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Home >> Mercury >> 1992 >> Capri Base, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 1.3L 4-CYL - VIN [H] & 1.6L 4-CYL - VINS [Z,6] >> Removal & Installation >> Engine >> Installation (1.6L & 1.6L Turbo)

Installation (1.6L & 1.6L Turbo)

  1. Install transaxle to engine in reverse order of removal. Attach hoist to engine/transaxle assembly and position assembly in vehicle. Before engine contacts mounts, route starter, alternator and oil pressure sensor wiring, and connect oil pressure sensor. Lower engine until front mount seats on crossmember. Install through bolt on RH engine mount. DO NOT  tighten bolt.
  2. Remove hoist. Raise vehicle and support with jackstands. Align rear engine mount to crossmember, and install retaining nuts to front and rear engine mounts. Tighten nuts to specification. See TORQUE SPECIFICATIONS  table at end of article.
  3. On manual transaxles, connect shift coupling and stabilizer. Tighten to specification. On automatic transaxles, connect shift linkage and oil cooler lines. Tighten linkage retaining bolt, shift cable pivot and oil cooler hose clamps to specification. Connect front exhaust pipe to manifold (or turbocharger). Install exhaust pipe to support bracket. Tighten bolts to specification. Tighten manifold (or turbocharger) to specification. Attach rubber exhaust hangers. Position cross brace. Tighten retaining nut and bolt and right control arm front bolt.
  4. Install drive axles. Install ball joint retaining bolts and tighten to specification. Mount A/C Compressor to engine (if equipped). Tighten lower retaining bolts to specification. Install splash guards. Install tire and wheel assemblies. Tighten retaining nuts to specification.
  5. Lower vehicle. Install upper A/C compressor retaining bolts (if equipped). Tighten bolts to specification. Tighten RH engine mount through bolt to specification. Connect alternator wiring.
  6. Position power steering pump bracket on stud. Lower pump into engine compartment. Install power steering pump bracket retaining bolts and nut. Tighten to specification. Install power steering pump and belt. Tighten adjustment nut and pivot bolt to specification.
  7. Install engine oil dipstick and retaining clip. Install ground strap and ground wire to cylinder head. Install clutch cable (if equipped). Connect clutch hydraulic line if equipped with manual transaxle or naturally aspirated. Connect transmission electrical connectors. Connect fuel lines to fuel filter and pressure regulator. Install intake air tube to throttle body.
  8. Install intercooler hoses on turbocharged models. Install air cleaner assembly brackets. Install air cleaner assembly with airflow meter attached. Install intake air tube. Install coil and airflow meter connectors. Connect coolant crankcase and air bypass hoses. Install vacuum hoses as noted in disassembly.
  9. Connect accelerator cable. Install retaining bracket. Install power brake booster hose. Remove speedometer cable from transaxle. Fill transaxle to specification. See CAPACITIES in SERVICE & ADJUSTMENT SPECIFICATIONS article. Install speedometer cable. Connect speedometer cable connector. Fill engine oil to capacity.
  10. Install radiator/fan assembly. Tighten bracket retaining bolts to specification. Connect coolant hoses and fan electrical connector. Fill coolant to specification.
  11. Install hood and connect washer hose. Install battery tray support, battery tray, battery and battery hold-down. Connect battery terminal. Evacuate and charge air conditioning system (if equipped). Road test vehicle and inspect for leaks.
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