Removal and Installation
REMOVAL1. Disconnect battery ground cable at battery.
2. Drain engine cooling system.
3. Recover refrigerant from A/C system.
4. Remove cowl top vent panel.
5. Disconnect wiring connectors from generator (GEN).
6. Loosen air cleaner outlet tube clamp at throttle body and remove engine air cleaner (ACL) and air cleaner outlet tube.
7. Disconnect upper radiator hose at radiator and secure to engine.
8. Disconnect heater water hoses and secure to body.
9. Remove A/C discharge at condenser and suction hoses at suction accumulator/drier and secure to engine.
10. Disconnect accelerator cable and speed control actuator cable (if equipped) from throttle body lever and remove accelerator cable bracket from throttle body. Position accelerator cable bracket with accelerator cable and speed control actuator cable out of the way.
11. Disconnect fuel supply and return lines from fuel injection supply manifold.
12. Disconnect engine to body ground at RH cylinder head, fuel charging wiring from powertrain control module (PCM) at upper right rear corner of engine compartment, A/C high pressure sensor and low pressure sensor connectors at A/C suction accumulator/drier, harness connector (42-pin) attached to power brake booster, harness connector (2-pin) to transaxle LH side of engine compartment, behind engine air cleaner.
13. Mark and disconnect vacuum hoses, heater control and aspirator hose from vacuum tree and evaporative emission hose from throttle body.
14. Remove gear shift cable from transaxle.
15. Lock steering wheel with wheels and tires in a straight-ahead position by turning ignition switch to the OFF position.
CAUTION: Damage to the steering column air bag wiring can result if the steering wheel is allowed to rotate freely. The wire is wound like a watch spring and can be overtightened and break if steering wheel is rotated too far in either direction.
16. Raise vehicle on hoist.
17. Remove front wheel and tire assemblies.
18. Drain engine oil.
19. Disconnect transmission fluid cooler lines at transaxle and secure to radiator support.
20. Disconnect wiring connectors from the heated oxygen sensors (H02S).
21. Remove the dual converter Y pipe retaining bolts at the pipe outlet and flex joint and install flex joint Exhaust Connector Holder T94T-6000-AH.
NOTE: Do not allow the flex connector of the dual converter Y pipe to hang unsupported, or damage to the flex joint will result.
22. Remove nuts securing dual converter Y pipe to exhaust manifolds and hanger bolt and remove dual converter Y pipe.
23. Disconnect wires to starter motor and secure out of the way.
NOTE: The routing of the battery ground cable to cylinder block is very critical. It should go between the transaxle and the bracket. Take note during disassembly.
24. Remove starter motor.
25. Remove engine rear plate and torque converter to flywheel retaining nuts.
26. Remove nut retaining battery cable support bracket to upper starter motor mounting stud bolt.
27. Disconnect power steering cooler lines.
28. Disconnect lower radiator hose at radiator.
29. Remove heater water hoses to auxiliary heater (if equipped).
30. Remove upper bolt from sway bar links.
31. Remove dust boot from steering rack pinion support by gently spreading the integral tension ring and pushing upward.
32. Remove steering coupling pinch bolt from steering column intermediate shaft at steering gear.
33. Remove intermediate shaft from steering gear.
34. Remove RH and LH front stabilizer bar links from front stabilizer bar.
35. Separate RH and LH front suspension lower arms from front wheel knuckle at ball joint.
36. Separate RH and LH tie rod ends from front wheel knuckle.
37. Remove RH and LH front axle wheel hub retainers from halfshaft ends.
38. Remove RH and LH halfshafts from front wheel knuckle.
39. Support front sub-frame, engine and transaxle assembly using Rotunda Powertrain Lift 014-00765 and Adapter 014-00341 or equivalent.
40. Remove four front sub-frame retaining bolts.
41. Lower engine transaxle and front sub-frame from vehicle.
42. Disconnect power steering pressure hose from the power steering pump.
43. Install Engine Lifting Eyes D81L-6001-D or equivalent.
44. Connect engine lifting spreader bar from Rotunda Engine Lift Bracket Set 014-00340 or equivalent to lifting eyes. Support engine and transaxle.
