Installation

NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.

1. Remove engine from engine stand using Rotunda Floor Crane Positioning Sling 014-00036 and Rotunda Floor Crane 014-00071 or equivalents attached to the engine lifting eyes.
2. Install engine rear plate and flywheel. Tighten retaining bolts in alternating sequence to 107-117 Nm (79-86 ft. lbs.).
3. On manual transaxle-equipped vehicles, install clutch disc and clutch pressure plate. See Transmission and Drivetrain.
4. Align torque converter and flywheel and install transaxle to engine. Tighten retaining bolts to 34-46 Nm (25-34 ft. lbs.).
5. If removed, place front sub-frame on Powertrain Fixture 134-00250 or equivalent.
6. Install engine and transaxle assembly onto Rotunda Powertrain Fixture 134-00250 or equivalent.
7. Install Powertrain Alignment Gauge T94P-6000-AH to LH front engine support bracket and front sub-frame. Tighten two retaining bolts and then through bolt to 27 Nm (20 ft. lbs.).
8. Install RH front engine support insulator retaining bolts to front sub-frame. Through bolt should be finger-tight.
9. Install battery ground cable to engine at transaxle stud bolt. Tighten retaining nut to 20-30 Nm (15-22 ft. lbs.).
10. Install starter motor.
11. Install LH and RH halfshafts into transaxle.





12. Partially lower vehicle on hoist and install engine and transaxle assembly with front sub-frame to body.

Fig. 9 Powertrain & subframe support bracket tool installation:

13. Install front sub-frame bolts. Tighten front sub-frame bolts to 125-135 Nm (92-100 ft. lbs.).

NOTE: Make sure engine and transaxle are firmly seated against front and rear insulator brackets.

