Part 2
Engine - Manual TransaxleInstallation (Steps 33-75)
33. Install the heat shield and 6 bolts.
^ Tighten to 11 Nm (8 lb-ft).
34. Install the catalytic converter support bracket and the 2 bolts.
^ Tighten to 22 Nm (16 lb-ft).
35. Install the 2 catalytic converter support bracket-to-engine bolts.
^ Tighten to 48 Nm (35 lb-ft).
36. NOTE: Clean the mating surfaces of the muffler assembly and catalytic converter.
Using a new gasket and 2 new nuts, connect the flexpipe to the catalytic converter.
^ Tighten to 48 Nm (35 lb-ft).
37. Install 2 new O-ring seals and install the power steering tubes to the steering gear and install the bolt.
^ Tighten to 18 Nm (13 lb-ft).
38. Install the power steering tube clip and the bolt.
^ Tighten to 10 Nm (89 lb-in).
39. Install the LH halfshaft.
40. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
Install a new engine oil filter.
^ Tighten the oil filter 3/4 turn after the oil filter gasket makes contact with the oil filter adapter.
41. Connect the lower radiator hose to the radiator.
42. Install the cooling fan motor and shroud.
43. Using 2 new O-ring seals, connect the A/C tubes to the A/C compressor.
44. Install the A/C tube bracket to the A/C compressor stud bolt and install the nut.
^ Tighten to 10 Nm (89 lb-in).
45. Install the 2 A/C tube nuts.
^ Tighten to 15 Nm (11 lb-ft).
46. Position and attach the 4 B+ battery cable wire harness retainers (2 shown).
47. Install the generator. For additional information, refer to Alternator.
48. Install the accessory drive belt and tensioner.
49. Install the retainers and the splash shield.
50. Install the 2 front wheels and tires.
51. Install the radio capacitor ground cable and the bolt.
^ Tighten to 10 Nm (89 lb-in).
52. Install the engine oil level indicator.
53. Connect the hydraulic clutch line and grommet to the retaining bracket.
54. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
Connect the clutch slave cylinder supply tube.
^ Install the clip.
55. NOTE: The shift cable abutment sleeve is colored white.
NOTE: The selector cable abutment sleeve is colored black.
Attach the transaxle cables to the bracket.
1 Attach the shifter cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
2 Attach the selector cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
56. Attach the gearshift cables.
1 Attach the shifter cable to the shift mass.
2 Attach the selector cable to the selector lever.
57. Adjust the gearshift cables and bleed the clutch system.
58. Connect the HO2S and catalyst monitor sensor electrical connectors and attach the wire harness retainer.
59. Connect the starter wire harness electrical connector.
60. Connect the 3 PCM electrical connectors.
61. Attach the engine harness to the coolant outlet bracket harness retainer.
62. Connect and attach the 2 engine harness electrical connectors.
63. Attach the brake booster vacuum hose retainer.
64. Install the power brake booster vacuum tube into the quick connect fitting.
65. Position and connect the evaporative emissions tube. For additional information, refer to Evaporative Emissions System.
66. Connect the fuel tube quick connect coupling to the fuel rail.
67. Install the negative battery cable ground and the bolt.
^ Tighten to 6 Nm (53 lb-in).
68. Attach the 2 positive battery cable wire harness retainer.
69. Connect the positive battery cable nut.
^ Tighten to 10 Nm (89 lb-in).
70. Install the battery tray. For additional information, refer to Battery.
71. Connect the crankcase vent tube to the valve cover.
72. Install the air cleaner and outlet tube.
73. Fill the engine with clean engine oil.
74. Fill and bleed the cooling system. For additional information, refer to Cooling System.
75. Evacuate and charge the A/C system. For additional information, refer to Heating and Air Conditioning.