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

Fiesta 2002.25 (11.2001-)

Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) - Engine Fiesta 2002.25 (11/2001-)
Installation

Special Tool(s)

Wrench, Hydraulic Line Union Nut

211-269 (13-027)

Lifting Bracket, Engine

303-122 (21-068A)

Remover/Installer, Hose Clamp

303-397 (24-003)
General Equipment
Securing straps
Workshop table
Engine hoist

Installation

All vehicles
WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. CAUTION:
    CAUTION:Make sure that the two locating dowels are installed.
    Install the transaxle to the engine.

  1. Install the transaxle lower retaining bolts.

  1. WARNING:
    WARNING:Support the engine and transaxle assembly on wooden blocks and secure it with suitable securing straps.
    Using the special tool and the engine hoist position the engine and transaxle assembly on the workshop table.

  1. Install the transaxle right-hand retaining bolt.

  1. Install the starter motor and the transaxle left-hand retaining bolt.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
  1. Position the engine and transaxle assembly in the engine compartment.
    • Carefully lower the vehicle.

  1. NOTE:
    NOTE:Install new engine front mount retaining nuts.
    NOTE:
    NOTE:Do not tighten the engine front mount retaining bolts and nuts at this stage.
    Install the engine front mount.

  1. NOTE:
    NOTE:Install new engine rear mount retaining nuts.
    NOTE:
    NOTE:Do not tighten the engine rear mount center retaining nut at this stage.
    Install the engine rear mount.

  1. Install the battery tray support bracket.

  1. Install the engine rear support insulator.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    NOTE:
    NOTE:Install a new center bearing cap and locknuts.
    Attach the right-hand halfshaft and the intermediate shaft to the transaxle.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    CAUTION:
    CAUTION:Make sure the snap ring is correctly seated.
    NOTE:
    NOTE:Install a new snap ring.
    Attach the left-hand halfshaft to the transaxle.

  1. Attach the lower arm to the wheel knuckle on both sides (right-hand side shown).
    • Install the heat shield.

  1. Using the special tool, connect the coolant hose to the distribution pipe

  1. Using the special tool, connect the coolant hose to the radiator.

  1. Connect the A/C high-pressure cut-off switch electrical connector.

  1. Install the cooling fan motor and shroud.
    1. Push the cooling fan motor and shroud upwards and then downwards to install.
    1. Install the cooling fan motor and shroud to the retaining brackets.

  1. Connect the cooling fan motor and cooling fan resistor electrical connectors.

  1. Using the special tool, attach the power steering line to the power steering pump.

  1. Connect the power steering line to the steering pump.

  1. Attach the power steering line support bracket to the engine block.

  1. Attach the air conditioning (A/C) compressor to the cylinder block.

  1. Connect the A/C compressor clutch electrical connector.
  1. Install the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning (303-05 Accessory Drive, Removal and Installation).

  1. Connect the starter motor electrical connectors.

  1. Connect the reversing lamp switch electrical connector.

  1. Connect the crankshaft position (CKP) sensor electrical connector.

  1. Connect the oil pressure switch electrical connector.

  1. NOTE:
    NOTE:Install new exhaust flange nuts and a new exhaust flange gasket.
    Attach the exhaust flexible pipe to the catalytic converter.

  1. Remove the exhaust flexible pipe support.
Vehicles without automated gearshift
  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    NOTE:
    NOTE:Make sure the spring clip is correctly seated.
    Connect the clutch slave cylinder supply line.
    • Install the spring clip.

  1. Attach the gearshift cables to the bracket and turn the abutment sleeves counterclockwise.
  1. NOTE:
    NOTE:Do not install the air cleaner at this stage.
    Adjust the gearshift cable.
    For additional information, refer to: Gearshift Cable Adjustment (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  1. NOTE:
    NOTE:Do not install the air cleaner at this stage.
    Bleed the hydraulic clutch system.
    For additional information, refer to: Clutch System Bleeding (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
Vehicles with automated gearshift
  1. Connect the gearshift actuator electrical connector (colored grey).

  1. Connect the gearshift actuator electrical connector (colored black).

  1. Install the gearshift actuator cover.

  1. Connect the clutch slave cylinder supply line.
    • Install the spring clip.
  1. Bleed the hydraulic clutch system.
    For additional information, refer to: Clutch System Bleeding - Vehicles With: Automated Gearshift (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
All vehicles
  1. Lower the vehicle.

  1. Tighten the engine front mount retaining nuts and bolts.

  1. NOTE:
    NOTE:Install a new engine rear mount center retaining nut.
    Tighten the engine rear mount center retaining nut.

  1. Attach the power steering line support bracket to the cylinder head.

  1. Attach the power steering line to the power steering pump mounting bracket.

  1. Install the engine wiring harness support brackets.
    • Connect the engine ground cable.

  1. Connect the electronic ignition (EI) coil electrical connector.

  1. Connect the engine coolant temperature (ECT) sensor electrical connector.

  1. Connect the generator electrical connectors.

  1. Connect the air conditioning (A/C) lower-pressure cut-off switch electrical connector.
  1. Install the right-hand headlamp assembly.
    For additional information, refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).

  1. Connect the knock sensor (KS) electrical connector.

  1. Connect the evaporative emission (EVAP) electrical connector.

  1. Connect the engine wiring harness electrical connector.

  1. Connect the power steering pressure (PSP) switch electrical connector.

  1. Connect the catalyst monitor sensor electrical connector.

  1. Connect the heated oxygen sensor (HO2S) electrical connector.

  1. Using the special tool, connect the coolant hose to the coolant distribution housing.

  1. Using the special tool, connect the coolant hose to the coolant distribution housing.

  1. Attach the brake booster vacuum line to the intake manifold.

  1. Connect the low-pressure EVAP hose.

  1. Connect the fuel supply line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Connect the fuel return line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Attach the coolant expansion tank to the bracket.

  1. Using the special tool, connect the degas hose to the cylinder head.

  1. Attach the fuel line and the degas line to the intake manifold.
    • Install the cable tie.

  1. Attach the power steering fluid reservoir to the bracket.

  1. Tighten the strut and spring assembly top mount nuts on both sides.
  1. Connect the powertrain control module (PCM) electrical connector.
    For additional information, refer to: Powertrain Control Module (PCM) - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (303-14 Electronic Engine Controls, Removal and Installation).
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Install the front wheels and tires.
    For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
  1. Fill the engine cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding - 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (303-03A Engine Cooling - 1.25L Duratec-16V (Sigma)/1.3L Duratec-8V (Rocam)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), General Procedures).

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