Engine: Service and Repair
Removal
1. Disconnect battery ground cable.
2. Disconnect steering coupling at pinch bolt joint inside passenger compartment.
3. Remove engine appearance cover retaining bolt and nuts and remove engine appearance cover from vehicle.
Engine Appearance Cover
4. Disconnect engine control sensor wiring from the intake air temperature sensor (IAT sensor) and crankcase ventilation tube from air cleaner outlet tube.
5. Loosen clamps on air cleaner outlet tube to engine air cleaner (ACL) and throttle body. Remove air cleaner outlet tube.
6. Drain engine cooling system. Refer to Section Cooling System. Cooling System
7. Recover air conditioning system. Refer to Heating and Air Conditioning. Heating and Air Conditioning
8. Relieve fuel system pressure and disconnect fuel tubes from fuel injection supply manifold. Refer to Fuel Delivery and Air induction. Fuel Delivery and Air Induction
9. Disconnect chassis vacuum supply hose at connection on intake manifold. Position hose out of the way.
10. Remove ground straps from dash panel.
11. Disconnect engine control sensor wiring from the powertrain control module (PCM) and position the engine control sensor wiring out of the way.
12. Remove connectors for engine control sensor wiring from retaining bracket on power brake booster. Disconnect engine control sensor wiring at two connectors.
13. Disconnect engine control sensor wiring from mass air flow sensor (MAF sensor).
14. Disconnect engine control sensor wiring from evaporative emission canister purge valve (EVAP canister purge valve).
15. Disconnect evaporative emission hose at crankcase vent connector and hose. Position evaporative emission hose out of the way.
16. Remove shield and disconnect accelerator cable and speed control actuator cable from throttle body and also from accelerator cable bracket. Position cables out of the way.
17. Remove retaining nut and disconnect the manual control lever from the manual control lever shaft at the transmission range (TR) sensor.
18. Remove connectors for engine control sensor wiring from retaining bracket on top of transaxle. Disconnect engine control sensor wiring at two connectors.
19. Disconnect wiring connector from secondary air injection pump relay located on retaining bracket on top of transaxle.
20. Disconnect main emission vacuum control connector at connection near fan shroud. Refer to Emission Control Systems. Emission Control Systems
21. Disconnect fluid cooler inlet tube from transaxle.
22. Remove oil level dipstick from oil level indicator tube.
23. Disconnect heater water hose from water bypass tube.
24. Disconnect heater water hose at rear of RH cylinder head.
25. Disconnect upper radiator hose at water bypass tube.
26. Remove power steering return hose from power steering oil reservoir and drain.
27. Disconnect generator wiring harness from generator (GEN) at B+ terminal and stator connector plug. Remove wiring harness retaining clip from generator mounting bracket.
28. Partially raise vehicle on hoist.
29. Remove front wheels and tires. Refer to Wheels and Tires. Wheels and Tires
30. Disconnect RH and LH ride height sensor links from front suspension lower arm.
31. Remove RH and LH front stabilizer bar links from front stabilizer bar link from front stabilizer bar. Refer to Suspension Systems. Suspension
32. Separate RH and LH front suspension lower arms from front wheel knuckle at ball joint. Refer to Suspension Systems. Suspension
33. Separate RH and LH tie rod ends from front wheel knuckle. Refer to Steering Systems. Steering
34. Remove RH and LH front axle wheel hub retainers from halfshaft ends. Refer to Axle Shaft Assembly. Axle Shaft Assembly
35. Remove RH and LH halfshafts from front wheel knuckle. Refer to Axle Shaft Assembly. Axle Shaft Assembly
36. Raise vehicle.
37. Remove splash shield from radiator support and front sub-frame.
38. Drain engine oil.
39. Remove dual converter Y pipe. Refer to Exhaust System. Exhaust System
40. Disconnect power steering pressure hose from power steering/transmission oil cooler connection. Position hose out of the way.
