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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 358 (Engine - 2.0L ZETEC) >> Installation >> Engine - Manual Transaxle >> Installation >> All vehicles

All vehicles

WARNING: This page is about a different car, the 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the transaxle on the engine and install the bolts.
    Fig 1: Installing Transaxle On Engine
    G03430589Courtesy of FORD MOTOR CO.
  2. Install the bolts.
    Fig 2: Installing Bolts
    G03430590Courtesy of FORD MOTOR CO.
  3. Install the starter and the bolts.
    Fig 3: Installing Starter & Bolts
    G03430591Courtesy of FORD MOTOR CO.
  4. Install the starter wiring harness.
  5. Install the engine wiring harness.
    1. Attach the wiring harness to the engine/transaxle assembly.
    2. Connect the differential pressure feedback exhaust gas recirculation (EGR) system electrical connector.
    Fig 4: Installing Starter Wiring Harness
    G03430592Courtesy of FORD MOTOR CO.
  6. Connect the ignition coil electrical connector.
  7. Connect the reversing lamp switch electrical connector.
    Fig 5: Connecting Reversing Lamp Switch Electrical Connector
    G03430593Courtesy of FORD MOTOR CO.
  8. Connect the ground wire.
    Fig 6: Connecting Ground Wire
    G03430594Courtesy of FORD MOTOR CO.
  9. Connect the powertrain control module (PCM) wiring harness to the bracket.
    Fig 7: Connecting Powertrain Control Module (PCM) Wiring Harness To Bracket
    G03430595Courtesy of FORD MOTOR CO.
  10. Connect the fuel charging wiring harness electrical connector.
    Fig 8: Connecting Fuel Charging Wiring Harness Electrical Connector
    G03430596Courtesy of FORD MOTOR CO.
  11. Install the ground wire and the bolt on the bell housing.
  12. Connect the crankshaft position (CKP) sensor electrical connector.
  13. Connect the vehicle speed sensor electrical connector.
    Fig 9: Connecting Vehicle Speed Sensor Electrical Connector
    G03430597Courtesy of FORD MOTOR CO.
  14. Connect the electrical connectors.
    • Connect the knock sensor electrical connector.
    • Connect the oil pressure sender electrical connector.
    • Connect the starter electrical connector.
    Fig 10: Connecting Electrical Connectors
    G03430598Courtesy of FORD MOTOR CO.
  15. Connect the generator electrical connectors.
    Fig 11: Connecting Generator Electrical Connectors
    G03430599Courtesy of FORD MOTOR CO.
  16. Position the engine/transaxle assembly into the vehicle.
  17. Install the LH transaxle mount.
    Fig 12: Installing LH Transaxle Mount
    G03430600Courtesy of FORD MOTOR CO.
  18. Install the engine mount upper bracket.
    Fig 13: Installing Engine Mount Upper Bracket
    G03430601Courtesy of FORD MOTOR CO.
  19. Connect the ground wire.
    Fig 14: Connecting Ground Wire
    G03430602Courtesy of FORD MOTOR CO.
  20. Install the front transaxle support insulator and bracket.
    1. Position the front transaxle support insulator.
    2. Install the four transaxle support insulator bracket bolts.
    3. Loosely install the front transaxle support insulator bolt.
    Fig 15: Installing Front Transaxle Support Insulator & Bracket
    G03430603Courtesy of FORD MOTOR CO.
  21. Install the rear transaxle mount.
    Fig 16: Installing Rear Transaxle Mount
    G03430604Courtesy of FORD MOTOR CO.
  22. Remove the lifting device.
  23. Install the speed control unit (if equipped).
    Fig 17: Removing Lifting Device
    G03430605Courtesy of FORD MOTOR CO.
  24. Position the power steering pump and loosely install the upper bolts.
    Fig 18: Installing Upper Bolts
    G03430606Courtesy of FORD MOTOR CO.
  25. Install the power steering hose bracket bolt.
    Fig 19: Installing Power Steering Hose Bracket Bolt
    G03430607Courtesy of FORD MOTOR CO.
  26. Install the power steering hose bracket bolt.
    Fig 20: Installing Power Steering Hose Bracket Bolt
    G03430608Courtesy of FORD MOTOR CO.
  27. Position the slave cylinder line and install the clip.
    Fig 21: Installing Clip
    G03430609Courtesy of FORD MOTOR CO.
  28. Install the clutch slave cylinder bolts.
    Fig 22: Installing Clutch Slave Cylinder Bolts
    G03430610Courtesy of FORD MOTOR CO.
  29. Position the power steering hoses and install the bolts.
    Fig 23: Installing Bolts
    G03430611Courtesy of FORD MOTOR CO.
  30. Raise and support the vehicle. .
  31. Install the lower power steering bolts.
    Fig 24: Installing Lower Power Steering Bolts
    G03430612Courtesy of FORD MOTOR CO.
  32. Connect the power steering pressure sensor electrical connector.
    Fig 25: Connecting Power Steering Pressure Sensor Electrical Connector
    G03430613Courtesy of FORD MOTOR CO.
  33. Connect the lower radiator hose.
    Fig 26: Connecting Lower Radiator Hose
    G03430614Courtesy of FORD MOTOR CO.
  34. Install the engine to transaxle bolts.
    Fig 27: Installing Engine To Transaxle Bolts
    G03430615Courtesy of FORD MOTOR CO.
  35. Install the intermediate shaft and the bracket as an assembly.
    Fig 28: Installing Intermediate Shaft
    G03430616Courtesy of FORD MOTOR CO.

