Removal and Installation

Special Tools:

Removal
1. Disconnect battery ground cable.
2. Disconnect steering coupling at pinch bolt joint inside passenger compartment.
3. Disconnect engine control sensor wiring from the Intake Air Temperature Sensor (IAT sensor).
4. Disconnect crankcase ventilation tube and aspirator hose from air cleaner outlet tube.
5. Loosen clamps on air cleaner outlet tube to engine Air Cleaner (ACL)and throttle body. Remove air cleaner outlet tube.
6. Drain engine cooling system.
7. Recover air conditioning system.
8. Relieve fuel system pressure and disconnect fuel tubes from fuel injection supply manifold.
9. Disconnect chassis vacuum supply hose and evaporative emission hose at connection on upper intake manifold. Position hoses out of the way.
10. Remove ground straps from dash panel.
Disconnect engine control sensor wiring from the powertrain control module (PCM) and position the engine control sensor wiring out of the way.
12. Remove connectors for engine control sensor wiring from retaining bracket on power brake booster. Disconnect engine control sensor wiring at two connectors.
13. Disconnect engine control sensor wiring from Mass Air Flow Sensor (MAF sensor).
14. Disconnect engine control sensor wiring from evaporative emission canister purge valve (EVAP canister purge valve).
15. Remove shield and disconnect accelerator cable and speed control actuator cable from throttle body and also from accelerator cable bracket. Position cables out of the way.
16. Remove retaining nut and disconnect the manual control lever from the manual control lever shaft at the Transmission Range (TR) sensor.
17. Remove connectors for engine control sensor wiring from retaining bracket on top of transaxle. Disconnect engine control sensor wiring at two connectors.
18. Disconnect wiring connector from secondary air injection pump relay located on retaining bracket on top of transaxle.
19. Disconnect fluid cooler inlet tube from transaxle.
20. Disconnect heater water hoses from the water pump and water hose connection.
21. Disconnect upper radiator hose and degas tube from water hose connection.
22. Remove power steering return hose from power steering oil reservoir and drain.
23. Disconnect generator wiring harness from generator (GEN) at B+ terminal and stator connector plug. Remove wiring harness retaining clip from generator mounting bracket.
24. Disconnect A/C compressor lines from A/C compressor.
25. Partially raise vehicle on hoist.
26. Remove front wheels and tires.
27. Remove RH and LH front stabilizer bar link from front stabilizer bar.
28. Separate RH and LH front suspension lower arms from front wheel knuckle at ball joint.
29. Separate RH and LH tie rod ends from front wheel knuckle.
30. Remove RH and LH front axle wheel hub retainers from halfshaft ends.
31. Remove RH and LH halfshafts from front wheel knuckle.
32. Raise vehicle.
33. Remove splash shield from radiator support and front bumper.
34. Drain engine oil.
35. Remove dual converter Y pipe.
36. Disconnect power steering pressure hose from power steering/transaxle fluid cooler connection. Position hose out of the way.
37. Disconnect lower radiator hose at radiator and at radiator overflow hose.
38. Disconnect wiring for starter motor and remove starter motor.
39. Disconnect lower fluid cooler tube from transaxle.





40. Support front sub-frame, engine and transaxle assembly using Rotunda Powertrain Lift 014-00765 and Universal Powertrain Removal Bracket 014-00766 or equivalents.
41. Remove four front sub-frame retaining bolts.
42. Lower engine transaxle and front sub-frame from vehicle.
43. Disconnect power steering pressure hose from the power steering pump.
44. Install Engine Lifting Brackets 303-050 (T70P-6000).
45. Connect Rotunda Separator Bar 303-F054 (014-00793) or equivalent to lifting brackets. Support engine and transaxle.
46. Remove LH front engine support insulator, RH front engine support insulator and engine and transmission support.
47. Lift engine and transaxle from front sub-frame.
48. Lower engine and transaxle. Support transaxle on a level, stationary surface for transaxle storage.
49. Remove transaxle-to-cylinder block mounting bolts and separate engine from transaxle /torque converter assembly.
50. Place engine on suitable workstand.
51. Remove engine lifting equipment.
52. Remove water jacket pipe plugs in cylinder block and drain balance of engine coolant. Reinstall pipe plugs.