41. Disconnect lower radiator hose at radiator and water thermostat housing and remove lower radiator hose.
42. Disconnect wiring for starter motor and remove starter motor. Refer to Starting System. Starting System
43. Disconnect lower fluid cooler tube from transaxle.
44. Disconnect retaining clips and A/C compressor lines from A/C compressor.
45. Support front sub-frame, engine and transaxle assembly using Rotunda Powertrain Lift 014-00765 and Universal Powertrain Removal Bracket 014-00766.
46. Remove eight front sub-frame retaining bolts.
47. Lower engine transaxle and front sub-frame from vehicle.
48. Disconnect power steering pressure hose from the lower power steering line. Refer to Steering System. Steering
49. Install engine lifting brackets from Rotunda Engine Lift Bracket Set 014-00796 or equivalent.
Engine Lifting Brackets, RH Side
Engine Lifting Brackets, LH Side
50. Connect engine lifting spreader bar from Rotunda Engine Lift Bracket Set 014-00796 or equivalent to lifting eyes. Using a suitable floor crane, support engine and transaxle.
51. Remove front engine support insulator, transmission support insulator and engine and transmission support as outlined in Engine mounts. Engine Mount
52. Lift engine and transaxle from front sub-frame.
53. Lower engine and transaxle. Support transaxle on a level, stationary surface for transaxle storage.
54. Remove transaxle-to-cylinder block mounting bolts and separate engine from transaxle/torque converter assembly.
55. Place engine on suitable work stand.
56. Remove engine lifting equipment.
57. Remove water jacket pipe plugs in cylinder block and drain balance of engine coolant. Reinstall pipe plugs.
Installation
1. Install engine lifting bracketry from Rotunda Engine Lift Bracket Set 014-00796 or equivalent.
2. Remove engine from stand using spreader bar and chains from Rotunda Engine Lift Bracket Set 014-00796 or equivalent and a suitable floor crane.
3. Install transaxle/torque converter assembly to engine. Tighten transaxle/torque converter assembly mounting bolts to 40-60 Nm (30-44 lb-ft). Tighten torque converter nuts to 27-46Nm (20-34 lb-ft).
4. Position engine and transaxle assembly on front sub-frame.
5. Install front engine support insulator, transmission support insulator and engine and transmission support as outlined in Engine mounts. Engine Mount
6. Connect power steering pressure hose to the lower power steering line. Refer to Steering System. Steering
7. Raise engine, transaxle and front sub-frame into position using Rotunda Powertrain Lift 014-00765 and Universal Powertrain Removal Bracket 014-00766 or equivalent.
8. Align front sub-frame to body and install sub-frame-to-body bolts. Tighten bolts to 75-102 Nm (55-75 lb-ft).
9. Remove lifting equipment and move out of way.
10. Connect A/C lines to A/C compressor and install retaining clips. Refer to Heating and Air Conditioning. Heating and Air Conditioning
11. Connect lower fluid cooler tube to transaxle and install retaining clip. Refer to Automatic Transmission-AX4N. Automatic Transmission/Transaxle
12. Install starter motor. Refer to Starting System. Starting System
13. Install lower radiator hose to radiator and water thermostat housing. Position clamps securely. Refer to Cooling System. Cooling System
14. Connect power steering pressure hose to power steering/transmission oil cooler connection and tighten hose clamp securely.
15. Install dual converter Y pipe. Refer to Exhaust System. Exhaust System
16. Install splash shield to radiator support and front sub-frame. Tighten retaining screws securely.
17. Partially lower vehicle.
18. Install RH and LH halfshaft into front wheel knuckle. Refer to Axle Shaft Assembly. Axle Shaft Assembly
19. Install RH and LH front axle wheel hub retainers onto halfshaft end. Refer to Axle Shaft Assembly. Tighten front axle wheel hub retainers to 230-275 Nm (170-202 lb-ft). Axle Shaft Assembly
20. Connect RH and LH tie rod ends to the front wheel knuckle. Refer to Steering System. Tighten retaining nuts to 47-63 Nm (35-46 lb-ft). Steering
21. Connect RH and LH front suspension lower arms to the front wheel knuckle at balljoints. Install and tighten retaining nuts to 68-92 Nm (50-68 lb-ft).
