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Engine - Manual Transaxle: Material

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MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada) XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada) WSS-M2C945-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 Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 5 transaxle-to-engine bolts.
  2. Using the Floor Crane and Spreader Bar, position the engine and transaxle onto the lift table.
  3. Using the Powertrain Lift and Adjustable Grip Arm, secure the engine to the lift table.
    Fig 1: Securing Engine And Transaxle Onto Powertrain Lift
    G07439744Courtesy of FORD MOTOR CO.
  4. Install the starter motor isolator.
    Fig 2: Locating Starter Motor Isolator
    G07439745Courtesy of FORD MOTOR CO.
  5. Install the starter motor and the 2 stud bolts.
    • Tighten to 35 Nm (26 lb-ft).
    Fig 3: Locating Starter Motor Stud Bolts
    G07439746Courtesy of FORD MOTOR CO.
  6. Install the ground wire and the nut.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 4: Locating Ground Wire Nut
    G07439747Courtesy of FORD MOTOR CO.
  7. Install the starter motor harness connector.
    1. Install the starter motor solenoid battery nut.
      • Tighten to 12 Nm (106 lb-in).
    2. Install the starter motor solenoid nut.
    • Tighten to 5 Nm (44 lb-in).
    Fig 5: Identifying Battery Cable And Starter Solenoid Terminal Nuts
    G07439748Courtesy of FORD MOTOR CO.
  8. Raise the engine and transaxle into the vehicle.
  9. Install the bolt in the LH transaxle mount.
    • Tighten to 103 Nm (76 lb-ft).
    Fig 6: Locating LH Transaxle Mount Bolt
    G07439749Courtesy of FORD MOTOR CO.
  10. Install the bolt in the rear transaxle mount.
    • Tighten 115 Nm (85 lb-ft).
    Fig 7: Locating Transaxle Rear Mount Bolt
    G07439750Courtesy of FORD MOTOR CO.
  11. Install the engine mount bracket and nuts.
    • Tighten 115 Nm (85 lb-ft).
    Fig 8: Locating Engine Mount Bracket Nuts
    G07439751Courtesy of FORD MOTOR CO.
  12. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
    Fig 9: Locating Engine Mount Bracket Bolt
    G07439752Courtesy of FORD MOTOR CO.
  13. Install a new spin-on engine oil filter.
    • Lubricate the spin-on 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.
    Fig 10: Locating Engine Oil Filter
    G07439753Courtesy of FORD MOTOR CO.
  14. Install the 2 engine-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 11: Locating Transaxle-To-Engine Bolts
    G07439754Courtesy of FORD MOTOR CO.
  15. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 12: Locating Transaxle-To-Engine Bolts
    G07439755Courtesy of FORD MOTOR CO.
  16. Install the engine support crossmember and new nut.
    • Tighten to 175 Nm (129 lb-ft).
    Fig 13: Locating Engine Support Crossmember Rear Nut
    G07439756Courtesy of FORD MOTOR CO.
  17. 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 14: Locating Front Roll Restrictor And Engine Support Crossmember Bolts
    G07439757Courtesy of FORD MOTOR CO.
  18. Connect the lower radiator hose to the radiator.
    Fig 15: Locating Lower Radiator Hose
    G07439758Courtesy of FORD MOTOR CO.
  19. Position the A/C compressor and install the 3 bolts.
    • Tighten the bolts to 25 Nm (18 lb-ft).
    • Connect the A/C compressor electrical connector. Attach the wire harness retainer.
    Fig 16: Locating A/C Compressor Electrical Connector And Bolts
    G07439759Courtesy of FORD MOTOR CO.
  20. Connect the generator electrical connector and attach the 2 retainers.
    Fig 17: Locating Generator Electrical Connector And Retainers
    G07439760Courtesy of FORD MOTOR CO.
  21. Connect the engine control harness electrical connector.
    Fig 18: Locating Engine Control Harness Electrical Connector
    G07439761Courtesy of FORD MOTOR CO.
  22. Connect the PCM electrical connector and attach the wire harness retainer.
    Fig 19: Locating PCM Electrical Connector And Wire Harness Retainer
    G07439762Courtesy of FORD MOTOR CO.
  23. Connect the fuel supply tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
    Fig 20: Locating Fuel Supply Tube Quick Connect Coupling
    G07439763Courtesy of FORD MOTOR CO.
  24. Connect the fuel vapor return tube and retainer.
    • Attach the fuel vapor tube retainer to the wire harness.
