LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2000 >> ZX2 Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1327 (Engine - 2.3L) >> Installation >> Engine
April 5, 2026: LEMON Manuals is launched! Read the announcement.

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

G04035827
Powertrain Lift With Tilting Plate
014-00765 or equivalent
G04035828
Universal Adapter Brackets
014-0001
G04035829
Heavy Duty Floor Crane
014-00071 or equivalent
G04035830
Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04035831
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 

  1. Remove the special tool from the torque converter.
    • Install the dowel pins.
    Fig 1: Removing Special Tool From Torque Converter
    G04035832Courtesy of FORD MOTOR CO.
  2. NOTE: Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 2: Checking Installation Depth Of Torque Converter
    G04035833Courtesy of FORD MOTOR CO.
  3. Check the installation depth of the torque converter.
    1. Lay a steel straightedge on the automatic transaxle flange.
    2. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
  4. NOTE: The engine and transaxle are shown separated for clarity.
    Fig 3: Installing Five Of Six Top Bolts
    G04035834Courtesy of FORD MOTOR CO.
  5. Using the engine crane, position the engine and transaxle together and install five of the six top bolts.
  6. NOTE: Make sure to note the location of the different length bolts.
    Fig 4: Installing LH Flange Bolts
    G04035835Courtesy of FORD MOTOR CO.
  7. Install the LH flange bolts.
  8. Vehicles equipped with manual transmissions 

  9. Install the transaxle. Make sure the transaxle is flush to the engine.
  10. CAUTION: Failure to follow these steps will result in gear rattle at idle.
  11. Install the two bolts at the dowels first. Tighten to specification.
  12. Install the remaining transaxle RH flange bolts.
    Fig 5: Installing Remaining Transaxle RH Flange Bolts
    G04035836Courtesy of FORD MOTOR CO.
  13. All vehicles 

  14. Using the special tools, raise the engine and transaxle assembly.
    Fig 6: Raising Engine Using Special Tools
    G04035837Courtesy of FORD MOTOR CO.
    Fig 7: Raising Transaxle Assembly Using Special Tools
    G04035838Courtesy of FORD MOTOR CO.
  15. Using the special tools, secure the engine and transaxle assembly to the lift table.
  16. Vehicles equipped with automatic transmissions 

  17. Connect the output shaft speed (OSS) sensor electrical connector.
    Fig 8: Connecting Output Shaft Speed Sensor Electrical Connector
    G04035839Courtesy of FORD MOTOR CO.
  18. Connect the solenoid body and the transmission range (TR) sensor electrical connectors.
    Fig 9: Connecting Solenoid Body And Transmission Range Sensor Electrical Connectors
    G04035840Courtesy of FORD MOTOR CO.
  19. Connect the turbine shaft speed (TSS) sensor electrical connector.
    Fig 10: Connecting Turbine Shaft Speed Sensor Electrical Connector
    G04035841Courtesy of FORD MOTOR CO.
  20. Vehicles equipped with manual transmissions 

  21. Connect the vehicle speed sensor (VSS) electrical connector.
    Fig 11: Connecting Vehicle Speed Sensor Electrical Connector
    G04035842Courtesy of FORD MOTOR CO.
  22. All vehicles 

  23. Using the lift table, position the engine and transaxle assembly in the vehicle.
  24. Install the RH motor mount nuts.
    Fig 12: Installing RH Motor Mount Nuts
    G04035843Courtesy of FORD MOTOR CO.
  25. Install the LH motor mount nut.
    Fig 13: Installing LH Motor Mount Nut
    G04035844Courtesy of FORD MOTOR CO.
  26. Remove the special tools and the lift table.
    Fig 14: Removing Special Tools
    G04035845Courtesy of FORD MOTOR CO.
  27. Install the lower motor mount.
    1. Install the lower mount.
    2. Install the bolts.
    Fig 15: Installing Lower Motor Mount
    G04035846Courtesy of FORD MOTOR CO.
  28. Install the two lower engine-to-bellhousing bolts.
    Fig 16: Installing Lower Engine-To-Bellhousing Bolts
    G04035847Courtesy of FORD MOTOR CO.
  29. Install the remaining engine-to-bellhousing bolts.
    Fig 17: Installing Remaining Engine-To-Bellhousing Bolts
    G04035848Courtesy of FORD MOTOR CO.
  30. 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.
    Fig 18: Installing Torque Converter Nuts
    G04035849Courtesy of FORD MOTOR CO.
  31. Install the four torque converter nuts.
  32. All vehicles 

  33. Install the starter motor isolator.
    Fig 19: Identifying Starter Motor Isolator
    G03897895Courtesy of FORD MOTOR CO.
  34. Install the starter motor and the bolts.
    Fig 20: Installing Starter Motor And Bolts
    G04035851Courtesy of FORD MOTOR CO.
  35. Install the generator heat shield and the lower nut.
    Fig 21: Installing Generator Heat Shield And Lower Nut
    G04035852Courtesy of FORD MOTOR CO.
  36. Vehicles with air conditioning 