22. Install RH and LH front stabilizer bar links to the front stabilizer bar. Tighten retaining nuts to 40-55 Nm (30-40 lb-ft). Refer to Suspension System. Suspension
23. Connect ride height sensor wiring links to the front suspension lower arm.
24. Install front wheel and tires. Refer to Wheels and Tires. Wheels and Tires
25. Lower vehicle.
26. Remove engine lifting brackets from Rotunda Engine Lift Bracket Set 014-00796 or equivalent.
27. Connect separator wiring harness to the generator at the B+ terminal and stator connector plug. Install wiring harness retainer clip to the generator mounting bracket. Tighten retaining screw securely.
28. Connect power steering return hose to power steering oil reservoir. Position clamp securely. Refer to Steering System. Steering
29. Connect upper radiator hose at water bypass tube.
30. Connect heater water hose at rear of RH cylinder head.
31. Connect heater water hose to the water bypass tube. Position clamp securely.
32. Install oil level dipstick into the oil level indicator tube.
33. Connect upper fluid cooler inlet tube and retaining clip to transaxle. Refer to Cooling System. Cooling System
34. Connect main emission vacuum control connector at connection near fan shroud. Refer to Emission Control Systems. Emission Control Systems
35. Connect wiring connector to the secondary air injection pump relay located on bracket at top of transaxle. Verify connection is secure.
36. Connect engine control sensor wiring at two connectors located at top of transaxle above secondary air injection pump relay bracket.
37. Install engine control sensor wiring to bracket with retaining strap. Tighten retaining strap screw securely.
38. Connect the manual control lever to the manual control lever shaft at the T.R. sensor. Install and tighten retaining nut to 16-22 Nm (12-16 lb-ft). Refer to Section 07-14.
39. Connect accelerator cable and speed control actuator cable to the throttle body lever and the accelerator cable bracket. Tighten retaining screws securely.
40. Install the accelerator cable shield and tighten the retaining screws securely. Verify throttle linkage does not bind or stick.
41. Connect engine control sensor wiring to evaporative emission canister purge valve.
42. Connect evaporative emission hose to the crankcase vent connector and hose at connector near the throttle body.
43. Connect the engine control sensor wiring to the mass air flow sensor.
44. Connect the engine control sensor wiring at two connectors near the power brake booster. Install the engine control sensor wiring. to retaining bracket with strap. Tighten strap retaining screw securely.
45. Position ground strap to the dash panel. Install and tighten retaining screw securely.
46. Connect chassis vacuum supply hose to connector on the intake manifold.
47. Connect fuel tubes and retaining clips to the fuel injection supply manifold. Refer to Fuel Delivery and Air Induction. Fuel Delivery and Air Induction
48. Install air cleaner outlet tube. Tighten engine air cleaner tube clamps to 1.4-2.5 Nm (12-22 lb-in). Refer to Fuel Delivery and Air Induction. Fuel Delivery and Air Induction
49. Connect the engine control sensor wiring to the intake air temperature sensor and connect the crankcase ventilation tube to the air cleaner outlet tube.
50. Connect steering coupling at pinch bolt inside passenger compartment. Refer to Steering System. Steering
51. Fill crankcase to proper level with engine oil meeting Ford specification ESE-M2C153-E.
52. Fill power steering pump. Refer to Steering System. Steering
53. Fill radiator with engine coolant. Refer to Cooling System. Cooling System
54. Connect battery ground cable.
55. Start engine and check for leaks.
56. Recheck all fluid levels. Fill as required.
57. Evacuate and recharge air conditioning system. Refer to Heating and Air Conditioning. Heating and Air Conditioning
58. Install engine appearance cover as outlined. Tighten retaining nuts to 7-9 Nm (61-79 lb-in).
59. Check front end alignment. Refer to Alignment. Alignment