the cable bracket.
    1. Screw in the bolts.
  1. Standard finishing operations.
    • Secure the cables and hoses with cable ties as necessary.
    • Check the engine and the cooling system for leaks (visual check).

Engine - Vehicles With: Manual Transaxle > < Assembly|Engine