Engine - Manual Transaxle
Engine - Manual Transaxle
All vehicles
1. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 engine-to-bellhousing bolts.
- Tighten to 48 Nm (35 lb-ft).
2. Using the Floor Crane and Spreader Bar, raise the engine and transaxle assembly onto the lift table.
3. Using the Powertrain Lift and Adjustable Grip Arms, secure the engine and transaxle assembly to the lift table.
4. Install the 2 upper bellhousing-to-engine bolts and bracket.
- Tighten to 48 Nm (35 lb-ft).
- Attach the wiring harness pin-type retainer to the bracket.
5. Install the starter motor and the 3 bolts (2 shown).
- Install the 3 bolts finger-tight.
- Tighten the 2 upper bolts to 48 Nm (35 lb-ft).
- Tighten the lower bolt to 48 Nm (35 lb-ft).
6. Connect the starter motor electrical terminals and install the 2 nuts.
- Tighten to 10 Nm (89 lb-in).
7. Connect the RH Knock Sensor (KS) electrical connector.
- Attach the 2 wiring harness retainers to the intake manifold.
8. Connect the Engine Oil Pressure (EOP) switch electrical connector.
- Attach the wiring harness retainer to the engine block.
9. Connect the Crankshaft Position (CKP) sensor electrical connector.
10. Connect the Throttle Body (TB) electrical connector.
- Attach the 2 wiring harness retainers to the TB (Throttle Body).
11. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
12. Connect the 4 fuel injector electrical connectors.
- Attach the wiring harness retainers to the valve cover stud bolts.
13. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors.
- Attach the 2 wiring harness retainers.
14. Connect and attach the LH KS (Knock Sensor) electrical connector.
15. Connect the 2 Camshaft Position (CMP) sensor electrical connectors.
16. Attach the Heated Oxygen Sensor (HO2S) sensor electrical connector pin-type retainer to the bracket.
17. Connect the ignition coil and Engine Coolant Temperature (ECT) sensor electrical connectors.
18. Attach the 2 wiring harness retainers to the coolant outlet bracket.
19. Install the 4 new catalytic converter studs.
- Tighten to 17 Nm (150 lb-in).
20. NOTICE: The engine mount studs must be torqued or damage to the powertrain may occur.
Torque the engine mount studs before installing the engine mount nuts.
- Tighten to 8 Nm (71 lb-in).
21. Using the lift table, position the engine and transaxle assembly in the vehicle.
22. Align the transaxle support insulator, install and tighten the 2 nuts and 2 bolts.
- Tighten the 2 nuts to 125 Nm (92 lb-ft).
- Tighten the 2 bolts to 90 Nm (66 lb-ft).
23. NOTE: Do not loosen the engine mount center bolt or the engine may become improperly positioned.
Install the engine mount and the 2 nuts.
- Tighten the 2 nuts to 80 Nm (59 lb-ft).
24. Lower the powertrain to the installed position.
25. Install the 3 engine mount bolts.
- Tighten to 48 Nm (35 lb-ft).
26. Install the transaxle roll restrictor bolt.
- Tighten to 70 Nm (52 lb-ft).
27. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
Install a new engine oil filter.
- Tighten to 15 Nm (133 lb-in).
28. If equipped, connect the block heater electrical connector.
29. NOTICE: Failure to tighten the catalytic converter manifold fasteners in 20 Nm increments until reaching final torque of 55 Nm will cause the converter to develop an exhaust leak.
Tighten the bolt and 4 nuts in the sequence shown, in 3 stages.
- Stage 1: Tighten all fasteners in sequence to 20 Nm (177 lb-in).
- Stage 2: Tighten all fasteners in sequence to 40 Nm (30 lb-ft).
- Stage 3: Tighten all fasteners in sequence to 55 Nm (41 lb-ft).
30. Position the catalytic converter heat shield and install the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
31. Install the lower catalytic converter bracket and the 4 bolts and tighten in sequence shown.
1. Tighten the catalytic converter bracket-to-engine block bolts to 50 Nm (37 lb-ft).
2. Tighten the catalytic converter bracket-to-catalytic converter bolts to 25 Nm (18 lb-ft).
32. NOTICE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.
Remove the support for the exhaust flexible pipe.
