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Engine - Manual Transaxle

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL DESCRIPTION

G04680578Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04680579Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04680580Courtesy of FORD MOTOR CO.
 Powertrain Lift
014-00765
G04680581Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets
014-0001
Lifting Bracket Set, Engine
303-D095 (D94L-6001-A) or equivalent
ITEM SPECIFICATION

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent WSS-M2C930-A
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
  1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
  2. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
    3. NOTE: Position a suitable block of wood under the transaxle.
    Fig 1: Identifying Special Tools
    G04680582Courtesy of FORD MOTOR CO.
  3. Install the special tools onto the engine.
  4. Connect the vehicle speed sensor (VSS) electrical connector.
    Fig 2: Locating Vehicle Speed Sensor (VSS) Electrical Connector
    G04680583Courtesy of FORD MOTOR CO.
  5. Connect the backup lamp electrical connector.
    Fig 3: Locating Backup Lamp Electrical Connector
    G04680584Courtesy of FORD MOTOR CO.
  6. Install the engine wiring harness bracket and nut.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 4: Locating Engine Wiring Harness Bracket And Nut
      G04680585Courtesy of FORD MOTOR CO.
  7. Install the ground wire and bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 5: Locating Ground Wire Bolt
      G04680586Courtesy of FORD MOTOR CO.
  8. Install the starter and the 2 stud bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 6: Locating Starter Stud Bolts
      G04680587Courtesy of FORD MOTOR CO.
  9. Connect the starter wires and install the 2 nuts.
    • Tighten the large nut to 12 Nm (9 lb-ft).
    • Tighten the small nut to 5 Nm (44 lb-in).
      Fig 7: Locating Starter Wire Nuts
      G04680588Courtesy of FORD MOTOR CO.
  10. Attach the 2 wiring harness retainers to the starter stud bolts.
  11. Raise the engine and transaxle into the vehicle.
  12. Install the 2 transaxle mount bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 8: Locating Transaxle Mount Bolts
      G04680589Courtesy of FORD MOTOR CO.
  13. Install the engine mount bracket, 2 nuts and the bolt.
    • Tighten the nuts to 103 Nm (76 lb-ft).
    • Tighten the bolt to 115 Nm (85 lb-ft).
      Fig 9: Locating Engine Mount Bracket Nuts And Bolt
      G04680590Courtesy of FORD MOTOR CO.
  14. Install the 2 oil pan-to-bellhousing bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 10: Locating Oil Pan-To-Bellhousing Bolts
      G04680591Courtesy of FORD MOTOR CO.
  15. Install the bellhousing-to-oil pan bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 11: Locating Bellhousing-To-Oil Pan Bolt
      G04680592Courtesy of FORD MOTOR CO.
  16. Install the RH halfshaft into the transaxle.
    Fig 12: Locating RH Halfshaft
    G04680593Courtesy of FORD MOTOR CO.
  17. Install the 2 RH halfshaft carrier bearing bracket bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 13: Locating RH Halfshaft Carrier Bearing Bracket Bolts
      G04680594Courtesy of FORD MOTOR CO.
    18. NOTE: Start one end of the circlip in the groove and work the circlip over the halfshaft and into the groove to prevent the circlip from overexpanding.
    Fig 14: Locating Halfshaft Circlip
    G03972275Courtesy of FORD MOTOR CO.
  18. Install a new circlip in the groove on the LH halfshaft.
  19. Install LH halfshaft into the transaxle.
  20. Connect the lower radiator hose and install the retaining clip.
    Fig 15: Identifying Lower Radiator Hose And Installing Retaining Clip
    G04680596Courtesy of FORD MOTOR CO.
  21. Install the radio frequency interference capacitor and the bolt on the engine mount bracket.
    • Tighten to 10 Nm (89 lb-in).
      Fig 16: Locating Radio Frequency Interference Capacitor And Bolt
      G04680597Courtesy of FORD MOTOR CO.
  22. Connect the A/C tube to the condenser and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 17: Locating A/C Tube To Condenser Nut
      G04680598Courtesy of FORD MOTOR CO.
  23. Connect the A/C tubes and install the 2 nuts.
    • Tighten to 8 Nm (71 lb-in).
