Engine - Automatic Transaxle: Installation

All Vehicles 

CAUTION: Insert a wooden block between jack and transaxle.
1. Support the transaxle with a jack.
2. Using the special tool and a suitable floor crane to bring the engine into installation position and lower it.
   Fig 1: Supporting Transaxle With Jack

   Courtesy of FORD MOTOR CO.
3. Install the transaxle upper flange bolts.
   Fig 2: Installing Transaxle Upper Flange Bolts

   Courtesy of FORD MOTOR CO.
4. Connect the crankshaft position (CKP) sensor electrical connector.
   Fig 3: Connecting Crankshaft Position Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.
5. Install the engine front mount.
   • Remove the engine crane and floor jack.
   Fig 4: Installing Engine Front Mount

   Courtesy of FORD MOTOR CO.
6. Remove left and right side lifting brackets.
   Fig 5: Removing Left And Right Side Lifting Brackets

   Courtesy of FORD MOTOR CO.
7. Raise and support the vehicle. For additional information, refer to JACKING AND LIFTING .
8. Install the transaxle right-hand flange bolt.
   Fig 6: Installing Transaxle Right-Hand Flange Bolt

   Courtesy of FORD MOTOR CO.
9. Install the transaxle left-hand flange bolts.
   Fig 7: Installing Transaxle Left-Hand Flange Bolts

   Courtesy of FORD MOTOR CO.
10. Install the crankshaft pulley.
    • Tighten the crankshaft pulley bolt.
    Fig 8: Installing Crankshaft Pulley

    Courtesy of FORD MOTOR CO.
11. Install the starter motor.
    Fig 9: Installing Starter Motor

    Courtesy of FORD MOTOR CO.
12. Install the starter motor electrical connectors.
    Fig 10: Installing Starter Motor Electrical Connectors

    Courtesy of FORD MOTOR CO.
13. Install the intermediate shaft bracket.
    Fig 11: Installing Intermediate Shaft Bracket

    Courtesy of FORD MOTOR CO.
NOTE: Use a new retaining clamp.
Fig 12: Installing Retaining Clamp
Courtesy of FORD MOTOR CO.
14. Install the retaining clamp.
15. Attach the intake manifold bracket.
    • Install the bolts and tighten the nuts.
    Fig 13: Installing Intake Manifold Bracket Bolts

    Courtesy of FORD MOTOR CO.
16. Install the torque converter to the engine drive plate (four nuts).
    • Rotate flywheel to install nuts.
    Fig 14: Installing Torque Converter To Engine Drive Plate

    Courtesy of FORD MOTOR CO.
17. Install the torque converter cover.
    Fig 15: Installing Torque Converter Cover

    Courtesy of FORD MOTOR CO.
18. Install the transaxle lower flange bolts.
    Fig 16: Installing Transaxle Lower Flange Bolts

    Courtesy of FORD MOTOR CO.
19. Install the accessory drive bracket.
    Fig 17: Installing Accessory Drive Bracket

    Courtesy of FORD MOTOR CO.
20. Position back tube and install bolt.
    Fig 18: Installing Bolt

    Courtesy of FORD MOTOR CO.
21. Install the coolant pipe bolt.
    Fig 19: Installing Coolant Pipe Bolt

    Courtesy of FORD MOTOR CO.
22. Connect the coolant hose to the coolant tube.
    Fig 20: Connecting Coolant Hose To Coolant Tube

    Courtesy of FORD MOTOR CO.
23. Install the generator (engine removed shown).
    Fig 21: Installing Generator

    Courtesy of FORD MOTOR CO.

Vehicles with air conditioning 

24. Install the compressor.
    Fig 22: Installing Compressor

    Courtesy of FORD MOTOR CO.

All Vehicles 

25. Position back drive belt.
26. Install fan shroud.
    Fig 23: Installing Fan Shroud

    Courtesy of FORD MOTOR CO.
27. Attach the harness retainers.
    Fig 24: Attaching Harness Retainers

    Courtesy of FORD MOTOR CO.
28. Position and support the catalytic converter.
29. Loosely install the lower clamp.
    Fig 25: Installing Lower Clamp

    Courtesy of FORD MOTOR CO.
30. Remove the support from the catalytic converter.
31. Lower the vehicle.
CAUTION: Never use jointing compound forward of the catalytic converter.
Fig 26: Installing Catalytic Converter To Manifold
Courtesy of FORD MOTOR CO.
32. Install the catalytic converter to the manifold.
    • Use a new gasket and nuts.
33. Install the heat shield.
    Fig 27: Installing Heat Shield

    Courtesy of FORD MOTOR CO.
34. Install the upper starter bolts.
    Fig 28: Installing Upper Starter Bolts

    Courtesy of FORD MOTOR CO.
35. Install the power steering pump.
    Fig 29: Installing Power Steering Pump

    Courtesy of FORD MOTOR CO.
36. Using the special tool to prevent the power steering pump pulley from rotating install the power steering pump nut.

