Steps 61-101

Engine Front Cover













All vehicles

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

61. Install the LH splash shield and the 6 pin-type retainers (4 shown).





62. Position the LH fender splash shield and install the 4 screws.





63. NOTE: Align the index marks made during removal.

Install the steering intermediate shaft onto the steering gear and install a new bolt.

- Tighten to 23 Nm (17 lb-ft).





64. Install the steering joint cover and the 2 nuts.





65. Using a new banjo bolt and 2 new seals, install the PSP tube onto the steering gear.
- Tighten to 37 Nm (27 lb-ft).





66. Install the PSP tube bracket and bolt.
- Tighten to 10 Nm (89 lb-in).





67. Connect the PCM connectors and pin-type retainers.





68. Install the engine mount brace and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).





69. Install the ground wire and the bolt.
- Tighten to 10 Nm (89 lb-in).





70. Connect the fuel supply tube to the fuel rail.





71. Attach the power steering reservoir onto the cowl.





72. Connect the hose to the power steering reservoir.
- Attach the pin-type retainer to the engine mount brace.





73. Install the oil level indicator.





74. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.





75. Connect the 2 engine wiring harness electrical connectors.





76. Attach the 2 wiring harness retainers.





77. Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
- Tighten to 8 Nm (71 lb-in).





78. Install the A/C tube bracket bolt.
- Tighten to 8 Nm (71 lb-in).





79. Install the 2 A/C tube retaining clamp bolts.
- Tighten to 10 Nm (89 lb-in).





80. Using a new O-ring seal, connect the A/C tube to the condenser and install the nut.
- Tighten to 8 Nm (71 lb-in).





81. Attach the coolant tube retainer clips to the A/C tube.





82. If equipped, attach the engine block heater harness to the radiator support, power steering hose, A/C tube and the engine wiring harness.

83. Install the ground wire and bolt.
- Tighten to 12 Nm (106 lb-in).





84. Position the transaxle control cable bracket in place and install the 3 nuts.
- Tighten to 12 Nm (106 lb-in).





85. Connect the transaxle control cable to the control lever.





86. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.





87. Connect the vacuum hose and the Evaporative Emission (EVAP) tube to the upper intake manifold.





88. Install the ground wire and the bolt.
- Tighten to 10 Nm (89 lb-in).





89. Connect the power feed to the battery terminal and install the nut.
- Tighten to 6 Nm (53 lb-in).





90. Attach the 2 wiring harness retainers to the transmission mount and the battery tray bracket.





91. Connect the 2 engine wiring harness electrical connectors.





92. Install the battery tray.

93. Install the engine Air Cleaner (ACL) and the ACL outlet pipe.

94. Install the degas bottle.

95. Install the LH halfshaft and the intermediate shaft.

96. Install the accessory drive belt and the power steering belt.

97. NOTICE: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.

Fill the engine with clean engine oil.

98. Fill and bleed the cooling system.

99. Fill the power steering system.

100. Check the transaxle fluid and add fluid if necessary.

101. Recharge the A/C system.