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Engine - Manual Transaxle

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL DESCRIPTION

G03898823
 Heavy Duty Floor Crane 014-00071 or equivalent
G03898617
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
G03897842
 Powertrain Lift 014-00765
G03899013
 Universal Adapter Brackets 014-0001
Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent
MATERIAL SPECIFICATIONS

Item Specification
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: Identifying Engine Lift Table
    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 Nm (76 lb-ft).
      Fig 2: Installing Bolt In LH Transaxle Mount
      G03897894Courtesy of FORD MOTOR CO.
  6. Install the bolt in the rear transaxle mount.
    • Tighten 115 Nm (85 lb-ft).
      Fig 3: Installing Bolt In Rear Transaxle Mount
      G03897893Courtesy of FORD MOTOR CO.
  7. Install the engine mount bracket and nuts.
    • Tighten 90 Nm (66 lb-ft).
      Fig 4: Installing Engine Mount Bracket And Nuts
      G03897892Courtesy of FORD MOTOR CO.
  8. Install the engine mount bracket bolt.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 5: Installing Engine Mount Bracket Bolt
      G03897891Courtesy of FORD MOTOR CO.
  9. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 6: Installing Transaxle-To-Engine Bolts
      G03897889Courtesy of FORD MOTOR CO.
  10. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 7: Installing Transaxle-To-Engine Bolts
      G03897888Courtesy of FORD MOTOR CO.
  11. Install the engine support crossmember and nut.
    • Tighten to 175 Nm (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 Nm (66 lb-ft)
    • Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
      Fig 9: Identifying Front Roll Restrictor Bolt And 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 Nm (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: Connecting Power Steering Pressure Sensor Electrical Connector
    G03897884Courtesy of FORD MOTOR CO.
  15. Install the A/C compressor and connect the A/C compressor electrical connector.
    • Tighten the bolts to 25 Nm (18 lb-ft).
      Fig 12: Installing A/C Compressor And Connect A/C Compressor Electrical Connector
      G03897883Courtesy of FORD MOTOR CO.
  16. Connect the lower radiator hose to the radiator.
    Fig 13: Locating Lower Radiator Hose At Radiator
    G03897882Courtesy of FORD MOTOR CO.
  17. Install the 2 power steering pump bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 14: Identifying Power Steering Pump Bolts
      G03897741Courtesy of FORD MOTOR CO.
  18. Install the ground wire and bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 15: Installing Ground Wire And 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 Nm (71 lb-in).
      Fig 16: Connecting Powertrain Control Module Electrical Connectors
      G03897879Courtesy of FORD MOTOR CO.
  20. Attach the electrical connector retainers.
    Fig 17: Attaching Electrical Connector Retainers
    G03897878Courtesy of FORD MOTOR CO.
  21. Connect the fuel supply tube.
    Fig 18: Locating Fuel Supply Tube
    G03897877Courtesy of FORD MOTOR CO.
  22. Connect the vacuum reservoir tube.
    Fig 19: Connecting Vacuum Reservoir Tube
    G03897876Courtesy of FORD MOTOR CO.
  23. Connect the fuel vapor return tube and retainer.
    Fig 20: Connecting Fuel Vapor Return Tube And Retainer
    G03897875Courtesy of FORD MOTOR CO.
  24. Connect the vacuum supply tube.
    Fig 21: Connecting Vacuum Supply Tube
    G03897874Courtesy of FORD MOTOR CO.
  25. Install the power steering tube, bracket and nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 22: Installing Power Steering Tube, Bracket And Nut
      G03897873Courtesy of FORD MOTOR CO.
  26. Position the accelerator control cable and bracket and install the nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 23: Installing Accelerator Control Cable, Bracket And Nut
      G03897871Courtesy of FORD MOTOR CO.
  27. Install the accelerator control cable and bracket and nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 24: Installing Accelerator Control Cable And Bracket And Nut
      G03897872Courtesy 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 Nm (89 lb-in).
        Fig 25: Installing Accelerator Cable Bracket And Bolts
        G03897870Courtesy of FORD MOTOR CO.
  29. Install the accelerator cable snow shield and retainers.
    • Tighten to 10 Nm (89 lb-in).
      Fig 26: Installing Accelerator Cable Snow Shield And Retainers
      G03897869Courtesy of FORD MOTOR CO.
  30. Connect the heater hoses to the heater core.
    Fig 27: Locating Heater Hoses At Heater Core
    G03897868Courtesy of FORD MOTOR CO.
  31. Attach the heater hose support strap to the stud.
    Fig 28: Locating Heater Hose Support Strap Stud
    G03897867Courtesy of FORD MOTOR CO.
  32. Position the coolant vent hose and install the coolant vent hose brackets and nuts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 29: Installing Coolant Vent Hose Brackets And Nuts
      G03897866Courtesy of FORD MOTOR CO.
  33. Connect the upper radiator and coolant vent hoses.
    Fig 30: Connecting Upper Radiator And Coolant Vent Hoses
    G03897865Courtesy 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
    G03897864Courtesy of FORD MOTOR CO.
  35. Connect the reversing lamp indicator switch and attach the wiring harness retainers.
    Fig 32: Connecting Reversing Lamp Indicator Switch
    G03897917Courtesy of FORD MOTOR CO.
  36. Connect the vehicle speed sensor (VSS) electrical connector and pin-type retainer.
    Fig 33: Connecting Vehicle Speed Sensor Electrical Connector And Pin-Type Retainer
    G03897916Courtesy of FORD MOTOR CO.
  37. Connect the transaxle control cable and install the retaining clips.
    Fig 34: Connecting Transaxle Control Cable
    G03897915Courtesy of FORD MOTOR CO.
  38. Connect the transaxle control cable and install the retaining clips.
    Fig 35: Connecting Transaxle Control Cable
    G03897914Courtesy 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: Connecting Clutch Hydraulic Tube Fitting
    G03897913Courtesy of FORD MOTOR CO.
  40. Attach the wiring harness retainers to the battery tray bracket.
    Fig 37: Attaching Wiring Harness Retainers To Battery Tray Bracket
    G03897853Courtesy of FORD MOTOR CO.
  41. Connect the 42-pin electrical connector and tighten the bolt. Install the ground strap and bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 38: Connecting 42-Pin Electrical Connector
      G03897852Courtesy of FORD MOTOR CO.
  42. Connect the electrical connector to the power distribution box.
    Fig 39: Connecting Electrical Connector To Power Distribution Box
    G03897851Courtesy of FORD MOTOR CO.
  43. Connect the cables and install the nuts.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 40: Installing Power Distribution Box Nuts
      G03897850Courtesy of FORD MOTOR CO.
  44. Install the power distribution box cover.
    Fig 41: Installing Power Distribution Box Cover
    G03897849Courtesy of FORD MOTOR CO.
  45. If equipped, install the ground eyelet and bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 42: Installing Ground Eyelet And Bolt
      G03897848Courtesy of FORD MOTOR CO.

