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Engine - Manual Transaxle

WARNING: This page is about a different variant/trim than selected.
Special Tools

Illustration Tool Name Tool Number
GF0000536
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0017081
 Powertrain Lift 014-00765
GF0000267
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0024108
 Universal Adapter Brackets 014-0001
Material

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		 WSS-M2C930-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 transaxle-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.
    3. NOTE: Position a suitable block of wood under the transaxle.
  3. Install the Powertrain Lift and Universal Adapter Brackets onto the engine.
    4. Fig 1: Identifying Special Tools (014-0001, 014-00765)
    GF0028780Courtesy of FORD MOTOR CO.
  4. Connect the Vehicle Speed Sensor (VSS) electrical connector.
    5. Fig 2: Locating Vehicle Speed Sensor (VSS) Electrical Connector
    GF0028799Courtesy of FORD MOTOR CO.
  5. Connect the backup lamp electrical connector.
    6. Fig 3: Locating Backup Lamp Electrical Connector
    GF0028798Courtesy of FORD MOTOR CO.
  6. Install the engine wiring harness bracket and nut.
    • Tighten to 20 Nm (177 lb-in).
    7. Fig 4: Locating Engine Wiring Harness Bracket And Nut
    GF0028787Courtesy of FORD MOTOR CO.
  7. Install the transaxle ground wire and bolt.
    • Tighten to 10 Nm (89 lb-in).
    8. Fig 5: Locating Ground Wire Bolt
    GF0028786Courtesy of FORD MOTOR CO.
  8. Install the starter and the 2 stud bolts.
    • Tighten to 25 Nm (18 lb-ft).
    9. Fig 6: Locating Starter And Stud Bolts
    GF0028784Courtesy of FORD MOTOR CO.
  9. Connect the starter wires and install the 2 nuts.
    • Tighten the large nut to 12 Nm (106 lb-in).
    • Tighten the small nut to 5 Nm (44 lb-in).
    10. Fig 7: Locating Starter Wire Nuts
    GF0028783Courtesy of FORD MOTOR CO.
  10. Attach the 2 wiring harness retainers to the starter stud bolts.
  11. Raise the engine and transaxle into the vehicle.
  12. Install the 2 transaxle mount bolts.
    • Tighten to 90 Nm (66 lb-ft).
    13. Fig 8: Locating Transaxle Mount Bolts
    GF0028781Courtesy of FORD MOTOR CO.
  13. 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).
    14. Fig 9: Locating Engine Mount Bracket Bolt And Nuts
    GF0028782Courtesy of FORD MOTOR CO.
  14. Install the 2 oil pan-to-bellhousing bolts.
    • Tighten to 48 Nm (35 lb-ft).
    15. Fig 10: Locating Oil Pan-To-Bellhousing Bolts
    GF0028777Courtesy of FORD MOTOR CO.
  15. Install the bellhousing-to-oil pan bolt.
    • Tighten to 48 Nm (35 lb-ft).
    16. Fig 11: Locating Bellhousing-To-Oil Pan Bolt
    GF0028776Courtesy of FORD MOTOR CO.
  16. Install the RH halfshaft into the transaxle.
    17. Fig 12: Locating RH Halfshaft
    GF0028775Courtesy of FORD MOTOR CO.
  17. Install the 2 RH halfshaft carrier bearing bracket bolts.
    • Tighten to 40 Nm (30 lb-ft).
    18. Fig 13: Locating RH Halfshaft Carrier Bearing Bracket Bolts
    GF0028774Courtesy of FORD MOTOR CO.
    NOTE: Start one end of the circlip in the groove and work the circlip over the halfshaft and into the groove to prevent the circlip from overexpanding.
  18. Install a new circlip in the groove on the LH halfshaft.
    19. Fig 14: Locating Halfshaft Circlip
    G03972275Courtesy of FORD MOTOR CO.
  19. Install LH halfshaft into the transaxle.
  20. Connect the lower radiator hose and install the retaining clip.
    21. Fig 15: Identifying Lower Radiator Hose And Installing Retaining Clip
    GF0028859Courtesy of FORD MOTOR CO.
  21. Install the radio frequency interference capacitor and the bolt on the engine mount bracket.
    • Tighten to 10 Nm (89 lb-in).
    22. Fig 16: Locating Radio Frequency Interference Capacitor Bolt
    GF0028772Courtesy of FORD MOTOR CO.
