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.
Special Tools:
1. General note.
- The location of the engine mountings and engine support insulators are described looking from the transaxle to the engine.
- Steps which apply only to particular variants are indicated with a note.
NOTE: Install new snap rings, cotter pins and self-locking nuts.
2. NOTE: Apply the spline grease thinly enough so that when the clutch disc is fitted onto the transaxle input shaft, no grease is squeezed out from the splines.
Coat the drive splines of the clutch disc evenly with High-temperature grease.
CAUTION: Make sure to avoid damage during the positioning of the engine.
3. Secure the engine in a floor crane and lower into the engine compartment to install the power steering pump.
4. Install the power steering pump.
5. Lower the engine further, position the transaxle to the engine and install the flange bolts finger tight.
6. NOTE: Install new self-locking nuts. Do not tighten the nuts and bolts.
NOTE: Note the marked position for installation.
Install the transaxle rear support insulators.
1 Install the nuts
2 Install the bolts.
7. NOTE: Install new self-locking nuts. Do not tighten the nuts and bolts.
Install the engine front support insulators.
1 Install the nuts.
2 Install the bolts.
8. Remove the special tool.
9. Install the special tool.
10. Raise and support the vehicle.
11. Install the transaxle flange bolts on the left-hand side of the transaxle.
12. Install the transaxle flange bolts on the right-hand side of the transaxle.
13. Install the special tool in place of the engine left-hand support insulator.
1 Install the special tool.
2 Install the bolts.
3 Install the center bolt.
14. Lower the vehicle.
15. CAUTION: Do not twist or strain the engine rear support insulators.
NOTE: Install new self-locking nuts.
Install the transaxle rear support insulator.
1 Install the bolts.
2 Install the nuts.
16. CAUTION: Do not twist or strain the engine front mounting brackets.
NOTE: Install new self-locking nuts.
Align and tighten the engine front support insulator.
17. Remove the special tool.
18. Raise and support the vehicle.
19. NOTE: The left-hand support insulator position must be aligned in the middle of the support insulator bracket. If not, align the support insulator to the support insulator bracket.
Remove the special tool, install the engine left-hand support insulator and the Three Way Catalytic Converter (TWC).
1 Install the center bolt.
2 Install the nuts.
- Install the TWC.
3 Tighten the TWC clamp bolt.
20. Install the engine right-hand support insulator bracket to the transaxle.
21. NOTE: The right-hand support insulator position must be aligned in the middle of the support insulator bracket. If not, align the support insulator to the support insulator bracket.
Install the engine right-hand support insulator.
1 Install the bracket bolts.
2 Install the center bolt.
Vehicles With Air Conditioning
22. Attach the compressor bolts.
All Vehicles
23. Install the Three Way Catalytic Converter (TWC).
- Guide the TWC onto the exhaust manifold studs and into the exhaust pipe.
1 Attach the TWC to the bracket
2 Connect to H02S electrical connector.
3 Attach the TWC to the hanger insulator.
4 Connect the TWC to the exhaust.
NOTE: The TWC must be up against the exhaust manifold.
5 Secure the retaining clip for the TWC and install the bolt.
24. Install the right-hand halfshaft and intermediate shaft bracket.
CAUTION: To avoid damage to the halfshaft joints and boots, do not bend the inner halfshaft joint by more than 18 degrees, the outer one by not more than 45 degrees.
25. NOTE: Do not damage the oil seal.
Install the heat shield to the intermediate shaft bracket and connect the right-hand halfshaft to the intermediate shaft.
26. CAUTION: Do not damage the CV joint boot and the wheel speed sensor ring.
Connect the lower arm to the wheel knuckle.
- Attach the wheel speed wiring harness bracket to the suspension strut.
27. Install the accessory drive belt tensioner.
28. Install the crankshaft pulley/vibration damper.
29. NOTE: Note the direction mark if the original belt is being installed.
Install the accessory drive belt.
1 Install the belt idler pulley.
- Install the water pump pulley.
2 Tension the belt tensioner clockwise and position the belt in place.
3 Tighten the water pump pulley bolts.
30. Install the right-hand splash shield (wheel shown removed).
31. Connect the Vehicle Speed Sensor (VSS) electrical connector.
32. Install the starter motor.
33. Install the starter motor wiring.
34. Insert the brake booster vacuum hose into the intake manifold.
35. Install the radiator lower hose.
1 To the coolant pipe
2 To the radiator
36. Install the radiator splash shield.
37. Lower the vehicle.
38. Install the generator.
1 Install and tighten the bolt.
2 Install and tighten the bolt.
3 Connect the positive lead.
4 Connect the electrical connector.
39. Install the coolant hose to the coolant pipe and to the water pump.
40. Install the coolant expansion tank.
41. Connect the coolant hoses.
42. Install the accessory drive belt upper guard.
43. NOTE: Use an Allen key to stop the piston rod from turning.
Tighten the suspension strut top mount nuts (right-hand side shown).
44. Tighten the suspension strut top mount nuts with a torque wrench (right-hand side shown).
45. Connect the TWC to the exhaust manifold.
46. Install the transaxle upper flange bolts.
- Install the battery ground cable
47. Connect the electrical connector.
- Install the cover.
48. Connect the vacuum hoses to the intake manifold.
49. Connect the electrical connectors.
1 Power Steering Pressure (PSP) switch
2 Heated Oxygen Sensor (H02S)
50. Connect the main wiring harness to the Powertrain Control Module (PCM).
1 Connect the main wiring harness electrical connector.
2 Connect the two ground cables.
3 Secure the wiring.
4 Install the power steering reservoir.
51. Connect the engine coolant temperature sensor electrical connector.
52. Connect the reversing light switch electrical connector.
53. Connect the engine wiring harness electrical connector.
54. Install the heat shield.
- Apply Threadlock 262 or equivalent meeting Ford Specification WSK-M2G1351-A6 to the end of the oil level dipstick tube.
1 Install the coolant hose brackets, and the engine oil level dipstick tube.
- Install the engine lifting eye.
2 Install the brackets for the coolant hose.
3 install the bolts.
Vehicles With Air Conditioning
55. Install the coolant pipe bracket.
56. Connect and secure the fuel lines.
- Push on the retaining clips.
57. Connect the accelerator cable.
- Install the cable in the bracket and slide on the plastic clip.
- Hook the cable in place.
Vehicles With Speed Control
58. Connect the speed control cable.
1 Press the retaining bushing into the bracket.
NOTE: An audible click indicates that it has snapped into place.
2 Slide the cable into the retaining bushing.
3 Connect the cable to the throttle valve.
All Vehicles
59. Install the air cleaner resonator.
- Insert the air cleaner resonator (push fit).
1 Install the crankcase ventilation hose.
2 Install the air hose.
60. Install the air cleaner outlet tube.
1 Install the one bolt and two nuts.
2 Connect the IAT sensor electrical connector.
3 Connect the MAF sensor electrical connector.
61. Remove the auxiliary tool from the hood.
NOTE: 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.
62. Connect the battery ground cable.
63. Fill the engine cooling system.
64. Check the fluid levels after the road test and correct as necessary.
65. Check the routing of the vacuum hoses and wiring and secure them with cable ties.