Engine - Automatic Transaxle

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

All vehicles 

1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts.
   • Tighten to 48 Nm (35 lb-ft).
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.
Fig 1: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
Courtesy of FORD MOTOR CO.
4. Install new torque converter nuts.
   • Tighten to 35 Nm (26 lb-ft).
Fig 2: Locating Torque Converter Nut
Courtesy of FORD MOTOR CO.

All wheel drive (AWD) vehicles 

5. Install the power transfer unit (PTU) and the 3 PTU-to-transaxle bolts.
   • Tighten to 70 Nm (52 lb-ft).
Fig 3: Identifying PTU-To-Transaxle Bolts
Courtesy of FORD MOTOR CO.
6. Install the 1 transaxle-to-PTU bolt.
   • Tighten to 48 Nm (35 lb-ft).
Fig 4: Identifying Transaxle-To-PTU Bolt
Courtesy of FORD MOTOR CO.
7. Attach the PTU vent hose.
Fig 5: Identifying PTU Vent Hose
Courtesy of FORD MOTOR CO.
8. Install the PTU bracket and the 2 bolts.
   • Tighten to 45 Nm (33 lb-ft).
Fig 6: Identifying PTU Bracket And Bolts
Courtesy of FORD MOTOR CO.
9. Install the 3 PTU bracket-to-engine bolts.
   • Tighten to 40 Nm (30 lb-ft).
Fig 7: Identifying Bracket-To-Engine Bolts
Courtesy of FORD MOTOR CO.
10. Install 7 new exhaust manifold studs in the cylinder head.
    • Tighten to 17 Nm (13 lb-ft).
11. Install the new exhaust manifold gasket on the engine.
12. Position the catalytic converter and tighten the 7 new exhaust manifold nuts in the sequence shown in 2 stages:
    • Stage 1: Tighten to 47 Nm (35 lb-ft).
    • Stage 1: Tighten to 47 Nm (35 lb-ft).
Fig 8: Identifying Tightening Sequence Of Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
13. Install the heat shield and the 6 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 9: Locating Heat Shield & Bolts
Courtesy of FORD MOTOR CO.
14. Install the 2 lower catalytic converter bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 10: Locating Lower Catalytic Converter Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

15. Install the starter motor isolator.
Fig 11: Identifying Starter Motor Isolator
Courtesy of FORD MOTOR CO.
16. Install the starter motor.
    • Tighten to 35 Nm (26 lb-ft).
Fig 12: Identifying Starter Motor Bolts
Courtesy of FORD MOTOR CO.
17. 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).
Fig 13: Identifying Battery Cable & Starter Solenoid Terminal Nut
Courtesy of FORD MOTOR CO.
18. Install the wire harness clip retainer and the ground wire and nut to the starter bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 14: Locating Wire Harness Clip Retainer & Starter Bolts
Courtesy of FORD MOTOR CO.
19. Raise the engine and transaxle into the vehicle.
20. Install the bolt in the LH transaxle mount.
    • Tighten to 103 Nm (76 lb-ft).
Fig 15: Locating Transaxle Mount Bolt
Courtesy of FORD MOTOR CO.
21. Install the bolt in the rear transaxle mount.
    • Tighten to 115 Nm (85 lb-ft).
Fig 16: Transaxle Rear Mount Bolt
Courtesy of FORD MOTOR CO.
22. Install the engine mount bracket and nuts.
    • Tighten to 115 Nm (85 lb-ft).
Fig 17: Engine Mount Bracket Nuts
Courtesy of FORD MOTOR CO.
23. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
Fig 18: Engine Mount Bracket Bolt
Courtesy of FORD MOTOR CO.
24. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 19: Locating Engine-To-Bellhousing Bolts
Courtesy of FORD MOTOR CO.
25. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 20: Locating Lower Bellhousing Bolts
Courtesy of FORD MOTOR CO.

Front wheel drive (FWD) vehicles 

26. Install the damper and the 3 bolts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 21: Locating Bolts & Dampener
Courtesy of FORD MOTOR CO.

