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Section 300 (Engine-2.3L): Installation: Engine: 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 engine and transaxle are shown separated for clarity.
    Fig 1: Positioning Engine And Transaxle
    G01611702Courtesy of FORD MOTOR CO.
  1. Using the engine crane, position the engine and transaxle together and install five of the six top bolts.
  2. Using the special tools, secure the engine and transaxle assembly to the lift table.
    Fig 2: Securing Engine And Transaxle Assembly To Lift Table
    G01611703Courtesy of FORD MOTOR CO.
  3. Using the lift table, position the engine and transaxle assembly in the vehicle.
  4. Connect the output shaft speed (OSS) sensor electrical connector.
    Fig 3: Connecting Output Shaft Speed (OSS) Sensor Electrical Connector
    G01611704Courtesy of FORD MOTOR CO.

    5. Vehicles Equipped With An Automatic Transmission 

  5. 5.
    NOTE: If new parts are not being used, be sure to align the marks on the flexplate and the stud made during engine removal.

    Install the four torque converter nuts.

    Fig 4: Installing Torque Converter Nuts
    G01611705Courtesy of FORD MOTOR CO.
  6. Connect the solenoid body and the transmission range (TR) sensor electrical connectors.
    Fig 5: Connecting Solenoid Body And Transmission Range (TR) Sensor Electrical Connectors
    G01611706Courtesy of FORD MOTOR CO.
  7. Connect the turbine speed shaft (TSS) sensor electrical connector.
    Fig 6: Connecting Turbine Speed Shaft (TSS) Sensor Electrical Connector
    G01611707Courtesy of FORD MOTOR CO.

    8. All vehicles 

  8. Install the LH motor mount nut.
    Fig 7: Installing LH Motor Mount Nut
    G01611708Courtesy of FORD MOTOR CO.
  9. Install the RH motor mount and the bolts.
    Fig 8: Installing RH Motor Mount
    G01611709Courtesy of FORD MOTOR CO.
  10. Install the RH motor mount nuts.
    Fig 9: Installing RH Motor Mount Nuts
    G01611710Courtesy of FORD MOTOR CO.
  11. Install the lower motor mount.
    1. Install the lower mount.
    2. Install the bolts.
      Fig 10: Installing Lower Motor Mount
      G01611711Courtesy of FORD MOTOR CO.
  12. Install the two lower engine-to-bell housing bolts.
    Fig 11: Installing Lower Engine-To-Bell Housing Bolts
    G01611712Courtesy of FORD MOTOR CO.
  13. Install the remaining engine-to-bell housing bolts.
    Fig 12: Installing Remaining Engine-To-Bell Housing Bolts
    G01611713Courtesy of FORD MOTOR CO.
  14. Position the ground cable and install the bolt.
    Fig 13: Installing Ground Cable
    G01611714Courtesy of FORD MOTOR CO.
  15. Install the starter motor isolator.
    Fig 14: Installing Starter Motor Isolator
    G01611715Courtesy of FORD MOTOR CO.
  16. Install the starter motor and the bolts.
    Fig 15: Installing Starter Motor Bolts
    G01611716Courtesy of FORD MOTOR CO.
  17. Position the power steering pump and install the bolts.
    Fig 16: Installing Power Steering Pump Bolts
    G01611717Courtesy of FORD MOTOR CO.
  18. Connect the generator electrical connectors.
    Fig 17: Connecting Generator Electrical Connectors
    G01611718Courtesy of FORD MOTOR CO.
  19. Install the generator coolant tube.
    Fig 18: Installing Generator Coolant Tube
    G01611719Courtesy of FORD MOTOR CO.
  20. Install the upper radiator hose.
    Fig 19: Installing Upper Radiator Hose
    G01611720Courtesy of FORD MOTOR CO.
  21. Install the A/C compressor and the three bolts.
    Fig 20: Installing A/C Compressor
    G01611721Courtesy of FORD MOTOR CO.
  22. Install the power steering pressure (PSP) tube retaining bolt.
    Fig 21: Installing Power Steering Pressure (PSP) Tube Retaining Bolt
    G01611722Courtesy of FORD MOTOR CO.
  23. Connect the starter motor electrical connections.
    Fig 22: Connecting Starter Motor Electrical Connections
    G01611723Courtesy of FORD MOTOR CO.
  24. Install the cooling fan.
    Fig 23: Installing Cooling Fan
    G01611724Courtesy of FORD MOTOR CO.

