Installing the Engine

This evening the Zetec engine was installed in the chassis. In preparation, the car was placed on jack stands to allow rotation of the prop shaft. Some cardboard was taped at various spots around the engine bay, and the steering column removed. The engine mounts were also removed. A leveler was not used, but the engine was hung from the hoist at an approximate 30 degree angle. This worked well.

The engine was raised so the oil pan cleared the chassis. Since the engine was at an angle, the gearbox had to be lifted by hand to clear the front of the car as the hoist rolled. At first, the boom of the hoist was not extended at all resulting in a failed first attempt when the hoist touched the chassis prematurely. The engine had to be removed, set on the ground, and the hoist adjusted.

Once inside the engine bay, the process was: lower a couple inches, then roll a few, and repeat. When the gearbox output shaft touched the propshaft, some finessing was required, but surprisingly they coupled without incident. After the engine had cleared the sides, the engine mounts were installed again. Two bolts hold the engine at the mounts, and two at the gearbox. The entire process took only a couple hours for two guys with no prior experience.