      Fig 18: Locating A/C Tubes Nuts
      G04680599Courtesy of FORD MOTOR CO.
  24. Install the 2 A/C tube bracket bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 19: Locating A/C Tube Bracket Bolts
      G04680600Courtesy of FORD MOTOR CO.
  25. Attach the coolant vent hose retaining clip to the A/C tube.
    Fig 20: Locating Coolant Vent Hose Retaining Clip
    G04680601Courtesy of FORD MOTOR CO.
  26. Install the radio frequency interference capacitor, ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 21: Locating Radio Frequency Interference Capacitor, Ground Wire And Bolt
      G04680602Courtesy of FORD MOTOR CO.
  27. Connect the power steering cooler tube.
    Fig 22: Locating Power Steering Cooler Tube
    G04680603Courtesy of FORD MOTOR CO.
  28. Attach the transaxle control cables to the bracket.
    • Connect the control cables to the control levers.
      Fig 23: Locating Transaxle Control Cables To Bracket
      G04680604Courtesy of FORD MOTOR CO.
  29. Install the clutch slave cylinder and the 2 bolts.
    • Tighten to 22 Nm (16 lb-ft).
      Fig 24: Locating Clutch Slave Cylinder And Bolts
      G04680605Courtesy of FORD MOTOR CO.
  30. Install the 2 clutch tube bracket bolts.
    • Tighten to 22 Nm (16 lb-ft).
      Fig 25: Locating Clutch Tube Bracket Bolts
      G04680606Courtesy of FORD MOTOR CO.
  31. Connect the heater hose inline connector.
    Fig 26: Locating Heater Hose Inline Connector
    G04680607Courtesy of FORD MOTOR CO.
  32. If equipped, connect the block heater electrical connector and attach the harness retaining clips to the heater hose.
    Fig 27: Locating Block Heater Electrical Connector Harness Retaining Clips
    G04680608Courtesy of FORD MOTOR CO.
  33. Connect the upper radiator and heater hoses to the coolant bypass.
    Fig 28: Locating Upper Radiator And Heater Hoses
    G04680609Courtesy of FORD MOTOR CO.
  34. Attach the evaporative emissions (EVAP) tube bundle retaining clip to the bracket.
    Fig 29: Locating Evaporative Emissions (EVAP) Tube Bundle Retaining Clip
    G04680610Courtesy of FORD MOTOR CO.
  35. Connect the EVAP tube to the intake manifold.
    Fig 30: Locating EVAP Tube
    G04680611Courtesy of FORD MOTOR CO.
  36. Insert the brake booster vacuum supply tube into the locking ring on the intake manifold.
    Fig 31: Locating Brake Booster Vacuum Supply Tube
    G04680612Courtesy of FORD MOTOR CO.
  37. Connect the crankcase vent tube to the valve cover.
    Fig 32: Locating Crankcase Vent Tube
    G04680613Courtesy of FORD MOTOR CO.
  38. Connect the fuel supply tube to the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  39. Connect the powertrain control module (PCM) electrical connector and the pin-type retainer.
    Fig 33: Locating Powertrain Control Module (PCM) Electrical Connector
    G04680614Courtesy of FORD MOTOR CO.
  40. Install the ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 34: Installing Ground Wire And Bolt
      G04680615Courtesy of FORD MOTOR CO.
  41. Connect the 2 engine wiring harness electrical connectors.
    Fig 35: Locating Engine Wiring Harness Electrical Connectors
    G04680616Courtesy of FORD MOTOR CO.
  42. Connect the wire and install the nut on the battery cable.
    • Tighten to 10 Nm (89 lb-in).
      Fig 36: Locating Battery Cable And Nut
      G04680617Courtesy of FORD MOTOR CO.
  43. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  44. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.3L .
  45. Install the generator air inlet duct, bolt and the 2 nuts.
    • Tighten to 6 Nm (53 lb-in).
      Fig 37: Locating Generator Air Inlet Duct, Bolt And Nuts
      G04680618Courtesy of FORD MOTOR CO.
  46. Place the subframe assembly on the special tool and raise the subframe into the installed position.
    Fig 38: Identifying Special Tool
    G04680619Courtesy of FORD MOTOR CO.
