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303-03 Engine Cooling > < Assembly|Engine

Ikon 1999 (01.2000-)

Engine - 1.8L Endura-DE (Kent) Diesel - Engine Ikon 1999 (01/2000-)
Installation

Special Tool(s)

Engine Lifting Bracket

21-068A (21068A)

Cooling Hose Clamp Remover/Installer

24-003 (24003)
General Equipment
Assembly table with tensioning straps
Workshop hoist
Auxiliary plugs
Puller
New 9 mm twist drill bit
Materials
Name
Specification
Motorcraft super-plus 4 coolant concentrate
ESD-M97B49-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 6C9103A 
High temperature grease for transaxle input shaft, clutch release bearing guide sleeve, crankshaft pilot bearing and clutch splines
ESD-M1C220-A 
  1. Standard preparatory measures.
    • Clean the internal splines of the clutch disc, the splines on the transaxle input shaft and the clutch release bearing guide sleeve.
    • Apply a thin coating of High-temperature grease to the transaxle input shaft, the clutch release bearing guide sleeve, the crankshaft pilot bearing and the clutch splines.
    • Renew circlips and self-locking nuts.
    • If necessary, use Special Tool 24-003 when installing coolant and vent hoses.

  1. NOTE:
    NOTE:Make sure the guide sleeves are sitting correctly.
    Align the adaptor plate on the two guide sleeves on the cylinder block.

  1. NOTE:
    NOTE:The transaxle is centered with two guide sleeves on the engine.
    Locate the transaxle in position and tighten the rear flange bolts.

  1. Tighten the front flange bolts.

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

  1. Install the resonator.
  1. Lower the engine and transaxle assembly onto the assembly table and secure it with tensioning straps.
  1. Locate the engine and transaxle assembly in position under the vehicle.
  1. Unhook the workshop hoist and detach the engine lifting bracket.
  1. Slowly lower the vehicle and guide the engine and transaxle assembly into the engine compartment.

  1. NOTE:
    NOTE:Do not tighten the nuts and bolts.
    Attach the rear engine mounting.
    1. Install the transaxle breather
    1. Nuts
    1. Bolts.

  1. NOTE:
    NOTE:Do not tighten the nuts.
    Attach the front engine mounting.
    • Remove the tensioning straps.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Install the engine roll restrictor.

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

  1. NOTE:
    NOTE:Do not tighten the shift rod bolt.
    NOTE:
    NOTE:Position of washer.
    Attach the gearshift stabiliser.
    1. Stabiliser - gearshift
    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. Put the transaxle into 4th gear.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. CAUTION:
    CAUTION:The inner joint should not be bent at more than 18 degrees and the outer joint should 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 halfshaft in the transaxle.

  1. CAUTION:
    CAUTION:The inner joint should not be bent at more than 18 degrees and the outer joint should not be bent at more than 45 degrees.
    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 halfshaft, together with new retaining ring, in the transaxle.
  1. Check the transmission fluid level and top up as necessary. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.

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

  1. Attach the exhaust downpipe and intermediate pipe.

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

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

  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. Connect the generator electrical.
  1. Attach the wiring harness to the transaxle.

  1. Attach the speedometer drive cable.

  1. Connect the alternator.

  1. Connect the starter motor.

  1. Connect the plug of the reversing light switch.

  1. Install the air conditioning compressor.

  1. Install the drive belt.
    1. Install the drive belt. Tension using the drive belt tensioner bolt.
    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.

  1. Connect the electrical connectors at the lower left-hand side of the radiator.

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

  1. Connect the air conditioning diode.

  1. Connect the coolant hose to the radiator.

  1. Connect the bottom coolant hose.

  1. Install the auxiliary drive shield.
    • Install the bolt.
    • Install the clip.
  1. Install the engine undershield. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.
  1. Lower the vehicle.

  1. Attach the front engine mounting auxiliary bracket.

  1. Connect the power steering hose and pressure pipe.

  1. Connect the power steering pressure pipe bracket and shield.

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

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

  1. Attach the accelerator cable.
    1. Install the rubber bush into the bracket.
    1. Hook the inner cable in place.
    1. adjust the cable.

  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 the brake servo vacuum line.
  1. Attach the brake servo vacuum line.

  1. Install the battery box.

  1. Install the battery.

  1. Attach the radiator vent hose.

  1. Attach the hoses.
    1. Vent hoses
    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 inlet manifold (clamp).

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

  1. Bleed the hydraulic clutch operating system.
  1. Fill up the power steering fluid reservoir and bleed system.
  1. Standard finishing operations.
    • Fill up with coolant.
    • Check the transaxle 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.
    • Reprogramme the preset radio stations.
    • Check the engine and cooling system for leaks (visual inspection).
    • Check the fluid levels and correct as necessary.

303-03 Engine Cooling > < Assembly|Engine