Installation

Special Tools:

General Equipment:

Materials:

Installation
1. General instructions.

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

^ New self-locking nuts must be installed.

2. Move the selector lever into the "D" position.





3. NOTE: The torque converter hub must engage fully in the oil pump drive gear.

Check the installation, depth of the torque converter.
1 Steel straightedge - place it on the automatic transaxle flange.
2 The installation depth between the automatic transaxle flange and the centering spigot bore of the torque converter is 12 mm.
4. Apply a thin layer of High-temperature grease meeting Ford Specification ESD-MIC220-A or equivalent to the centering spigot bore on the torque converter.

5. CAUTION: The torque converter must remain at the correct installation depth throughout the whole installation procedure. Check that the adapter plate is in correct position.

Using, the Floor crane bring the automatic transaxle into installation position on the engine and insert the stud of the torque converter into the engine drive plate.
6. Screw in all flange bolts.





7. Install the lower flange bolts.





8. NOTE: Install the ground cable. Install the upper flange bolts.





9. Install the LH flange bolts.





10. Install the RH flange bolts.





11. Attach the torque converter to the engine drive plate (four nuts).
^ Install the plastic cover.





12. Install the starter motor bracket and connect the starter motor.





13. Install the oil level indicator tube.





14. Connect the TSS sensor connector.





15. Connect the following electrical connectors.
1 TR sensor
2 Transmission control connector.
3 ECT sensor connector
4 Clip the wiring harness in place.





16. NOTE: The special tool is marked with an arrow and "Front".

Install the special tool.

17. NOTE: Correct position of the support insulator.

Install the engine and transaxle assembly.





18. Loosen the nuts of the rear transaxle mount.





19. Screw the center bolt into the special tool and tighten it.





20. Install the rear transaxle mount to the side member.





21. Install the upper front engine mount to the side member.





22. Tighten the nuts of the rear transaxle mount.
23. Raise and support the vehicle.





24. Install the center bolt into the RH support insulator.





25. Remove the special tool.





26. Install the LH support insulator.
1 Center bolt
2 Nuts

Vehicles with air conditioning





27. Install the compressor.

Vehicles with air conditioning





28. Install the compressor heat shield.

All Vehicles





29. Install the accessory drive belt.
1 Left-hand stop
2 3/8" square drive (ratchet)
^ Push the belt tensioner as far as the left-hand stop using the square drive (e.g. ratchet) and install the accessory drive belt.





30. Install the coolant pipe.





31. Connect the H02S electrical connector.





32. Install the radiator.

Vehicles with air conditioning





33. Attach condenser core to the radiator.

Vehicles with air conditioning





34. Connect the compressor electrical connector.

All Vehicles





35. Attach the transaxle lower cooling line and the coolant hose to the radiator.





36. Install the transaxle cooling line.





37. Install the transaxle cooling line.





38. Connect and install the H02S electrical connector.

CAUTION: To avoid to damage 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.





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

Install the LH front drive halfshaft.





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

NOTE: Use a new cotter pin.

Install the left-hand suspension.
1 Install the lower arm ball joint to the wheel knuckle.
2 Install the tie-rod end.
3 Install the stabilizer link rod to the strut.
^ Attach the ABS wiring harness bracket to the strut,





41. CAUTION: If an intermediate shaft bracket with two sets of holes (one set for CD4E application and one set for MTX application) is installed, take care to install the mounting bolts into the correct holes.

CAUTION: To avoid to damage 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.

Install the RI-I front drive halfshaft center bearing.





42. Install the RH control arm.





43. Install the RH front fender splash shields.





44. Install the dual converter Y-pipe.





45. Install the dual converter Y-pipe (cont.).





46. Connect and attach the H02S electrical connector.
47. Lower the vehicle.





48. Install the fan to the radiator (one screw on each side).





49. Install the upper transaxle line tube.





50. Install the coolant expansion tank.
1 Connect the coolant lever sensor.
2 Install the bolts.





51. Connect the coolant expansion tank hoses.





52. Connect the PCM and attach the ground cable.





53. Connect the power steering lines.
1 Connect the connector.
2 Connect the power steering lines.
3 Install the bolt and the ground cable.





54. Install the power steering fluid reservoir.





55. NOTE: The nuts do not need to be installed new.

Pre-tighten the nut on both suspension struts.





56. Tighten the nut on both suspension struts.





57. Connect the upper intake vacuum supply line and the heater control vacuum hoses.





58. Connect the evaporative emission control (EVAP) system hose.

Vehicles with air conditioning





59. Connect the suction accumulator electrical connector.

All Vehicles





60. Attach the coolant hoses to the radiator and to the coolant passage.





61. Connect the heater hoses.





62. Connect the fuel lines and attach the safety clips.





63. Install the battery bracket.





64. NOTE: Install two ground cables together with one of the battery bracket screws.

Install the battery bracket (continued).





65. Connect the fan motor electrical connectors.





66. Connect the cables.
1 Battery cable
2 Connect the electrical connector.
3 Ground cable





67. Install the central junction box (CJB).





68. Connect the bulkhead connector.
1 Connect the connector.
2 Connect the bulkhead connector and install the bolt.





69. Install the selector cable.
1 Push the selector cable into the selector lever and clip it in place.
2 Install the selector cable bracket.
70. Raise and support the vehicle.
71. Remove the rear exhaust system heat shield.





72. Move the selector lever on the automatic transaxle into the "D" position and check the selector cable adjustment.
1 Hold the adjusting mechanism still.
2 Open the selector cable lock.
3 The markings on the selector lever must line up.





73. Lock the selector cable in place.
1 Hold the adjusting mechanism still.
2 Close the selector cable lock.
74. Install the rear exhaust system heat shield.
75. Install the LH and RH front wheels.
76. Lower the vehicle.





77. Connect the accelerator and speed control cables.
1 Connect the cables.
2 Clip the cables into the bracket.





78. Install the water pump pulley cover.
^ Position the coolant hose in the clip and install the cover.

79. Install the hood.
^ Connect the hoses, install the screws and install the damping matting.

80. Install the air cleaner.
81. Coolant - fill the engine cooling system.
82. Automatic transmission fluid - fill the transaxle with fluid. 83. Install the battery.
84. Fill and bleed the power steering system.

85. NOTE: 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.

Finishing operations.
^ Check the routing of the vacuum hoses and wiring and secure them with Cable ties.
^ Check the fluid level after the road test and correct as necessary.
^ Check the engine and cooling system for leaks (visual inspection).