Engine - refitting (manual gearbox in vehicle)

1 Reverse the procedure described in paragraphs 1 to 40, Section 5, noting the following points.

2 Before attempting to refit the engine, check that the clutch friction disc is centralised.

3 Check that the clutch release arm and bearing are correctly fitted, and lightly grease the input shaft splines.

4 Check that the engine adapter plate is correctly positioned on its locating dowels. If necessary, a cable-tie can be used to temporarily secure the adapter plate in position on the cylinder block using one of the engine-to-gearbox bolt holes.

5 If shims were fitted between the sump and the gearbox, refit them in their original locations when mating the engine to the gearbox. If the engine has been overhauled, where applicable fit the relevant shims as calculated during engine reassembly.

6 Reconnect the clutch cable to the release arm, ensuring that it is routed as noted during removal.

7 Ensure that the roadwheels and the steering wheel are in the straight-ahead position before reconnecting the lower steering column to the intermediate shaft, and tighten the clamp bolt to the specified torque.

8 Fill the engine with the correct grade and quantity of oil.

9 Check the throttle cable adjustment.

10 Fill the cooling system.

11 Tighten all fixings to the specified torque, where applicable.

    See also:

    Fuel pump - testing
    1 If the fuel pump is functioning, it should be possible to hear it “buzzing” by listening under the rear of the vehicle when the ignition is switched on. Unless the engine is started, the fuel pu ...

    Timing belt and sprockets - removal and refitting
    Note: The belt tension should be checked using Ford special tool No 21-113 after refitting. A suitable puller may be required to remove the sprockets. If the camshaft sprocket is removed, a new re ...

    Knock sensor - removal and refitting
    Removal 1 The knock sensor is screwed into the cylinder block, near the oil filter (see illustration). 15.1 Knock sensor location - 1.4 CFI engine A Knock sensor B Wiring plug C Securing bolt ...