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Engine - Automatic 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. General note.
    • If necessary, use Special Tool 412-108 to install coolant and ventilation hoses.
  2. Preparatory operations
    • Using a retaining strap, secure the transmission on the assembly stand.
    • Hook the engine into the crane, bring into position at the transmission and support using wooden blocks.
      Fig 1: Hooking Engine Into Crane
      G01614931Courtesy of FORD MOTOR CO.
  3. Install the flange bolts.
    Fig 2: Installing Flange Bolts (1 Of 2)
    G01614932Courtesy of FORD MOTOR CO.
  4. Install the flange bolts.
    • Detach the crane from the engine.
      Fig 3: Installing Flange Bolts (2 Of 2)
      G01614933Courtesy of FORD MOTOR CO.
  5. Install the starter motor and ground cable.
    Fig 4: Installing Starter Motor And Ground Cable
    G01614934Courtesy of FORD MOTOR CO.
  6. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  7. Position the engine and transmission assembly on the assembly stand below the vehicle.
    • Carefully lower the vehicle.
      Fig 5: Positioning Engine And Transmission Assembly On Assembly Stand
      G01614935Courtesy of FORD MOTOR CO.
    8. NOTE: Do not fully tighten the bolts and nuts at this stage.
    Fig 6: Installing Engine Front Mounting
    G01614936Courtesy of FORD MOTOR CO.
  8. Install the engine front mounting.
    9. NOTE: Do not fully tighten the nuts at this stage.
    Fig 7: Installing Engine Rear Mounting
    G01614937Courtesy of FORD MOTOR CO.
  9. Install the engine rear mounting.
  10. Remove the retaining strap from the transmission.
  11. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
    • Remove the assembly stand.
  12. Install the engine roll restrictor.
    Fig 8: Installing Engine Roll Restrictor
    G01614938Courtesy of FORD MOTOR CO.
    13. CAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
    NOTE: Use new bolts and new center bearing caps.
    Fig 9: Attaching Right-Hand Input Shaft With Intermediate Shaft
    G01614939Courtesy of FORD MOTOR CO.
  13. Attach the right-hand input shaft with intermediate shaft.
    14. CAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
    NOTE: Use a new snap ring.
    NOTE: Click the snap ring into place.
    Fig 10: Attaching Left-Hand Drive Shaft
    G01614940Courtesy of FORD MOTOR CO.
  14. Attach the left-hand drive shaft.
  15. Attach the both suspension lower arms (left-hand side shown).
    1. Attach the lower arm ball joint.
    2. Install the bolt.
      Fig 11: Attaching Both Suspension Lower Arms
      G01614941Courtesy of FORD MOTOR CO.
  16. Install the flexible exhaust pipe.
    Fig 12: Installing Flexible Exhaust Pipe
    G01614942Courtesy of FORD MOTOR CO.
  17. Lower the vehicle.
  18. Tighten the engine rear mounting nuts/bolts.
    Fig 13: Tightening Engine Rear Mounting Nuts/Bolts
    G01614943Courtesy of FORD MOTOR CO.
  19. Tighten the engine front mounting nuts.
    Fig 14: Tightening Engine Front Mounting Nuts
    G01614944Courtesy of FORD MOTOR CO.
  20. Attach the power steering pump and install the upper bolts.
    Fig 15: Attaching Power Steering Pump
    G01614945Courtesy of FORD MOTOR CO.
  21. Attach the bracket to power steering high-pressure pipe.
    Fig 16: Attaching Bracket To Power Steering High-Pressure Pipe
    G01614946Courtesy of FORD MOTOR CO.
  22. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  23. Attach the power steering pump lower bolts, power steering pressure switch electrical connector and the radiator lower coolant hose.
    1. Power steering pump lower bolts.
    2. Power steering pump pressure switch electrical connector.
    3. Radiator lower coolant hose.
      Fig 17: Attaching Power Steering Pump Lower Bolts, Pressure Switch And Radiator Lower Coolant Hose
      G01614947Courtesy of FORD MOTOR CO.

    24. Vehicles With Air Conditioning 

  24. Attach the air conditioning compressor.
    Fig 18: Attaching Air Conditioning Compressor (W/ A/C)
    G01614948Courtesy of FORD MOTOR CO.

