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Engine - Manual Transaxle: Material

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL SPECIFICATIONS TABLE

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 WSSM2C930-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 Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the bellhousing-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
  2. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift table.
    NOTE: Position a suitable block of wood under the transaxle.
  3. Install the Powertrain Lift and Universal Adapter Brackets onto the engine.
    Fig 1: Positioning Suitable Block Of Wood Under Transaxle
    G06262021Courtesy of FORD MOTOR CO.
  4. Position the generator wiring harness and attach the 4 wiring harness retainers (3 shown) to the valve cover stud bolts.
    Fig 2: Locating Generator Wiring Harness & Retainers
    G06262033Courtesy of FORD MOTOR CO.
  5. Connect the generator B+ wiring harness and install the nut.
    • Tighten to 12 Nm (106 lb-in).
    Fig 3: Locating Generator B+ Wiring Harness & Nut
    G06262032Courtesy of FORD MOTOR CO.
  6. Connect the generator electrical connection.
    Fig 4: Locating Generator Electrical Connection
    G06262425Courtesy of FORD MOTOR CO.
  7. Install the generator air duct.
    Fig 5: Locating Locking Tab & Generator Air Duct
    G06095034Courtesy of FORD MOTOR CO.
  8. Install the starter motor isolator.
    Fig 6: Locating Starter Motor Isolator
    G06262029Courtesy of FORD MOTOR CO.
  9. Install the starter, bolt and stud bolt.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 7: Locating Bolt, Stud Bolt & Starter
    G06262028Courtesy of FORD MOTOR CO.
  10. Position the wiring harness and install the ground wire to the starter motor stud bolt and install the nut.
    • Tighten to 18 Nm (159 lb-in).
    Fig 8: Locating Ground Wire & Starter Motor Stud Nut
    G06262027Courtesy of FORD MOTOR CO.
  11. Connect the starter wires and install the 2 nuts.
    • Tighten the large starter motor B+ wire nut to 12 Nm (106 lb-in).
    • Tighten the small starter motor solenoid wire nut to 5 Nm (44 lb-in).
    Fig 9: Locating Starter Wires & Nuts
    G06262093Courtesy of FORD MOTOR CO.
  12. Attach the A/C compressor wiring harness pin-type retainer to the intake manifold.
    Fig 10: Locating A/C Compressor Wiring Harness Pin-Type Retainer
    G06262368Courtesy of FORD MOTOR CO.
  13. Connect the A/C compressor electrical connector.
    Fig 11: Locating A/C Compressor Electrical Connector
    G06262024Courtesy of FORD MOTOR CO.
  14. Raise the engine and transaxle into the vehicle.
  15. Raise the engine and transaxle into the vehicle.
  16. Install the 2 transaxle mount bolts.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 12: Locating Transaxle Mount Bolts
    G06262089Courtesy of FORD MOTOR CO.
  17. Install the engine mount bracket, 2 nuts and the bolt.
    • Tighten the nuts to 103 Nm (76 lb-ft).
    • Tighten the bolt to 115 Nm (85 lb-ft).
    Fig 13: Locating Bolt, Nuts & Motor Mount Bracket
    G06262023Courtesy of FORD MOTOR CO.
  18. Install the 2 oil pan-to-bellhousing bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 14: Locating Oil Pan-To-Bellhousing Bolts
    G06262020Courtesy of FORD MOTOR CO.
  19. Install the bellhousing-to-oil pan bolt.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 15: Locating Bellhousing-To-Oil Pan Bolt
    G06262436Courtesy of FORD MOTOR CO.
  20. Attach the lower radiator hose pin-type retainer to the cooling fan shroud.
    Fig 16: Locating Lower Radiator Hose Pin-Type Retainer
    G06262018Courtesy of FORD MOTOR CO.
  21. If equipped, connect the block heater electrical connector and position back the block heater shield.
    • Attach the 8 block heater wiring harness retainers (1 shown).
    Fig 17: Locating Block Heater Wiring Harness & Retainers
    G06262084Courtesy of FORD MOTOR CO.
  22. Install the lower radiator hose to the thermostat housing.
    Fig 18: Locating Lower Radiator Hose
    G06262016Courtesy of FORD MOTOR CO.
  23. Attach the Knock Sensor (KS) electrical connector to the intake manifold.
    Fig 19: Locating Knock Sensor Electrical Connector
    G06262015Courtesy of FORD MOTOR CO.
