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Engine - Manual Transaxle

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000536Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0017081Courtesy of FORD MOTOR CO.
 Powertrain Lift 014-00765
GF0000267Courtesy of FORD MOTOR CO.
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0024108Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets 014-0001
Material

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent		 WSS-M2C930-A
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
  1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 5 transaxle-to-engine bolts.
  2. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
  3. Using the special tools, secure the engine to the lift table.
    4. Fig 1: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
    G03897890Courtesy of FORD MOTOR CO.
  4. Install the starter motor.
    • Tighten to 35 Nm (26 lb-ft).
    5. Fig 2: Identifying Starter Motor Bolts
    GF0042049Courtesy of FORD MOTOR CO.
  5. Install the starter motor harness connector.
    1. Install the starter motor solenoid battery nut.
      • Tighten to 12 Nm (9 lb-ft).
    2. Install the starter motor solenoid nut.
      • Tighten to 5 Nm (44 lb-in).
    6. Fig 3: Identifying Battery Cable & Starter Solenoid Terminal Nut
    GF0024836Courtesy of FORD MOTOR CO.
  6. Install the wire harness clip retainer and the ground wire and nut to the starter bolts.
    • Tighten to 25 Nm (18 lb-ft).
    7. Fig 4: Locating Wire Harness Clip Retainer & Starter Bolts
    GF0024837Courtesy of FORD MOTOR CO.
  7. Raise the engine and transaxle into the vehicle.
  8. Install the bolt in the LH transaxle mount.
    • Tighten to 103 Nm (76 lb-ft).
    9. Fig 5: Locating Transaxle Mount Bolt
    G03897894Courtesy of FORD MOTOR CO.
  9. Install the bolt in the rear transaxle mount.
    • Tighten 115 Nm (85 lb-ft).
    10. Fig 6: Transaxle Rear Mount Bolt
    GF0024141Courtesy of FORD MOTOR CO.
  10. Install the engine mount bracket and nuts.
    • Tighten 115 Nm (85 lb-ft).
    11. Fig 7: Engine Mount Bracket Nuts
    GF0024402Courtesy of FORD MOTOR CO.
  11. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
    12. Fig 8: Engine Mount Bracket Bolt
    GF0024401Courtesy of FORD MOTOR CO.
  12. Install the 2 engine-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
    13. Fig 9: Locating Engine-To-Bellhousing Bolts
    GF0024138Courtesy of FORD MOTOR CO.
  13. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    14. Fig 10: Locating Lower Bellhousing Bolts
    GF0024137Courtesy of FORD MOTOR CO.
  14. Install the engine support crossmember and new nut.
    • Tighten to 175 Nm (129 lb-ft).
    15. Fig 11: Identifying Cross Brace And Rear Nut
    G03897887Courtesy of FORD MOTOR CO.
  15. Install the 2 bolts for the engine support crossmember and the front roll restrictor bolt.
    • Tighten the engine support crossmember bolts to 90 Nm (66 lb-ft).
    • Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
    16. Fig 12: Identifying Front Roll Restrictor Bolt & Bolts For Engine Support Crossmember
    G04619986Courtesy of FORD MOTOR CO.
  16. Position the A/C compressor and install the bolts.
    • Tighten the bolts to 25 Nm (18 lb-ft).
    • Connect the A/C compressor electrical connector.
    17. Fig 13: A/C Compressor Electrical Connector & Bolts
    GF0024135Courtesy of FORD MOTOR CO.
  17. Connect the lower radiator hose to the radiator.
    18. Fig 14: Locating Lower Radiator Hose
    G03897882Courtesy of FORD MOTOR CO.
  18. Connect the PCM electrical connectors.
    • Position the harness and install the nut.
      • Tighten to 6 Nm (53 lb-in).
    19. Fig 15: Identifying Connectors And Nut
    GF0042048Courtesy of FORD MOTOR CO.
  19. Install the ground wire and bolt.
    • Tighten to 10 Nm (89 lb-in).
    20. Fig 16: Locating Ground Wire & Bolt
    G03897880Courtesy of FORD MOTOR CO.
  20. Attach the electrical connector retainers.
    21. Fig 17: Electrical Connector Retainers
    GF0024134Courtesy of FORD MOTOR CO.