    46. 4x4 vehicles 

  46. Install the driveshaft and bolts.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 43: Installing Driveshaft And Bolts
      G03897905Courtesy of FORD MOTOR CO.

    47. All vehicles 

  47. Install the front drive intermediate halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  48. Install the LH front drive halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  49. Install the lateral support crossmember and bolts.
    • Tighten to 115 Nm (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 Nm (15 lb-ft).
      Fig 45: Installing Generator Shield
      G03897846Courtesy of FORD MOTOR CO.
  51. Install the lower air duct and install the bolt.
    • Tighten to 4 Nm (35 lb-in).
      Fig 46: Installing Lower Air Duct And Bolt
      G03897845Courtesy of FORD MOTOR CO.
  52. Install the accessory drive belt tensioner. For additional information, refer to ACCESSORY DRIVE - 2.3L .
  53. Connect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
    Fig 47: Connecting Heated Oxygen Sensor And Catalyst Monitor Sensor Electrical Connectors
    G03897844Courtesy of FORD MOTOR CO.
  54. Install the exhaust flex pipe. For additional information, refer to EXHAUST SYSTEM .
  55. Install the starter. For additional information, refer to STARTING SYSTEM .
  56. Install the battery tray and battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  57. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L .
  58. Fill the engine with clean engine oil.
  59. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  60. Bleed the clutch system. For additional information, refer to MANUAL TRANSAXLE-TRANSMISSION AND CLUTCH - GENERAL INFORMATION .
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