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Engine-Automatic Transaxle: Installation

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

    All Vehicles 

    NOTE: The location of the engine mountings and the engine support insulators are given looking from the automatic transaxle to the engine.
    Fig 1: Removing Special Tool
    G01615489Courtesy of FORD MOTOR CO.
  1. Remove the special tool.
    2. CAUTION: Insert a wooden block between jack and transaxle.
  2. Support the transaxle with a jack.
  3. Using the special tool and a suitable floor crane to bring the engine into installation position and lower it.
    Fig 2: Identifying Engine Into Installation Position
    G01615490Courtesy of FORD MOTOR CO.
  4. Install the transaxle upper flange bolts.
    Fig 3: Installing Transaxle Upper Flange Bolts
    G01615491Courtesy of FORD MOTOR CO.
  5. Install the upper starter bolts.
    Fig 4: Installing Upper Starter Bolts
    G01615492Courtesy of FORD MOTOR CO.
  6. Connect the crankshaft position (CKP) sensor electrical connector.
    Fig 5: Connecting Crankshaft Position Sensor Electrical Connector
    G01615493Courtesy of FORD MOTOR CO.
    7. NOTE: Do not tighten the bolts.
    Fig 6: Installing Engine Front Mount
    G01615494Courtesy of FORD MOTOR CO.
  7. Install the engine front mount.
  8. Connect the fuel hose.
    Fig 7: Connecting Fuel Hose
    G01615495Courtesy of FORD MOTOR CO.
  9. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  10. Install the transaxle right-hand flange bolt.
    Fig 8: Installing Transaxle Right-Hand Flange Bolt
    G01615496Courtesy of FORD MOTOR CO.
  11. Install the transaxle left-hand flange bolts.
    Fig 9: Installing Transaxle Left-Hand Flange Bolts
    G01615497Courtesy of FORD MOTOR CO.
  12. Install the transaxle lower flange bolts.
    Fig 10: Installing Transaxle Lower Flange Bolts
    G01615498Courtesy of FORD MOTOR CO.
  13. Install the torque converter to the engine drive plate (four nuts).
    Fig 11: Installing Torque Converter To Engine Drive Plate
    G01615499Courtesy of FORD MOTOR CO.
  14. Install the torque converter cover.
    Fig 12: Installing Torque Converter Cover
    G01615500Courtesy of FORD MOTOR CO.
  15. Install the starter motor.
    Fig 13: Installing Starter Motor
    G01615501Courtesy of FORD MOTOR CO.
  16. Install the starter motor electrical connectors.
    Fig 14: Installing Starter Motor Electrical Connectors
    G01615502Courtesy of FORD MOTOR CO.
  17. Install the engine roll restrictor.
    Fig 15: Installing Engine Roll Restrictor
    G01615503Courtesy of FORD MOTOR CO.
  18. Install the intermediate shaft bracket.
    Fig 16: Installing Intermediate Shaft Bracket
    G01615504Courtesy of FORD MOTOR CO.
    19. NOTE: Use a new retaining clamp.
    Fig 17: Installing Retaining Clamp
    G01615505Courtesy of FORD MOTOR CO.
  19. Install the retaining clamp.
    20. CAUTION: The inner part of the joint must not be bent at more than 18 degrees, the outer part no more than 45 degrees.
    NOTE: Use new clamping strap.
    Fig 18: Installing Front Drive Halfshafts
    G01615506Courtesy of FORD MOTOR CO.
  20. Using the special tool, install both front drive halfshafts (left-hand side shown).
  21. Install both suspension arms (right-hand side shown).
    Fig 19: Installing Suspension Arms
    G01615507Courtesy of FORD MOTOR CO.
  22. Connect the exhaust pipe.
    Fig 20: Connecting Exhaust Pipe
    G01615508Courtesy of FORD MOTOR CO.
  23. Connect the HO2S electrical connector.
    Fig 21: Connecting HO2S Electrical Connector
    G01615509Courtesy of FORD MOTOR CO.

    24. Vehicles With Air Conditioning 

  24. Install the compressor.
    Fig 22: Installing Compressor (W/ A/C)
    G01615510Courtesy of FORD MOTOR CO.

    25. All Vehicles 

  25. Install the crankshaft pulley.
    • Tighten the crankshaft pulley bolt.
      Fig 23: Installing Crankshaft Pulley
      G01615511Courtesy of FORD MOTOR CO.
  26. Lower the vehicle.
  27. Install the accessory drive bracket.
    Fig 24: Installing Accessory Drive Bracket
    G01615512Courtesy of FORD MOTOR CO.
  28. Install the coolant pipe.
    Fig 25: Installing Coolant Pipe
    G01615513Courtesy of FORD MOTOR CO.
  29. Install the generator (engine removed shown).
    Fig 26: Installing Generator
    G01615514Courtesy of FORD MOTOR CO.
  30. Tighten the nuts and bolts on the engine front mount.
    Fig 27: Tightening Nuts And Bolts On Engine Front Mount
    G01615515Courtesy of FORD MOTOR CO.
  31. Install the power steering pump.
    Fig 28: Installing Power Steering Pump
    G01615516Courtesy of FORD MOTOR CO.
  32. Using the special tool to prevent the power steering pump pulley from rotating install the power steering pump nut.