    NOTE: Install new O-ring seals.
    Fig 22: Installing Compressor Manifold And Tube Assembly
    G04035853Courtesy of FORD MOTOR CO.
  37. Position the compressor to the manifold and tube assembly and tighten the bolt.
  38. Install the A/C compressor and the three bolts and connect the field coil electrical connector.
    Fig 23: Installing A/C Compressor And Three Bolts
    G04035854Courtesy of FORD MOTOR CO.
  39. All vehicles 

  40. Attach the power steering pressure tube brackets to the stud bolts and install the nuts.
    Fig 24: Attaching Power Steering Pressure Tube Brackets To Stud Bolts
    G04035855Courtesy of FORD MOTOR CO.
  41. Connect the starter motor electrical connections.
    Fig 25: Connecting Starter Motor Electrical Connections
    G04035856Courtesy of FORD MOTOR CO.
  42. Install the cooling fan.
    Fig 26: Installing Cooling Fan
    G04035857Courtesy of FORD MOTOR CO.
  43. Vehicles equipped with automatic transmissions 

  44. Connect the transmission cooler hoses.
    Fig 27: Connecting Transmission Cooler Hoses
    G04035858Courtesy of FORD MOTOR CO.
  45. Connect the transmission shifter cable.
    Fig 28: Connecting Transmission Shifter Cable
    G04035859Courtesy of FORD MOTOR CO.
  46. All vehicles 

  47. Position the battery cable and install the cable bracket nut.
    Fig 29: Installing Cable Bracket Nut
    G04035860Courtesy of FORD MOTOR CO.
  48. Install the generator cooling tube.
    Fig 30: Installing Generator Cooling Tube
    G04035861Courtesy of FORD MOTOR CO.
  49. Install the generator heat shield top nut.
    Fig 31: Installing Generator Heat Shield Top Nut
    G04035862Courtesy of FORD MOTOR CO.
  50. Install the generator B+ cable and install the cable nut.
    Fig 32: Installing Generator B+ Cable
    G04035863Courtesy of FORD MOTOR CO.
  51. Install the upper radiator hose.
    Fig 33: Installing Upper Radiator Hose
    G04035864Courtesy of FORD MOTOR CO.
  52. Position the ground cable and install the bolt.
    Fig 34: Installing Bolt
    G04035865Courtesy of FORD MOTOR CO.
  53. Connect the cooling fan electrical connector.
    Fig 35: Connecting Cooling Fan Electrical Connector
    G04035866Courtesy of FORD MOTOR CO.
  54. Connect the cooling fan electrical connector.
    Fig 36: Connecting Cooling Fan Electrical Connector
    G04035867Courtesy of FORD MOTOR CO.
  55. Connect the wiring harness retainers to the valve cover studs.
    Fig 37: Connecting Wiring Harness Retainers To Valve Cover Studs
    G04035868Courtesy of FORD MOTOR CO.
  56. Position the power steering pump (PSP) and install the bolts.
    Fig 38: Installing PSP Bolts
    G04035869Courtesy of FORD MOTOR CO.
  57. Connect the PSP tube.
    Fig 39: Connecting PSP Tube
    G04035870Courtesy of FORD MOTOR CO.
  58. NOTE: Make sure the pulley is flush with the end of the power steering pump shaft.
    Fig 40: Installing Power Steering Pump Pulley
    G04035871Courtesy of FORD MOTOR CO.
  59. Using the special tool, install the power steering pump pulley.
  60. Connect the PSP switch electrical connector.
    Fig 41: Connecting PSP Switch Electrical Connector
    G04035872Courtesy of FORD MOTOR CO.
  61. Connect the three main engine wiring harness connectors.
    Fig 42: Connecting Main Engine Wiring Harness Connectors
    G04035873Courtesy of FORD MOTOR CO.
  62. Install the coolant expansion tank. For additional information, refer to ENGINE COOLING .
  63. Connect the heater hose to the "T" fitting.
    Fig 43: Connecting Heater Hose To "T" Fitting
    G04035874Courtesy of FORD MOTOR CO.
  64. Connect the exhaust gas recirculation (EGR) valve electrical connector.
    Fig 44: Connecting Exhaust Gas Recirculation Valve Electrical Connector
    G04035875Courtesy of FORD MOTOR CO.
  65. Connect the fuel injection supply manifold wiring harness electrical connector.
    Fig 45: Connecting Fuel Injection Supply Manifold Wiring Harness Electrical Connector
    G04035876Courtesy of FORD MOTOR CO.
  66. Reposition the accelerator cable bracket.
    1. Position the accelerator cable bracket.
    2. Install the speed control cable (if equipped) and the throttle cable.
    Fig 46: Installing Speed Control Cable And Throttle Cable
    G04035877Courtesy of FORD MOTOR CO.
  67. Attach the hose and install the screw and the pin-type retainer.
    • Install the snow shield.
    Fig 47: Installing Screw And Pin-Type Retainer
    G04035878Courtesy of FORD MOTOR CO.
  68. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
  69. Connect the lower radiator hose, the heater hose and the overflow hose to the coolant bypass.
    Fig 48: Connecting Lower Radiator Hose, Heater Hose And Overflow Hose To Coolant Bypass
    G04035879Courtesy of FORD MOTOR CO.
  70. Connect the engine emissions hose and EGR vacuum regulator solenoid electrical connector.
    Fig 49: Connecting Engine Emissions Hose And EGR Vacuum Regulator Solenoid Electrical Connector
    G04035880Courtesy of FORD MOTOR CO.
  71. Install the vapor tube.
    Fig 50: Installing Vapor Tube
    G04035881Courtesy of FORD MOTOR CO.
  72. Connect the fuel tube. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  73. Install the brake booster vacuum hose.
    Fig 51: Installing Brake Booster Vacuum Hose
    G04035882Courtesy of FORD MOTOR CO.
  74. Fill the engine with clean engine oil.
  75. NOTE: Install a new snap ring.
    Fig 52: Installing LH Front Drive Halfshaft
    G04035883Courtesy of FORD MOTOR CO.
  76. Install the LH front drive halfshaft.
  77. NOTE: Install new nuts and a new center bearing cap.
    Fig 53: Installing RH Front Halfshaft Together With Intermediate Shaft
    G04035884Courtesy of FORD MOTOR CO.
  78. Install the RH front halfshaft together with the intermediate shaft.
  79. Install the mounting bracket for the front drive halfshaft intermediate bearing.
    Fig 54: Installing Mounting Bracket For Front Drive Halfshaft Intermediate Bearing
    G04035885Courtesy of FORD MOTOR CO.
  80. Install both of the lower control arms to the knuckles.
    1. Connect the suspension arm ball joint.
    2. Install the bolt.
    Fig 55: Installing Lower Control Arms To Knuckles
    G04035886Courtesy of FORD MOTOR CO.
  81. Install both of the tie-rod ends to the knuckles.
    Fig 56: Installing Tie-Rod Ends To Knuckles
    G04035887Courtesy of FORD MOTOR CO.
  82. Connect the stabilizer bar at the strut.
    Fig 57: Connecting Stabilizer Bar At Strut
    G04035888Courtesy of FORD MOTOR CO.
  83. Tighten the LH strut and spring assembly top mount nuts.
    Fig 58: Tightening LH Strut And Spring Assembly Top Mount Nuts
    G04035889Courtesy of FORD MOTOR CO.
  84. Install the caliper.
    1. Install the bolts.
    2. Install the covers.
    Fig 59: Installing Caliper Bolt Covers
    G04035890Courtesy of FORD MOTOR CO.
  85. Install the brake hose onto the support bracket.
    Fig 60: Installing Brake Hose Onto Support Bracket
    G04035891Courtesy of FORD MOTOR CO.
  86. Install the accessory drive belt.
  87. Vehicle equipped with manual transmissions 

