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Section 461 (Engine - 2.3L): Installation: Engine

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tools
G03273916Courtesy of FORD MOTOR CO.
MATERIAL SPECIFICATIONS

Item Specification
Super Premium SAE 5W-20 Engine Oil
XO-5W20-QSP or equivalent		 WSS-M2C153-H

    ALL VEHICLES 

  1. Using the Spreader Bar and the Floor Crane, remove the engine from the stand.
  2. Position the engine in the vehicle. Make sure the index marks on the torque converter stud and flexplate made during removal are lined up.
  3. Install the two side transmission-to-engine bolts.
    4. NOTE: Left side shown, right side similar.
    Fig 2: Installing Engine Support Insulator Nuts
    G03273917Courtesy of FORD MOTOR CO.
  4. Install the four engine support insulator nuts.
  5. Remove the floor jack from the transmission.
  6. Remove the floor crane and the spreader bar.

    7. VEHICLES WITH AUTOMATIC TRANSMISSION 

  7. Install the four torque converter nuts.
    Fig 3: Installing Four Torque Converter Nuts
    G03273918Courtesy of FORD MOTOR CO.
  8. Install the transmission fluid indicator and tube assembly.
    Fig 4: Installing Transmission Fluid Indicator And Tube Assembly
    G03273919Courtesy of FORD MOTOR CO.

    9. ALL VEHICLES 

  9. Raise the vehicle.
  10. Install the remaining nine transmission-to-engine bolts.
    Fig 5: Installing Transmission-To-Engine Bolts
    G03273920Courtesy of FORD MOTOR CO.
  11. Install the oil filter adapter.
    Fig 6: Installing Oil Filter Adapter
    G03273921Courtesy of FORD MOTOR CO.
  12. Install the starter dust shield.
    Fig 7: Installing Starter Dust Shield
    G03273922Courtesy of FORD MOTOR CO.
  13. Install the starter and the starter bolts.
  14. Install the oil filter.
    Fig 8: Installing Oil Filter
    G03273923Courtesy of FORD MOTOR CO.
  15. Connect the oil pressure sensor electrical connector.
    Fig 9: Connecting Oil Pressure Sensor Electrical Connector
    G03273924Courtesy of FORD MOTOR CO.

    16. VEHICLES WITH AUTOMATIC TRANSMISSION 

  16. Connect the transmission wiring harness.
    • Position the transmission wiring and connect the pushpins.
    • Connect the transmission, the backup light switch, the transmission range sensor, if equipped, and the vehicle speed sensor electrical connectors.
      Fig 10: Connecting Transmission Wiring Harness
      G03273925Courtesy of FORD MOTOR CO.

    17. VEHICLES WITH MANUAL TRANSMISSION 

  17. Connect the lamp electrical connection and install the pin-type retainers.
    Fig 11: Connecting Lamp Electrical Connection
    G03273926Courtesy of FORD MOTOR CO.
  18. Connect the speed sensor electrical connector and the electrical connector on the crossmember.
    Fig 12: Connecting Speed Sensor Connector & Connector On Crossmember
    G03273927Courtesy of FORD MOTOR CO.

    19. ALL VEHICLES 

  19. Connect the heated oxygen sensor (HO2S) electrical connector at the rear of the transmission.
    Fig 13: Connecting HO2S Electrical Connector At Rear Of Transmission
    G03273928Courtesy of FORD MOTOR CO.
  20. Connect the HO2S electrical connector at the bell housing.
    Fig 14: Connecting HO2S Electrical Connector At Bell Housing
    G03273929Courtesy of FORD MOTOR CO.
  21. Install the exhaust manifold-to-front pipe nuts.
    Fig 15: Installing Exhaust Manifold-To-Front Pipe Nuts
    G03273930Courtesy of FORD MOTOR CO.
  22. Install the transmission dust shield.
    Fig 16: Installing Transmission Dust Shield
    G03273931Courtesy of FORD MOTOR CO.

    23. VEHICLES WITH AUTOMATIC TRANSMISSION 

  23. Install the bracket. Install the bolt retaining the transmission cooling tubes to the engine.
    Fig 17: Installing Bolt Retaining Transmission Cooling Tubes To Engine
    G03273932Courtesy of FORD MOTOR CO.