  21. Connect the fuel supply tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
    22. Fig 18: Identifying Fuel Supply Tube
    GF0042047Courtesy of FORD MOTOR CO.
  22. Connect the fuel vapor return tube and retainer.
    23. Fig 19: Fuel Vapor Return Tube
    GF0024131Courtesy of FORD MOTOR CO.
  23. Connect the vacuum supply tube.
    24. Fig 20: Vacuum Supply Tube
    GF0024130Courtesy of FORD MOTOR CO.
  24. Position the accelerator control cable and bracket and install the nut.
    • Tighten to 6 Nm (53 lb-in).
    25. Fig 21: Accelerator Control Cable Bracket & Nut
    GF0024127Courtesy of FORD MOTOR CO.
  25. Install the accelerator control cable and bracket and nut.
    • Tighten to 6 Nm (53 lb-in).
    26. Fig 22: Accelerator Control Cable Bracket & Nut
    GF0024128Courtesy of FORD MOTOR CO.
  26. Install the accelerator cable and speed control cable (if equipped).
    1. Connect the accelerator and speed control cable (if equipped) to the throttle body.
    2. Install the accelerator cable bracket and bolts.
      • Tighten to 10 Nm (89 lb-in).
    27. Fig 23: Accelerator Cable, Speed Control Cable & Bracket Bolts
    GF0024126Courtesy of FORD MOTOR CO.
  27. Install the accelerator cable snow shield and retainers.
    • Tighten to 4 Nm (35 lb-in).
    28. Fig 24: Accelerator Cable Snow Shield Retainers
    GF0024125Courtesy of FORD MOTOR CO.
  28. Connect the heater hoses to the heater core.
    29. Fig 25: Locating Heater Hoses
    G03897868Courtesy of FORD MOTOR CO.
  29. Attach the heater hose support strap to the stud.
    30. Fig 26: Heater Hose Support Strap & Stud
    GF0024124Courtesy of FORD MOTOR CO.
  30. Connect the upper radiator hose.
    31. Fig 27: Identifying Upper Radiator Hose
    GF0042046Courtesy of FORD MOTOR CO.
  31. If equipped, route the block heater wiring harness and attach all retainers.
    • Connect the block heater electrical connector.
    32. Fig 28: Block Heater Electrical Connector
    GF0024121Courtesy of FORD MOTOR CO.
  32. Install the shift cable bracket.
    1. Position the shift cable bracket.
    2. Install the 3 bolts.
      • Tighten to 22 Nm (16 lb-ft).
    33. Fig 29: Shift Cable Bracket & Bolts
    GF0025429Courtesy of FORD MOTOR CO.
  33. Connect the shift cables.
    34. Fig 30: Shift Cables
    GF0025334Courtesy of FORD MOTOR CO.
  34. Connect the reversing lamp indicator switch.
    35. Fig 31: Identifying Reversing Lamp Indicator Switch
    GF0042056Courtesy of FORD MOTOR CO.
  35. Connect the vehicle speed sensor (VSS) electrical connector and pin-type retainer.
    36. Fig 32: Locating Vehicle Speed Sensor (VSS) Electrical Connector
    GF0024147Courtesy of FORD MOTOR CO.
  36. Install the wiring harness bracket nut.
    • Tighten to 12 Nm (9 lb-ft).
    37. Fig 33: Identifying Bracket And Nut
    GF0042055Courtesy of FORD MOTOR CO.
  37. Connect the clutch hydraulic line.
    1. Position the clutch hydraulic line.
    2. Connect the clutch hydraulic line to the clutch slave cylinder.
      • Tighten to 25 Nm (18 lb-ft).
    3. Install the clutch hydraulic line bracket-to-transaxle bolt.
      • Tighten to 3 Nm (27 lb-in).
    38. Fig 34: Clutch Hydraulic Line & Components
    GF0025430Courtesy of FORD MOTOR CO.
  38. Attach the wiring harness retainers to the battery tray bracket.
    39. Fig 35: Wiring Harness Retainers
    GF0024114Courtesy of FORD MOTOR CO.
