With Manual 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.

1. Position the transaxle on the engine.





2. Install the flange bolts on the left-hand side of the transaxle.
- Coat the drive splines of the clutch disc evenly with Spline Grease F5RZ-19590-MA or equivalent meeting Ford specification ESD-M1 C220-A.





3. Install the flange bolts on the right-hand side of the transaxle and the lower starter motor bolt.





4. Move the engine/transaxle assembly with Spreader Bar and Engine Lifting Brackets, and the workshop hoist and secure it with retaining straps on Powertrain fixture or equivalent.
5. Remove the workshop hoist and the Spreader Bar and Engine Lifting Brackets.





6. Fit the upper flange bolts.
- Install the upper starter motor bolts.
- Install the two flange bolts.
- Attach the ground lead to the transmission.





7. Connect the starter motor electrical connectors.





8. Install the electrical connectors to the reversing light switch and the vehicle speed sensor (VSS).
9. Position the engine and transaxle assembly on Powertrain Fixture or equivalent underneath the vehicle in installation position and carefully lower the vehicle.

NOTE: Do not tighten the nuts.





10. Install the rear engine mounting bracket.

NOTE: Do not tighten the nuts and bolts.





11. Install the front engine mounting bracket.
12. Take the retaining straps off the engine/transaxle assembly. Remove the Powertrain Fixture or equivalent.





13. Attach the Three-Bar Engine Support.
- Hook it into the Engine Lifting brackets and support the weight of the engine on it.





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





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





16. Connect the vacuum hoses to the intake manifold.





17. 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.

18. Raise and support the vehicle.

NOTE: The transaxle is in neutral when both levers are vertical.





19. Set the shift lever and selector lever to the "Neutral" position.

NOTE:
- The adjusting mechanisms must be released by pressing them in.
- The abutment brackets are tensioned automatically once they have been released.





20. Connect the cables to the transaxle and adjust them.
1 Loosen the abutment bracket by turning it counter-clockwise and fit the cable in the bracket.
2 Disconnect the selector cable from the selector lever.
3 Loosen the abutment bracket by turning it counter-clockwise and install the cable in the bracket.
4 T Disconnect the selector cable from the selector lever.
5 Lock the adjusting mechanism by pressing down the clips.





21. Remove the fan motor and the radiator shroud from the radiator.
22. Working from below, hook the fan motor and radiator shroud into the vehicle.





23. 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.





24. Connect the lower coolant hose.





25. Connect the heater coolant hose.





26. Position and install the power steering pump.
27. Install the power steering pump pulley.





28. Install the air conditioning compressor.





29. Connect the air conditioning compressor electrical connector.
30. Lower the vehicle.





31. Install the upper bolts on the power steering pump, attach the wiring clamp to the fender apron panel and install the coolant hose.





32. Install the coolant hose bracket and the power steering me.
33. Raise and support the vehicle.





34. Connect the coolant hose to the heater coolant tube and install the bracket.
35. Install the halfshafts.





36. Position the drive belt in place and tension it.
- Turn the drive belt tensioner clockwise to relieve belt tension.

NOTE: The Powertrain Alignment Tool is marked with an arrow and "FRONT".





37. Install the Powertrain Alignment Tool.





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

NOTE:
- Align the steering gear and the fluid line bracket.
- The subframe must not move when tightening the bolts.





39. Move the subframe into installation position using Powertrain Fixture or equivalent and tighten the bolts.
1 Insert the Sub-frame Alignment Pin Set.
2 Insert the suspension arm into the spindle.
3 Tighten the bolts working diagonally.

- Remove the locating pins.





40. Align the engine and transaxle assembly.
- Install center bolt into the gauge and tighten it.





41. Install the steering gear using Steering Rack Socket Wrench (two bolts).





42. Attach the bracket for the right-hand engine roll restrictor to the transaxle.





43. Install the steering gear and the right-hand engine roll restrictor.
1 To the subframe.
2 To the bracket.
3 Install the steering gear bolts.





44. Install the steering gear heat shield.
- Install the power steering line bracket and the coolant hose bracket.

45. Lower the vehicle.

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





46. Align the rear engine mounting bracket and tighten the nuts.

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





47. Align the front engine mounting bracket and tighten the nuts.





48. Install the coolant recovery tank.
49. Raise and support the vehicle.





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





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





52. Install the air conditioning dehydrator on the subframe.





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





54. Attach the power steering lines to the subframe.





55. Attach the radiator at the bottom and connect both H02S electrical connectors.





56. 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.





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





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





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





60. Install the front wheels.
61. Lower the vehicle.





62. Remove the Three-Bar Engine Support.





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





64. Connect the two ground cables.





65. Install and connect the upper coolant hose.





66. Attach 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.





67. Install the upper drive belt cover.





68. Install the suspension strut locknut on both sides.





69. Connect the clutch slave cylinder.
- Attach the ground lead to the transaxle.
1 Install the slave cylinder pipe in the bracket.
2 Connect the slave cylinder pipe to the transaxle and slide on the clip.





70. Connect the electrical connectors.
1 Connect the engine wiring harness electrical connector.
2 Connect the transmission ground cable.
3 Secure the wiring harness using cable ties.





71. 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.





72. Install the air cleaner outlet tube.
1 Install the two clips.
2 Install the one bolt and two nuts.
3 Connect the electrical connector to the IAT sensor.
4 Connect the MAP sensor electrical connector.





73. Disconnect the Gear Lever Aligner from the shift lever and press in the shift lever boot.
74. Bleed the hydraulic clutch system.
- Use High Performance DOT 3 Brake Fluid C6AZ-19542-AB meeting Ford specification ESA-M6C25-A, DOT 3 or equivalent.

75. 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.

76. 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).