Section 1327 (Engine - 2.3L): 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
| Powertrain Lift With Tilting Plate 014-00765 or equivalent |
|
| Universal Adapter Brackets 014-0001 |
|
| Heavy Duty Floor Crane 014-00071 or equivalent |
|
| Spreader Bar 303-D089 (D93P-6001-A3) or equivalent |
|
| Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A) |
MATERIAL SPECIFICATIONS
| Item | Specification |
|---|---|
| Super Premium SAE 5W-20 Engine Oil XO-5W20-QSP or equivalent | WSS-M2C153-H |
| Motorcraft Premium Gold Engine Coolant VC-7-A or equivalent | WSS-M97B51-A1 |
| R-134a Refrigerant YN-19 | WSH-M17B19-A |
| MERCON V Automatic Transmission Fluid XT-5-QM | MERCON® V |
| Multi-Purpose Grease XG-4 | ESR-M1C159-A |
Vehicles equipped with automatic transmissions
- Remove the special tool from the torque converter.
- Install the dowel pins.
- Check the installation depth of the torque converter.
- Lay a steel straightedge on the automatic transaxle flange.
- Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
- Using the engine crane, position the engine and transaxle together and install five of the six top bolts.
- Install the LH flange bolts.
- Install the transaxle. Make sure the transaxle is flush to the engine.
- Install the two bolts at the dowels first. Tighten to specification.
- Install the remaining transaxle RH flange bolts.
- Using the special tools, raise the engine and transaxle assembly.
- Using the special tools, secure the engine and transaxle assembly to the lift table.
- Connect the output shaft speed (OSS) sensor electrical connector.
- Connect the solenoid body and the transmission range (TR) sensor electrical connectors.
- Connect the turbine shaft speed (TSS) sensor electrical connector.
- Connect the vehicle speed sensor (VSS) electrical connector.
- Using the lift table, position the engine and transaxle assembly in the vehicle.
- Install the RH motor mount nuts.
- Install the LH motor mount nut.
- Remove the special tools and the lift table.
- Install the lower motor mount.
- Install the lower mount.
- Install the bolts.
- Install the two lower engine-to-bellhousing bolts.
- Install the remaining engine-to-bellhousing bolts.
- Install the four torque converter nuts.
- Install the starter motor isolator.
- Install the starter motor and the bolts.
- Install the generator heat shield and the lower nut.
- Position the compressor to the manifold and tube assembly and tighten the bolt.
- Install the A/C compressor and the three bolts and connect the field coil electrical connector.
- Attach the power steering pressure tube brackets to the stud bolts and install the nuts.
- Connect the starter motor electrical connections.
- Install the cooling fan.
- Connect the transmission cooler hoses.
- Connect the transmission shifter cable.
- Position the battery cable and install the cable bracket nut.
- Install the generator cooling tube.
- Install the generator heat shield top nut.
- Install the generator B+ cable and install the cable nut.
- Install the upper radiator hose.
- Position the ground cable and install the bolt.
- Connect the cooling fan electrical connector.
- Connect the cooling fan electrical connector.
- Connect the wiring harness retainers to the valve cover studs.
- Position the power steering pump (PSP) and install the bolts.
- Connect the PSP tube.
- Using the special tool, install the power steering pump pulley.
- Connect the PSP switch electrical connector.
- Connect the three main engine wiring harness connectors.
- Install the coolant expansion tank. For additional information, refer to ENGINE COOLING .
- Connect the heater hose to the "T" fitting.
- Connect the exhaust gas recirculation (EGR) valve electrical connector.
- Connect the fuel injection supply manifold wiring harness electrical connector.
- Reposition the accelerator cable bracket.
- Position the accelerator cable bracket.
- Install the speed control cable (if equipped) and the throttle cable.
- Attach the hose and install the screw and the pin-type retainer.
- Install the snow shield.
- Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
- Connect the lower radiator hose, the heater hose and the overflow hose to the coolant bypass.
- Connect the engine emissions hose and EGR vacuum regulator solenoid electrical connector.
- Install the vapor tube.
- Connect the fuel tube. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
- Install the brake booster vacuum hose.
- Fill the engine with clean engine oil.
- Install the LH front drive halfshaft.
- Install the RH front halfshaft together with the intermediate shaft.
- Install the mounting bracket for the front drive halfshaft intermediate bearing.
- Install both of the lower control arms to the knuckles.
- Connect the suspension arm ball joint.
- Install the bolt.
- Install both of the tie-rod ends to the knuckles.
- Connect the stabilizer bar at the strut.
- Tighten the LH strut and spring assembly top mount nuts.
- Install the caliper.
- Install the bolts.
- Install the covers.
- Install the brake hose onto the support bracket.
- Install the accessory drive belt.
- Connect the reversing lamp switch electrical connector.
- Connect the clutch slave cylinder supply line.
- Insert the clip.
- Attach the gearshift cables to the bracket.
- Attach the shifter cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
- Attach the selector cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
- Attach the gearshift cables.
- Attach the shifter cable to the shift mast.
- Attach the selector cable to the selector lever.
- Check the shift cables at the metal holders. Pull outward on the cables. Cables should remain in the metal.
- Adjust the shift cables. For additional information, refer to MANUAL TRANSMISSION/TRANSAXLE & CLUTCH - GENERAL INFORMATION .
- Fill and bleed the clutch hydraulic system. For additional information, refer to CLUTCH CONTROLS - MT285/MTX75 TRANSAXLE .
- Evacuate and recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
- Install the air intake resonator. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
- Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
- Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
- Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
- Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
NOTE:
Lubricate the torque converter pilot hub with multi-purpose grease.
NOTE:
The engine and transaxle are shown separated for clarity.
NOTE:
Make sure to note the location of the different length bolts.
Vehicles equipped with manual transmissions
CAUTION:
Failure to follow these steps will result in gear rattle at idle.
All vehicles
Vehicles equipped with automatic transmissions
Vehicles equipped with manual transmissions
All vehicles
Vehicles equipped with automatic transmissions
NOTE:
If new parts are not being used, be sure to align the marks on the flexplate and the stud made during engine removal.
All vehicles
Vehicles with air conditioning
NOTE:
Install new O-ring seals.
All vehicles
Vehicles equipped with automatic transmissions
All vehicles
NOTE:
Make sure the pulley is flush with the end of the power steering pump shaft.
NOTE:
Install a new snap ring.
NOTE:
Install new nuts and a new center bearing cap.
Vehicle equipped with manual transmissions
WARNING:
Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or the eyes. If brake fluid does come into contact with the skin or the eyes, rinse the affected areas with water immediately. Failure to follow these instructions may result in personal injury.
CAUTION:
If brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.
NOTE:
The shift cable abutment sleeve is colored white.
NOTE:
The selector cable abutment sleeve is colored black.
Vehicles equipped with air conditioning
All vehicles