Engine installation 1.6L Zetec-E

Special tool

	Engine lift tool 303-122 (21068A)
	Radiator hose clamp remover and installer 303-397 (24-003)

General equipment:

• assembly table
• Fixing clamp
• Engine Crane
• wooden blocks

Name	Specification
High temperature grease	ESD-M1C220-A

All cars

NOTE: Use special tool 303-397 to install and remove coolant hoses and vent hoses if necessary.

1. Using a fixing collar and wooden blocks, fix the gearbox in the block with the drive axle on the assembly stand.

2. Using a suitable crane to lift the engine, align the position of the engine with the transaxle.



3. Establish the right bolts of fastening of a transmission in the block with the leading bridge.

• 1.Flange bolts
• 2. Starter bolts
• 3.Connect the ground cable.

4. Establish the bottom bolts of fastening of a transmission in the block with the leading bridge.




5. Establish the left bolts of fastening of a transmission in the block with the leading bridge.



6. Install starter and tighten flange bolt.

• 1.Starter bolt
• 2.Flange bolt

7. Raise the vehicle. Refer to Section 100-02 for more information.

8. Install the engine assembly with the gearbox in the block with the drive axle, fixed on the assembly stand, under the car. Lower the car carefully.




9.

NOTE: Do not fully tighten bolts and nuts at this stage.

Install the front engine mount.



10.

NOTE: Do not fully tighten bolts and nuts at this stage.

Install the rear engine mount.



11.

WARNING: If brake fluid comes into contact with the paintwork, the affected area must be washed immediately with cold water.

Connect the supply line to the clutch slave cylinder.



12. Remove the fixing collar from the gearbox in the block with the drive axle.

13. Raise the vehicle. Refer to Section 100-02 for more information. Remove the assembly stand.

14. Install the engine mount.



15. Connect the vehicle speed sensor connector (VSS).



16.

CAUTION: The inner hinge must not be tilted more than 18 degrees. External hinge - at an angle exceeding 45 degrees.

NOTE: Use new nuts and a new intermediate bearing cap.

Establish the right forward semiaxle and an intermediate shaft.



17.

NOTE: Make sure the retaining ring is installed correctly.

Install the left front axle shaft.



18.

CAUTION: Make sure a heat shield is installed to prevent damage to the ball joint.

Connect the lower arm ball joint to the steering knuckle (at both sides).

• 1. Install the lower arm ball joint.
• 2.Install the bolt.

19. Establish a flexible insert of system of release.



20. Install the front wheel and tire assembly. Refer to Section 204-04 for more information.

21. Tighten nuts and bolts of fastening of a back support of the engine.



22. Tighten the rear engine mount nuts.



23. Raise the vehicle. Refer to Section 100-02 for more information.

24. Install the power steering pump lower bolts.



25. Connect the coolant pump hose.



Vehicles with air conditioning

26. Connect the air conditioning compressor to the engine.



All cars

27. Install the accessory drive belt. (shown vehicle without air conditioning system). Turn the belt tensioner in a clockwise direction.



28. Install the accessory drive belt cover.



29. Connect shift cables and gear selection to the gearbox in the block with the drive axle. Rotate the support sleeve clockwise on the bracket.



30. Close the cover of the shift cables and gear selection.



31. Dock the plug connectors of the reversing light switch, crankshaft position sensor (CKP) and heated oxygen sensor (HO2S). Connect the wiring harness to the engine.



32. Install the air deflector and radiator fan. Install the air baffle and fix it at the top on both sides (left side shown).



33. Lower the car.

34. Connect the coolant hoses to the engine.



35. Connect the fuel lines and ground wire to the manifold.



36. Connect a vacuum hose of the vacuum amplifier of brakes.



37. Connect the vacuum hoses to the throttle body.



38. Dock the plug connector of the engine wiring harness.



39. Connect the alternator connector.



40.

WARNING: If brake fluid comes into contact with the paintwork, wash the affected area with cold water.

Connect the supply line to the clutch slave cylinder. Connect the spring clip.



41. Connect the radiator fan connector. Install new clamps.



42. Connect the powertrain control module connector (PCM). Install new clamps.



43. Connect the power steering pressure switch connector (PSP).



44. Connect the plug connectors of the EI coil and the plug connectors of the RFI filter.



45. Connect the accelerator cable to the throttle body.

• 1. Fix the cable in the required position.
• 2.Fix the plastic clip.

46. Connect the headlight ground wire.



47. Install the air filter housing.

• 1.Connect the plug connector of the mass air flow sensor (MAF).
• 2. Connect the breather line to the air filter.
• 3. Connect the air filter outlet pipe to the throttle body.

48. Tighten the nuts securing the upper support of the suspension strut assembly with the spring (at both sides).



49. Establish the top bolts of fastening of the pump of the amplifier of a steering.



50. Connect the power steering line to the engine.



51. Attach the power steering reservoir to the wheel arch.



52. Fix a broad tank of system of cooling on a wheel arch.



53. Remove the special tool.



54. Connect the plug connectors of the traction control and heated seats (in the presence of).



55. Connect the shift lever trim to the floor console.



56. Connect the shift lever cover to the floor console.



57. Install the battery shelf. Refer to Section 414-01 for more information.

58. Fill with coolant. Refer to Section 303-03 for more information.

59. Check the transaxle transmission fluid level and top up if necessary. Refer to Section 308-03A / 308-03B / 308-03C for more information.

60. Bleed the clutch fluid. Refer to Section 308-03A / 308-03B / 308-03C for more information.