If your engine is fitted with either a power steering or air con. pump, they will need to be removed. A 1250 Mk4 Fiesta belt and tensioner will need to be fitted. Please note, if you sourced your engine from a Focus, a 1250 Fiesta belt (1181 long) will not fit. Try a slightly longer 1195 belt as fitted to a BMW 750i or Fiat Punto 1.9D. Prior to dangling the engine into the engine bay it is important to offer up the engine bearers to the fixing positions both on the engine and chassis, it being much easier to rectify an slight hole position discrepancies with the engine out of the car. The long bearer should mount first on the three bolt extrusion on the upper gearbox casing; the secondary fixing to the rear of the box will almost certainly need prizing around a little. The shorter bearer mounts to the three bolt protrusion on the front of the cylinder head; this will need a little filing to give a radius on its outer edge to match the bearer.

Protect the roll bar and other vulnerable parts prior to the installation and try to have someone on hand to assist. The most difficult part of this operation is trying to find room under the chassis for the legs of an engine hoist, on its wheels it is too low and on trestles you have to move the rearmost forward to get it in and when the engine is in place the whole lot tries to overbalance!.

Get the engine roughly in place and fit the long bearer to the three bolts mentioned earlier then pull the assembly up to the lugs on the chassis. When in place the other bearer should be easy to fit. The uppermost chassis fixing position will need M12x60 bolts, anything longer and the end of the bolt will engage with inside face of the alloy side panel and distort it. The lower end of the long bearer is fitted using an M12x70 bolt and the short bearer will need an M12x100 bolt.

The Zetec SE engine gearbox assembly comes with a centre drive shaft and bearing bolted to the block, this has a “tripod” type CV joint as does the gearbox side and with the rubber gaiter removed the drive shafts will pull easily out. These need to be shortened by cutting and welding. The outer CV needs to be the Fiesta Mk.2 XR2 which has a matching spline.