    24. ALL VEHICLES 

  24. Position the engine wiring harness and install the anchor and the pin-type retainer.
    Fig 18: Installing Engine Harness & Anchor And Pin-Type Retainer
    G03273933Courtesy of FORD MOTOR CO.
  25. Install the engine wiring harness pin-type retainer.
    Fig 19: Installing Engine Wiring Harness Pin-Type Retainer
    G03273934Courtesy of FORD MOTOR CO.
  26. Connect the block heater electrical connector.
    Fig 20: Connecting Block Heater Electrical Connector
    G03273935Courtesy of FORD MOTOR CO.
  27. Attach alternator wiring pin-type retainer.
    Fig 21: Attaching Alternator Wiring Pin-Type Retainer
    G03273936Courtesy of FORD MOTOR CO.
  28. Connect the alternator electrical connectors.
    Fig 22: Connecting Alternator Electrical Connectors
    G03273937Courtesy of FORD MOTOR CO.
  29. Position the splash shield and install the pushpins.
    Fig 23: Installing Splash Shield Pushpins
    G03273938Courtesy of FORD MOTOR CO.
  30. Lower the vehicle.
  31. Position the starter wiring harness and install the bolt.
    Fig 24: Installing Stater Harness Bolt
    G03273939Courtesy of FORD MOTOR CO.
  32. Connect the solenoid control wire, the negative battery cable and the positive battery cable at the starter.
    Fig 25: Connecting Solenoid Control Wire & Battery Cables
    G03273940Courtesy of FORD MOTOR CO.
  33. Connect the brake booster vacuum hose and the engine ground strap.
    Fig 26: Connecting Brake Booster Vacuum Hose & Engine Ground Strap
    G03273941Courtesy of FORD MOTOR CO.
  34. Connect the following:
    • 42-pin electrical connector
    • Evaporative purge hose
      Fig 27: Connecting 42-Pin Connector & Evaporative Purge Hose
      G03273942Courtesy of FORD MOTOR CO.
  35. Connect the fuel supply tube to the supply manifold. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
    36. NOTE: Install a new nylon O-ring seal.
  36. Connect the following:
    1. The power steering high-pressure hose
    2. The power steering pressure (PSP) switch electrical connector
      Fig 28: Connecting Power Steering High-Pressure Hose & PSP Switch
      G03273943Courtesy of FORD MOTOR CO.
  37. Connect the accelerator and speed control cables.
    1. Position the accelerator cable and the speed control cable (if so equipped) into the mounting bracket.
    2. Connect the accelerator cable and the speed control cable (if so equipped) to the throttle linkage.
      Fig 29: Connecting Accelerator And Speed Control Cables
      G03273944Courtesy of FORD MOTOR CO.
  38. Remove the plugs and connect the A/C compressor manifold.
    Fig 30: Connecting A/C Compressor Manifold
    G03273945Courtesy of FORD MOTOR CO.
  39. Connect the mass air flow (MAF) sensor electrical connector.
    Fig 31: Connecting Mass Air Flow (MAF) Sensor Electrical Connector
    G03273946Courtesy of FORD MOTOR CO.
  40. Connect the A/C compressor clutch electrical connector.
    Fig 32: Connecting A/C Compressor Clutch Electrical Connector
    G03273947Courtesy of FORD MOTOR CO.
  41. Connect the coolant reservoir-to-engine supply hose.
    Fig 33: Connecting Coolant Reservoir-To-Engine Supply Hose
    G03273948Courtesy of FORD MOTOR CO.
  42. Connect the engine-to-coolant reservoir bypass hose.
    Fig 34: Connecting Engine-To-Coolant Reservoir Bypass Hose
    G03273949Courtesy of FORD MOTOR CO.
  43. Connect the vacuum hose to the vacuum reservoir.
    Fig 35: Connecting Vacuum Hose To Vacuum Reservoir
    G03273950Courtesy of FORD MOTOR CO.
  44. Install the heater hose assembly.
    1. Connect the heater hoses to the engine.
    2. Connect the vacuum hose.
    3. Connect the heater hoses to the heater core.
      Fig 36: Installing Heater Hose Assembly
      G03273951Courtesy of FORD MOTOR CO.
  45. Install the ground stud for the PCM.
    Fig 37: Installing Ground Stud For PCM
    G03273952Courtesy of FORD MOTOR CO.
  46. Position the PCM harness. Install the retaining nut on the harness clamp. Connect the PCM connector.
    Fig 38: Installing Retaining Nut On Harness Clamp & Connecting PCM
    G03273953Courtesy of FORD MOTOR CO.
  47. Install the lower radiator hose.
    Fig 39: Installing Lower Radiator Hose
    G03273954Courtesy of FORD MOTOR CO.
  48. Install the fan shroud. For additional information, refer to ENGINE COOLING .
  49. Install the upper radiator hose.
    Fig 40: Installing Upper Radiator Hose
    G03273955Courtesy of FORD MOTOR CO.
  50. Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  51. Install the accelerator control snow shield.
    Fig 41: Installing Accelerator Control Snow Shield
    G03273956Courtesy of FORD MOTOR CO.
  52. Install the hood.
  53. Fill the engine with clean engine oil.
  54. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  55. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
  56. Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
  57. Evacuate and charge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
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