  24. Install a new O-ring seal and connect the upper A/C tube to the condenser and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    Fig 20: Locating Upper A/C Tube Nut
    G06262014Courtesy of FORD MOTOR CO.
  25. Attach the coolant vent hose retaining clip to the A/C tube.
    Fig 21: Locating Coolant Vent Hose Retaining Clip
    G06262013Courtesy of FORD MOTOR CO.
  26. Install a new O-ring seal and connect the upper A/C tube and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    Fig 22: Locating Nut & A/C Tube
    G06262079Courtesy of FORD MOTOR CO.
  27. Install the A/C tube/windshield washer reservoir bracket bolt.
    • Tighten to 7 Nm (62 lb-in).
    Fig 23: Locating A/C Tube/Windshield Washer Reservoir Bracket Bolt
    G06262444Courtesy of FORD MOTOR CO.
  28. Install the ground wire on the engine mount and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 24: Locating Ground Wire & Bolt
    G06262010Courtesy of FORD MOTOR CO.
  29. Attach the transaxle control cables to the bracket.
    • Connect the control cables to the control levers.
    Fig 25: Locating Transaxle Control Cables
    G06262074Courtesy of FORD MOTOR CO.
  30. Install the clutch slave cylinder and the 2 bolts.
    • Tighten to 22 Nm (16 lb-ft).
    Fig 26: Locating Clutch Slave Cylinder Bolts
    G06262076Courtesy of FORD MOTOR CO.
  31. Install the 2 clutch tube bracket bolts.
    • Tighten to 22 Nm (16 lb-ft).
    Fig 27: Locating Clutch Tube Bracket Bolts
    G06262075Courtesy of FORD MOTOR CO.
  32. Connect the heater hose in-line connector and connect the upper radiator and heater hoses to the coolant outlet.
    Fig 28: Locating Heater Hoses & Heater Hose In-Line Connector
    G06262006Courtesy of FORD MOTOR CO.
  33. Attach the coolant hoses retainer.
    Fig 29: Locating Coolant Hoses Retainer
    G06262005Courtesy of FORD MOTOR CO.
  34. Connect the fuel supply tube quick connect coupling. For additional information, refer to QUICK CONNECT COUPLING .
    Fig 30: Locating Fuel Supply Tube Quick Connect Coupling
    G06095056Courtesy of FORD MOTOR CO.
  35. Connect the fuel vapor return tube.
    Fig 31: Locating Fuel Vapor Return Tube
    G06095055Courtesy of FORD MOTOR CO.
  36. Insert the brake booster vacuum supply tube into the locking ring on the intake manifold.
    Fig 32: Locating Brake Booster Vacuum Supply Tube & Locking Ring
    G06262002Courtesy of FORD MOTOR CO.
  37. Connect the crankcase vent tube to the valve cover.
    Fig 33: Connecting Crankcase Vent Tube To Valve Cover
    G06262001Courtesy of FORD MOTOR CO.
  38. Install the exhaust flexible pipe. For additional information, refer to INSTALLATION .
  39. Install the engine oil filter.
    • Lubricate the engine oil filter gasket with clean engine oil and tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
  40. Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position.
    Fig 34: Positioning Powertrain Lift Under Subframe Assembly
    G06062149Courtesy of FORD MOTOR CO.
  41. Install the front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    NOTE: LH shown, RH similar.
    Fig 35: Locating Front Subframe Nuts
    G06261999Courtesy of FORD MOTOR CO.
  42. Position the subframe brackets and install the bolts finger-tight.
    NOTE: LH shown, RH similar.
    Fig 36: Locating Subframe Brackets & Bolts
    G06262394Courtesy of FORD MOTOR CO.
  43. Install the subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    NOTE: LH shown, RH similar.
    Fig 37: Locating Subframe Nuts
    G06262395Courtesy of FORD MOTOR CO.
  44. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
    NOTE: LH shown, RH similar.
    Fig 38: Locating Subframe Bracket-To-Body Bolts
    G06262396Courtesy of FORD MOTOR CO.
  45. Install the sway bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
    NOTE: LH shown, RH similar.
    Fig 39: Locating Sway Bar Links & Nuts
    G06261995Courtesy of FORD MOTOR CO.
