Removal and Installation

Special Tools:

Removal
1. Disconnect battery ground cable.
2. Disconnect steering coupling at pinch bolt joint inside passenger compartment.
3. Remove cowl extension and windshield wiper.
4. Disconnect main emission vacuum control connector at two connectors located at RH side of dash panel.
5. Disconnect engine control sensor wiring from the Intake Air Temperature Sensor (IAT sensor).
6. Disconnect crankcase ventilation tube and aspirator hose from air cleaner outlet tube.
7. Loosen clamps on air cleaner outlet tube to engine Air Cleaner (ACL) and throttle body. Remove air cleaner outlet tube.
8. Drain engine cooling system.
9. Recover air conditioning system.
10. Relieve fuel system pressure and disconnect fuel tube from fuel injection supply manifold.
11. Disconnect chassis vacuum supply hose and evaporative emission hose at connection on upper intake manifold. Position hoses out of the way.
12. Remove ground straps from dash panel.
13. Disconnect engine control sensor wiring from the powertrain control module (PCM) and position the engine control sensor wiring out of the way.
14. Disconnect engine control sensor wiring from Mass Air Flow Sensor (MAF sensor).
15. Disconnect engine control sensor wiring from throttle body.
16. Disconnect evaporative emission hose at evaporative emission canister purge valve (EVAP canister purge valve).
17. Remove shield and disconnect accelerator cable and speed control actuator cable from throttle body and also from accelerator cable bracket. Position cables out of the way.
18. Disconnect electrical wiring connector from the Transmission Range (TR) sensor.
19. Remove retaining nut and disconnect the manual control lever from the manual control lever shaft at the Transmission Range (TR) sensor.
20. Remove engine air cleaner cover.
21. Disconnect connector for engine control sensor wiring at top of transaxle.
22. Disconnect A/C compressor line from A/C suction accumulator/ drier.
23. Disconnect heater water hose from the heater core inlet and outlet tubes.
24. Disconnect radiator coolant recovery reservoir hose from the upper radiator hose.
25. Disconnect upper radiator hose and lower radiator hose tube at water bypass tube. Position upper radiator hose out of the way.
26. Disconnect battery ground cable from starter motor mounting stud bolt.
27. Remove power steering return hose from power steering oil reservoir and drain.
28. Partially raise vehicle on hoist.
29. Remove front wheels and tires.
30. Disconnect generator wiring harness from Generator (GEN) at B+ terminal. Remove wiring harness retaining clip from starter motor.
31. Disconnect engine control sensor wiring at connector located at the RH top of the fan shroud.
32. Remove RH and LH front stabilizer bar links from front stabilizer bar.
33. Separate RH and LH front suspension lower arms from front wheel knuckles at ball joints.
34. Separate RH and LH tie rod ends from front wheel knuckles.
35. Remove RH and LH front axle wheel hub retainers from halfshaft ends.
36. Remove RH and LH halfshafts from front wheel knuckles.
37. Raise vehicle.
38. Remove splash shield from radiator support and front bumper.
39. Drain engine oil.

40. CAUTION: Heated oxygen sensors must be removed prior to removing dual converter Y pipe or damage to heated oxygen sensors may occur.

Remove dual converter Y pipe.
41. Disconnect power steering pressure hose from power steering/transmission fluid cooler connection. Position hose out of the way.
42. Disconnect fluid cooler tube from power steering/transmission fluid cooler connection. Position fluid cooler tube out of the way.
43. Disconnect fluid cooler inlet tube from radiator fluid cooler tube. Position fluid cooler inlet tube out of the way.
44. Disconnect lower radiator hose at radiator and radiator overflow hose.
45. Disconnect wiring for starter motor.
46. Disconnect A/C compressor from A/C condenser core.
47. Support front sub-frame engine and transaxle assembly using Rotunda Powertrain Lift 014-00765 and Universal Powertrain Removal Bracket 014-00766 or equivalents.





48. Remove front sub-frame retaining bolts.
49. Lower engine transaxle and front sub-frame from vehicle.
50. Disconnect engine control sensor wiring from power steering gear.
51. Disconnect power steering pressure hose from the power steering pump.








52. Install Universal Engine Lifting Brackets 303-050 (T70P-6000).
53. Connect Engine Lifting Spreader Bar 303-D089 (D93P-6001-A3) or equivalent to lifting eyes. Using a suitable floor crane, support engine and transaxle.
54. Remove LH front engine support insulator, RH front engine support insulator and engine and transmission support.
55. Lift engine and transaxle from front sub-frame.
56. Remove flywheel-to-torque converter retaining nuts.
57. Lower engine and transaxle. Support transaxle on a level, stationary surface for transaxle storage.
58. Remove transaxle-to-cylinder block mounting bolts and separate engine from transaxle/torque converter assembly.
59. Place engine on suitable work stand.
60. Remove engine lifting equipment.
61. Remove water jacket pipe plugs in cylinder block and drain balance of engine coolant. Reinstall pipe plugs. Tighten to 60-75 Nm (45-55 ft. lbs.)

