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Section 1326 (Engine - SVT): Installation: Engine

WARNING: This page is about a different car, the 2004 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL SPECIFICATIONS

G04035313
 Spreader Bar
303-D089 (D93P-6001-A3)
G04035314
 Remover/Installer, Cooling Hose Clamp
412-108 (T96P-18539-A)
G04035315
 Lifting Bracket, Engine
303-050 (T70P-6000)
GENERAL EQUIPMENT SPECIFICATIONS

Assembly Stand
Retaining Strap
MATERIAL SPECIFICATIONS

Item Specification
SAE 5W-30 Super Premium Motor Oil
XO-5W30-DSP		 WSS-M2C153-G
SAE 5W-30 Super Premium Motor Oil
XO-5W30-QSP		 WSS-M2C153-G

All vehicles 

  1. Install the transaxle.
  2. Install the transaxle LH retaining bolts.
    Fig 1: Installing Transaxle LH Retaining Bolts
    G04035316Courtesy of FORD MOTOR CO.
  3. Install the transaxle RH retaining bolts.
    Fig 2: Installing Transaxle RH Retaining Bolts
    G04035317Courtesy of FORD MOTOR CO.
  4. Install the starter motor.
    • Attach the ground cable to the transaxle.
    Fig 3: Installing Starter Motor
    G04035318Courtesy of FORD MOTOR CO.
  5. Connect the starter motor electrical connectors.
    Fig 4: Connecting Starter Motor Electrical Connectors
    G04035319Courtesy of FORD MOTOR CO.
  6. Install the transaxle upper retaining bolts.
    Fig 5: Installing Transaxle Upper Retaining Bolts
    G04035320Courtesy of FORD MOTOR CO.
  7. Using a retaining strap, secure the engine and transmission assembly on the assembly stand.
    • Remove the special tools.
    Fig 6: Removing Special Tools
    G04035321Courtesy of FORD MOTOR CO.
  8. Position the engine and transmission assembly under the vehicle.
    • Carefully lower the vehicle.
    Fig 7: Positioning Engine And Transmission Assembly Under Vehicle
    G04035322Courtesy of FORD MOTOR CO.
    9. NOTE: Do not tighten the bolts and nuts at this stage.
    Fig 8: Installing Engine Front Mount
    G04035323Courtesy of FORD MOTOR CO.
  9. Install the engine front mount.
    10. NOTE: Do not tighten the bolts at this stage.
    Fig 9: Installing Engine Rear Mount
    G04035324Courtesy of FORD MOTOR CO.
  10. Install the engine rear mount.
  11. Remove the retaining strap from the engine and transmission assembly, and remove the assembly stand.
  12. Raise and support the vehicle. For additional information, refer to JACKING AND LIFTING .
    13. CAUTION: Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION: Do not damage the halfshaft oil seal.
    NOTE: Install a new halfshaft center bearing cap and locknuts.
    Fig 10: Installing Center Bearing Cap
    G04035325Courtesy of FORD MOTOR CO.
  13. Attach the RH halfshaft and the intermediate shaft to the transaxle.
    • Install the center bearing cap.
    14. CAUTION: Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION: Do not damage the halfshaft oil seal.
    CAUTION: Make sure the snap ring is correctly seated.
    NOTE: Install a new snap ring.
    Fig 11: Installing Snap Ring
    G04035326Courtesy of FORD MOTOR CO.
  14. Attach the LH halfshaft to the transaxle.
    15. NOTE: Install a new exhaust flange gasket and new nuts.
    Fig 12: Installing Flexible Exhaust Pipe
    G04035327Courtesy of FORD MOTOR CO.
  15. Install the flexible exhaust pipe.
    16. NOTE: Install a new exhaust flange gasket and new nuts.
    Fig 13: Attaching Catalytic Converter To Exhaust Manifold
    G04035328Courtesy of FORD MOTOR CO.
  16. Attach the catalytic converter to the exhaust manifold.
    • Install the heated oxygen (HO2S) sensor.
  17. Install the catalytic converter bracket.