  46. Install tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install the cotter pin.
    NOTE: LH shown, RH similar.
    Fig 40: Locating Tie-Rod Ends & Nuts
    G06261993Courtesy of FORD MOTOR CO.
  47. Install the Electronic Power Assist Steering (EPAS) system wiring harness ground and the bolt.
    • Tighten to 12 Nm (106 lb-in).
    Fig 41: Locating Electronic Power Assist Steering System Wiring Harness Ground & Bolt
    G06261992Courtesy of FORD MOTOR CO.
  48. Attach the EPAS  system wiring harness pin-type retainer to the subframe under the LH fender splash shield.
    Fig 42: Locating EPAS System Wiring Harness Pin-Type Retainer
    G06261991Courtesy of FORD MOTOR CO.
  49. Attach the 2 EPAS  system wiring harness pin-type retainers to the subframe.
    Fig 43: Locating EPAS System Wiring Harness Pin-Type Retainers
    G06261990Courtesy of FORD MOTOR CO.
  50. Connect the 2 EPAS  system electrical connectors.
    Fig 44: Locating EPAS System Electrical Connectors
    G06262402Courtesy of FORD MOTOR CO.
  51. Install the LH halfshaft and the intermediate shaft. For additional information, refer to INSTALLATION .
  52. Install the LH splash shield and the 6 pin-type retainers (4 shown).
    Fig 45: Locating LH Splash Shield & Pin-Type Retainers
    G06261988Courtesy of FORD MOTOR CO.
  53. Position the LH fender splash shield and install the 4 screws.
    Fig 46: Locating LH Fender Splash Shield Screws
    G06261987Courtesy of FORD MOTOR CO.
  54. Install the RH splash shield and the 6 pin-type retainers (4 shown).
    Fig 47: Locating RH Splash Shield & Pin-Type Retainers
    G06269420Courtesy of FORD MOTOR CO.
  55. Position the RH fender splash shield and install the 4 screws.
    Fig 48: Locating RH Fender Splash Shield & Screws
    G06257214Courtesy of FORD MOTOR CO.
  56. Install the engine roll restrictor bolt.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 49: Locating Engine Roll Restrictor Bolt
    G06261984Courtesy of FORD MOTOR CO.
  57. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips (2 shown) into the body.
    • From under the vehicle, verify that the seal is correctly installed on the steering gear and the retaining clips are fully engaged into the dash.
    Fig 50: Locating Steering Gear-To-Dash Seal Retaining Clips
    G06262471Courtesy of FORD MOTOR CO.
  58. If equipped, install the 7 screws and the underbody cover.
    Fig 51: Locating Underbody Cover & Screws
    G06257240Courtesy of FORD MOTOR CO.
  59. Install the steering column shaft onto the steering gear and install the bolt.
    • Tighten to 20 Nm (177 lb-in).
    Fig 52: Locating Steering Column Shaft Bolt
    G06262048Courtesy of FORD MOTOR CO.
  60. Install the steering joint cover and the 2 nuts.
    Fig 53: Locating Steering Joint Cover & Nuts
    G06261980Courtesy of FORD MOTOR CO.
  61. Connect the 2 engine harness electrical connectors.
    Fig 54: Locating Engine Harness Electrical Connectors
    G06261978Courtesy of FORD MOTOR CO.
  62. Attach the 2 negative battery cable pin-type retainers to the transaxle mount and battery tray bracket.
    Fig 55: Locating Negative Battery Cable Pin-Type Retainers
    G06261977Courtesy of FORD MOTOR CO.
  63. Install the ground wire-to-body and the bolt.
    • Tighten to 12 Nm (106 lb-in).
    Fig 56: Locating Ground Wire-To-Body Bolt
    G06261976Courtesy of FORD MOTOR CO.
  64. Connect the engine wiring harness electrical connector.
    Fig 57: Locating Engine Wiring Harness Electrical Connector
    G06261975Courtesy of FORD MOTOR CO.
  65. Install the 2 battery cables to the positive battery cable and the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
    Fig 58: Locating Battery Cables & Nuts
    G06262041Courtesy of FORD MOTOR CO.
  66. Install the battery tray. For additional information, refer to REMOVAL AND INSTALLATION .
  67. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION .
  68. Fill the engine with clean engine oil.
  69. Fill and bleed the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  70. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
  71. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.
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