  22. Connect the A/C tube to the condenser and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    23. Fig 17: Locating A/C Tube To Condenser Nut
    GF0028771Courtesy of FORD MOTOR CO.
  23. Connect the A/C tubes and install the 2 nuts.
    • Tighten to 8 Nm (71 lb-in).
    24. Fig 18: Locating A/C Tubes Nuts
    GF0028770Courtesy of FORD MOTOR CO.
  24. Install the 2 A/C tube bracket bolts.
    • Tighten to 10 Nm (89 lb-in).
    25. Fig 19: Locating A/C Tube Bracket Bolts
    GF0028769Courtesy of FORD MOTOR CO.
  25. Attach the coolant vent hose retaining clip to the A/C tube.
    26. Fig 20: Locating Coolant Vent Hose Retaining Clip
    GF0028767Courtesy of FORD MOTOR CO.
  26. Install the radio frequency interference capacitor, ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    27. Fig 21: Locating Radio Frequency Interference Capacitor, Ground Wire And Bolt
    GF0028766Courtesy of FORD MOTOR CO.
  27. Connect the power steering cooler tube.
    28. Fig 22: Locating Power Steering Cooler Tube
    GF0028768Courtesy of FORD MOTOR CO.
  28. Attach the transaxle control cables to the bracket.
    • Connect the control cables to the control levers.
    29. Fig 23: Locating Control Cables
    GF0028796Courtesy of FORD MOTOR CO.
  29. Install the clutch slave cylinder and the 2 bolts.
    • Tighten to 22 Nm (16 lb-ft).
    30. Fig 24: Locating Clutch Slave Cylinder Bolts
    GF0028795Courtesy of FORD MOTOR CO.
  30. Install the 2 clutch tube bracket bolts.
    • Tighten to 22 Nm (16 lb-ft).
    31. Fig 25: Locating Clutch Tube Bracket Bolts
    GF0028794Courtesy of FORD MOTOR CO.
  31. Connect the heater hose in-line connector.
    32. Fig 26: Locating Heater Hose Inline Connector
    GF0028763Courtesy of FORD MOTOR CO.
  32. If equipped, connect the block heater electrical connector and attach the harness retaining clips to the heater hose.
    33. Fig 27: Locating Block Heater Electrical Connector Harness Retaining Clips
    GF0028762Courtesy of FORD MOTOR CO.
  33. Connect the upper radiator and heater hoses to the coolant bypass.
    34. Fig 28: Locating Upper Radiator & Heater Hoses To Coolant Bypass
    GF0041296Courtesy of FORD MOTOR CO.
  34. Attach the Evaporative Emission (EVAP) tube bundle retaining clip to the bracket.
    35. Fig 29: Locating Evaporative Emissions (EVAP) Tube Bundle Retaining Clip
    GF0028739Courtesy of FORD MOTOR CO.
  35. Connect the EVAP tube to the intake manifold.
    36. Fig 30: Locating Evaporative Emissions (EVAP) Tube From Intake Manifold
    GF0028760Courtesy of FORD MOTOR CO.
  36. Insert the brake booster vacuum supply tube into the locking ring on the intake manifold.
    37. Fig 31: Locating Locking Ring And Brake Booster Vacuum Supply Tube
    GF0028701Courtesy of FORD MOTOR CO.
  37. Connect the crankcase vent tube to the valve cover.
    38. Fig 32: Locating Crankcase Vent Tube
    GF0028759Courtesy of FORD MOTOR CO.
  38. Connect the fuel supply tube to the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  39. Connect the PCM electrical connector and the pin-type retainer.
    40. Fig 33: Locating Powertrain Control Module (PCM) Electrical Connector And Pin-Type Retainer
    GF0028758Courtesy of FORD MOTOR CO.
  40. Install the ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    41. Fig 34: Locating Ground Wire And Bolt
    GF0028757Courtesy of FORD MOTOR CO.
  41. Connect the 2 engine wiring harness electrical connectors.
    42. Fig 35: Locating Engine Wiring Harness Electrical Connectors
    GF0028756Courtesy of FORD MOTOR CO.
  42. Connect the wire and install the nut on the battery cable.
    • Tighten to 10 Nm (89 lb-in).
    43. Fig 36: Locating Battery Cable And Nut
    GF0028755Courtesy of FORD MOTOR CO.
  43. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  44. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L article.