    4x4 vehicles 

  36. Install the transfer case. For additional information, refer to TRANSFER CASE .
    Fig 29: Installing Transfer Case
    G03430617Courtesy of FORD MOTOR CO.

    All vehicles 

  37. Install a new oil filter.
  38. Install the front transaxle mount through bolt.
    Fig 30: Installing Oil Filter
    G03430618Courtesy of FORD MOTOR CO.
  39. Connect the block heater electrical connector.
    Fig 31: Connecting Block Heater Electrical Connector
    G03430619Courtesy of FORD MOTOR CO.

    4x2 vehicles 

  40. Connect the shifter linkages.
    Fig 32: Connecting Shifter Linkages
    G03430620Courtesy of FORD MOTOR CO.

    All vehicles 

    41. NOTE: When seated correctly, the driveshaft bearing retainer circlip can be felt as it snaps into the differential side gear groove.
    Fig 33: Installing Driveshafts
    G03430621Courtesy of FORD MOTOR CO.
  41. Install the driveshafts.
  42. Using the special tool, position the halfshaft into the front wheel knuckle.
    Fig 34: Positioning Halfshaft Into Front Wheel Knuckle
    G03430622Courtesy of FORD MOTOR CO.
  43. Install the lower control arm and the ball joint pinch bolt and nut.
    Fig 35: Installing Lower Control Arm & Ball Joint
    G03430623Courtesy of FORD MOTOR CO.
  44. Loosely install new front axle wheel hub nuts.
    Fig 36: Installing Front Axle Wheel Hub Nuts
    G03430624Courtesy of FORD MOTOR CO.
  45. Install the A/C compressor.
    Fig 37: Installing A/C Compressor
    G03430625Courtesy of FORD MOTOR CO.
  46. Install the A/C manifold and tube assembly bolt.
    Fig 38: Installing A/C Manifold & Tube Assembly
    G03430626Courtesy of FORD MOTOR CO.
  47. Connect the A/C clutch field coil electrical connector.
    48. Fig 39: Connecting A/C Clutch Field Coil Electrical Connector
    G03430627Courtesy of FORD MOTOR CO.
  48. Rotate the accessory drive belt tensioner clockwise and install the belt.
    Fig 40: Rotating Accessory Drive Belt Tensioner Clockwise
    G03430628Courtesy of FORD MOTOR CO.
  49. Connect the coolant hose.
    Fig 41: Connecting Coolant Hose
    G03430629Courtesy of FORD MOTOR CO.
  50. Install the engine/convertor bracket.
    Fig 42: Installing Engine/Convertor Bracket
    G03430630Courtesy of FORD MOTOR CO.
  51. Install the catalytic convertor. .
  52. Connect the coolant hose.
    Fig 43: Connecting Coolant Hose
    G03430631Courtesy of FORD MOTOR CO.
  53. Install the splash shield and bolts.
    Fig 44: Installing Splash Shield & Bolts
    G03430632Courtesy of FORD MOTOR CO.
    54. WARNING: Whenever a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surfaces of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheel without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Failure to follow these instructions may result in personal injury.
  54. Clean the wheel hub mounting surface and wheel pilot.
  55. Install the tire and wheel assembly.
    1. Position the tire and wheel assembly.
      • Install the wheel nuts hand-tight, then lower the vehicle.
    56. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration.
    Fig 45: Tightening Wheel Nuts In Sequence
    G03430633Courtesy of FORD MOTOR CO.
  56. Tighten the wheel nuts in the sequence shown.
  57. Tighten the LH and RH axle hub nuts.
    Fig 46: Tightening LH & RH Axle Hub Nuts
    G03430634Courtesy of FORD MOTOR CO.
  58. Install the center cap.
  59. Connect the heater hoses.
    Fig 47: Installing Center Cap
    G03430635Courtesy of FORD MOTOR CO.
  60. Tighten the upper power steering pump bolts to specification.