All vehicles 

27. Install the engine support crossmember and new nut.
    • Tighten to 175 Nm (129 lb-ft).
Fig 22: Identifying Cross Brace And Rear Nut
Courtesy of FORD MOTOR CO.
28. 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).
Fig 23: Identifying Front Roll Restrictor Bolt & Bolts For Engine Support Crossmember
Courtesy of FORD MOTOR CO.
29. Install the A/C compressor and connect the A/C compressor electrical connector.
    • Tighten the bolts to 25 Nm (18 lb-ft).
Fig 24: A/C Compressor Electrical Connector & Bolts
Courtesy of FORD MOTOR CO.
30. Connect the lower radiator hose to the radiator.
Fig 25: Locating Lower Radiator Hose
Courtesy of FORD MOTOR CO.
31. Connect the PCM electrical connectors.
    • Position the harness and install the nut.
      • Tighten to 6 Nm (53 lb-in).
Fig 26: Identifying Connectors And nut
Courtesy of FORD MOTOR CO.
32. Install the ground wire and bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 27: Locating Ground Wire & Bolt
Courtesy of FORD MOTOR CO.
33. Attach the electrical connector retainers.
Fig 28: Electrical Connector Retainers
Courtesy of FORD MOTOR CO.
34. Connect the fuel supply tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
Fig 29: Identifying Fuel Supply Tube
Courtesy of FORD MOTOR CO.
35. Connect the fuel vapor return tube and retainer.
Fig 30: Fuel Vapor Return Tube
Courtesy of FORD MOTOR CO.
36. Connect the vacuum supply tube.
Fig 31: Vacuum Supply Tube
Courtesy of FORD MOTOR CO.
37. Position the accelerator control cable and bracket and install the nut.
    • Tighten to 6 Nm (53 lb-in).
Fig 32: Accelerator Control Cable Bracket & Nut
Courtesy of FORD MOTOR CO.
38. Install the accelerator control cable and bracket and nut.
    • Tighten to 6 Nm (53 lb-in).
Fig 33: Accelerator Control Cable Bracket & Nut
Courtesy of FORD MOTOR CO.
39. 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).
Fig 34: Accelerator Cable, Speed Control Cable & Bracket Bolts
Courtesy of FORD MOTOR CO.
40. Install the accelerator cable snow shield and retainers.
    • Tighten to 4 Nm (35 lb-in).
Fig 35: Accelerator Cable Snow Shield Retainers
Courtesy of FORD MOTOR CO.
41. Connect the heater hoses to the heater core.
Fig 36: Locating Heater Hoses
Courtesy of FORD MOTOR CO.
42. Attach the heater hose support strap to the stud.
Fig 37: Heater Hose Support Strap & Stud
Courtesy of FORD MOTOR CO.
43. Connect the upper radiator hose.
Fig 38: Identifying Upper Radiator Hose
Courtesy of FORD MOTOR CO.
44. If equipped, route the block heater wiring harness and attach all retainers.
    • Connect the block heater electrical connector.
Fig 39: Block Heater Electrical Connector
Courtesy of FORD MOTOR CO.
45. Install the output shaft speed (OSS) sensor and bolt.
    • Tighten to 13 Nm (10 lb-ft).
Fig 40: Locating OSS Sensor Bolt
Courtesy of FORD MOTOR CO.
46. Install the fluid cooler tube.
    1. Connect the OSS sensor.
    2. Connect the turbine shaft speed (TSS) sensor (white connector).
       • Connect the wiring harness retainer to the transaxle case.
    3. Position the bracket and install the bolt.
       • Tighten 13 Nm (10 lb-ft).
    4. Install the fluid cooler tube fitting.
       • Tighten to 23 Nm (17 lb-ft).
Fig 41: Fluid Cooler Tube, Electrical Connectors & Bracket
Courtesy of FORD MOTOR CO.
47. Connect the rear transaxle fluid cooler tube.
    • Tighten to 23 Nm (17 lb-ft).
Fig 42: Rear Cooler Tube At Transaxle Case
Courtesy of FORD MOTOR CO.
48. Connect the front transaxle fluid cooler tube.
    • Tighten to 23 Nm (17 lb-ft).
Fig 43: Locating Transmission Fluid Cooler Tube
Courtesy of FORD MOTOR CO.
49. Connect the transaxle range sensor electrical connector.
Fig 44: Locating Transmission Range (TR) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
50. Install the transaxle control cable, bracket and bolts.
    • Tighten to 19 Nm (14 lb-ft).
    • Attach the wiring harness pin-type retainers.
Fig 45: Transaxle Control Cable & Bracket
Courtesy of FORD MOTOR CO.
51. Connect the shift cable to the transaxle manual lever.
Fig 46: Locating Shift Cable End At Manual Lever
Courtesy of FORD MOTOR CO.
52. Install the transaxle wiring harness bracket and nut and connect the transaxle electrical connector.
    • Tighten to 10 Nm (89 lb-in).
Fig 47: Identifying Bracket And Nut
Courtesy of FORD MOTOR CO.
53. Attach the transaxle vent tube retaining clip to the engine wiring harness.
Fig 48: Identifying Retaining Clip
Courtesy of FORD MOTOR CO.
54. Attach the wiring harness retainers to the battery tray bracket.
Fig 49: Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
55. Connect the 34-pin electrical connector.
Fig 50: Identifying Connector
Courtesy of FORD MOTOR CO.
56. Install the ground strap and bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 51: Identifying Bolt
Courtesy of FORD MOTOR CO.
57. Connect the electrical connector to the power distribution box (PDB).
Fig 52: Power Distribution Box Electrical Connector
Courtesy of FORD MOTOR CO.
58. Connect the cable to the PDB and install the nut.
    • Tighten to 12 Nm (9 lb-ft).
Fig 53: Identifying Nut
Courtesy of FORD MOTOR CO.
59. Install the PDB cover.
Fig 54: Locating Power Distribution Box Cover
Courtesy of FORD MOTOR CO.
60. If equipped, install the ground eyelet and bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 55: Ground Eyelet & Bolt
Courtesy of FORD MOTOR CO.