  45. Install the generator air inlet duct, bolt and the 2 nuts.
    • Tighten to 6 Nm (53 lb-in).
    46. Fig 37: Locating Generator Air Inlet Duct, Bolt And Nuts
    GF0028700Courtesy of FORD MOTOR CO.
  46. Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position.
    47. Fig 38: Positioning Special Tool (014-00765) Under Subframe Assembly
    GF0028656Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  47. Install the front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    48. Fig 39: Locating Front Subframe Nuts
    GF0028659Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  48. Position the subframe brackets and install the bolts finger-tight.
    49. Fig 40: Locating Subframe Brackets And Bolts Finger-Tight
    GF0028860Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  49. Install the subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    50. Fig 41: Locating Subframe Nuts
    GF0028861Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  50. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
    51. Fig 42: Locating Subframe Bracket-To-Body Bolts
    GF0028658Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  51. Install the through bolts into the lower control arms.
    • Tighten to 103 Nm (76 lb-ft).
    52. Fig 43: Locating Lower Control Arms Through Bolt
    GF0028655Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  52. Install the lower ball joint nuts.
    • Tighten to 200 Nm (148 lb-ft).
    53. Fig 44: Locating Lower Ball Joint Nuts
    GF0028653Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  53. Install the sway bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
    54. Fig 45: Locating Stabilizer Bar Links Nut
    GF0028754Courtesy of FORD MOTOR CO.
  54. Connect the power steering cooler tube.
    55. Fig 46: Locating Power Steering Cooler Tube
    GF0028753Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  55. Install tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install the cotter pin.
    56. Fig 47: Locating Tie-Rod Ends Nuts And Cotter Pin
    GF0028751Courtesy of FORD MOTOR CO.
  56. Install the LH splash shield and the 6 pin-type retainers (4 shown).
    57. Fig 48: Locating Pin-Type Retainers & LH Splash Shield
    GF0041295Courtesy of FORD MOTOR CO.
  57. Position the LH fender splash shield and install the 4 screws.
    58. Fig 49: Locating LH Fender Splash Shield Screws
    GF0028647Courtesy of FORD MOTOR CO.
  58. Install the RH splash shield and the 6 pin-type retainers (4 shown).
    59. Fig 50: Locating Splash Shield Pin-Type Retainers
    G04684103Courtesy of FORD MOTOR CO.
  59. Position the RH fender splash shield and install the 4 screws.
    60. Fig 51: Locating RH Fender Splash Shield Screws
    G04684102Courtesy of FORD MOTOR CO.
  60. Install the engine roll restrictor bolt.
    • Tighten to 90 Nm (66 lb-ft).
    61. Fig 52: Locating Engine Roll Restrictor Bolt
    GF0028646Courtesy of FORD MOTOR CO.
  61. Route the Power Steering Pressure (PSP) tube up into the engine compartment.
    62. Fig 53: Locating Power Steering Pressure (PSP) Tube
    GF0028862Courtesy of FORD MOTOR CO.
  62. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body.
    • From under the vehicle, verify that the seal is properly installed on the steering gear and the retaining clips are fully engaged into the dash.
    63. Fig 54: Locating Steering Gear-To-Dash Seal Clips
    GF0028750Courtesy of FORD MOTOR CO.
  63. Install the oil filter element. For additional information, refer to Engine Lubrication Components - Exploded View  and Oil Filter Element .
  64. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM article.
  65. If equipped, install the underbody cover and the 7 screws.
    66. Fig 55: Locating Splash Shield Bolts
    GF0028704Courtesy of FORD MOTOR CO.
  66. Connect the PSP tube to the power steering pump and install the bolt.
    • Tighten to 35 Nm (26 lb-ft).
    67. Fig 56: Locating Power Steering Pressure (PSP) Tube Bolt
    GF0028749Courtesy of FORD MOTOR CO.
    NOTE: Align the index marks made during removal.
  67. Install the steering intermediate shaft onto the steering gear and install the bolt.
    • Tighten to 23 Nm (17 lb-ft).
    68. Fig 57: Locating Steering Intermediate Shaft Bolt
    GF0028863Courtesy of FORD MOTOR CO.
  68. Install the steering joint cover and the 2 nuts.
    69. Fig 58: Locating Steering Joint Cover And Nuts
    GF0028747Courtesy of FORD MOTOR CO.
  69. Fill the engine with clean engine oil.
  70. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  71. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING article.
  72. Fill the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL INFORMATION article.
  73. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article
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