With Manual Transaxle
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:
Special Tools
Installation
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.
3. Install the flange bolts.
4. Install the flange bolts.
^ Detach the crane from the engine.
5. Install the starter motor and ground cable.
6. Raise and support the vehicle.
7. Position the engine and transmission assembly on the assembly stand below the vehicle.
^ Carefully lower the vehicle.
8. NOTE: Insert/screw on the bolts and nuts fingertight.
Install the front engine mounting.
9. NOTE: Screw on nuts fingertight.
Install the rear engine mounting.
10. Remove the retaining strap from the transmission.
11. Raise and support the vehicle.
^ Remove the assembly stand.
12. Install the engine roll restrictor.
13. CAUTION: The inner joint must not be bent at more than 18°; the outer joint must not be bent at more than 45°.
NOTE: Use new bolts and new center bearing caps.
Attach the right-hand input shaft with intermediate shaft.
14. CAUTION: The inner joint must not be bent at more than 18°; the outer joint must not be bent at more than 45°.
NOTE:
^ Use a new snap ring.
^ Click the snap ring into place.
Attach the left-hand drive shaft.
15. Attach both suspension lower arms (left-hand side shown).
1. Attach the lower arm ball joint.
2. Install the bolt.
16. Install the flexible exhaust pipe.
17. Lower the vehicle.
18. Tighten the rear engine mounting nuts/bolts.
19. Tighten the front engine mounting nuts.
20. Install the power steering pump and fit the upper bolts.
21. Attach the bracket to power steering high-pressure pipe.
22. Install the PAS reservoir.
23. Install the coolant expansion tank.
24. Raise and support the vehicle.
25. Attach the power steering pump lower bolts, power steering pump 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.
Vehicles with air conditioning
26. Attach the air conditioning compressor
All Vehicles
27. Install and tension the drive belt and connect the power steering pressure switch (PSPS).
^ Turn the belt tensioner clockwise.
28. Install the drive belt cover.
29. NOTE: Screw on wheel nuts fingertight.
Install the front wheel.
30. Lower the vehicle.
NOTE: The adjusting mechanisms must be released by pressing them in.
31. NOTE: The abutment brackets are tensioned automatically once they have been released.
Connect the cables to the transaxle and adjust them.
1. Release the abutment bracket by turning it counterclockwise and install the cable in the bracket.
2. Connect the shift cable from the gear selector lever.
3. Release the abutment bracket by turning it counterclockwise and install the cable in the bracket.
4. Connect the shift cable to the gearshift lever.
5. Lock the adjusting mechanism by pressing down the clips.
32. Attach the coolant hoses (continued).
33. Attach the fuel pipes.
34. Attach the brake servo vacuum host
35. Attach the vacuum hoses.
36. Install the air deflector and the radiator fan.
^ Hook the air deflector in place.
^ Install the clips on both sides (left side shown).
37. Connect the plug for the reversing lamp switch and the crankshaft position sensor (CKP sensor).
^ Clip on the wiring loom.
38. Connect the plug to the vehicle speed sensor (VSS)
39. Connect the harness connectors.
40. WARNING: Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or eyes. If brake fluid should come into contact with your skin or eyes, rinse the affected area immediately with water.
CAUTION: If any brake fluid gets on the paintwork wash it off immediately with water.
Attach the high-pressure pipe to the clutch slave cylinder
^ Slide on the clip
41. Attach the generator connector.
42. Connect the fuel injector wiring.
43. Connect the radiator fan connector.
^ Install the cable ties.
44. Attach the heated oxygen sensor (HO2S) connector.
45. Attach the connectors of the EI coil and the radio interference filter.
46. Attach the accelerator cable and the speed control cable (if equipped).
47. Install the air cleaner intake with resonator.
48. Attach the ground cable.
49. Install the air cleaner housing.
^ Press the air filter housing into the rubber bushings.
1. Push on the mass air flow (MAP) sensor multiplug.
2. Attach the PCV hose.
3. Attach the intake hose.
50. NOTE: Stop it from turning using an Allen key.
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.
51. 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.
52. Tighten the wheel nuts.
53. Remove the special tool 308-437.
54. 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.
Install and connect the battery.
55. Fill the cooling system.
56. Fill manual transmission fluid.
57. Fill the engine with engine oil.
58. Check the routing of the vacuum hoses and wiring and secure them with cable ties.
59. Bleed the hydraulic clutch operating system.
60. Check the fluid levels after the road test and correct as necessary.
61. Check the engine and cooling system for leaks (visual inspection).