    Fig 48: Tightening Upper Power Steering Pump Bolts
    G03430636Courtesy of FORD MOTOR CO.
  61. Connect the upper radiator hose.
    Fig 49: Connecting Upper Radiator Hose
    G03430637Courtesy of FORD MOTOR CO.
  62. Connect the evaporative emission (EVAP) canister vacuum lines.
    Fig 50: Connecting Evaporative Emission (EVAP) Canister Vacuum Lines
    G03430638Courtesy of FORD MOTOR CO.
  63. Connect the power distribution box electrical connections.
    Fig 51: Connecting Power Distribution Box Electrical Connections
    G03430639Courtesy of FORD MOTOR CO.
  64. Connect the wire harness electrical connector.
    Fig 52: Connecting Wire Harness Electrical Connector
    G03430640Courtesy of FORD MOTOR CO.
  65. Connect the ground wire.
    Fig 53: Connecting Ground Wire
    G03430641Courtesy of FORD MOTOR CO.
  66. Connect the powertrain control module (PCM) wire harness and ground.
    Fig 54: Connecting Powertrain Control Module (PCM) Wire Harness & Ground
    G03430642Courtesy of FORD MOTOR CO.
  67. Connect the brake booster vacuum supply hose to the intake manifold.
    Fig 55: Connecting Brake Booster Vacuum Supply Hose To Intake Manifold
    G03430643Courtesy of FORD MOTOR CO.
  68. Connect the EGR vacuum regulator valve.
    • Connect the electrical connector.
    • Connect the vacuum hoses.
    Fig 56: Connecting EGR Vacuum Regulator Valve
    G03430644Courtesy of FORD MOTOR CO.
  69. Connect the throttle cables and, if equipped, speed control cable.
    Fig 57: Connecting Throttle Cables
    G03430645Courtesy of FORD MOTOR CO.
  70. Connect the fuel hose.
    Fig 58: Connecting Fuel Hose
    G03430646Courtesy of FORD MOTOR CO.

    4x4 vehicles 

  71. Install the shifter cables.
    1. Install the cables into the brackets.
    2. Position the shifter cables onto the shifter levers and install the clips.
    Fig 59: Installing Shifter Cables
    G03430647Courtesy of FORD MOTOR CO.

    All vehicles 

  72. Install the air cleaner (ACL) and outlet pipe.
    1. Position the ACL and outlet pipe as an assembly in the vehicle.
    2. Install the bolt.
    3. Connect the mass air flow sensor electrical connector.
    Fig 60: Connecting Mass Air Flow Sensor Electrical Connector
    G03430648Courtesy of FORD MOTOR CO.
  73. Connect the air cleaner outlet tube.
    1. Connect the outlet tube to the throttle body.
    2. Tighten the clamp.
    3. Connect the crankcase ventilation hose.
    4. Attach the emission tube and hose.
    5. Attach the accelerator cable.
    Fig 61: Attaching Accelerator Cable
    G03430649Courtesy of FORD MOTOR CO.
  74. Install the accelerator control cable support bracket bolt.
    Fig 62: Installing Accelerator Control Cable Support Bracket Bolt
    G03430650Courtesy of FORD MOTOR CO.
  75. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  76. Fill the engine with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2CH153-H.
  77. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  78. Charge the A/C system. For additional information, refer to MANUAL A/C-HEATER SYSTEMS .
  79. Fill the transaxle fluid. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .

    4x4 vehicles 

  80. Adjust the gear shift cables. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .

    All vehicles 

    81. NOTE: RH side shown, LH side similar.
    Fig 63: Connecting Washer Hose
    G03430651Courtesy of FORD MOTOR CO.
  81. Install the hood.
    1. Connect the washer hose.
    2. Install the bolts.
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