With Automatic Transmission

NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.

NOTE:
- Replace all snap-rings, split pins and self-locking nuts.
- The torque converter hub must fully engage with the oil pump drive gear.





1. Check the installation depth of the torque converter.
1 Lay a straightedge on the transaxle flange.
2 Check the depth between the transaxle flange and the torque converter centering pin for the correct clearance.

2. Apply a thin layer of Spline Grease F5RZ-19590-MA meeting Ford specification ESD-MlC220-A or equivalent to the centering pin bore on the torque converter.

CAUTION: The torque converter must remain at the correct installation depth throughout the entire installation procedure. Check that the adapter plate is in the correct position.

3. Position the transaxle in installation position next to the engine and guide the torque converter stud into the drive plate.
4. Install the flange bolts.





5. Tighten the flange bolts on the left-hand side.





6. Tighten the upper flange bolts.
- Install the starter motor cable bracket.





7. Move the engine/transmission assembly using Spreader Bar and Engine Lifting Brackets and the workshop hoist and secure it with retaining straps on Powertrain Fixture or equivalent.
8. Remove Spreader Bar and Engine Lifting Brackets.





9. Tighten the flange bolts on the right-hand side.





10. Attach the torque converter to the engine drive plate (four nuts).
- Install the plastic cover.





11. Install the starter motor.
- Install the ground cable.





12. Connect the starter motor electrical connectors.
13. Move the engine and transaxle assembly on Powertrain lift underneath the vehicle into installation position and carefully lower the vehicle.

NOTE: Do not tighten the nuts.





14. Loosely install the rear engine mounting bracket nuts.

NOTE: Do not tighten the nuts and bolts.





15. Install the front engine mounting bracket nuts.





16. Install Three-Bar Engine Support bar, hook it into Engine Lifting Brackets and support the weight of the engine.
17. Remove the retaining straps from the engine and the transmission. Remove the Powertrain Lift.





18. Connect and secure the fuel lines.
- Push on the retaining clips.





19. Connect the battery leads and connectors and secure the wiring harness with cable ties.





20. Connect the vacuum hoses to the intake manifold.





21. Connect the main wiring harness to the PCM.
1 Connect the main wiring harness connector.
2 Connect the two ground cables.
3 Install the wiring bracket.
4 Install the power steering reservoir.

22. Raise and support the vehicle.





23. Remove the fan motor and the radiator shroud from the radiator.
24. Working from below, loosely hook the fan motor and radiator shroud into the vehicle.





25. Attach the radiator to the condenser.
- Working from below, move the radiator into installation position (push fit at the top).
1 Screw in one bolt on each side.
2 Connect the electrical connector to the fan motor ballast resistor.





26. Connect the lower coolant hose.





27. Connect the heater coolant hose.





28. Position and install the power steering pump.
29. Install the power steering pump pulley.





30. Install the air conditioning compressor.





31. Connect the air conditioning compressor electrical connector.
32. Lower the vehicle.





33. Screw in the upper bolts on the power steering pump, attach the wiring clamp to the fender apron panel and fit the coolant hose.





34. Install the coolant hose bracket and the power steering line.
35. Raise the vehicle.





36. Connect the coolant hose to the heater coolant tube and install the bracket.
37. Install the halfshafts.





38. Install the accessory drive belt.
1 Turn the belt tensioner clockwise.
2 Install the accessory drive belt.





39. Connect the electrical turbine shaft speed connector to the TSS sensor.
- Clip the wiring in place.

NOTE: Remove the plug prior to installation of the tube.





40. Connect the fluid tube.

NOTE: Remove the plug prior to installation of the tube.





41. Connect the fluid cooler tube to the transaxle.

NOTE: The gauge is marked with an arrow and "FRONT".





42. Install Powertrain Alignment Gauge.





43. Insert the rubber guides of the lower radiator supports into the subframe.

NOTE:
- Do not tighten the bolts.
- Align the steering gear and the fluid line bracket.





44. Move the subframe into installation position using Powertrain Fixture or equivalent and attach it at the front.
- Insert the radiator into the subframe.





45. Attach the steering gear using the Steering Rack Socket Wrench (two bolts).





46. Install the heat shield for the steering gear.
- Install the power steering line bracket and the coolant line bracket.

NOTE: The subframe must not move when tightening the bolts.





47. Align the subframe and tighten the bolts.
1 Insert the Subframe Alignment Pin Set.
2 Insert the suspension arm into the spindle.
3 Tighten the bolts working diagonally.