  88. Connect the reversing lamp switch electrical connector.
    Fig 61: Connecting Reversing Lamp Switch Electrical Connector
    G04035892Courtesy of FORD MOTOR CO.
  89. 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.
    Fig 62: Connecting Clutch Slave Cylinder Supply Line
    G04035893Courtesy of FORD MOTOR CO.
  90. Connect the clutch slave cylinder supply line.
    • Insert the clip.
  91. NOTE: The shift cable abutment sleeve is colored white.
    NOTE: The selector cable abutment sleeve is colored black.
    Fig 63: Attaching Gearshift Cables To Bracket
    G04035894Courtesy of FORD MOTOR CO.
  92. Attach the gearshift cables to the bracket.
    1. Attach the shifter cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
    2. Attach the selector cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
  93. Attach the gearshift cables.
    1. Attach the shifter cable to the shift mast.
    2. Attach the selector cable to the selector lever.
    Fig 64: Attaching Gearshift Cables
    G04035895Courtesy of FORD MOTOR CO.
  94. Check the shift cables at the metal holders. Pull outward on the cables. Cables should remain in the metal.
  95. Adjust the shift cables. For additional information, refer to MANUAL TRANSMISSION/TRANSAXLE & CLUTCH - GENERAL INFORMATION .
  96. Fill and bleed the clutch hydraulic system. For additional information, refer to CLUTCH CONTROLS - MT285/MTX75 TRANSAXLE .
  97. Vehicles equipped with air conditioning 

  98. Evacuate and recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  99. All vehicles 

  100. Install the air intake resonator. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  101. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  102. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  103. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  104. Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .