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Engine Mechanical: Mechanical: Engine-SVT: Installation: Engine: Installation

    All vehicles 

  1. 1.  Install the transaxle.
  2. 2.  Install the transaxle left-hand retaining bolts.
    Fig 1: Installing Transaxle Left-Hand Retaining Bolts
    G01615834Courtesy of FORD MOTOR CO.
  3. 3.  Install the transaxle right-hand retaining bolts.
    Fig 2: Installing Transaxle Right-Hand Retaining Bolts
    G01615835Courtesy of FORD MOTOR CO.
  4. 4.  Attach the starter motor to the transaxle.
    Fig 3: Attaching Starter Motor To Transaxle
    G01615836Courtesy of FORD MOTOR CO.
  5. 5.  Install the starter motor upper retaining bolts.
    • Attach the ground cable to the transaxle.
      Fig 4: Installing Starter Motor Upper Retaining Bolts
      G01615837Courtesy of FORD MOTOR CO.
  6. 6.  Install the transaxle upper retaining bolts.
    Fig 5: Installing Transaxle Upper Retaining Bolts
    G01615838Courtesy of FORD MOTOR CO.
    7. NOTE: Install a new exhaust flange gasket and new nuts.
    Fig 6: Attaching Catalytic Converter To Exhaust Manifold
    G01615839Courtesy of FORD MOTOR CO.
  7. 7.  Attach the catalytic converter to the exhaust manifold.
  8. 8.  Install the catalytic converter bracket.
    Fig 7: Installing Catalytic Converter Bracket
    G01615840Courtesy of FORD MOTOR CO.
  9. 9.  Using a securing strap, secure the transmission on the assembly table.
    • Remove the special tools.
      Fig 8: Securing Transmission On Assembly Table
      G01615841Courtesy of FORD MOTOR CO.
  10. 10.  Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  11. Position the engine and transmission assembly under the vehicle.
    • Carefully lower the vehicle.
      Fig 9: Positioning Engine And Transmission Assembly Under Vehicle
      G01615842Courtesy of FORD MOTOR CO.
    12. NOTE: Do not tighten the engine front mount bolts and nuts at this stage.
    Fig 10: Installing Engine Front Mount
    G01615843Courtesy of FORD MOTOR CO.
  12. Install the engine front mount.
    13. NOTE: Do not tighten the engine rear mount bolts at this stage.
    Fig 11: Installing Engine Rear Mount
    G01615844Courtesy of FORD MOTOR CO.
  13. Install the engine rear mount.
  14. Remove the securing strap from the engine and transmission assembly, and remove the assembly table.
  15. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  16. Connect the reversing lamp switch electrical connector.
    • Clip on the wiring loom.
      Fig 12: Connecting Reversing Lamp Switch Electrical Connector
      G01615845Courtesy of FORD MOTOR CO.
  17. Connect the vehicle speed sensor (VSS) electrical connector.
    Fig 13: Connecting Vehicle Speed Sensor Electrical Connector
    G01615846Courtesy of FORD MOTOR CO.
  18. Connect the heated oxygen (H02S) sensor and the crankshaft position (CKP) sensor electrical connector.
    Fig 14: Connecting Heated Oxygen Sensor And Crankshaft Position Sensor Electrical Connector
    G01615847Courtesy of FORD MOTOR CO.
  19. Connect the catalyst monitor sensor electrical connector.
    Fig 15: Connecting Catalyst Monitor Sensor Electrical Connector
    G01615848Courtesy of FORD MOTOR CO.
    20. 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 intermediate shaft center bearing cap and locknuts.
  20. Attach the right-hand halfshaft and the intermediate shaft to the transaxle.
    • Install the center bearing cap.
      Fig 16: Attaching Right-Hand Halfshaft And Intermediate Shaft To Transaxle
      G01615849Courtesy of FORD MOTOR CO.
    21. CAUTION: The drive halfshaft stub nut can be re-used four times; observe the marking on the nut and renew it if necessary.
    NOTE: Do not tighten the halfshaft stub nut at this stage.
    Fig 17: Pulling Drive Halfshaft Stub Axle Into Wheel Hub
    G01615850Courtesy of FORD MOTOR CO.
  21. Pull the drive halfshaft stub axle into the wheel hub using the special tool.
    22. 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 18: Attaching Left-Hand Halfshaft To Transaxle
    G01615851Courtesy of FORD MOTOR CO.
  22. Attach the left-hand halfshaft to the transaxle.
  23. Install the crossmember. .
  24. Install the flexible exhaust pipe.
    Fig 19: Installing Flexible Exhaust Pipe
    G01615852Courtesy of FORD MOTOR CO.
  25. Lower the vehicle.
  26. Tighten the engine rear mount nuts and bolts.
    Fig 20: Tightening Engine Rear Mount Nuts And Bolts
    G01615853Courtesy of FORD MOTOR CO.
  27. Tighten the engine front mount nuts.
    Fig 21: Tightening Engine Front Mount Nuts
    G01615854Courtesy of FORD MOTOR CO.
  28. Connect the power steering supply hose to the power steering fluid reservoir.
    Fig 22: Connecting Power Steering Supply Hose
    G01615855Courtesy of FORD MOTOR CO.
  29. Install the coolant expansion tank.
    Fig 23: Installing Coolant Expansion Tank
    G01615856Courtesy of FORD MOTOR CO.
  30. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  31. Connect the radiator lower coolant hose to the radiator.
    Fig 24: Connecting Radiator Lower Coolant Hose To Radiator
    G01615857Courtesy of FORD MOTOR CO.
  32. Connect the coolant hose to the oil cooler.
    Fig 25: Connecting Coolant Hose To Oil Cooler
    G01615858Courtesy of FORD MOTOR CO.