    Install the power steering pump pulley.

    Fig 29: Installing Power Steering Pump Pulley
    G01615517Courtesy of FORD MOTOR CO.
  33. Install the accessory drive belt.
    • Turn the belt tensioner clockwise.
      Fig 30: Installing Accessory Drive Belt
      G01615518Courtesy of FORD MOTOR CO.
  34. Push the power steering fluid reservoir into place.
    Fig 31: Pushing Power Steering Fluid Reservoir Into Place
    G01615519Courtesy of FORD MOTOR CO.
  35. Install the coolant expansion tank.
    Fig 32: Installing Coolant Expansion Tank
    G01615520Courtesy of FORD MOTOR CO.
  36. Install the fan to the radiator.
    • Position the air deflector and clip on the top on both sides (left-hand side shown).
    • Install the fan wiring harness.
      Fig 33: Installing Fan To Radiator
      G01615521Courtesy of FORD MOTOR CO.
  37. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  38. Install the accessory drive belt cover.
    Fig 34: Installing Accessory Drive Belt Cover
    G01615522Courtesy of FORD MOTOR CO.
  39. Lower the vehicle.
  40. Install the coolant hoses to the coolant hose connector.
    Fig 35: Installing Coolant Hoses To Coolant Hose Connector
    G01615523Courtesy of FORD MOTOR CO.
  41. Install the coolant hose to the coolant tube.
    Fig 36: Installing Coolant Hose To Coolant Tube
    G01615524Courtesy of FORD MOTOR CO.
  42. Install the coolant hose to the water pump.
    Fig 37: Installing Coolant Hose To Water Pump
    G01615525Courtesy of FORD MOTOR CO.
  43. Install the coolant hose to the intake manifold.
    Fig 38: Installing Coolant Hose To Intake Manifold
    G01615526Courtesy of FORD MOTOR CO.
  44. Connect the vacuum hose to the intake manifold.
    Fig 39: Connecting Vacuum Hose To Intake Manifold
    G01615527Courtesy of FORD MOTOR CO.
  45. Connect the vacuum hoses.
    1. EVAP
    2. Brake servo hose
    3. Delta pressure feedback vacuum hoses
    4. EGR hose
      Fig 40: Connecting Vacuum Hoses
      G01615528Courtesy of FORD MOTOR CO.
  46. Connect the radiator fan electrical connector.
    • Connect the cable ties.
      Fig 41: Connecting Radiator Fan Electrical Connector
      G01615529Courtesy of FORD MOTOR CO.
  47. Connect both PCM connectors.
    Fig 42: Connecting PCM Connectors
    G01615530Courtesy of FORD MOTOR CO.
  48. Connect the electrical connectors.
    1. Power steering pump pressure switch electrical connector
    2. Generator electrical connector
    3. Heated oxygen sensor electrical connector
      Fig 43: Connecting Electrical Connectors
      G01615531Courtesy of FORD MOTOR CO.
  49. Install the speed control cable.
    1. Hook the cable in place.
    2. Clip on the plastic clip.
      Fig 44: Installing Speed Control Cable
      G01615532Courtesy of FORD MOTOR CO.
  50. Install the accelerator cable.
    1. Hook the cable in place.
    2. Clip on the plastic clip.
      Fig 45: Installing Accelerator Cable
      G01615533Courtesy of FORD MOTOR CO.
  51. Install the intake pipe.
    Fig 46: Installing Intake Pipe
    G01615534Courtesy of FORD MOTOR CO.
  52. Install the air cleaner (ACL) housing.
    • Insert the ACL housing into the rubber bushing.
    1. Connect the MAF sensor electrical connector.
    2. Install the outlet pipe.
      Fig 47: Installing Air Cleaner Housing
      G01615535Courtesy of FORD MOTOR CO.
  53. Attach the ground cable.
    Fig 48: Attaching Ground Cable
    G01615536Courtesy of FORD MOTOR CO.
    54. NOTE: Use an Allen key to prevent the piston rod turning.
    Fig 49: Tightening Suspension Strut Nut
    G01615537Courtesy of FORD MOTOR CO.
  54. Tighten the suspension strut nut on both sides.
  55. Install the battery console.
    1. Install the positive and negative cables.
    2. Install the bolts.
    3. Clip on the wiring harness.
    4. Connect the electrical connector.
      Fig 50: Installing Battery Console
      G01615538Courtesy of FORD MOTOR CO.
  56. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  57. Fill the cooling system. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  58. Fill the engine with engine oil.
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