45. Remove LH front engine support insulator RH front engine support insulator and engine and transmission support.
46. Lift engine and transaxle from front sub-frame.
47. Lower engine and transaxle. Support transaxle on a level, stationary surface for transaxle storage.
48. Remove transaxle-to-cylinder block mounting bolts and separate engine from transaxle/torque converter assembly.
49. Place engine on suitable work stand.
50. Remove engine lifting equipment.
51. Remove water jacket pipe plugs in cylinder block and drain balance of engine coolant. Reinstall pipe plugs.
INSTALLATION
1. Install Engine Lifting Eyes D81L-6001-D or equivalent.
2. Remove engine from stand using spreader bar and chains from Rotunda Engine Lift Bracket Set 014-00340 or equivalent.
3. Install transaxle/torque converter assembly to engine. Tighten transaxle-to-engine bolts to 40-60 Nm (30-44 ft. lbs.). Tighten torque converter nuts to 27-46 Nm (20-34 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 (57-76 ft. lbs.).
9. Remove Rotunda Powertrain Lift 014-00765 or equivalent and move out of way.
10. Partially lower vehicle.
11. Install RH and LH halfshaft into front wheel knuckle.
12. Install RH and LH front axle wheel hub retainers onto halfshaft end.
13. Connect RH and LH tie rod ends to the front wheel knuckle.
14. Connect RH and LH front suspension lower arms to the front wheel knuckle at ball joints.
15. Install RH and LH front stabilizer bar links to the front stabilizer bar.
16. Install front wheel and tires.
17. Reconnect intermediate shaft to pinion gear of steering gear. Install the pinch bolt and nut and tighten to 34-46 Nm (25-34 ft. lbs.).
18. Install dust boot on pinion support of steering gear. Gently squeeze the integral tension ring and slide dust boot on pinion support housing.
19. Install lower radiator hose and heater water hoses to auxiliary heater (if equipped).
20. Install power steering fluid cooler lines.
21. Install starter motor.
22. Install transaxle fluid cooler lines.
23. Install dual converter Y pipe to exhaust manifold and tighten retaining nuts to 34-47 Nm (25-34 ft. lbs.).
24. Remove flex pipe support tool and connect dual converter Y pipe and flex pipe (with new gasket) and tighten retaining bolts to 34-47 Nm (25-34 ft. lbs.).
25. Connect wiring harness connectors to the heated oxygen sensors.
26. Lower vehicle.
27. Remove engine lifting eyes from engine.
28. Install accelerator cable and speed control actuator cable to throttle body lever and accelerator cable bracket to throttle body. Tighten accelerator cable bracket retaining bolts to 8-12 Nm (71-106 inch lbs.).
29. Install upper radiator hose to radiator.
30. Install heater water hoses.
31. Install vacuum hoses at vacuum tree and evaporative emission hose to throttle body.
32. Reinstall gear shift cable to transaxle.
33. Connect engine to body ground at A/C suction accumulator bracket, fuel charging wiring to powertrain control module, A/C high pressure sensor and low pressure sensor connectors at suction accumulator/drier, harness connector (42-pin), harness connector (2-pin) to transaxle LH side of engine compartment and behind engine air cleaner.
34. Connect A/C discharge and suction hoses at suction accumulator/drier.
35. Connect supply and return fuel lines to fuel injection supply manifold.
36. Reconnect generator wiring to generator.
37. Install engine air cleaner and air cleaner outlet tube.
38. Replace oil bypass filter.
39. Fill crankcase to proper level with engine oil XO-10W30-QSP or -DSP meeting Ford specification ESE-M2C153-E.
40. Fill power steering system.
41. Fill engine cooling system.
42. Start engine and check for leaks.
43. Recheck all fluid levels. Fill as required.
44. Evacuate and recharge air conditioning system.
45. Install cowl top vent panel.
46. Check front end alignment.