Installation

1. Install Engine Lifting Brackets T70P-6000.
2. Remove engine from stand using Rotunda Separator Bar 014-00793 or equivalent, chains 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 ft. lbs.). Tighten torque converter nuts to 27-46 Nm (20-33 ft. lbs.).
4. Position engine and transaxle assembly on front sub-frame.
5. Install LH front engine support insulator, RH front engine support insulator and engine and transmission support.
6. Connect power steering pressure hose to the power steering pump.
7. Raise engine, transaxle and front sub-frame into position.
8. Align front sub-frame to body and install sub-frame-to-body bolts. Tighten bolts to 77-103 Nm (57-75 ft. lbs.). Refer to Steering and Suspension for proper procedures.
9. Remove Rotunda Powertrain Lift 014-00765 or equivalent and move out of way.
10. Connect lower fluid cooler tube to transaxle and install retaining clip.
11. Install starter motor.
12. Install lower radiator hose to radiator and radiator overflow hose. Position clamp securely.
13. Connect power steering pressure hose to power steering/transmission oil cooler connection and tighten hose clamp securely.
14. Install dual converter Y pipe.
15. Install splash shield to radiator support and front bumper. Tighten retaining screws securely.
16. Partially lower vehicle.
17. Install RH and LH halfshaft into front wheel knuckle.
18. Install RH and LH front axle wheel hub retainers onto halfshaft end.
19. Connect RH and LH tie rod ends to the front wheel knuckle.
20. Connect RH and LH front suspension lower arms to the front wheel knuckle at ball joints.
21. Install RH and LH front stabilizer bar links to the front stabilizer bar.
22. Install front wheel and tires.
23. Lower vehicle.
24. Remove Engine Lifting Brackets D70P-6000.
25. Connect A/C lines to A/C compressor.
26. 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.
27. Connect power steering return hose to power steering oil reservoir. Position clamp securely.
28. Connect upper radiator hose to water hose connection.
29. Connect heater water hoses to the water hose connection and water pump. Position clamps securely. Refer to Cooling System.
30. Connect upper fluid cooler inlet tube and retaining clip to transaxle.
31. Connect wiring connector to the secondary air injection pump relay located on bracket at top of transaxle. Verify connection is secure.
32. Connect engine control sensor wiring at two connectors located at top of transaxle above secondary air injection pump relay bracket.
33. Install engine control sensor wiring to bracket with retaining strap. Tighten retaining strap screw securely.
34. Connect the manual control lever to the manual control lever shaft at the transmission range sensor. Install and tighten retaining nut to 16-22 Nm (12-16 ft. lbs.).
35. Connect accelerator cable and speed control actuator cable to the throttle body lever and the accelerator cable bracket. Tighten retaining screws securely.
36. Install the accelerator cable shield and tighten the retaining screws securely. Verify throttle linkage does not bind or stick.
37. Connect engine control sensor wiring to evaporative emission canister purge valve.
38. Connect the engine control sensor wiring to the mass air flow sensor.
39. 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.
40. Position ground straps to the dash panel. Install and tighten retaining screw securely.
41. Connect chassis vacuum supply hose and evaporative emission hose to connectors on the upper intake manifold.
42. Connect fuel tubes and retaining clips to the fuel injection supply manifold. Refer to Powertrain Management.
43. Install air cleaner outlet tube. Tighten engine air cleaner tube clamps to 1.6-2.2 Nm (14-19 inch lbs.).
44. Connect the engine control sensor wiring to the intake air temperature sensor and install the crankcase ventilation tube and aspirator hose to the air cleaner outlet tube.
45. Connect steering coupling at pinch bolt inside passenger compartment.
46. Fill crankcase to proper level with engine oil meeting Ford specification WSS-M2C153-F.
47. Fill power steering pump.
48. Fill engine cooling system with coolant.
49. Connect battery ground cable.
50. Start engine and check for leaks.
51. Recheck all fluid levels. Fill as required.
52. Evacuate and recharge air conditioning system refrigerant. Refer to Heating and Air Conditioning.
53. Check front end alignment.