Steps 1 - 42

Special Tools:

NOTE: The locations of the engine mountings and the engine support insulators are given looking from the automatic transaxle to the engine.

NOTE: Install new snap rings, cotter pins and self-locking nuts.

1. NOTE: The torque converter hub must fully engage with the oil pump drive gear.

Check the installation depth of the torque converter.
1 Lay a straight edge on the transaxle flange.
2 Check the installation depth between the transaxle flange and the torque: converter centering spigot for the correct clearance: 12 mm.
2. Apply a thin layer of High-temperature grease meeting Ford Specification ESD-M1C220-A or equivalent to the centering spigot bore of 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. CAUTION: Using the floor crane and the special tool, carefully lower the engine assembly into the engine compartment to the power steering pump installation position.

Use the floor crane to bring the engine into installation position and lower it
4. Position the jack under the oil pan and unhook the engine

5. Install the special tool.

NOTE: Do not tighten the bolts.

6. Install the engine front support insulator.

7. Install the accessory drive belt tensioner.

NOTE: Do not tighten the nuts.

8. Install the engine front support insulator bracket.

9. Install the starter motor.

10. Install the transaxle flange upper bolts.
11. Raise and support the vehicle.

12. Install the transaxle flange left-hand bolts.

13. Install the transaxle flange lower bolts.

14. Attach the torque converter to the engine drive plate (four nuts).
- Install the compressor bracket bolts.

15. Remove the left-hand engine support insulator.

16. Remove the right-hand engine support insulator center bolt.

17. Install the special tool to the subframe.
- Install the center bolt into the special tool.

18. Lower the vehicle.

19. NOTE: Make sure that the new nuts line up with the marks on the engine support bracket.

Tighten the engine front support insulator bracket.

20. Tighten the engine front support insulator.
21. Remove the special tool.

22. Install the ignition wire bracket to the upper front support insulator bracket.
23. Raise and support the vehicle.

24. NOTE: The installed position of the engine support insulator must be to the center of the bracket, otherwise realignment of the engine/transaxle assembly will be required.

Install the left-hand engine support insulator.
- Remove the special tool.
1 Tighten the nuts.
2 Tighten the support insulator center bolt.

25. NOTE: The installed position of the engine support insulator must be to the center of the bracket, otherwise realignment of the engine/transaxle assembly will be required.

Install the right-hand engine support insulator.
1 Tighten the bolts.
2 Tighten the support insulator center bolt.

Vehicles With Air Conditioning

26. Install the compressor.

Vehicles With Air Conditioning

27. Install the compressor heat shield.

28. Install the accessory drive belt.
1 Left-hand moving stop.
2 Square ratchet wrench 3/8 inch.
- Using the square ratchet wrench press the belt tensioner to the left-hand moving stop and install the drive belt.

29. Install the coolant pipe.

30. Connect the left Heated Oxygen Sensor (H02S) electrical connector.
31. Insert the fan.

Vehicles With Air Conditioning
32. Connect the compressor electrical connector.

33. Install the radiator.

Vehicles With Air Conditioning

34. Install the condenser core to the radiator.
- Cut the cable tie.
- One bolt on each side.

35. Install the intermediate shaft.

CAUTION: To prevent damage to the halfshaft joints and boots, do not bend the inner halfshaft joints by more than 18 degrees, the outer one by not more than 45 degrees.

NOTE: Secure the halfshaft.

36. Install the heat shield to the intermediate shaft bracket and the halfshaft to the intermediate shaft.

CAUTION: Do not damage the boot and the wheel speed sensor ring.

37. Install the right-hand lower suspension arm (left-hand side shown).
- Install the lower suspension aria ball joint to the wheel knuckle.

38. Tighten the subframe bolts on the right-hand side.

39. Connect the Vehicle Speed Sensor (VSS) electrical connector.

40. Install the front lower right-hand splash shield.

NOTE: Install a new gasket.

41. Install the dual converter Y-pipe and the Three Way Catalytic Converter (TWC).
- Suspend the catalytic converter from the rubber hangers.

NOTE: Install a new gasket.

42. Install the dual converter Y-pipe and the TWC (continued).