48. Align the engine and transaxle assembly.
- Screw the center bolt into the Powertrain Alignment Tool and tighten it.





49. Install the right-hand engine roll restrictor.
1 Install the center through bolt.
2 Install the bolts.





50. Install the vehicle speed sensor (VSS).
- Attach the retaining clip with one bolt.

51. Lower the vehicle.

CAUTION: Do not twist or strain the rear engine mounting bracket.





52. Tighten the nuts on the rear engine mounting bracket.

CAUTION: Do not twist or strain the front engine mounting bracket.





53. Align and tighten the front engine mounting bracket.





54. Install the coolant recovery tank.
55. Raise and support the vehicle.





56. Remove the Powertrain Alignment Tool and install the engine roll restrictor.
1 Install the center through bolt.
2 Install nuts.





57. Insert the brake booster vacuum hose into the intake manifold.





58. Install the air conditioning dehydrator on the subframe.





59. Attach the front exhaust tube with a new gasket and hook it in place.





60. Attach the power steering lines to the subframe.





61. Attach the radiator at the bottom and connect both HO2S electrical connectors.
- Secure the wiring harness with cable ties.





62. Connect the front wheel suspension on both sides (left-hand side shown).
1 Install the suspension arm bolt and nut.
2 Install the tie-rod with new self-locking nut.
3 Install the stabilizer link rod to suspension strut bolt.
- Insert the brake hose in the stabilizer link rod bracket.





63. Install the splash shields.
1 Position the splash shields.
2 Install the bolts.





64. Install the radiator splash shield (nine bolts) and attach the bracket on each side (left-hand side shown).





65. Install the front wheels.
66. Lower the vehicle.





67. Remove the Three-Bar Engine Support.





68. Attach the fan motor and the radiator shroud to the radiator (one nut on each side, right-hand side shown).





69. Connect the hoses to the transaxle oil cooler.





70. Connect the two ground cables.





71. Install and connect the upper coolant hose.





72. Attach the selector cable.
1 Press the selector cable into the selector lever and clip it in place.
2 Install the selector cable abutment bracket bolts.

73. Raise and support the vehicle.
74. Remove the heat shield for the rear exhaust system.

NOTE: The selector lever has its own engagement system.





75. Move the selector lever to "D" and check the selector cable adjustment.
1 Hold the adjusting mechanism still.
2 Release the selector cable locking mechanism.
3 The markings on the selector lever must line up.





76. Lock the selector cable in place.
1 Hold the adjusting mechanism still.
2 Secure the selector cable locking mechanism.

77. Install the heat shield for the rear exhaust system.





78. Connect the accelerator cable and adjust it.
1 Guide the cable into the abutment bracket and push on the plastic clip.

- Hook the cable in place.

2 Pull the clip off the accelerator cable.

- Pull the cable out a few notches.
- Fully depress the accelerator pedal once and slide the clip back on.
- Check whether the throttle valve opens fully when the accelerator pedal is fully depressed -repeat adjustment if necessary.





79. Stall the upper drive belt cover.





80. Install the suspension strut locknut on both sides.
- Hold the suspension strut steady.





81. Fill the transaxle with the same amount of MERCON Motorcraft Automatic Transmission Fluid XT-2-BOX, DDX, QDX meeting Ford specification MERCON or equivalent.
- Insert the oil dipstick.





82. Connect the electrical connectors.
1 Connect the CKP sensor electrical connector.
2 Connect the ECT sensor electrical connector.





83. Connect the electrical connectors.
1 Connect the automatic transaxle control plug.
2 Clip the wiring harness in place.
3 Connect the TR switch electrical connector.





84. Connect the wiring.
1 Connect the main wiring harness connector.
2 Connect the automatic transmission ground cable.
3 Secure the wiring harness using cable ties.





85. Install the air cleaner body.
- Insert the air cleaner body (push fit).

1 Attach the rubber ring.
2 Install the air hose.
3 Install the crankcase ventilation hose.





86. Install the air intake tube.
1 Install the two clips.
2 Install the one bolt, and nuts.
3 Install the IAT sensor electrical connector.
4 Install the MAP sensor electrical connector.

87. Install the battery.

NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10mi) or more to relearn the strategy.

86. Refill the cooling system.
- Check the fluid levels after the road test and correct as necessary.
- Check the engine and cooling system for leaks (visual inspection).