    Fig 21: Locating Fuel Vapor Tube Retainer
    G07439764Courtesy of FORD MOTOR CO.
  25. Connect the vacuum supply tube.
    Fig 22: Locating Vacuum Supply Tube
    G07439765Courtesy of FORD MOTOR CO.
  26. Connect the heater hoses to the heater core.
    Fig 23: Locating Heater Hoses Of Heater Core
    G07439766Courtesy of FORD MOTOR CO.
  27. Attach the heater hose support strap to the stud.
    Fig 24: Locating Heater Hose Support Strap Of Stud
    G07439767Courtesy of FORD MOTOR CO.
  28. Connect the upper radiator hose.
    Fig 25: Locating Upper Radiator Hose
    G07439768Courtesy of FORD MOTOR CO.
  29. If equipped, route the block heater wiring harness and attach all retainers.
    • Connect the block heater electrical connector.
    Fig 26: Locating Block Heater Electrical Connector
    G07439769Courtesy of FORD MOTOR CO.
  30. Install the shift cable bracket.
    1. Position the shift cable bracket.
    2. Install the 3 bolts.
    • Tighten to 22 Nm (16 lb-ft).
    Fig 27: Identifying Shift Cable Bracket And Bolts
    G07439770Courtesy of FORD MOTOR CO.
  31. Connect the shift cables.
    Fig 28: Locating Shift Cables
    G07439771Courtesy of FORD MOTOR CO.
  32. Connect the reversing lamp indicator switch electrical connector and attach the 2 wiring harness retainers.
    Fig 29: Locating Reversing Lamp Indicator Switch Electrical Connector And Wiring Harness Retainers
    G07439772Courtesy of FORD MOTOR CO.
  33. Connect the Vehicle Speed Sensor (VSS) electrical connector and attach the 2 pin-type retainers.
    Fig 30: Locating Vehicle Speed Sensor Electrical Connector And Pin-Type Retainers
    G07439773Courtesy of FORD MOTOR CO.
  34. Connect the clutch hydraulic line.
    1. Position the clutch hydraulic line.
    2. Connect the clutch hydraulic line to the clutch slave cylinder.
      • Tighten to 25 Nm (18 lb-ft).
    3. Install the clutch hydraulic line bracket-to-transaxle bolt.
      • Tighten to 3 Nm (27 lb-in).
    Fig 31: Identifying Clutch Hydraulic Line And Bracket-To-Transaxle Bolt
    G07439774Courtesy of FORD MOTOR CO.
  35. Position the wiring harness and attach the 2 wiring harness retainers to the battery tray bracket.
    Fig 32: Locating Wiring Harness Retainers Of Battery Tray Bracket
    G07439775Courtesy of FORD MOTOR CO.
  36. Install the ground strap and bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 33: Locating Ground Strap Bolt
    G07439776Courtesy of FORD MOTOR CO.
  37. Connect the electrical connector to the Power Distribution Box (PDB).
    Fig 34: Locating PDB Electrical Connector
    G07439777Courtesy of FORD MOTOR CO.
  38. Connect the cable to the PDB  and install the nut.
    • Tighten to 12 Nm (106 lb-in).
    Fig 35: Locating PDB Cable Nut
    G07439778Courtesy of FORD MOTOR CO.
  39. Install the PDB  cover.
    Fig 36: Locating Power Distribution Box (PDB) Cover
    G07439779Courtesy of FORD MOTOR CO.
  40. If equipped, install the ground eyelet and bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 37: Locating Ground Eyelet Bolts
    G07439780Courtesy of FORD MOTOR CO.
  41. Install the generator air duct and make sure the tab is latched.
    Fig 38: Locating Locking Tab And Generator Air Duct
    G07439781Courtesy of FORD MOTOR CO.
  42. Install the accessory drive belt tensioner. For additional information, refer to ACCESSORY DRIVE - 2.5L article.
  43. Install the exhaust downpipe and exhaust intermediate pipe. For additional information, refer to EXHAUST SYSTEM article.
  44. Install the lateral support crossmember and bolts.
    • Tighten to 115 Nm (85 lb-ft).
    Fig 39: Locating Lateral Support Crossmember Bolts
    G07439782Courtesy of FORD MOTOR CO.
  45. Install the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
  46. Install the battery tray. For additional information, refer to BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES article.
  47. Install the engine Air Cleaner (ACL) and ACL  outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L article.
  48. Fill the engine with clean engine oil.
  49. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING article.
  50. Bleed the clutch system. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION article.
  51. 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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