With Automatic Transmission

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

Special Tools:

NOTE: The locations of engine mountings and engine support insulators are given looking from the automatic transaxle to the engine.

NOTE: Install new snap rings, cotter pins and self-locking nuts.

1. NOTE: The torque converter hub must fully engage with the oil pump drive gear.





Check the installation depth of the torque converter.
1 Lay a straight edge on the transaxle flange.
2 Check the installation depth between the transaxle Range and the torque converter centering spigot for the correct clearance: 12 mm.

2. Apply a thin layer of High-temperature grease meeting Ford Specification ESD-M1C220-A or equivalent to the centering spigot bore on the torque converter.

3. CAUTION: The torque converter must remain at the correct installation depth throughout the entire installation procedure. Check that the adapter plate is in the correct position.

Using the floor crane and special tools 303-D089 and 303-05O, carefully lower the engine assembly into the engine compartment to the power steering pump installation position.

CAUTION: Make sure that the pipes and hoses are not stressed.





4. Install the power steering pump.
5. Position the engine in the installation position next to the transaxle and guide the torque converter stud into the drive plate.
6. Screw in all the flange bolts.





7. Tighten the upper flange bolts.
- Install the starter motor cable bracket.

8. CAUTION: Do not twist or strain the engine front mounting brackets.





Align and tighten the engine front support insulator.
9. Remove the special tools 303-089, 303-050 and the floor Crane.
10. Raise and support the vehicle.





11. Tighten the flange bolts on the left-hand side.





12. Tighten the flange bolts on the right-hand side.





13. Connect the torque converter to the engine drive plate (four nuts) and install the plastic cover.





14. Connect the oil pressure switch and the Knock Sensor (KS) electrical connectors.





15. Connect the heater coolant hose.

Vehicles With Air Conditioning





16. Install the compressor.

All Vehicles





17. Connect the lower radiator hose to the radiator.





18. Connect the coolant hose to the heater coolant tube and install the bracket.





19. Install the right-hand halfshaft and intermediate shaft bracket.

20. NOTE: Do not damage the oil seal.





Install the right-hand halfshaft and intermediate shaft.





21. Install the Three Way Catalytic Converter (TWC).
- Install the TWC.
- Tighten the TWC bracket.





22. Attach the front exhaust pipe.
- Use a new gasket.





23. Connect the brake booster vacuum line to the intake manifold.





24. Connect Heated Oxygen Sensor (H02S) electrical connector.





25. Position the accessory drive belt in place and tension it.
- Turn the accessory belt tensioner clockwise to relieve belt tension.





26. Install the right-hand splash shield.





27. Install the starter motor.
- Install the ground cable.





28. Install the starter motor wiring.





29. Install the radiator splash shield (nine bolts) and attach the bracket on each side (left-hand side shown).
30. Lower the vehicle.





31. Connect the fuel lines.
- Push on the retaining clips.





32. Install the accessory drive belt upper guard.





33. Install the clamp to the fender apron panel and install the coolant hoses.





34. Install the coolant pipe and connect the coolant hoses.
1 Install the coolant pipe.
2 Install the coolant hose to the coolant pipe.
3 Install the coolant hose to the water pump.





35. Connect the Electronic Ignition (EI) coil electrical connectors.
1 Electrical connector
2 Radio suppressor electrical connector





36. Connect the coolant hoses.





37. Connect the electrical connectors.
1 Crankshaft Position (CKP) sensor
2 Engine Coolant Temperature (ECT) sensor





38. Connect the Three Way Catalytic Converter (TWC) to the exhaust manifold.





39. Connect the Heated Oxygen Sensor (H02S).





40. Install the heat shield.
- Apply Threadlock 262 or equivalent meeting Ford Specification WSK-M2G351-A6 to the end of the oil level dipstick tube.
1 Install the coolant hose brackets, and the engine oil level dipstick tube.
- Install the engine lifting eye.

2 Install the brackets for the coolant hose.
3 Install the bolts.





41. Connect the vacuum hoses to the intake manifold.
42. Raise and support the vehicle.





43. Install the coolant expansion tank.
- Connect the speed control cable (if equipped) to the coolant expansion tank.





44. Connect the throttle cable.
1 Guide the cable into the abutment bracket and push on the plastic clip.
- Hook the cable in place.

2 Pull the clip off the throttle cable.
- Pull the cable out a few notches.
- Fully depress the accelerator pedal once and slide the clip back on.
- Check whether the throttle valve opens fully when the accelerator pedal is fully depressed. Repeat the adjustment, if necessary.





45. Connect the battery starter motor positive cable.





46. Install the air cleaner resonator.
- Insert the air cleaner resonator (push fit).
1 Install the crankcase ventilation hose.
2 Install the air hose.





47. Install the air cleaner outlet tube.
1 Install the one bolt and two nuts.
2 Connect the IAT sensor electrical connector.
3 Connect the MAF sensor electrical connector.





48. Install the ground cable and the power steering line bracket to the engine lifting eye.
49. Remove the auxiliary tool from the hood.

NOTE: 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.

50. Connect the battery ground cable.
51. Fill the engine cooling system.
52. Check the fluid levels after the road test and correct as necessary.
53. Check the routing of the vacuum hoses and wiring and secure them with cable ties.
54. Automatic transaxle: check the fluid levels.