14. Using new nuts, install upper front engine support bracket and engine and transmission support insulator. Tighten nuts to 10 Nm (7 ft. lbs.).
15. Raise vehicle and remove Rotunda Powertrain Fixture 134-00250 or equivalent.
16. Tighten RH front engine support insulator to sub-frame bolts to 41-55 Nm (30-41 ft. lbs.). Observe position of RH front engine support insulator, it must be centered in bracket and in perfect alignment front to rear.
17. Lower vehicle on hoist.
18. Tighten front engine support bracket nuts to 70-95 Nm (52-70 ft. lbs.).
19. Tighten engine and transmission support insulator nuts to 41-55 Nm (30-41 ft. lbs.) with automatic transaxle or 70-95 Nm (52-70 ft. lbs.) with manual transaxle.
20. Tighten RH front engine support insulator through bolt to 103-137 Nm (75-102 ft. lbs.).
21. Remove Powertrain Alignment Gauge T94P-6000-AH.
22. Install LH front engine support insulator to front sub-frame with two bolts. Tighten bolts to 10 Nm (7 ft. lbs.). Observe LH front engine support insulator to ensure perfect front to rear alignment. Re-tighten bolts to 41-55 Nm (30-41 ft. lbs.).
23. Install LH front engine support insulator through bolt. Tighten to 103-137 Nm (75-102 ft. lbs.).
24. Connect power steering oil cooler hoses at RH front of front sub-frame. Tighten hose clamps securely.
25. Connect engine control sensor wiring to heated oxygen sensor, engine coolant temperature sensor and crankshaft position sensor.
26. Connect wire harness to A/C compressor.
27. Install radiator supports to front sub-frame bolts. Tighten to 8-11 Nm (71-97 inch lbs.).
28. Connect lower radiator hose to the radiator.
29. On manual transaxle-equipped vehicles, install shift rod stabilizer to transaxle. Tighten shift rod bolt to 23 Nm (17 ft. lbs.) and stabilizer nut to 55 Nm (41 ft. lbs.).
30. On automatic transaxle-equipped vehicles, install transmission oil cooler lines. Tighten nuts to 24-31 Nm (18-22 ft. lbs.).
31. Connect heater water hose at heater water tube located under engine.
32. Lower vehicle.
33. If equipped, connect block heater power supply wiring to LH side of radiator support.
34. On manual transaxle-equipped vehicles, connect clutch hydraulic line to clutch actuator pipe at transaxle case. Install retainer.
35. Connect positive and negative battery cable retainer to battery tray.
36. Install heater water hose to the connector tube located near the EGR valve. Install heater hose spring clamp securely.
37. Connect evaporative emission hose at connector located near the radio ignition interference capacitor.
38. Connect upper radiator hose to the radiator.
39. Connect the vacuum supply line to the power brake booster.
40. Connect engine control sensor wiring to ignition coil and radio ignition interference capacitor.
41. Connect ground strap to the transaxle case.
42. Connect engine control sensor wiring to transmission range sensor.
43. On automatic transaxle-equipped vehicles, install shift cable and bracket to transaxle. Tighten bolts to 20-25 Nm (15-19 ft. lbs.).
44. Connect vacuum hoses from the EGR backpressure transducer to the EGR valve to exhaust manifold tube. Connect vacuum supply hose to the EGR valve.
45. Connect fuel supply and return lines to fuel injection supply manifold.
46. Connect hoses to A/C compressor.
47. Connect coolant hoses to radiator coolant recovery reservoir.
48. Connect vacuum supply hose for body to intake manifold at fitting on rear of intake manifold.
49. Install ground strap on generator mounting bracket.
50. Connect engine control sensor wiring to generator.
51. Connect engine control sensor wiring to the power steering pressure switch located on the power steering pressure hose.
52. Connect power steering return hose to the power steering pump. Tighten hose clamp securely.
53. Install power steering pump reservoir to bracket.
54. Install retainer screws for engine control sensor wiring to the intake manifold. Tighten retainer screws securely.
55. Connect the engine control sensor wiring to the fuel charging wiring at the connector located near the fuel pressure regulator.
56. Connect the accelerator cable and speed control actuator cable to the accelerator cable bracket and the throttle body.
57. Remove safety wire retaining radiator to radiator support.
58. Raise and support vehicle.
59. Connect engine control sensor wiring to knock sensor and oil pressure sensor located on RH side of cylinder block.
60. On automatic transaxle-equipped vehicles, install four torque converter to flywheel retaining nuts. Tighten nuts in alternating sequence to 73-87 Nm (54-64 ft. lbs.).
61. On automatic transaxle-equipped vehicles, install access plug onto engine rear plate. Tighten screws securely.
62. Install RH splash shield onto front fender apron. Tighten retaining screws securely.
63. Connect vehicle speed sensor wiring harness at connector.
64. Install A/C accumulator retaining screws to front sub-frame. Tighten screws securely.
65. Install LH and RH halfshafts into front wheel hubs.
66. Install LH and RH front wheel knuckles onto front suspension lower arms at ball joint. Tighten bolts to 50-58 Nm (37-43 ft. lbs.).
67. Install LH and RH tie rod ends to the front wheel knuckle. Install new nuts on tie rod end studs. Tighten nuts to 28 Nm (21 ft. lbs.) and continue tightening nuts to align the next castellation of the nut with the cotter pin hole in the stud. Install new cotter pins.
68. Connect LH and RH front stabilizer bar link to front stabilizer bar. Tighten nuts to 48 Nm (35 ft. lbs.).
69. Install front wheel and tire assemblies. Tighten lug nuts to 85 Nm (62 ft. lbs.).
70. Install three way catalytic converter.
71. Install splash shield to front of front sub-frame and body. Tighten screws securely.
72. Rotate front bumper cover braces rearward. Install two screws to front sub-frame and tighten securely.
73. Lower vehicle.
74. Install engine air cleaner and engine intake air resonators.
75. Connect steering shaft and joint in vehicle. Tighten bolt to 24 Nm (18 ft. lbs.).
76. Connect positive and battery ground cable and wiring to battery.
77. On automatic transaxle-equipped vehicles, fill transaxle with approved fluid. See Transmission and Drivetrain.
78. Fill power steering system with approved fluid.
79. Fill engine cooling system.
80. Recharge A/C system. See Heating and Air Conditioning.
81. Run engine and check for oil, coolant or fuel leaks. Verify proper operation of the engine cooling fan and A/C system.