With Manual 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:

Materials:

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

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

1. NOTE: Apply the spline grease thinly enough so that when the clutch disk is fitted onto the transaxle input shaft, no grease is squeezed out from the splines.

Coat the drive splines of the clutch disk evenly with High-temperature grease.
2. Position the transaxle on the engine.





3. Install the transaxle flange bolts on the left-hand side of the transaxle.





4. Install the transaxle flange bolts on the right-hand side of the transaxle. and the lower starter motor bolt.





5. Using the special tools and a Suitable Floor Crane, raise the engine/transaxle assembly to remove the pressure, from the powertrain lift. Take the retaining straps off the engine/transaxle assembly.
^ Remove the powertrain lift.





6. Install the upper transaxle flange bolts.
^ Install the upper starter motor bolts.
^ Install the two flange bolts.
^ Attach the ground lead to the transaxle.





7. Install the starter motor electrical connections.





8. Connect the reversing light switch and the Vehicle Speed Sensor (VSS) electrical connector.

CAUTION: The engine/transaxle assembly has to be in a diagonal position to pull it out below the tube/hose (A/C). Make sure, that the tube/hose (A/C) is not in stress.

NOTE: Install the power steering pump before the engine/transaxle assembly is in place.





9. Install the engine/transaxle assembly.

CAUTION: Make sure, that the pipes and hoses are not in stress.





10. Install the power steering pump bolts.





11. NOTE: Do not tighten the nuts.

Install the rear transaxle support insulators.





12. NOTE: Do not tighten the nuts and bolts.

Install the front engine support insulators.





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





14. Connect and secure the fuel lines.
15. Raise and support the vehicle.





16. Install the special tool.
1 Install the special tool.
2 Install the bolts.
3 Install the center bolt.





17. NOTE: The transaxle is in neutral when both levers are vertical.

Set the gearshift lever and selector lever to the "Neutral" position.

NOTE: The adjusting mechanisms must be released by pressing them in.





18. 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.





19. Connect the heater coolant hoses.

Vehicles with air conditioning





20. Install the compressor bolts.

All Vehicles





21. Connect the coolant hose.

CAUTION: To avoid to damage the halfshaft joints and boots, do not bend the inner halfshaft joint by more than 18 degrees, the outer one by not more than 45 degrees.





22. Install a new snap ring.





23. NOTE: Do not damage the oil seal. Check that the snap ring engages correctly.

Install the left-hand halfshaft.





24. NOTE: Install a new snap ring. Do not damage the oil seal. Check that the snap ring engages correctly.

Install the right-hand halfshaft.





25. Install the bracket for the right-hand engine support insulator to the transaxle.





26. Install the right-hand engine support insulator.
1 Install the bracket bolts.
2 Install the center bolt.





27. Remove the special tool, install the engine support insulator and the Three-Way Catalytic Converter (TWC).
1 Install the center bolt.
2 Install the nuts.
^ Install the TWC.

3 Tighten the TWC bolt.

Vehicles with air conditioning





28. Install the suction accumulator bracket bolts.

All Vehicles





29. Install the front exhaust tube with a new gasket and hook it in place.
^ Install a new gasket.





30. Install the radiator brackets and connect both Heated Oxygen Sensor (H02S) electrical connectors.
^ Secure the wiring harness with cable ties.





31. CAUTION: Do not damage boot and ABS sensor ring.

Connect the lower suspension arm ball joints.
^ Attach the ABS wiring harness bracket to the suspension strut.





32. Insert the brake booster vacuum hose into the intake manifold.





33. Position the accessory drive belt in place and tension it (removed engine shown).





34. Install the fender splash shields (right-hand side shown).





35. Install the radiator splash shield (nine bolts) and install the brackets on both sides (left-hand side shown).
36. Lower the vehicle.

CAUTION: Do not twist or strain the rear engine support insulators.





37. NOTE: Install new self-locking nuts.

Install the rear transaxle support insulator.
1 Install the bolts.
2 Install the nuts.





38. CAUTION: Do not twist or strain the front engine support insulators.

Align the front engine support insulators and tighten the nuts.





39. Install the coolant expansion tank.
^ Attach the speed control cable (if equipped) to the coolant expansion tank.

Vehicles with air conditioning





40. Connect the compressor electrical connector (without accessory belt drive shown).

All Vehicles





41. Install the TWC to the exhaust manifold.





42. Connect the coolant hoses and install the coolant pipe.
1 Install the coolant pipe.
2 Install the coolant hose to the coolant pipe.
3 Install the coolant hose to the water pump.





43. Install the heat shield.
1 Install the coolant hose brackets, and the engine oil level indicator tube.
^ Install the upper bolt.

2 Install the brackets for the coolant hose.
3 Install the bolts.
44. Install the front wheels.
45. Lower the vehicle.





46. Tighten the front wheel nuts.





47. Connect the battery cables and electrical connectors and secure the wiring harness with cable ties.





48. Connect the vacuum hoses to the intake manifold.





49. Connect the main wiring harness to the powertrain control module (PCM).
1 Connect the main wiring harness electrical connector.
2 Connect the two ground cables.
3 Close the wiring bracket.
4 Install the power steering reservoir.





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





51. Disconnect the electrical connector and the upper coolant hoses.
1 Clip the wiring harnesses in place.
2 Connect the coolant hoses.
3 Connect fan motor electrical connector.





52. Install the throttle cable and adjust it.
1 Guide the cable into the abutment bracket and push on the plastic clip.
^ Hook the cable in place.

2 Install the clip.
^ 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 adjustment if necessary.





53. Install the upper accessory drive belt cover.





54. NOTE: Use an Allen Key to stop the piston rod from turning.

Tighten the suspension strut locknuts (right-hand side shown).





55. Tighten the suspension strut locknut (right side shown).





56. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.





57. Install the ground cable and the power steering line bracket to the engine lifting eye.





58. Connect the throttle cable.
1 Install the plastic clip.
2 Install the cable.





59. Connect the speed control cable.
1 Press the retaining bush in the bracket.
2 Pull the cable in the retaining bush.
3 Connect the cable to throttle valve.





60. Install the battery bracket.





61. NOTE: Two ground cables. Install the battery bracket.





62. Install the central junction box (CJB).





63. NOTE: There is an audible click when it engages.

Connect the clutch slave cylinder.
^ Attach the ground lead to the transaxle.

1 Install the slave cylinder pipe in the bracket.
2 Connect the slave cylinder pipe to the transaxle and slide on the clip.





64. Connect the wiring.
1 Engine wiring harness connector
2 Transaxle ground cable
3 Secure the wiring harness using cable ties.





65. Install the air cleaner (ACL).
^ Insert the ACL (push fit).

1 Install the rubber ring.
2 Install the air hose.
3 Install the crankcase ventilation hose.





66. Install the air intake tube.
^ Move the air intake tube into installation position.

1 Install the two clips.
2 Install one bolt and two nuts.
3 Connect the intake air temperature (IAT) sensor electrical connector.
4 Install the MAF electrical connector.





67. Install the hood.

Connect the hose and install the bolts (right hand side shown).





68. Remove the special tool from the gearshift lever and press in the boot.
69. Bleed the hydraulic clutch system.

70. 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.
71. Fill the cooling system.
72. Fill Merkur manual transmission fluid.
73. Check the routing of the vacuum hoses and wiring and secure them with cable ties.
74. Check the fluid levels after the road test and correct as necessary.
75. Check the engine and cooling system for leaks (visual inspection).