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Engine - Manual Transaxle

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G04618396Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04618397Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04618398Courtesy of FORD MOTOR CO.
 Powertrain Lift
014-00765
G04618399Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets
014-0001
Lifting Bracket Set, Engine
303-D095 (D94L-6001-A) or equivalent
MATERIALS

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalent		 WSS-M2C930-A
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

    All vehicles 

  1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 6 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.
    Fig 1: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
    G03897890Courtesy of FORD MOTOR CO.
  4. Raise the engine and transaxle into the vehicle.
  5. Install the bolt in the LH transaxle mount.
    • Tighten to 103 N.m (76 lb-ft).
      Fig 2: Locating Transaxle Mount Bolt
      G03897894Courtesy of FORD MOTOR CO.
  6. Install the bolt in the rear transaxle mount.
    • Tighten 115 N.m (85 lb-ft).
      Fig 3: Locating Rear Transaxle Mount Bolt
      G04618402Courtesy of FORD MOTOR CO.
  7. Install the engine mount bracket and nuts.
    • Tighten 115 N.m (85 lb-ft).
      Fig 4: Locating Engine Mount Bracket & Nuts
      G04618403Courtesy of FORD MOTOR CO.
  8. Install the engine mount bracket bolt.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 5: Locating Engine Mount Bracket Bolt
      G04618404Courtesy of FORD MOTOR CO.
  9. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 N.m (35 lb-ft).
      Fig 6: Locating Transaxle-To-Engine Bolts
      G04618405Courtesy of FORD MOTOR CO.
  10. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 N.m (35 lb-ft).
      Fig 7: Locating Transaxle-To-Engine Bolts
      G04618406Courtesy of FORD MOTOR CO.
  11. Install the engine support crossmember and new nut.
    • Tighten to 175 N.m (129 lb-ft).
      Fig 8: Identifying Cross Brace And Rear Nut
      G03897887Courtesy of FORD MOTOR CO.
  12. Install the 2 bolts for the engine support crossmember and the front roll restrictor bolt.
    • Tighten the engine support crossmember bolts to 90 N.m (66 lb-ft)
    • Tighten the front roll restrictor bolt to 115 N.m (85 lb-ft).
      Fig 9: Identifying Front Roll Restrictor Bolt & Bolts For Engine Support Crossmember
      G04619986Courtesy of FORD MOTOR CO.
    13. NOTE: The bolt under the power steering pressure tube will remain with the power steering pump.
  13. Position the power steering pump and install the bolts.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 10: Identifying Power Steering Pump Bolts
      G03897742Courtesy of FORD MOTOR CO.
  14. Connect the power steering pressure (PSP) sensor electrical connector.
    Fig 11: Locating Power Steering Pressure (PSP) Sensor Electrical Connector
    G04618410Courtesy of FORD MOTOR CO.
  15. Install the A/C compressor and connect the A/C compressor electrical connector.
    • Tighten the bolts to 25 N.m (18 lb-ft).
      Fig 12: Locating A/C Compressor Bolts
      G04618411Courtesy of FORD MOTOR CO.
  16. Connect the lower radiator hose to the radiator.
    Fig 13: Locating Lower Radiator Hose
    G03897882Courtesy of FORD MOTOR CO.
  17. Install the 2 power steering pump bolts.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 14: Locating Power Steering Pump Bolts
      G03897741Courtesy of FORD MOTOR CO.
  18. Install the ground wire and bolt.
    • Tighten to 10 N.m (89 lb-in).
      Fig 15: Locating Ground Wire & Bolt
      G03897880Courtesy of FORD MOTOR CO.
  19. Connect the powertrain control module (PCM) electrical connectors. Position the harness and install the nut.
    • Tighten to 8 N.m (71 lb-in).
      Fig 16: Locating Powertrain Control Module (PCM) Electrical Connectors
      G03897879Courtesy of FORD MOTOR CO.
  20. Attach the electrical connector retainers.
    Fig 17: Locating Electrical Connector Retainers
    G04618416Courtesy of FORD MOTOR CO.
  21. Connect the fuel supply tube.
    Fig 18: Locating Fuel Supply Tube
    G04618417Courtesy of FORD MOTOR CO.
  22. Connect the vacuum reservoir tube.
    Fig 19: Locating Vacuum Reservoir Tube
    G04618418Courtesy of FORD MOTOR CO.
  23. Connect the fuel vapor return tube and retainer.
    Fig 20: Locating Fuel Vapor Return Tube & Retainer
    G04618419Courtesy of FORD MOTOR CO.
  24. Connect the vacuum supply tube.
    Fig 21: Locating Vacuum Supply Tube
    G04618420Courtesy of FORD MOTOR CO.
  25. Install the power steering tube, bracket and nut.
    • Tighten to 6 N.m (53 lb-in).
      Fig 22: Locating Power Steering Tube, Bracket & Nut
      G04618421Courtesy of FORD MOTOR CO.
  26. Position the accelerator control cable and bracket and install the nut.
    • Tighten to 9 N.m (80 lb-in) (vehicles built through 10/2005).
    • Tighten to 5 N.m (44 lb-in) (vehicles built after 10/2005).
      Fig 23: Locating Accelerator Control Cable & Bracket
      G04618422Courtesy of FORD MOTOR CO.
  27. Install the accelerator control cable and bracket and nut.
    • Tighten to 9 N.m (80 lb-in) (vehicles built through 10/2005).
    • Tighten to 5 N.m (44 lb-in) (vehicles built after 10/2005).
      Fig 24: Locating Accelerator Control Cable, Bracket & Nut
      G04618423Courtesy of FORD MOTOR CO.
  28. 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 N.m (89 lb-in).
        Fig 25: Locating Accelerator Cable Bracket & Bolts
        G04618424Courtesy of FORD MOTOR CO.
  29. Install the accelerator cable snow shield and retainers.
    • Tighten to 10 N.m (89 lb-in).
      Fig 26: Locating Accelerator Cable Snow Shield & Retainers
      G04618425Courtesy of FORD MOTOR CO.
  30. Connect the heater hoses to the heater core.
    Fig 27: Locating Heater Hoses
    G03897868Courtesy of FORD MOTOR CO.
  31. Attach the heater hose support strap to the stud.
    Fig 28: Locating Heater Hose Support Strap
    G04618427Courtesy of FORD MOTOR CO.
  32. Position the coolant vent hose and install the coolant vent hose brackets and nuts.
    • Tighten to 10 N.m (89 lb-in).
      Fig 29: Locating Coolant Vent Hose
      G04618428Courtesy of FORD MOTOR CO.
  33. Connect the upper radiator and coolant vent hoses.
    Fig 30: Locating Upper Radiator & Coolant Vent Hoses
    G04618429Courtesy of FORD MOTOR CO.
  34. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
    Fig 31: Locating Block Heater Electrical Connector
    G04618430Courtesy of FORD MOTOR CO.
  35. Connect the reversing lamp indicator switch and attach the wiring harness retainers.
    Fig 32: Locating Reversing Lamp Indicator Switch & Wiring Harness Retainers
    G04618431Courtesy of FORD MOTOR CO.
  36. Connect the vehicle speed sensor (VSS) electrical connector and pin-type retainer.
    Fig 33: Locating Vehicle Speed Sensor (VSS) Electrical Connector
    G04618432Courtesy of FORD MOTOR CO.
  37. Connect the transaxle control cable and install the retaining clips.
    Fig 34: Locating Transaxle Control Cable (1 Of 2)
    G04618433Courtesy of FORD MOTOR CO.
  38. Connect the transaxle control cable and install the retaining clips.
    Fig 35: Locating Transaxle Control Cable (2 Of 2)
    G04618434Courtesy of FORD MOTOR CO.
  39. Connect the clutch hydraulic tube fitting. Position the clutch hydraulic tube, attach the spring clip and tighten the mounting bolt to 3 Nm (27 lb-in).
    Fig 36: Locating Clutch Hydraulic Tube Fitting
    G04618435Courtesy of FORD MOTOR CO.
  40. Attach the wiring harness retainers to the battery tray bracket.
    Fig 37: Locating Wiring Harness Retainers
    G04618436Courtesy of FORD MOTOR CO.
  41. Connect the 42-pin electrical connector and tighten the bolt. Install the ground strap and bolt.
    • Tighten to 10 N.m (89 lb-in).
      Fig 38: Locating Ground Strap & Electrical Connector
      G03897852Courtesy of FORD MOTOR CO.
  42. Connect the electrical connector to the power distribution box.
    Fig 39: Locating Electrical Connector
    G04618438Courtesy of FORD MOTOR CO.
  43. Connect the cables and install the nuts.
    • Tighten to 12 N.m (9 lb-ft).
      Fig 40: Locating Cables & Nuts
      G03897850Courtesy of FORD MOTOR CO.
  44. Install the power distribution box cover.
    Fig 41: Locating Power Distribution Box Cover
    G03897849Courtesy of FORD MOTOR CO.
  45. If equipped, install the ground eyelet and bolt.
    • Tighten to 10 N.m (89 lb-in).
      Fig 42: Locating Ground Eyelet & Bolt
      G04618441Courtesy of FORD MOTOR CO.