    47. NOTE: LH shown, RH similar.
  47. Install the front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 39: Locating Front Subframe Nuts
      G04680620Courtesy of FORD MOTOR CO.
    48. NOTE: LH shown, RH similar.
    Fig 40: Locating Subframe Brackets Bolts
    G04680621Courtesy of FORD MOTOR CO.
  48. Position the subframe brackets and install the bolts finger-tight.
    49. NOTE: LH shown, RH similar.
  49. Install the subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 41: Locating Subframe Nut
      G04680622Courtesy of FORD MOTOR CO.
    50. NOTE: LH shown, RH similar.
    Fig 42: Locating Subframe Bracket-To-Body Bolts
    G04680623Courtesy of FORD MOTOR CO.
  50. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
    51. NOTE: LH shown, RH similar.
  51. Install the through bolts into the lower control arms.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 43: Locating Lower Control Arms Bolt
      G04680624Courtesy of FORD MOTOR CO.
    52. NOTE: LH shown, RH similar.
  52. Install the lower ball joint nuts.
    • Tighten to 200 Nm (148 lb-ft).
      Fig 44: Locating Lower Ball Joint Nuts
      G04680625Courtesy of FORD MOTOR CO.
    53. NOTE: LH shown, RH similar.
  53. Install the sway bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 45: Locating Sway Bar Links And Nuts
      G04680626Courtesy of FORD MOTOR CO.
  54. Connect the power steering cooler tube.
    Fig 46: Locating Power Steering Cooler Tube
    G04680627Courtesy of FORD MOTOR CO.
    55. NOTE: LH shown, RH similar.
  55. Install tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install the cotter pin.
      Fig 47: Locating Tie-Rod Ends Nuts And Cotter Pin
      G04680628Courtesy of FORD MOTOR CO.
  56. Install the LH splash shield and the 6 pin-type retainers (4 shown).
    Fig 48: Locating LH Splash Shield Pin-Type Retainers
    G04680629Courtesy of FORD MOTOR CO.
  57. Position the LH fender splash shield and install the 4 screws.
    Fig 49: Locating LH Fender Splash Shield Screws
    G04680630Courtesy of FORD MOTOR CO.
  58. Install the RH splash shield and the 6 pin-type retainers (4 shown).
    Fig 50: Locating Splash Shield Pin-Type Retainers
    G04684103Courtesy of FORD MOTOR CO.
  59. Position the RH fender splash shield and install the 4 screws.
    Fig 51: Locating RH Fender Splash Shield Screws
    G04684102Courtesy of FORD MOTOR CO.
  60. Install the engine roll restrictor bolt.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 52: Locating Engine Roll Restrictor Bolt
      G04680633Courtesy of FORD MOTOR CO.
  61. Route the power steering pressure (PSP) tube up into the engine compartment.
    Fig 53: Locating Power Steering Pressure (PSP) Tube
    G04680634Courtesy of FORD MOTOR CO.
  62. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body.
    • From under the vehicle, verify that the seal is properly installed on the steering gear and the retaining clips are fully engaged into the dash.
      Fig 54: Locating Retaining Clips
      G04680635Courtesy of FORD MOTOR CO.
  63. Install the oil filter element. For additional information, refer to ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW  and OIL FILTER ELEMENT .
  64. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .
  65. If equipped, install the underbody cover and the 7 screws.
    Fig 55: Locating Underbody Cover Screws
    G04680636Courtesy of FORD MOTOR CO.
  66. Connect the PSP tube to the power steering pump and install the bolt.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 56: Locating Power Steering Pump Bolt
      G04680637Courtesy of FORD MOTOR CO.
    67. NOTE: Align the index marks made during removal.
  67. Install the steering intermediate shaft onto the steering gear and install the bolt.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 57: Locating Steering Intermediate Shaft Bolt
      G04680638Courtesy of FORD MOTOR CO.
  68. Install the steering joint cover and the 2 nuts.
    Fig 58: Locating Steering Joint Cover And Nuts
    G04680639Courtesy of FORD MOTOR CO.
  69. Fill the engine with clean engine oil.
  70. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  71. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  72. Fill the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
  73. Recharge the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS
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