  39. Connect the 34-pin electrical connector.
    40. Fig 36: Identifying Connector
    GF0042043Courtesy of FORD MOTOR CO.
  40. Install the ground strap and bolt.
    • Tighten to 10 Nm (89 lb-in).
    41. Fig 37: Identifying Bolt
    GF0042042Courtesy of FORD MOTOR CO.
  41. Connect the electrical connector to the power distribution box (PDB).
    42. Fig 38: Power Distribution Box Electrical Connector
    GF0024113Courtesy of FORD MOTOR CO.
  42. Connect the cable to the PDB and install the nut.
    • Tighten to 12 Nm (9 lb-ft).
    43. Fig 39: Identifying Nut
    GF0042041Courtesy of FORD MOTOR CO.
  43. Install the PDB cover.
    44. Fig 40: Locating Power Distribution Box Cover
    G03897849Courtesy of FORD MOTOR CO.
  44. Install the intermediate shaft.
    45. Fig 41: Locating Intermediate Shaft
    GF0024827Courtesy of FORD MOTOR CO.
  45. Install the intermediate shaft retaining nuts.
    • Tighten to 27 Nm (20 lb-ft).
    46. Fig 42: Locating Intermediate Shaft Retaining Nuts
    GF0024826Courtesy of FORD MOTOR CO.
  46. Install the LH halfshaft in the transaxle and the RH halfshaft to the intermediate shaft.
    • Install the ball joints in the knuckles.
  47. Connect the RH suspension.
    1. Install the lower ball joint-to-knuckle bolt.
      • Tighten to 63 Nm (46 lb-ft).
    2. Position the tie-rod end and install the retaining nut.
      • Tighten to 55 Nm (41 lb-ft).
    3. Connect the stabilizer bar link.
      • Tighten to 63 Nm (46 lb-ft).
    48. Fig 43: Identifying Lower Ball Joint-To-Knuckle Bolt, Retaining Nut And Stabilizer Bar Link
    GF0042067Courtesy of FORD MOTOR CO.
  48. Install the RH brake hose retainer and the anti-lock brake system (ABS) sensor bolt.
    • Tighten to 15 Nm (11 lb-ft).
    49. Fig 44: Identifying Bolt
    GF0042039Courtesy of FORD MOTOR CO.
  49. Connect the LH suspension.
    1. Install the lower ball joint-to-knuckle bolt.
      • Tighten to 63 Nm (46 lb-ft).
    2. Position the tie-rod end and install the retaining nut.
      • Tighten to 55 Nm (41 lb-ft).
    3. Connect the stabilizer bar link.
      • Tighten to 63 Nm (46 lb-ft).
    50. Fig 45: Identifying Lower Ball Joint-To-Knuckle Bolt, Retaining Nut And Stabilizer Bar Link
    GF0042068Courtesy of FORD MOTOR CO.
  50. Install the LH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (11 lb-ft).
    51. Fig 46: Identifying Bolt
    GF0042037Courtesy of FORD MOTOR CO.
  51. Install the lateral support crossmember and bolts.
    • Tighten to 115 Nm (85 lb-ft).
    52. Fig 47: Identifying Lateral Support Crossmember And Bolts
    G03897847Courtesy of FORD MOTOR CO.
  52. Install the generator shield, the nut and the pin-type retainer.
    • Tighten to 20 Nm (15 lb-ft).
    • Attach the wire retainers.
    53. Fig 48: Generator Shield
    GF0024111Courtesy of FORD MOTOR CO.
  53. Install the lower air duct.
    54. Fig 49: Identifying Lower Air Duct
    GF0042036Courtesy of FORD MOTOR CO.
  54. Install the accessory drive belt tensioner. For additional information, refer to ACCESSORY DRIVE - 2.3L article.
  55. Connect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
    56. Fig 50: Heated Oxygen Sensor (HO2S) And Catalyst Monitor Sensor Electrical Connectors
    GF0024109Courtesy of FORD MOTOR CO.
  56. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM article.
  57. Install the front wheels and tires. For additional information, refer to WHEELS AND TIRES article.
  58. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  59. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L article.
  60. Fill the engine with clean engine oil.
  61. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING article.
  62. Bleed the clutch system. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION article.
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