All wheel drive (AWD) vehicles 

61. Align index mark and position the driveshaft to the PTU and install the 6 bolts.
    • Tighten to 37 Nm (27 lb-ft).
Fig 56: Locating Driveshaft & Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

62. Install the intermediate shaft.
Fig 57: Locating Intermediate Shaft
Courtesy of FORD MOTOR CO.
63. Install the intermediate shaft retaining nuts.
    • Tighten to 27 Nm (20 lb-ft).
Fig 58: Locating Intermediate Shaft Retaining Nuts
Courtesy of FORD MOTOR CO.
64. Install the LH halfshaft in the transaxle and the RH halfshaft to the intermediate shaft.
    • Install the ball joints in the knuckles.
65. 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).
Fig 59: Identifying Lower Ball Joint-To-Knuckle Bolt, Retaining Nut And Stabilizer Bar Link
Courtesy of FORD MOTOR CO.
66. Install the RH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (11 lb-ft).
Fig 60: Identifying Bolt
Courtesy of FORD MOTOR CO.
67. 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).
Fig 61: Identifying Lower Ball Joint-To-Knuckle Bolt, Retaining Nut And Stabilizer Bar Link
Courtesy of FORD MOTOR CO.
68. Install the LH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (11 lb-ft).
Fig 62: Identifying Bolt
Courtesy of FORD MOTOR CO.
69. Install the lateral support crossmember and bolts.
    • Tighten to 115 Nm (85 lb-ft).
Fig 63: Identifying Lateral Support Crossmember And Bolts
Courtesy of FORD MOTOR CO.
70. Install the generator shield, the nut and the pin-type retainer.
    • Tighten to 20 Nm (15 lb-ft).
    • Attach the wire retainers.
Fig 64: Generator Shield
Courtesy of FORD MOTOR CO.
71. Install the lower air duct.
Fig 65: Identifying lower Air Duct
Courtesy of FORD MOTOR CO.
72. Install the accessory drive belt and tensioner. For additional information, refer to ACCESSORY DRIVE - 2.3L article.
73. Connect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
Fig 66: Heated Oxygen Sensor (HO2S) And Catalyst Monitor Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
74. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM article.
75. Install the front wheels and tires. For additional information, refer to WHEELS AND TIRES article.
76. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
77. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L article.
78. Fill the engine with clean engine oil.
79. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING article.