Installation
1. Install Engine Lifting Brackets 303-050 (T70P-6000).
2. Remove engine from stand using Rotunda Separator Bar 303-F054 (014-00793) or equivalent, chains and a suitable floor crane.
3. Install transaxle/torque converter assembly to engine. Tighten transaxle to engine bolts to 40-60 Nm (30-44 ft. lbs.). Tighten torque converter nuts to 27-46 Nm (20-33 ft. lbs.).
4. Position engine and transaxle assembly on front sub-frame.
5. Install LH front engine support insulator, RH front engine support insulator and engine and transmission support.
6. Connect power steering pressure hose to the power steering pump.
7. Raise engine, transaxle and front sub-frame into position.
8. Align front sub-frame to body and install sub-frame-to-body bolts. Tighten bolts to 77-103 Nm (57-75 ft. lbs.).
9. Remove Rotunda Powertrain Lift 014-00765 or equivalent and move out of way.
10. Connect lower fluid cooler tube to transaxle and install retaining clip.
11. Install starter motor.
12. Install lower radiator hose to radiator and radiator overflow hose. Position clamp securely.
13. Connect power steering pressure hose to power steering/transmission oil cooler connection and tighten hose clamp securely.
14. Install dual converter Y pipe.
15. Install splash shield to radiator support and front bumper. Tighten retaining screws securely.
16. Partially lower vehicle.
17. Install RH and LH halfshaft into front wheel knuckle.
18. Install RH and LH front axle wheel hub retainers onto halfshaft end.
19. Connect RH and LH tie rod ends to the front wheel knuckle.
20. Connect RH and LH front suspension lower arms to the front wheel knuckle at ball joints.
21. Install RH and LH front stabilizer bar links to the front stabilizer bar.
22. Install front wheel and tires.
23. Lower vehicle.
24. Remove Engine Lifting Brackets D70P-6000.
25. Connect A/C lines to A/C compressor.
26. Connect separator wiring harness to the generator at the B+ terminal and stator connector plug. Install wiring harness retainer clip to the generator mounting bracket. Tighten retaining screw securely.
27. Connect power steering return hose to power steering oil reservoir. Position clamp securely.
28. Connect upper radiator hose to water hose connection.
29. Connect heater water hoses to the water hose connection and water pump. Position clamps securely.
30. Connect upper fluid cooler inlet tube and retaining clip to transaxle.
31. Connect wiring connector to the secondary air injection pump relay located on bracket at top of transaxle. Verify connection is secure.
32. Connect engine control sensor wiring at two connectors located at top of transaxle above secondary air injection pump relay bracket.
33. Install engine control sensor wiring to bracket with retaining strap. Tighten retaining strap screw securely.
34. Connect the manual control lever to the manual control lever shaft at the transmission range sensor. Install and tighten retaining nut to 16-22 Nm (12-16 ft. lbs.).
35. Connect accelerator cable and speed control actuator cable to the throttle body lever and the accelerator cable bracket. Tighten retaining screws securely.
36. Install the accelerator cable shield and tighten the retaining screws securely. Verify throttle linkage does not bind or stick.
37. Connect engine control sensor wiring to evaporative emission canister purge valve.
38. Connect the engine control sensor wiring to the mass air flow sensor.
39. Connect the engine control sensor wiring at two connectors near the power brake booster. Install the engine control sensor wiring to retaining bracket with strap. Tighten strap retaining screw securely.
40. Position ground straps to the dash panel. Install and tighten retaining screw securely.
41. Connect chassis vacuum supply hose and evaporative emission hose to connectors on the upper intake manifold.
42. Connect fuel tubes and retaining clips to the fuel injection supply manifold.
43. Install air cleaner outlet tube. Tighten engine air cleaner tube clamps to 1.6-2.2 Nm (14-19 inch lbs.).
44. Connect the engine control sensor wiring to the intake air temperature sensor and install the crankcase ventilation tube and aspirator hose to the air cleaner outlet tube.
45. Connect steering coupling at pinch bolt inside passenger compartment.
46. Fill crankcase to proper level with Motorcraft Super Premium 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
47. Fill power steering pump.
48. Fill and bleed engine cooling system.
49. Connect battery ground cable.
50. Start engine and check for leaks.
51. Recheck all fluid levels. Fill as required.
52. Evacuate and recharge air conditioning system.
53. Check front end alignment.