33. Using a new gasket, position the catalytic converter to the muffler and install the 2 catalytic converter nuts.
- Tighten to 48 Nm (35 lb-ft).
34. Install the Catalyst Monitor Sensor (CMS).
Vehicles without A/C
35. Install the accessory drive belt idler pulley bracket and the 3 bolts.
- Tighten to 24 Nm (18 lb-ft).
Vehicles with A/C
36. Position the A/C compressor and install the 2 bolts and stud bolt.
- Tighten to 25 Nm (18 lb-ft).
37. Attach the wiring harness retainer to the lower A/C compressor bracket.
38. Connect the A/C pressure transducer electrical connector.
- Attach the wiring harness retainer.
39. Position the A/C line bracket and install the nut.
- Tighten to 9 Nm (80 lb-in).
40. Connect the A/C compressor electrical connector.
All vehicles
41. Install the halfshaft bracket and the 3 bolts and tighten in sequence shown.
1. Tighten the top bolt to 48 Nm (35 lb-ft).
2. Tighten the 2 bottom bolts to 24 Nm (18 lb-ft).
42. Install the RH and LH halfshafts.
43. Position the engine ground wire and install the bolt.
- Tighten to 10 Nm (89 lb-in).
44. Attach the clutch hydraulic hose to the transaxle retainer.
45. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.
Connect the clutch hydraulic hose and install the clip.
46. Connect the lower radiator hose and coolant hose to the thermostat housing.
47. Connect the upper radiator hose to the engine.
48. Connect the EVAP (Evaporative Emission) tube quick connect coupling near the bulk head.
49. Attach the coolant hose retainer to the coolant outlet bracket.
50. Connect the lower heater hose to the heater core.
51. Install the HO2S (Heated Oxygen Sensor).
52. Connect the 2 coolant hoses to the engine oil cooler.
- Attach the oil cooler hose retainer to the upper radiator hose.
53. Install the cooling fan motor and shroud.
54. Install the gearshift cables.
1. Attach the gearshift cables to the transaxle gearshift control levers.
2. Install the gearshift cable by pulling the lower part of abutment down and installing them in the brackets.
55. Install the generator.
56. Attach the fuel tube to the coolant outlet bracket retainer.
57. Connect the fuel tube spring lock couplings to the fuel rail.
58. Connect the brake booster vacuum hose.
59. Connect the engine harness electrical connector.
60. Install the battery tray bracket and the 3 battery tray nuts.
- Attach the 2 wiring harness retainers to the bottom of the battery tray bracket.
- Tighten nuts and bolt to 10 Nm (89 lb-in).
61. Attach the 2 positive battery cable wire harness retainers to battery tray bracket.
62. Install the battery tray and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
63. Connect the 3 PCM electrical connectors.
64. Install the PCM cover and the bolt.
- Tighten to 5.4 Nm (47.8 lb-in).
65. Install the cable and nut to the positive battery cable terminal.
- Tighten to 10 Nm (89 lb-in).
66. Install the battery.
67. Install the positive battery cable cover.
68. Connect the crankcase vent tube to the valve cover.
- Attach the crankcase vent tube to the 2 retainers.
69. Install the Air Cleaner (ACL) and ACL (Air Cleaner) outlet pipe.
70. Fill the engine with clean engine oil.
71. Install the degas bottle.
72. Fill the and bleed cooling system.
73. NOTE: Before removing, clean the area around the fill plug.
Remove the fill plug and using a fluid suction gun, fill the transaxle with manual transmission fluid until fluid level is 0.0-5.0 mm (0.0-0.2 in) below the lower edge of the fill hole.
- Install the fill plug and tighten to 35 Nm (26 lb-ft).
74. Bleed the clutch hydraulic system.
75. Adjust the gearshift cables.
76. Install the gearshift cable cover and attach the 7 retainers (2 shown).
