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303-01C Engine - 1.4L PTE (CVH)|Engine > < Assembly|Engine

Fiesta 1996 (08.1995-02.2002)

Engine - 1.4L PTE (CVH) - Engine Fiesta 1996 (08/1995-02/2002)
Installation

Special Tool(s)

Lifting bracket, engine

21-068A

Remover/installer, cooling hose clamp

24-003
Materials
Name
Specification
Cable tie
 
Coolant
ESDM-97B49-A 
Grease
WSD-M1C230-A 
Transmission fluid
WSD-M2C200-C 
Brake fluid
SAM-6C9103-A 

Installation

  1. Preparatory operations.
    • Clean inner clutch disc and pressure plate gear, input shaft bearing and clutch pilot bearing bushing.
    • Apply high temperature grease (ESD-M1C220-A) lightly onto input shaft bearing, clutch pilot bearing bushing, crankshaft bushing and clutch gear.
  1. CAUTION:
    CAUTION:Position of bushings.
    Apply the separator panel on both bushings onto the cylinder block.
    • Apply high temperature grease (ESD-M1C220-A) lightly to the separator panel.

  1. CAUTION:
    CAUTION:Make sure that the two locating tubes are installed.
    Place the transmission into position and tighten the rear flange bolts.

  1. Tighten the flange bolts.

  1. Tighten the flange bolt and install the starter motor.
  1. Lower engine/transmission assembly onto the assembly table and secure it using securing straps.
  1. Detach the floor crane lifting tackles and remove powertrain lift.
  1. General note.
    • Renew all snap rings and self-locking nuts.
    • To install coolant hoses and ventilation hoses, use tool 24-003.
  1. Lower the vehicle and move engine/transmission assembly into installation position.

  1. NOTE:
    NOTE:Do not tighten the nuts yet.
    NOTE:
    NOTE:Use new nuts.
    Install the rear engine mounting bracket by turning the nuts five threads.

  1. Install the front engine mounting bracket.
    • Detach the securing strap.
  1. Raise the vehicle.

  1. Install the engine roll restrictor.
  1. Lower the vehicle.

  1. Tighten the rear engine mounting.
      NOTE:
      NOTE:The arrow on the transmission breather points towards the front of the vehicle.
    • Fit the transmission breather.

  1. NOTE:
    NOTE:Renew the O-ring.
    Connect the hydraulic pipe of the clutch operating system.
      NOTE:
      NOTE:Make sure the spring clip engages securely.
    1. Insert the pipe into the pre-loading valve and fit the spring clip.
    1. Fit the hydraulic pipe in the bracket.
  1. Raise the vehicle.

  1. NOTE:
    NOTE:If it is not possible to attach the gearshift mechanism stabilizer without tension, align the engine and transmission so that the gearshift mechanism stabiliser can be attached without tension. Do not tighten the shift rod clamp.
    Attach the gearshift mechanism stabiliser and the shift rod to the transmission.
      NOTE:
      NOTE:There is a washer.
    1. Stabiliser - Gearshift.
    1. Shift rod.

  1. Adjust the gearshift mechanism.
    • Engage fourth gear (push selector shaft from the neutral position to the stop).
    • Hold the gear lever in the fourth gear position with a 9 mm drill shaft.
  1. Tighten the shift rod clamp.
  1. Install the heat shield.

  1. NOTE:
    NOTE:Use a new gasket.
    Connect the exhaust system.

  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18°, the outer at more than 45°.
    CAUTION:
    CAUTION:When installing the front drive shafts, use the locating sleeve (supplied with each new oil seal) to protect the oil seal.
    NOTE:
    NOTE:Make sure the circlip engages correctly.
    Install the right-hand front driveshaft with a new circlip and the intermediate shaft into the transmission.

  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18°, the outer at more than 45°.
    Tighten the front driveshaft centre bearing.

  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18°, the outer at more than 45°.
    CAUTION:
    CAUTION:When installing the front drive shafts, use the locating sleeve (supplied with each new oil seal) to protect the oil seal.
    NOTE:
    NOTE:Make sure the circlip engages correctly.
    Install the left-hand front driveshaft with a new circlip into the transmission.
  1. Fill up with transmission fluid (WSD-MWC200-C) to 10 - 15 mm below the lower edge of the level check bore.

  1. Attach the vibration damper lever suspension arm.

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

  1. Fit the air conditioning compressor.
    • Tighten the four bolts.

  1. Put the drive belt in place and tension it.

  1. NOTE:
    NOTE:Top of radiator is plug mounted.
    Install radiator (two screws per side; right-hand side shown).

  1. Connect the coolant hoses.

  1. NOTE:
    NOTE:Top of condenser - air conditioning is plug mounted.
    Place condensor - air conditioning into position and tighten bottom screws.

  1. Install lower radiator shield.

  1. Connect the oil pressure switch plug.

  1. Connect plugs and attach ground cable to crossmember.
    • Fit cable with clip.
    • Fit with cable tie at crossmember.
  1. Lower the vehicle.

  1. Remove cable tie for condensor - air conditioning (left-hand side shown).
    • Install radiator grille.

  1. NOTE:
    NOTE:Use new seal for pressure pipe.
    Attach the pipes.

  1. Install the speedometer drive cable.

  1. Attach ground cable and connect the electrical connector(s).
    1. Connector - reversing lamps.
    1. Connector - CKP Sensor.

  1. Install the ground cable.
    • Insert the oil dipstick.

  1. Join/connect the multiplug.
    1. Engine wiring harness
    1. VSS
    1. EI ignition coil

  1. Connect the fuel pipes.

  1. Connect the pipes.

  1. Install the coolant hose and cable.
    1. Coolant temperature gauge sender.
    1. Negative lead.

  1. Connect the heater hoses.

  1. Install the coolant hose.

  1. Install the air cleaner.
    1. Hang in the rubber ring.
    1. Install the bolts.
    1. Connect the hose.
    1. Insert the breather hose.

  1. NOTE:
    NOTE:Coat the spark plug sealing with silicone grease (A960-M1C171-AA).
    Install the throttle cable.
    • Remove the clip.
    • Disconnect the throttle cable.
    • Connect the spark plug connector for cylinders 1 and 2.

  1. Install the battery box.

  1. Install the battery.
    1. Install the bracket.
    1. Install the battery positive lead.
    1. Connect the battery positive lead.
    1. Fit insulating tape (if removed).

  1. On each side fasten the suspension strut nut.
  1. Standard finishing operations.
    • Check that the wiring and hoses are correctly routed and secure them with cable ties if necessary.
    • Fill up with coolant.
    • Connect the battery negative lead.
    • Bleed the cooling system.
    • Check the engine and cooling system for leaks (visual inspection).
    • Check the transmission fluid level and correct as necessary.
    • Enter the radio keycode.
    • Reprogram the preset radio stations.
    • Reset the clock.
    • Carry out a road test to allow the PCM (EEC IV) to re-learn values.
    • Check the fluid levels and rectify as necessary.
  1. Standard finishing operations (continued).

303-01C Engine - 1.4L PTE (CVH)|Engine > < Assembly|Engine