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303-03 Engine Cooling > < Assembly|Engine

Puma 1998 (06.1997-12.2001)

Engine - 1.4L Zetec-SE (Sigma)/1.6L - Engine Puma 1998 (06/1997-12/2001)
Installation

Special Tool(s)

Engine lifting bracket

303-122 A

Remover/installer, coolant hose clip

303-397 (24-003)
General Equipment
Auxiliary plugs
Assembly stand
Retaining strap
Workshop hoist
Materials
Name
Specification
High-durability grease
WSD-M1C230-A 
Engine Oil
WSS-M2C912-A1 

Installation

All Vehicles
  1. Join the engine and transmission.

  1. Screw in the left-hand flange bolts.

  1. Screw in the right-hand flange bolts.
    • Attach bracket for the gearshift cables.
  1. Place the engine and transmission assembly on the assembly table.
    • Support the transmission on wooden blocks and secure it with a retaining strap.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.
  1. Move the engine and transmission assembly on the assembly table into position underneath the vehicle.
  1. Lower the vehicle and guide the engine/transmission assembly into the engine compartment.

  1. NOTE:
    NOTE:Do not tighten the nuts.
    Install the transmission on the rear engine mounting bracket.
Vehicles built up to 07/1998
  1. NOTE:
    NOTE:Do not tighten the nuts.
    Install the front engine mounting.

  1. NOTE:
    NOTE:Do not tighten the bolts.
    Install the engine roll restrictor.

  1. NOTE:
    NOTE:Do not tighten the bolt on the shift rod.
    Install the stabiliser and shift rod.
    1. Shift rod stabiliser
    1. Shift rod
    1. Washer

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

  1. Tighten the nuts on the front engine mounting.

  1. Tighten the nuts on the rear engine mounting.

  1. Put in the transmission vent and attach the rear engine mounting brace.
Vehicles built from 08/1998
  1. Attach the front engine mounting.
All vehicles
  1. Take off the retaining strap.
    Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.
    • Pull the assembly table out from underneath the engine and transmission assembly.

  1. Attach the line to the clutch master cylinder.

  1. Connect the fuel lines. For additional information, refer to Section  310-00 Fuel System - General Information.
  1. Raise the vehicle. For additional information, refer to Section  100-2 .
  1. Adjust the gearshift mechanism. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.

  1. Install the heat shield.

  1. CAUTION:
    CAUTION:The flexible pipe can be damaged if it is bent too far.
    Support the flexible pipe using a suitable protective gaiter.

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

  1. Install the drivebelt tensioner (three bolts).

  1. Attach the speedometer drive cable.
Vehicles without air conditioning
  1. Install the power steering pump and vacuum pipe bracket.
All vehicles
  1. Install and tension the drive belt.

  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
    Pack the tripode joint with high-durability grease (fill quantity 100 g).

  1. Put the clamping strap for the tripode joint gaiter in place.

  1. Install the vibration damper on the lower suspension arm.

  1. Install the starter motor.
    • Attach the ground lead.
    • Attach the cable guide.

  1. CAUTION:
    CAUTION:Make sure that the heat shield for protecting the ball joint is installed.
    Install the heat shield.

  1. Install the right and left<-> hand lower suspension arm on the spindle carrier.
Vehicles without air conditioning
  1. Install the fan.
    • Pull the radiator crossmember downwards. First slide the fan upwards and insert it in the supports.
    1. Secure the wiring with cable ties.
    1. Connect the plug.
    1. Install the radiator crossmember bolts.
Vehicles with air conditioning
  1. Install the A/C compressor.
    • Connect the connector to the air conditioning compressor.

  1. Install the power steering pump with bracket.

  1. Install the radiator crossmember together with the fan and radiator.
    1. Attach the ground lead.
    1. Connect the fan motor plug.
    1. Tighten the bolts.

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

  1. Attach the air conditioning condenser.

  1. Attach the thermostat housing coolant hose.

  1. Connect the coolant hose of the coolant expansion tank.
All vehicles
  1. Attach the transmission control unit multiplug and clip it in place.

  1. Install the drive belt cover.
  1. Lower the vehicle.
Vehicles with air conditioning
  1. Detach the air conditioning condenser.
All vehicles
  1. Attach the vent hose to the radiator.

  1. Install the coolant hose.

  1. Tighten the upper bolts of the power steering pump.

  1. Attach the activated carbon canister vacuum line.

  1. Install the coolant hose.

  1. Connect the coolant hoses.
    1. Install the heating hose.
    1. Attach the coolant expansion tank hose.

  1. Push on the vacuum hoses.
    • Push on the brake servo vacuum hose.
    • Connect the fuel pressure control vacuum hose.

  1. Connect the heated oxygen sensor (HO2S) multiplug and the ground lead.

  1. Attach the ground lead.

  1. Install the leads.
    1. Connect the plug.
    1. Connect the ground cable.
    1. Connect the positive battery lead.

  1. Connect the engine wiring harness multiplug.

  1. Join the connectors.
    1. Connect the ignition coil connectors.
    1. Connect the engine wiring harness multiplug.

  1. Attach the throttle cable.
    1. Install the clip.
    1. Twist the cable into the bracket.

  1. Attach the crankcase ventilation hose.

  1. Install the intake hose.

  1. Tighten the suspension strut nut on both sides.

  1. Install the battery box.
    1. Secure the wiring with cable ties.
    1. Screw in the bolts.
  1. Install a new oil filter.
  1. Top up the engine oil .
  1. Standard finishing operations.
    • Check the level of the engine oil.
    • Secure the wiring as necessary using cable ties.
    • Check fluid levels and correct them as necessary.

303-03 Engine Cooling > < Assembly|Engine