Contents: Removal ↳ Installation ↳
Removal
1. Disconnect the ground wire from the battery.
2. Remove the hood.
3. Drain the cooling system (see subsection 3.2.1.11).
4. Disconnect the air supply line to the turbocharger, the flexible crankcase ventilation line from the cylinder head cover and the air supply line between the air filter and the radiator shroud (the line is fitted with fastening tips).
5. Disconnect all flexible cooling system lines from the engine.
6. Disconnect the coolant pipes connected to the expansion tank of the cooling system from the cylinder head and from the thermostat cover.
7. Cut the clamps holding the electrical wire to the oil pressure sensor.
8. Disconnect the accelerator pedal cable from the fuel pump lever and from the bracket.
9. Disconnect the fuel supply lines from the filter and fuel pump, and then the return line from the fuel pump.
10. Disconnect the vacuum line from the vacuum pump.
11. Disconnect the electrical wire connectors from the following components: generator, coolant temperature sensor, oil pressure sensor, radiator fan thermal switch, engine shut-off solenoid valve (STOP valve), cold engine fuel injection advance corrector, and cold engine automatic fast idle thermal switch.
12. Cut the clips securing the wiring harness to the left engine mount bracket and move the wiring harness away from the engine.
13. Disconnect the electrical connector from the radiator fan.
14. Remove the radiator fan together with the radiator shroud.
15. Unscrew the upper right bolts connecting the engine to the gearbox.
16. Remove the clamps securing the front suspension stabilizer bushing to the body (four bolts).
17. Disconnect the outlet pipe from the turbocharger.
18. Disconnect the bracket that supports the front exhaust pipe from the transmission crossmember.
19. Disconnect the electrical wire connectors from the starter.
20. Remove the starter.
21. Unscrew one nut from the engine mount beam securing the left and right elastic engine mount support.
22. Disconnect the electrical connector from the reverse light sensor, then remove the bracket with the electrical wire from the reverse light switch.
23. Unscrew the bolts securing the sheet metal partition of the clutch housing.
24. Disconnect the end of the clutch cable from the clutch release forks.
25. Unscrew all other bolts connecting the engine to the gearbox.
26. Support the gearbox using a jack.
27. Using a hoist, suspend the engine by the lifting brackets, disconnect the engine from the gearbox (until the end of the primary shaft appears) and remove the engine from the top of the vehicle's engine compartment.
Installation
Attention! Replace all self-locking nuts with new ones.
1. Lightly lubricate the end of the gearbox input shaft with oil.
2. Carefully lower the engine into the engine compartment of the car, insert the primary shaft of the gearbox into the hub of the clutch disc. Using the two bolts securing the clutch housing to the engine (located as far apart as possible), connect the engine and gearbox.
3. Lower the engine slightly and insert the bolts of the elastic engine mounts into the holes in the engine mount crossmember.
4. Move aside the hoist on which the engine was suspended and the jack supporting the gearbox from below.
5. Insert and tighten the bolts connecting the engine to the gearbox to the appropriate torque. Connect the ground wire and secure the bracket with the reverse light switch wire.
6. Install the clutch housing sheet metal partition, tightening the mounting bolts.
7. Connect the electrical connector to the reverse light switch.
8. Attach two elastic engine mount supports to the engine mount cross member.
9. Install the starter together with the bracket.
10. Connect the electrical wire connectors to the starter.
11. Connect the end of the control cable to the clutch release forks.
12. Screw the outlet pipe to the turbocharger flange.
13. Bolt the front exhaust pipe support bracket to the transmission crossmember.
14. Install the clamps securing the front suspension stabilizer bushing to the body (four bolts).
15. Install the radiator fan together with the radiator shroud.
16. Connect the radiator fan motor electrical wire connector.
17. Connect all electrical wire connectors and use the latch to secure the harness to the left engine mount bracket.
18. Connect the vacuum line to the vacuum pump.
19. Connect the fuel lines to the fuel filter and fuel pump using new copper washers.
20. Connect the accelerator pedal cable to the fuel pump.
21. Connect the flexible pipes of the vehicle interior heating system to the cylinder head and to the oil radiator.
22. Connect the elastic hose from the expansion tank of the cooling system to the cylinder head and to the thermostat cover.
23. Attach the oil pressure sensor electrical wire to the flexible hose using a clip.
24. Connect the two lower flexible lines from the radiator to the coolant pump and oil cooler.
25. Insert the hose between the air filter and the upper radiator shroud; connect the air supply lines to the turbocharger and the engine ventilation lines.
26. Connect the vehicle's ground wire to the battery.
27. Fill the engine with the appropriate amount of oil.
28. Fill the engine cooling system.
29. Remove air from the fuel system.
30. Remove air from the cooling system.
31. Install the hood.
32. Check the maximum speed and idle speed of the engine. Adjust them if necessary.
33. Check the tightness of the fuel and cooling system connections.
This article was borrowed from the website: FORDBOOK