    • Install the catalyst monitor sensor (CMS).
    Fig 14: Installing Catalytic Converter Bracket
    G04035329Courtesy of FORD MOTOR CO.
  18. Lower the vehicle.
  19. Tighten the engine rear mount nuts and bolts.
    Fig 15: Tightening Engine Rear Mount Nuts And Bolts
    G04035330Courtesy of FORD MOTOR CO.
  20. Tighten the engine front mount nuts.
    Fig 16: Tightening Engine Front Mount Nuts
    G04035331Courtesy of FORD MOTOR CO.
  21. Install the power steering pump bracket.
    Fig 17: Installing Power Steering Pump Bracket
    G04035332Courtesy of FORD MOTOR CO.
  22. Raise and support the vehicle. For additional information, refer to JACKING AND LIFTING .
  23. Install the power steering pump lower retaining bolts.
    Fig 18: Installing Power Steering Pump Lower Retaining Bolts
    G04035333Courtesy of FORD MOTOR CO.
  24. Connect the power steering pressure switch electrical connector.
    Fig 19: Connecting Power Steering Pressure Switch Electrical Connector
    G04035334Courtesy of FORD MOTOR CO.
  25. Connect the crankshaft position sensor electrical connector.
    Fig 20: Connecting Crankshaft Position Sensor Electrical Connector
    G04035335Courtesy of FORD MOTOR CO.
  26. Connect the radiator lower coolant hose to the coolant pump housing.
    Fig 21: Connecting Radiator Lower Coolant Hose To Coolant Pump Housing
    G04035336Courtesy of FORD MOTOR CO.
  27. Connect the radiator lower coolant hose to the oil cooler.
    Fig 22: Connecting Radiator Lower Coolant Hose To Oil Cooler
    G04035337Courtesy of FORD MOTOR CO.
  28. Connect the reversing lamp switch electrical connector.
    • Clip on the wiring loom.
    Fig 23: Connecting Reversing Lamp Switch Electrical Connector
    G04035338Courtesy of FORD MOTOR CO.
  29. Connect the vehicle speed sensor (VSS) electrical connector.
    Fig 24: Connecting Vehicle Speed Sensor Electrical Connector
    G04035339Courtesy of FORD MOTOR CO.
  30. Install the crossmember.
  31. Connect the oil cooler hose.
    Fig 25: Connecting Oil Cooler Hose
    G04035340Courtesy of FORD MOTOR CO.
  32. Attach the gearshift cables to the transaxle.
    1. Attach the retaining bracket to the transaxle.
    2. Attach the gearshift cable and the selector cable to the selector levers.
    Fig 26: Attaching Gearshift Cables To Transaxle
    G04035341Courtesy of FORD MOTOR CO.
  33. Connect the starter field wire electrical connector.
    Fig 27: Connecting Starter Field Wire Electrical Connector
    G04035342Courtesy of FORD MOTOR CO.
  34. Install the power steering pump upper bolts.
    Fig 28: Installing Power Steering Pump Upper Bolts
    G04035343Courtesy of FORD MOTOR CO.
  35. Attach the coolant hoses to the thermostat housing.
    Fig 29: Attaching Coolant Hoses To Thermostat Housing
    G04035344Courtesy of FORD MOTOR CO.
  36. Attach the fuel pipes to the fuel rail.
    Fig 30: Attaching Fuel Pipes To Fuel Rail
    G04035345Courtesy of FORD MOTOR CO.
  37. Attach the brake servo vacuum hose to the intake manifold.
    Fig 31: Attaching Brake Servo Vacuum Hose To Intake Manifold
    G04035346Courtesy of FORD MOTOR CO.
  38. Attach the vacuum hoses to the throttle body.
    Fig 32: Attaching Vacuum Hoses To Throttle Body
    G04035347Courtesy of FORD MOTOR CO.
  39. Attach the power steering line bracket to the cylinder head.
    Fig 33: Attaching Power Steering Line Bracket To Cylinder Head
    G04035348Courtesy of FORD MOTOR CO.
  40. Install the power assisted steering (PAS) reservoir.
    Fig 34: Installing Power Assisted Steering Reservoir
