LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> ZX2 Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 318 (Engine-2.0L SPI) >> Installation >> Engine - iB5 Transaxle >> Installation

Engine - iB5 Transaxle: Installation

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

    All Vehicles 

  1. Using the special tool and a floor crane to position the engine to the transaxle.
    Fig 1: Positioning Engine To Transaxle
    G01615440Courtesy of FORD MOTOR CO.
  2. Tighten the transaxle flange lower bolts.
    Fig 2: Tightening Transaxle Flange Lower Bolts
    G01615441Courtesy of FORD MOTOR CO.
  3. Tighten the transaxle flange left-hand bolts.
    Fig 3: Tightening Transaxle Flange Left-Hand Bolts
    G01615442Courtesy of FORD MOTOR CO.
  4. Install the starter motor and tighten the flange bolt.
    1. Starter motor bolt
    2. Flange bolt
      Fig 4: Installing Starter Motor
      G01615443Courtesy of FORD MOTOR CO.
    5. NOTE: Use new retaining clamp.
    Fig 5: Installing Retaining Clamp
    G01615444Courtesy of FORD MOTOR CO.
  5. Install the retaining clamp.
  6. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  7. Locate the engine and transmission assembly on the assembly stand in installation position underneath the vehicle.
    Fig 6: Identifying Engine And Transmission Assembly Underneath Vehicle
    G01615445Courtesy of FORD MOTOR CO.
  8. Carefully lower the vehicle.
  9. Install the bolts.
    1. Transaxle upper flange bolts.
    2. Starter motor bolts.
    • Install the ground strap.
      Fig 7: Installing Transaxle Upper Flange And Starter Motor Bolts
      G01615446Courtesy of FORD MOTOR CO.
    10. NOTE: Install the bolts and nuts finger tight.
    Fig 8: Installing Engine Front Mount
    G01615447Courtesy of FORD MOTOR CO.
  10. Install the engine front mount.
    11. NOTE: Install the nuts finger tight.
    Fig 9: Installing Engine Rear Mount
    G01615448Courtesy of FORD MOTOR CO.
  11. Install the engine rear mount.
    12. CAUTION: Brake fluid will escape. Observe the safety regulations for the use of brake fluid. .
    Fig 10: Connecting High-Pressure Tube To Clutch Slave Cylinder
    G01615449Courtesy of FORD MOTOR CO.
  12. Connect the high-pressure tube to the clutch slave cylinder.
  13. Remove the retaining strap from the transaxle.
  14. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
    • Remove the assembly stand.
    15. CAUTION: The inner part of the constant velocity joint must not be bent at more than 18 degrees, the outer part no more than 45 degrees.
    NOTE: Use a new boot clamp.
    Fig 11: Installing Front Drive Halfshafts
    G01615450Courtesy of FORD MOTOR CO.
  15. Using the special tool, install both front drive halfshafts (right-hand side shown).
  16. Install the right-hand engine support insulator.
    Fig 12: Installing Right-Hand Engine Support Insulator
    G01615451Courtesy of FORD MOTOR CO.
  17. Attach both lower arms (right-hand side shown).
    Fig 13: Attaching Lower Arms
    G01615452Courtesy of FORD MOTOR CO.
  18. Install the flexible exhaust pipe.
    Fig 14: Installing Flexible Exhaust Pipe
    G01615453Courtesy of FORD MOTOR CO.
  19. Install the gearshift cables.
    • Attach the gearshift cables to the brackets by twisting the abutment brackets counterclockwise.
      Fig 15: Installing Gearshift Cables
      G01615454Courtesy of FORD MOTOR CO.
  20. Install the cover for the gearshift cables.
    Fig 16: Installing Cover For Gearshift Cables
    G01615455Courtesy of FORD MOTOR CO.

    21. Vehicles With Air Conditioning 

  21. Install the air conditioning compressor.
    Fig 17: Installing Air Conditioning Compressor (W/ A/C)
    G01615456Courtesy of FORD MOTOR CO.

    22. All Vehicles 

  22. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
  23. Tighten the engine front mount nuts and bolts.
    Fig 18: Tightening Engine Front Mount Nuts And Bolts
    G01615457Courtesy of FORD MOTOR CO.
  24. Tighten the engine rear mount nuts.
    Fig 19: Tightening Engine Rear Mount Nuts
    G01615458Courtesy of FORD MOTOR CO.
  25. Install the power steering pump.
    Fig 20: Installing Power Steering Pump
    G01615459Courtesy of FORD MOTOR CO.
  26. Using the special tool to prevent the power steering pump from rotating install the power steering pump pulley nut.

    Install the power steering pump pulley.