Installation
1. Install Universal Engine Lifting Brackets 303-050 (T70P-6000).
2. Remove engine from stand using Spreader Bar 303-D089 (D93P-6001-A3) or equivalent and chains and a suitable floor crane.
3. Install transaxle/torque converter assembly to engine. Tighten transaxle to engine mounting bolts to 34-46 Nm (25-33 ft. lbs.). Tighten torque converter nuts to 27-46 Nm (20-33 ft. lbs.).
4. Position engine and transaxle assembly on front sub-frame.
5. Install LH front engine support insulator, RH front and engine and transmission support.
6. Connect power steering pressure hose to the power steering pump.
7. Connect engine control sensor wiring to the power steering gear.
8. Raise engine, transaxle and front sub-frame into position using Powertrain Lift 014-00765 and Universal Powertrain Removal Bracket 014-00766 or equivalent.
9. Align front sub-frame to body and install sub-frame-to-body bolts. Tighten bolts to 77-103 Nm (57-75 ft. lbs.).
10. Remove lifting equipment and move out of the way.
11. Connect A/C line to A/C condenser core.
12. Connect wiring for starter motor.
13. Connect lower radiator hose to radiator and radiator overflow hose. Position clamps securely.
14. Connect fluid cooler inlet tube to the radiator fluid cooler tube. Position clamp securely.
15. Connect fluid cooler tube to the power steering/transmission fluid cooler. Position clamp securely.
16. Connect power steering pressure hose to power steering/transmission fluid cooler connection and tighten hose clamp securely.
17. Install dual converter Y pipe.
18. Install splash shield to radiator support and front bumper. Tightening retaining screws securely.
19. Partially lower vehicle.
20. Install RH and LH halfshafts into front wheel knuckles.
21. Install RH and LH front axle wheel hub retainer onto half shaft end. Tighten front axle wheel hub retainer to 230-275 Nm (170-202 ft. lbs.).
22. Connect RH and LH tie rod ends to the front wheel knuckles. Tighten retaining nuts to 47-63 Nm (35-46 ft. lbs.).
23. Connect RH and LH front suspension lower arms to the front wheel knuckles at ball joints. Install and tighten retaining nuts to 68-92 Nm (50-67 ft. lbs.).
24. Install RH and LH front stabilizer bar links to the front stabilizer bars. Tighten retaining nuts to 40-55 Nm (30-40 ft. lbs.).
25. Connect engine control sensor wiring at connector located at the RH top of fan shroud.
26. Connect separator wiring harness to the generator at the B+ terminal. Install wiring harness retainer clip to the generator mounting bracket.
27. Install front wheel and tires.
28. Lower vehicle.
29. Remove Universal engine Lifting Brackets 303-050 (T70P-6000).
30. Connect power steering return hose to power steering oil reservoir. Position clamp securely.
31. Install battery ground cable to the starter motor mounting stud bolts. Install and tighten retaining nut to 20-30 Nm 05-22 ft. lbs.).
32. Connect upper radiator hose at water bypass tube and lower radiator hose tube. Position clamps securely.
33. Connect radiator coolant recovery reservoir hose to the upper radiator hose. Position clamp securely.
34. Connect heater water hoses to the heater core inlet and outlet tubes. Position clamps securely.
35. Connect A/C compressor line to the A/C suction accumulator/ drier.
36. Connect engine control sensor wiring at top of transaxle.
37. Install engine air cleaner cover.
38. Connect the manual control ever to the manual control lever shaft at the transmission range sensor. Install and tighten retaining nut to 16-22 Nm (12-16 ft. lbs.).
39. Connect electrical wiring connector to the TR sensor.
40. Connect accelerator cable and speed control actuator cable to the throttle body lever and the accelerator cable bracket
41. Install the accelerator cable shield and tighten the retaining screws securely. Verify throttle linkage does not bind or stick.
42. Connect engine control sensor wiring to evaporative emission canister purge valve.
43. Connect evaporative emission hose to evaporative emission canister purge valve.
44. Connect the engine control sensor wiring to the mass air flow sensor.
45. Connect the engine control sensor wiring to the powertrain control module bracket (PCM bracket). Tighten bolt to 3.7 Nm (32 inch lbs.).
46. Position ground strap to the dash panel. Install and tighten retaining screw securely.
47. Connect chassis vacuum supply hose and evaporative emission hose to connector on the upper intake manifold.
48. Connect fuel tube and retaining clips to the fuel injection supply manifold.
49. Install air cleaner outlet tube. Tighten engine air cleaner tube clamp to 1.4-2.5 Nm (12-22 inch lbs.).
50. Connect engine control sensor wiring to the intake air temperature sensor. Connect the crankcase ventilation tubes and aspirator hose to the air cleaner outlet tube.
51. Connect main emission vacuum control connector at two connectors located at RH side of dash panel.
52. Install windshield wiper and cowl extension.
53. Connect steering coupling at pinch bolt inside passenger compartment.
54. Fill crankcase to proper level with Motorcraft Super Premium 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
55. Fill power steering pump.
56. Fill engine cooling system with engine coolant.
57. Connect battery ground cable.
58. Start engine and check for leaks.
59. Recheck all fluid levels. Fill as required.
60. Evacuate and recharge air conditioning system.
61. Check front end alignment.