    Install the power steering pump pulley.

    Fig 30: Installing Power Steering Pump Pulley

    Courtesy of FORD MOTOR CO.
37. Install the accessory drive belt.
    • Turn the belt tensioner clockwise.
    Fig 31: Installing Accessory Drive Belt

    Courtesy of FORD MOTOR CO.
38. Install the coolant hoses to the water pump.
    Fig 32: Installing Coolant Hoses To Water Pump

    Courtesy of FORD MOTOR CO.
39. Install the coolant hose to the intake manifold.
    Fig 33: Installing Coolant Hose To Intake Manifold

    Courtesy of FORD MOTOR CO.
40. Connect the coolant hoses to the coolant hose connector.
    Fig 34: Connecting Coolant Hoses To Coolant Hose Connector

    Courtesy of FORD MOTOR CO.
41. Push the power steering fluid reservoir into place.
    Fig 35: Pushing Power Steering Fluid Reservoir Into Place

    Courtesy of FORD MOTOR CO.
42. Connect the vacuum hose to the evaporative canister purge valve.
    Fig 36: Connecting Vacuum Hose To Evaporative Canister Purge Valve

    Courtesy of FORD MOTOR CO.
43. Connect the vacuum hoses.
    1. Evaporative emission (EVAP).
    2. Brake servo.
    3. Delta pressure feedback electronic (DPFE).
    4. Exhaust gas recirculation (EGR) valve and EGR vacuum regulator solenoid.
    Fig 37: Connecting Vacuum Hoses

    Courtesy of FORD MOTOR CO.
44. Install the fan to the radiator.
    • Install the fan wiring harness.
    Fig 38: Installing Fan To Radiator

    Courtesy of FORD MOTOR CO.
45. Connect the radiator fan electrical connector.
    Fig 39: Connecting Radiator Fan Electrical Connector

    Courtesy of FORD MOTOR CO.
46. Connect both powertrain control module (PCM) connectors.
    Fig 40: Connecting Both Powertrain Control Module Connectors

    Courtesy of FORD MOTOR CO.
47. Connect the electrical connectors.
    1. Power steering pump pressure switch.
    2. Generator.
    3. Heated oxygen sensor (HO2S).
    Fig 41: Connecting Electrical Connectors

    Courtesy of FORD MOTOR CO.
48. Connect the cable to the generator.
    Fig 42: Connecting Cable To Generator

    Courtesy of FORD MOTOR CO.
49. Install the speed control cable (if equipped).
    1. Hook the cable in place.
    2. Clip on the plastic clip.
    Fig 43: Installing Speed Control Cable

    Courtesy of FORD MOTOR CO.
50. Install the accelerator cable.
    1. Hook the cable in place.
    2. Clip on the plastic clip.
    Fig 44: Installing Accelerator Cable

    Courtesy of FORD MOTOR CO.
51. Connect the fuel line spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
52. Install the intake pipe.
    Fig 45: Installing Intake Pipe

    Courtesy of FORD MOTOR CO.
53. Install the air cleaner (ACL) housing.
    1. Connect the MAF sensor electrical connector.
    2. Install the outlet pipe.
    Fig 46: Installing Air Cleaner (ACL) Housing

    Courtesy of FORD MOTOR CO.
54. Attach the crankcase breather hose.
    Fig 47: Attaching Crankcase Breather Hose

    Courtesy of FORD MOTOR CO.
55. Raise and support the vehicle. For additional information, refer to JACKING AND LIFTING .
56. Install the accessory drive belt cover.
    Fig 48: Installing Accessory Drive Belt Cover

    Courtesy of FORD MOTOR CO.
57. Connect the catalytic converter to the flexible pipe.
    • Use a new gasket and nuts.
    Fig 49: Connecting Catalytic Converter To Flexible Pipe

    Courtesy of FORD MOTOR CO.
58. Install the bracket.
    • Tighten the bolts.
    Fig 50: Installing Bracket

    Courtesy of FORD MOTOR CO.
59. Tighten the bracket adjusting bolts.
    Fig 51: Tightening Bracket Adjusting Bolts

    Courtesy of FORD MOTOR CO.
60. Install the catalyst monitor sensor.
    Fig 52: Installing Catalyst Monitor Sensor

    Courtesy of FORD MOTOR CO.
61. Install the catalyst monitor sensor electrical connector.
    Fig 53: Installing Catalyst Monitor Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
62. Lower the vehicle.
63. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
64. Fill the engine with engine oil.
65. Install the coolant expansion tank. For additional information, refer to ENGINE COOLING .
NOTE: Line up the hinge-to hood reference mark when installing hood.
Fig 54: Installing Windshield Washer Hose And Clips
Courtesy of FORD MOTOR CO.
66. Install the hood.
    1. Position the hood and install the four bolts (two each side).
    2. Install the windshield washer hose and clips.