    33. Vehicles with air conditioning 

  33. Attach the air conditioning compressor.
    Fig 26: Attaching Air Conditioning Compressor (W/ A/C)
    G01615859Courtesy of FORD MOTOR CO.

    34. All vehicles 

  34. Install the accessory drive belt. For additional information, refer to JACKING & HOISTING .
  35. 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 27: Attaching Gearshift Cables To Transaxle
      G01615860Courtesy of FORD MOTOR CO.
  36. Adjustment the gearshift cable. .
  37. Attach the coolant hoses to the thermostat housing.
    Fig 28: Attaching Coolant Hoses To Thermostat Housing
    G01615861Courtesy of FORD MOTOR CO.
  38. Attach the fuel lines to the fuel rail.
    Fig 29: Attaching Fuel Lines To Fuel Rail
    G01615862Courtesy of FORD MOTOR CO.
  39. Attach the brake booster pipe to the intake manifold.
    Fig 30: Attaching Brake Booster Pipe To Intake Manifold
    G01615863Courtesy of FORD MOTOR CO.
  40. Attach the vacuum hoses to the throttle body.
    Fig 31: Attaching Vacuum Hoses To Throttle Body
    G01615864Courtesy of FORD MOTOR CO.
  41. Connect the wiring harness electrical connectors.
    Fig 32: Connecting Wiring Harness Electrical Connectors
    G01615865Courtesy of FORD MOTOR CO.
    42. 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.
  42. Attach the clutch supply line to the clutch slave cylinder.
    • Install the clip.
      Fig 33: Attaching Clutch Supply Line To Clutch Slave Cylinder
      G01615866Courtesy of FORD MOTOR CO.
  43. Connect the generator electrical connector.
    Fig 34: Connecting Generator Electrical Connector
    G01615867Courtesy of FORD MOTOR CO.
  44. Connect the fuel injector wiring harness electrical connectors.
    Fig 35: Connecting Fuel Injector Wiring Harness Electrical Connectors
    G01615868Courtesy of FORD MOTOR CO.
  45. Connect the ground cable to the engine lifting eye.
    Fig 36: Connecting Ground Cable To Engine Lifting Eye
    G01615869Courtesy of FORD MOTOR CO.
  46. Attach the accelerator cable and the speed control cable (if equipped) to the throttle body.
    Fig 37: Attaching Accelerator Cable And Speed Control Cable
    G01615870Courtesy of FORD MOTOR CO.
  47. Install the air cleaner intake tube and resonator.
    Fig 38: Installing Air Cleaner Intake Tube And Resonator
    G01615871Courtesy of FORD MOTOR CO.
  48. Tighten the strut and spring assembly top mount retaining nuts on both sides.
    Fig 39: Tightening Strut And Spring Assembly Top Mount Retaining Nuts
    G01615872Courtesy of FORD MOTOR CO.
  49. Attach the ground cable to the inner fender.
    Fig 40: Attaching Ground Cable To Inner Fender
    G01615873Courtesy of FORD MOTOR CO.
  50. Install the air cleaner. .
  51. Connect the battery positive cable to the battery terminal clamp.
    52. 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.
  52. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  53. Install the right hand-front wheel. For additional information, refer to WHEELS & TIRES .
  54. Tighten the halfshaft stud nuts.
    Fig 41: Tightening Halfshaft Stud Nuts
    G01615874Courtesy of FORD MOTOR CO.
  55. Fill the cooling system. For additional information, refer to ENGINE COOLING .
  56. Fill the transaxle with manual transmission fluid. For additional information, refer to SERVICING - M/T .
  57. Fill the engine with engine oil.
  58. Bleed the hydraulic clutch operating system. For additional information, refer to SERVICING - M/T .
  59. Fill and bleed the PAS system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
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