    25. All Vehicles 

  25. Install and tension the drive belt and connect the power steering pressure switch (PSPS).
    • Turn the belt tensioner clockwise.
      Fig 19: Installing Drive Belt And Power Steering Pressure Switch
      G01614949Courtesy of FORD MOTOR CO.
  26. Install the drive belt cover.
    Fig 20: Installing Drive Belt Cover
    G01614950Courtesy of FORD MOTOR CO.
  27. Install both front wheels and tires. For additional information, refer to WHEELS & TIRES .
  28. Install the oil filler pipe/selector cable bracket.
    Fig 21: Installing Oil Filler Pipe/Selector Cable Bracket
    G01614951Courtesy of FORD MOTOR CO.
  29. Connect the selector lever cable to the automatic transaxle selector lever assembly.
    Fig 22: Connecting Selector Lever Cable To Automatic Transaxle Selector Lever Assembly
    G01614952Courtesy of FORD MOTOR CO.
  30. Attach the oil cooler pipes to the transaxle.
    Fig 23: Attaching Oil Cooler Pipes To Transaxle
    G01614953Courtesy of FORD MOTOR CO.
  31. Attach the coolant hoses (continued).
    Fig 24: Attaching Coolant Hoses
    G01614954Courtesy of FORD MOTOR CO.
  32. Attach the fuel pipes.
    Fig 25: Attaching Fuel Pipes
    G01614955Courtesy of FORD MOTOR CO.
  33. Attach the brake servo vacuum hose.
    Fig 26: Attaching Brake Servo Vacuum Hose
    G01614956Courtesy of FORD MOTOR CO.
  34. Attach the vacuum hoses.
    Fig 27: Attaching Vacuum Hoses (1 Of 2)
    G01614957Courtesy of FORD MOTOR CO.
  35. Attach the vacuum hoses.
    Fig 28: Attaching Vacuum Hoses (2 Of 2)
    G01614958Courtesy of FORD MOTOR CO.
  36. Install the air deflector and the radiator fan.
    • Hook the air deflector in place.
    • Install the clips on both sides (left side shown).
      Fig 29: Installing Air Deflector And Radiator Fan
      G01614959Courtesy of FORD MOTOR CO.
  37. Connect the harness connectors.
    Fig 30: Connecting Harness Connectors
    G01614960Courtesy of FORD MOTOR CO.
  38. Attach the generator connector.
    Fig 31: Attaching Generator Connector
    G01614961Courtesy of FORD MOTOR CO.
  39. Install the ground cable.
    Fig 32: Installing Ground Cable
    G01614962Courtesy of FORD MOTOR CO.
  40. Connect the fuel injector cable ties.
    Fig 33: Connecting Fuel Injector Cable Ties
    G01614963Courtesy of FORD MOTOR CO.
  41. Connect the radiator fan connector.
    • Install the cable ties.
      Fig 34: Connecting Radiator Fan Connector
      G01614964Courtesy of FORD MOTOR CO.
  42. Attach the heated oxygen sensor (HO2S) connector.
    Fig 35: Attaching Heated Oxygen Sensor Connector
    G01614965Courtesy of FORD MOTOR CO.
  43. Attach the connectors of the EI coil and the radio interference filter.
    Fig 36: Attaching EI Coil And Radio Interference Filter Connectors
    G01614966Courtesy of FORD MOTOR CO.
  44. Attach the accelerator cable and the speed control cable (if equipped).
    Fig 37: Attaching Accelerator Cable And Speed Control Cable
    G01614967Courtesy of FORD MOTOR CO.
  45. Install the air cleaner intake with resonator.
    Fig 38: Installing Air Cleaner Intake With Resonator
    G01614968Courtesy of FORD MOTOR CO.
  46. Attach the ground cable.
    Fig 39: Attaching Ground Cable
    G01614969Courtesy of FORD MOTOR CO.
  47. Attach the ground cable to the battery terminal.
  48. Install the air cleaner housing.
    • Press the air filter housing into the rubber bushings.
    1. Push on the mass air flow (MAF) sensor multiplug.
    2. Attach the PCV hose.
    3. Attach the intake hose.
      Fig 40: Installing Air Cleaner Housing
      G01614970Courtesy of FORD MOTOR CO.
    49. NOTE: Stop it from turning using an Allen key.
  49. Tighten the suspension strut nuts on the right and left.
    • Tighten by hand with a ring spanner.
    • Use a torque wrench to tighten to specification.
      Fig 41: Tightening Suspension Strut Nuts
      G01614971Courtesy of FORD MOTOR CO.
  50. Install the battery tray.
    1. Attach the ground cable to the body.
    2. Attach the battery positive and negative cables.
    3. Install the bolts.
    4. Clip the wiring harness in place.
    5. Connect and clip in the plug.
      Fig 42: Installing Battery Tray
      G01614972Courtesy of FORD MOTOR CO.
  51. Install the battery.
    52. CAUTION: 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.
  52. Install and connect the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  53. Fill the cooling system. For additional information, refer to ENGINE COOLING .
  54. Fill automatic transmission fluid. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION .
  55. Fill the engine with engine oil.
  56. Check the routing of the vacuum hoses and wiring and secure them with cable ties.
  57. Check the fluid levels after the road test and correct as necessary.
  58. Check the engine and cooling system for leaks (visual inspection).
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