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

Fiesta 1996 (08.1995-02.2002)

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

Special Tool(s)

Remover, driveshaft

16-087

21-068 A Engine lifting bracket

21-068 A Engine lifting bracket

Remover/installer, radiator hose clamps

24-003
General Equipment
Puller
New 9 mm twist drill bit
Materials
Name
Specification
Motorcraft Super-Plus 4 coolant concentrate
ESDM-97B49-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-6C9103-A 
High temperature grease for transmission input shaft, guide sleeve - clutch release bearing, pilot bearing - crankshaft and clutch splines
ESD-M1C220-A 

Installation

All Vehicles
  1. Preparatory operations
    • Clean the internal splines of the clutch disc, the splines on the transmission input shaft and the clutch release bearing guide sleeve.
    • Apply a thin coating of high-temperature grease (ESD-M1C220-A) to the transmission input shaft, the clutch release bearing guide sleeve, the crankshaft pilot bearing and the clutch splines.

  1. NOTE:
    NOTE:Make sure that the two locating dowels are installed.
    Align the adapter plate on the two guide sleeves on the cylinder block.
    • Fix the adapter plate with a small amount of high-temperature grease (ESD-M1C220-A).

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

  1. Tighten the front flange bolts.

  1. NOTE:
    NOTE:Install the bracket for the cable tie for the starter motor wiring.
    Install the starter motor.

  1. Install the resonator.
  1. Lower the engine and transmission assembly onto the assembly table and secure it with tensioning straps.
  1. Unhook the workshop hoist and detach the engine lifting bracket.
  1. General Remarks.
    • Renew circlips and self-locking nuts.
    • When installing coolant and ventilation hoses, if necessary For additional information, refer to Section  303-03 Engine Cooling.
  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. Attach the rear engine mounting.
      NOTE:
      NOTE:Do not tighten the nuts and bolts.
    1. Bolts
    1. Nuts.
    1. Fit the transmission breather.

  1. NOTE:
    NOTE:Do not tighten the nuts.
    Attach the front engine mounting.
    • Remove the tensioning straps.
  1. Raise the vehicle.

  1. Fit the engine roll restrictor.

  1. NOTE:
    NOTE:Do not tighten the bolt on the shift rod.
    NOTE:
    NOTE:Washer
    Fit the gearshift stabilizer.
    1. Gearshift stabilizer
    1. Shift rod
  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 elongated holes of the rear engine mounting bracket.
    Tighten the nuts of the front engine mounting bracket.

  1. Tighten the bolts and nuts of the rear engine mounting bracket.
  1. Put the transmission into 4th gear.
  1. Raise the vehicle.
Vehicles from build month 01/1997 for European markets
  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 intermediate shaft, use the locating sleeve (supplied with every new oil seal), to protect the oil seal.
    Install the right-hand driveshaft, together with the intermediate shaft, in the transmission.
Vehicles up to build month 12/1996 and vehicles for non-European markets
  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 axle driveshafts 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 driveshaft, together with new retaining ring and intermediate shaft, in the transmission.
All vehicles
  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 driveshaft center 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 axle driveshafts 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 driveshaft, together with new retaining ring, in the transmission.
  1. Top up the transmission fluid to 10 - 15 mm below the lower edge of the filler/check bore.

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

  1. Attach the rear exhaust pipe to the flexible intermediate pipe.

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

  1. Adjust the gearshift mechanism (continued).
    • The detailed illustration shows the shank of the drill bit inserted.

  1. Adjust the gearshift mechanism (continued).
    • Tighten the shift rod clamp.
    • Withdraw the drill bit from the gearshift mechanism housing.

  1. Attach the speedometer drive cable.

  1. Connect the generator.

  1. Connect the starter motor.

  1. Connect the plug of the multi-function switch (where fitted).

  1. Connect the plug of the reversing light switch (where fitted).

  1. Fit the A/C compressor.

  1. Fit the drive belt.
    1. Lay the drive belt in place and tension it via the bolt of the belt tensioner. For additional information, refer to Section  303-05 Accessory Drive.
    1. Tighten the hexagon socket head bolt of the tensioning pulley.
  1. Locate the radiator and the fan plate with the fan in position on the radiator crossmember.

  1. NOTE:
    NOTE:The radiator is a push fit at the top.
    NOTE:
    NOTE:Secure the ground lead on the left-hand side using the radiator bolt.
    Install the radiator (two bolts on each side; right-hand side shown).

  1. NOTE:
    NOTE:The air conditioning condenser is a push fit at the top.
    Align the air conditioning condenser and screw it in place at the bottom.

  1. Connect the three plugs at the bottom of the radiator on the left-hand side.

  1. Connect the plug of the air conditioning wiring.
    • Secure the wiring to the radiator crossmember with cable ties.

  1. Connect the bottom right-hand coolant hose to the radiator.

  1. Connect the bottom coolant hose.

  1. Lower the vehicle.
  1. Attach the front engine mounting auxiliary bracket.

  1. Connect the power steering hose and pressure pipe.

  1. Connect the bracket of the power steering pressure pipe to the cylinder block.

  1. NOTE:
    NOTE:Insert new O-rings.
    Attach the hydraulic pipe of the clutch operating mechanism.
  1. Attach the transmission ground lead.

  1. Connect the fuel lines.
    1. Fuel return line
    1. Fuel feed line to diesel fuel heater

  1. Attach the throttle cable.
    1. Slide the rubber bush and clip onto the bracket.
    1. Hook the accelerator cable in place.
  1. Connect the plugs and wiring:
    1. Plug of the injection pump wiring loom.
    1. Glow plug wiring.
    1. Plug of the coolant temperature gauge sender unit.
    1. Plug of ECT sensor.
    1. Plug of oil pressure switch.
    1. Plug of diesel fuel heater.

  1. Attach the brake servo vacuum line.

  1. Connect the plug of the EGR valve.

  1. Fit the battery box.

  1. Install the battery.

  1. Attach the radiator vent hose.

  1. Attach the hoses.
    1. Vent hose.
    1. Heater coolant hoses.

  1. Attach the upper coolant hose.

  1. Install the air intake pipe.
    1. Attach the resonator hose (clamp).
    1. Insert it in the air cleaner housing (push fit).
    1. Clip it in place.
    1. Attach it to the intake manifold (clamp).

  1. NOTE:
    NOTE:When tightening the nuts, hold with an Allen key to prevent from turning.
    Tighten the nut on both suspension struts.

  1. Bleed the hydraulic clutch system For additional information, refer to Section  308-01 Clutch.
    • If necessary, fill up the brake fluid reservoir with Ford brake fluid (SAM-6C9103-A).
  1. Fill up the power steering reservoir and bleed the power steering. For additional information, refer to Section  211-00 Steering System - General Information.
  1. Standard finishing operations.
    • Fill up with coolant.
    • Check the transmission fluid level and correct as necessary.
    • Check the routing of vacuum hoses and wiring and secure with cable ties.
    • Connect the battery.
    • Enter the radio keycode.
    • Reprogram the preset radio stations.
    • Set the clock.
    • Carry out a road test to enable the PCM (EEC V) to collect data.
    • 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 > < Assembly|Engine