    Fig 21: Installing Power Steering Pump Pulley
    G01615460Courtesy of FORD MOTOR CO.
  27. Install the accessory drive belt.
    • Turn the belt tensioner clockwise.
      Fig 22: Installing Accessory Drive Belt
      G01615461Courtesy of FORD MOTOR CO.
  28. Push the power steering fluid reservoir into place.
    Fig 23: Pushing Power Steering Fluid Reservoir
    G01615462Courtesy of FORD MOTOR CO.
  29. Install the coolant expansion tank.
    Fig 24: Installing Coolant Expansion Tank
    G01615463Courtesy of FORD MOTOR CO.
  30. Install the cooling fan to the radiator.
    • Position the air deflector and clip on at the top on both sides (left-hand side shown).
    • Install the cooling fan wiring harness.
      Fig 25: Installing Cooling Fan To Radiator
      G01615464Courtesy of FORD MOTOR CO.
  31. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  32. Install the accessory drive belt cover.
    Fig 26: Installing Accessory Drive Belt Cover
    G01615465Courtesy of FORD MOTOR CO.
  33. Lower the vehicle.
  34. Install the coolant hoses to the coolant hose connector.
    Fig 27: Installing Coolant Hoses To Coolant Hose Connector
    G01615466Courtesy of FORD MOTOR CO.
  35. Install the coolant hose to the coolant tube.
    Fig 28: Installing Coolant Hose To Coolant Tube
    G01615467Courtesy of FORD MOTOR CO.
  36. Install the coolant hose to the water pump.
    Fig 29: Installing Coolant Hose To Water Pump
    G01615468Courtesy of FORD MOTOR CO.
  37. Install the coolant hose to the intake manifold.
    Fig 30: Installing Coolant Hose To Intake Manifold
    G01615469Courtesy of FORD MOTOR CO.
  38. Connect the fuel pipe.
    Fig 31: Connecting Fuel Pipe
    G01615470Courtesy of FORD MOTOR CO.
  39. Connect the vacuum hoses.
    Fig 32: Connecting Vacuum Hoses
    G01615471Courtesy of FORD MOTOR CO.
  40. Connect the vacuum hose.
    Fig 33: Connecting Vacuum Hose
    G01615472Courtesy of FORD MOTOR CO.
  41. Connect the vacuum hoses.
    1. EVAP hose
    2. Brake servo hose
    3. Delta pressure feedback vacuum hoses
    4. EGR hose
      Fig 34: Connecting EVAP Hose, Brake Servo Hose And EGR Vacuum Hoses
      G01615473Courtesy of FORD MOTOR CO.
  42. Connect the reversing lamp electrical connector.
    Fig 35: Connecting Reversing Lamp Electrical Connector
    G01615474Courtesy of FORD MOTOR CO.
  43. Connect the vehicle speed sensor (VSS) electrical connector.
    Fig 36: Connecting Vehicle Speed Sensor Electrical Connector
    G01615475Courtesy of FORD MOTOR CO.
  44. Connect the cooling fan electrical connector.
    • Secure the cable with cable ties.
    Fig 37: Connecting Cooling Fan Electrical Connector
    G01615476Courtesy of FORD MOTOR CO.
  45. Connect both PCM electrical connectors.
    Fig 38: Connecting PCM Electrical Connectors
    G01615477Courtesy of FORD MOTOR CO.
  46. Connect the electrical connectors.
    1. Power steering pump pressure switch electrical connector
    2. Generator electrical connector
    3. Heated oxygen sensor electrical connector
      Fig 39: Connecting Electrical Connectors
      G01615478Courtesy of FORD MOTOR CO.
  47. Install the speed control cable.
    1. Hook the cable in place.
    2. Clip on the plastic clip.
      Fig 40: Installing Speed Control Cable
      G01615479Courtesy of FORD MOTOR CO.
  48. Install the accelerator cable.
    1. Hook the cable in place.
    2. Clip on the plastic clip.
      Fig 41: Installing Accelerator Cable
      G01615480Courtesy of FORD MOTOR CO.
  49. Install the air cleaner intake pipe.
    Fig 42: Installing Air Cleaner Intake Pipe
    G01615481Courtesy of FORD MOTOR CO.
  50. Install the air cleaner (ACL).
    • Insert the air cleaner housing into the rubber bushing.
    1. Connect the MAF sensor electrical connector.
    2. Install the outlet pipe.
      Fig 43: Installing Air Cleaner
      G01615482Courtesy of FORD MOTOR CO.
  51. Attach the ground cable.
    Fig 44: Attaching Ground Cable
    G01615483Courtesy of FORD MOTOR CO.
    52. NOTE: Use an Allen key to stop the piston rod from turning.
  52. Tighten the suspension strut nut on both sides (right-hand side shown).
    • Use a box end wrench and tighten finger tight.
    • Use a torque wrench and tighten to the specified torque.
      Fig 45: Tightening Suspension Strut Nut
      G01615484Courtesy of FORD MOTOR CO.
  53. Install the battery tray.
    1. Install the positive and negative cables.
    2. Tighten the bolts.
    3. Clip on the wiring harness.
    4. Connect the electrical connector.
      Fig 46: Installing Battery Tray
      G01615485Courtesy of FORD MOTOR CO.
  54. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  55. Fill the cooling system. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  56. Fill the engine with engine oil.
scientia non olet · About LEMON Manuals