    G04035349Courtesy of FORD MOTOR CO.
  41. Install the coolant expansion tank.
    Fig 35: Installing Coolant Expansion Tank
    G04035350Courtesy of FORD MOTOR CO.
  42. Connect the wiring harness connectors.
    Fig 36: Connecting Wiring Harness Connectors
    G04035351Courtesy of FORD MOTOR CO.
    43. WARNING: Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or eyes. If brake fluid should come into contact with your skin or eyes, rinse the affected area immediately with water.
    CAUTION: If any brake fluid gets on the paintwork wash it off immediately with water.
    Fig 37: Attaching Clutch Supply Line To Clutch Slave Cylinder
    G04035352Courtesy of FORD MOTOR CO.
  43. Attach the clutch supply line to the clutch slave cylinder.
    • Install the clip.
  44. Bleed the hydraulic clutch operating system. For additional information, refer to MANUAL TRANSMISSION, CLUTCH & TRANSFER CASE - GENERAL INFORMATION .
  45. Connect the ignition coil pack electrical connector.
    • Connect the radio capacitor.
    Fig 38: Connecting Ignition Coil Pack Electrical Connector
    G04035353Courtesy of FORD MOTOR CO.
  46. Connect the generator electrical connector.
    Fig 39: Connecting Generator Electrical Connector
    G04035354Courtesy of FORD MOTOR CO.
  47. Connect the fuel injector wiring harness.
    Fig 40: Connecting Fuel Injector Wiring Harness
    G04035355Courtesy of FORD MOTOR CO.
  48. Install the ignition coil pack cover.
    Fig 41: Installing Ignition Coil Pack Cover
    G04035356Courtesy of FORD MOTOR CO.
  49. Attach the accelerator cable and the speed control cable (if equipped) to the throttle body.
    Fig 42: Attaching Accelerator Cable And Speed Control Cable
    G04035357Courtesy of FORD MOTOR CO.
  50. Install the splash shield.
    Fig 43: Installing Splash Shield
    G04035358Courtesy of FORD MOTOR CO.
  51. Connect the engine block heater (if equipped).
    Fig 44: Connecting Engine Block Heater
    G04035359Courtesy of FORD MOTOR CO.
  52. Connect the intake manifold runner control (IMRC).
    1. Rotate the IMRC lever.
    2. Connect the IMRC actuator cable.
    Fig 45: Connecting Intake Manifold Runner Control
    G04035360Courtesy of FORD MOTOR CO.
  53. Install the air cleaner intake tube and resonator.
    Fig 46: Installing Air Cleaner Intake Tube And Resonator
    G04035361Courtesy of FORD MOTOR CO.
  54. Tighten the strut and spring assembly upper mounting retaining nuts.
    Fig 47: Tightening Strut And Spring Assembly Upper Mounting Retaining Nuts
    G04035362Courtesy of FORD MOTOR CO.
  55. Attach the ground cable to the inner fender.
    Fig 48: Attaching Ground Cable To Inner Fender
    G04035363Courtesy of FORD MOTOR CO.
  56. Install the air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  57. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
    58. CAUTION: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
  58. Install and connect the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  59. Fill the transaxle. For additional information, refer to MANUAL TRANSMISSION, CLUTCH & TRANSFER CASE - GENERAL INFORMATION .

    60. Vehicles with air conditioning 

  60. Install the air conditioning (A/C) compressor.
    Fig 49: Installing Air Conditioning Compressor
    G04035364Courtesy of FORD MOTOR CO.

    61. All vehicles 

  61. Fill the engine with engine oil.
  62. Fill the cooling system. For additional information, refer to ENGINE COOLING .
  63. Fill and bleed the PAS system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
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