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303-01B Engine - 1.25L-1.4L Zetec-SE (Sigma)-1.6L|Engine > < Engine - Vehicles With: Automatic Transaxle

Fiesta 1996 (08.1995-02.2002)

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

Special Tool(s)

Remover/installer, radiator hose clip

303-397 (24-003)
General Equipment
9 mm twist drill
Locking clamp (Hazet 1847-1)
Materials
Name
Specification
Cable ties
 
Coolant
ESDM-97B49-A 
Grease
WSD-M1C230-A 
Transmission fluid
WSD-M2C200-C 
Power steering hydraulic fluid
ESP-M2C166-H 
Brake fluid DOT 4, clutch hydraulic system
SAM-6C9103-A 
High-durability grease
WSD-M1C230-A 

Installation

All Vehicles
  1. General note.
    • If necessary when installing coolant and ventilation hoses. Use Special Tool 303-397.

  1. CAUTION:
    CAUTION:Make sure that the two locating tubes are installed.
    Position the transaxle to the engine and install the right-hand flange bolts.

  1. Screw in the left-hand flange bolts.

  1. Install the starter motor.
    • Install the positive cable at the generator.
  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 engine front mounting bracket.

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

  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.
    NOTE:
    NOTE:Assemble the tripode joint with high-durability grease.
    Slide on the right-hand and left-hand tripode joints.

  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.
    Insert the small and large clamping straps in the boot ring grooves and tighten them with the strap pliers.

  1. Fill up with transmission fluid to 5-10 mm below the lower edge of the level check bore.

  1. NOTE:
    NOTE:If it is not possible to install the shift stabilizer without it being under stress, align the engine/transmission so that it can be installed without stress. Do not tighten the shift rod clamp.
    Install the stabilizer and shift rod.
    1. Insert the washer under the shift stabilizer and tighten the bolt.
    1. Install the bolt.

  1. Install the engine roll restrictor.

  1. WARNING:
    WARNING:Wrap insulating tape around the flutes of the twist drill several times.
    Adjust the gearshift mechanism.
    • Engage fourth gear (from the neutral position, press the shift rod in as far as the stop).
    • Lock the gear shift mechanism using a new 9 mm twist drill.

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

  1. Adjust the gearshift mechanism.
    • Tighten the shift linkage clamp.
    • Withdraw the drill bit from the gearshift mechanism housing.
  1. Lower the vehicle.

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

  1. Tighten the bolts on the engine rear mounting bracket.

  1. Insert the transmission breather and install the reinforcing brace (if equipped).
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. NOTE:
    NOTE:Use a new gasket.
    Connect the exhaust flange.
  1. Remove the boot from the flexible pipe.

  1. Install the heat shield.

  1. Attach the lower suspension arms to the spindle carriers.

  1. Install the transmission protection/bracket.

  1. Install the speedometer drive cable (if equipped).

  1. Connect the plug of the multi-function switch.
Vehicle without air conditioning
  1. Install the radiator fan.
    • Pull the crossmember downwards. First slide the cooling fan upwards and insert it in the guides.

  1. Connect the radiator fan plug.
    • Clip the wire in place.

  1. Connect the lower coolant hoses.
    1. To the radiator.
    1. To the coolant pump.
    1. To the coolant pump.

  1. Install the power assisted steering pump.
Vehicles with air conditioning
  1. Attach the coolant hose to the coolant pump.

  1. Install the A/C compressor.

  1. Install the radiator crossmember with the radiator and fan (left side shown).
    1. Connect the ground lead.
    1. Connect the blower motor multiplug and clip it in.
    1. Screw in the bolts.

  1. Attach the air conditioning condenser.

  1. Attach the right-hand radiator crossmember.
    • Clip the connectors in place.

  1. Attach the coolant hoses and push on the PSP switch connector.

  1. Install the bracket for the power steering pump/belt tensioner.
All vehicles
  1. Install and tension the drive belt.

  1. Install the drive belt cover.
  1. Lower the vehicle.
Vehicles with air conditioning
  1. Connect the coolant hose to the radiator.
All vehicles
  1. Connect the hydraulic pipe to the clutch slave cylinder.
    • Clip it into the guide.
    • Insert the clip.
Vehicle with 1.4L or 1.6L engine
  1. Attach the coolant hoses and the ground cable.
    1. Ground cable.
    1. From the thermostat housing to the radiator.
    1. To the coolant expansion tank.
    1. From the thermostat housing to the heater.

  1. Connect the vacuum hoses to the throttle valve housing.
    • To the brake servo.
    • To the fuel pressure regulator.
    • To the EGR vacuum control (if present).

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

  1. Join the connectors.
    1. EI ignition coil.
    1. Engine wiring loom plug.

  1. Attach the throttle cable.
    1. Locate it and install the clip.
    1. Twist it into the bracket.
Vehicles with 1.25L engine
  1. Attach the coolant hose to the thermostat housing.

  1. Connect the vacuum hoses to the throttle valve housing.
    • To the brake servo.
    • To the fuel pressure regulator.

  1. Join the connectors.
    1. EI ignition coil.
    1. HO2S sensor.

  1. Attach the throttle cable.
    • Hook the accelerator cable in place and secure it with a clip on the bracket.

  1. Connect the ground lead to the transmission.
All vehicles
  1. Connect the connector and the ground lead.
    1. HO2S.
    1. Engine wiring harness.
    1. Connector for injection nozzles.
    1. Vehicle speed sensor (VSS) (if equipped).
    1. Connect the ground lead.
    1. Secure the wiring harness with cable ties.

  1. Attach the hoses.
    • Heater coolant hoses.
    • Cylinder head vent hose

  1. Install the exhaust manifold front heat shield.

  1. Connect the multiplugs/cables.
    1. Connect the positive cable connector.
    1. Connect the ground lead.
Vehicle with 1.4L or 1.6L engine
  1. Install the intake hose on the throttle body.

  1. Attach the PCV hose.
Vehicles with 1.25L engine
  1. Install the centre part of the air filter housing.
    1. Engage the clip.
    1. Install the three bolts.

  1. Install the upper air filter housing.
    1. Screw in the bolts.
    1. Install the air hose on the upper air filter housing.
    1. Push on the positive crankcase ventilation hose.
    • Insert the oil dipstick.

  1. Install the air intake pipe.
    • Push on the throttle position sensor (TPS) multiplug.
All vehicles
  1. Install the battery box.
    1. Attach the cable bracket.
    1. Tighten the bolts.

  1. Install the battery.
    1. Connect the positive battery lead.
    1. Connect the positive lead to the battery.
    1. Install the bracket.
    1. Secure the wiring harness with cable ties.
  1. Standard finishing operations.
    • Check the fluid levels and correct as necessary.
    • Where necessary, secure the wiring and hoses with cable ties.
    • Check the engine and the cooling system for leaks (visual check).

303-01B Engine - 1.25L-1.4L Zetec-SE (Sigma)-1.6L|Engine > < Engine - Vehicles With: Automatic Transaxle