    46. All wheel drive (AWD) vehicles 

  46. Install the driveshaft and bolts.
    • Tighten to 20 N.m (15 lb-ft).
      Fig 43: Locating Driveshaft & Bolts
      G04618442Courtesy of FORD MOTOR CO.

    47. All vehicles 

  47. Install the front drive intermediate halfshaft. For additional information, refer to INSTALLATION .
  48. Install the LH front drive halfshaft. For additional information, refer to INSTALLATION .
  49. Install the lateral support crossmember and bolts.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 44: Identifying Lateral Support Crossmember And Bolts
      G03897847Courtesy of FORD MOTOR CO.
  50. Install the generator shield and the nut and the pin-type retainer and attach the wire retainers.
    • Tighten to 20 N.m (15 lb-ft).
      Fig 45: Locating Generator Shield & Nut
      G04618444Courtesy of FORD MOTOR CO.
  51. Install the lower air duct and install the bolt.
    • Tighten to 4 N.m (35 lb-in).
      Fig 46: Locating Lower Air Duct
      G04618445Courtesy of FORD MOTOR CO.
  52. Install the accessory drive belt tensioner. For additional information, refer to REMOVAL AND INSTALLATION .
  53. Connect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
    Fig 47: Locating Heated Oxygen Sensor (HO2S) & Catalyst Monitor Sensor Electrical Connectors
    G04618446Courtesy of FORD MOTOR CO.
  54. Install the exhaust flex pipe. For additional information, refer to REMOVAL AND INSTALLATION .
  55. Install the starter. For additional information, refer to STARTING SYSTEM .
  56. Install the battery tray and battery. For additional information, refer to REMOVAL AND INSTALLATION - BATTERY TRAY and REMOVAL AND INSTALLATION - BATTERY .
  57. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION - AIR CLEANER and REMOVAL AND INSTALLATION - AIR CLEANER OUTLET PIPE .
  58. Fill the engine with clean engine oil.
  59. Fill and bleed the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  60. Bleed the clutch system. For additional information, refer to CLUTCH SYSTEM BLEEDING .
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