    25. Vehicles Equipped With An Automatic Transmission 

  25. Connect the transmission cooler hoses.
    Fig 24: Connecting Transmission Cooler Hoses
    G01611725Courtesy of FORD MOTOR CO.
  26. Connect the transmission shifter cable.
    Fig 25: Connecting Transmission Shifter Cable
    G01611726Courtesy of FORD MOTOR CO.
  27. Install the three transmission shifter bracket bolts.
    Fig 26: Installing Three Transmission Shifter Bracket Bolts
    G01611727Courtesy of FORD MOTOR CO.

    28. All Vehicles 

  28. Connect the cooling fan electrical connector.
    Fig 27: Connecting Cooling Fan Electrical Connector
    G01611728Courtesy of FORD MOTOR CO.
  29. Connect the cooling fan electrical connector.
    Fig 28: Connecting Cooling Fan Electrical Connector
    G01611729Courtesy of FORD MOTOR CO.
  30. Position the radio interference capacitor and install the bolt.
    Fig 29: Installing Radio Interference Capacitor
    G01611730Courtesy of FORD MOTOR CO.
  31. Connect the wiring harness retainers to the valve cover studs.
    Fig 30: Connecting Wiring Harness Retainers To Valve Cover Studs
    G01611731Courtesy of FORD MOTOR CO.
  32. Connect the three main engine wiring harness connectors.
    Fig 31: Connecting Main Engine Wiring Harness Connectors
    G01611732Courtesy of FORD MOTOR CO.
  33. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
  34. Connect the PSP tube.
    Fig 32: Connecting PSP Tube
    G01611733Courtesy of FORD MOTOR CO.
  35. Connect the PSP switch electrical connector.
    Fig 33: Connecting PSP Switch Electrical Connector
    G01611734Courtesy of FORD MOTOR CO.
  36. Install the coolant overflow bottle. For additional information, refer to ENGINE COOLING .
  37. Connect the coil-on-plug electrical connectors.
    Fig 34: Connecting Coil-On-Plug Electrical Connectors
    G01611735Courtesy of FORD MOTOR CO.
  38. Connect the heater hose to the "T" fitting.
    Fig 35: Connecting Heater Hose To "T" Fitting
    G01611736Courtesy of FORD MOTOR CO.
  39. Connect the exhaust gas recirculation (EGR) valve electrical connector.
    Fig 36: Connecting Exhaust Gas Recirculation (EGR) Valve Electrical Connector
    G01611737Courtesy of FORD MOTOR CO.
  40. Connect the fuel injection supply manifold wiring harness electrical connector.
    Fig 37: Connecting Fuel Injection Supply Manifold Wiring Harness Electrical Connector
    G01611738Courtesy of FORD MOTOR CO.
  41. Reposition the accelerator cable bracket.
    1. Position the accelerator cable bracket.
    2. Install the speed control cable (if equipped) and the throttle cable.
      Fig 38: Repositioning Accelerator Cable Bracket
      G01611739Courtesy of FORD MOTOR CO.
  42. Connect the temperature manifold absolute pressure (TMAP) sensor electrical connector.
    Fig 39: Connecting Temperature Manifold Absolute Pressure (TMAP) Sensor Electrical Connector
    G01611740Courtesy of FORD MOTOR CO.
  43. Connect the lower radiator hose, the heater hose and the overflow hose to the coolant bypass.
    Fig 40: Connecting Lower Radiator Hose, Heater Hose And Overflow Hose To Coolant Bypass
    G01611741Courtesy of FORD MOTOR CO.
  44. Connect the EGR vacuum regulator solenoid hose.
    Fig 41: Connecting EGR Vacuum Regulator Solenoid Hose
    G01611742Courtesy of FORD MOTOR CO.
  45. Connect the engine emissions hose and EGR vacuum regulator solenoid electrical connector.
    Fig 42: Connecting Engine Emissions Hose And EGR Vacuum Regulator Solenoid Electrical Connector
    G01611743Courtesy of FORD MOTOR CO.
  46. Install the vapor tube.
    Fig 43: Installing Vapor Tube
    G01611744Courtesy of FORD MOTOR CO.
  47. Install the fuel tube.
    Fig 44: Installing Fuel Tube
    G01611745Courtesy of FORD MOTOR CO.
  48. Fill the engine oil.
  49. Fill the cooling system. For additional information, refer to ENGINE COOLING .
  50. Fill the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  51. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  52. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  53. Install the halfshafts. For additional information, refer to AXLE SHAFTS .
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