Special tool
 | Engine lift bracket 303-122 (21-068A) |
 | Clamp removal/installation tool 303-397 (24-003) |
General equipment:
- Fixing clamps
- Workbench
- Engine lifting crane
- Wooden block
All cars
WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.
1. Install the gearbox in the block with the drive axle.
2.
CAUTION: Support the engine/transaxle assembly with wooden blocks and secure it with suitable clamps.
Using a special tool and a crane to lift the engine, install the engine assembly with the gearbox in the block with the drive axle on the workbench.
3. Install the upper transmission mounting bolts in the block with the drive axle.
4. Install the lower transmission mounting bolts in the block with the drive axle.
5. Install the right transmission mounting bolts in the block with the drive axle.
6. Install the starter.
7. Connect the starter plug connectors.
8. Install the left gearbox mounting bolt in the block with the drive axle.
9. Raise and support the vehicle. Refer to Section 100-02 for additional information.
10. Position a work bench under the vehicle and carefully lower the vehicle until the engine/transaxle assembly is in the position required for installing the engine mounts.
11.
NOTE: Install new front engine mount nuts.
NOTE: Do not tighten the front engine mount nuts at this stage.
Install the front engine mount nuts.
12.
NOTE: Install new rear engine mount nuts.
NOTE: Do not tighten the rear engine mount nuts at this stage.
Install the rear engine mount.
13.
CAUTION: If brake fluid comes into contact with the paintwork, the affected area must be immediately washed with cold water.
Connect the clutch slave cylinder supply line.
14. Install the engine support cushion.
15.
CAUTION: Secure the axle shaft to prevent damage to the constant velocity joints. The inner joint should not be deflected more than 18 degrees. The outer joint should not be deflected more than 45 degrees.
CAUTION: Do not damage the axle shaft seal.
CAUTION: Make sure the snap ring is installed correctly.
NOTE: Install a new snap ring.
Connect the left axle shaft to the transaxle.
16.
CAUTION: Secure the axle shaft to prevent damage to the constant velocity joints. The inner joint should not be deflected more than 18 degrees. The outer joint should not be deflected more than 45 degrees.
NOTE: Install a new intermediate shaft bearing cap and locknuts.
Connect the axle shaft together with the intermediate shaft to the gearbox in the block with the driving axle.
17.
CAUTION: To prevent damage to the ball joint, make sure the heat shield is installed.
CAUTION: The lower control arm pinch bolt must be installed from the rear of the steering knuckle.
Connect the lower control arms to the steering knuckles on both sides.
Cars with air conditioning system
18. Attach the air conditioning (A/C) compressor to the appropriate bracket.
All cars
19. Connect the flexible exhaust pipe to the exhaust manifold.
20. Connect the gear shift cables to the transaxle. Turn the support bushings counterclockwise and connect the cables to the bracket.
21. Adjust the shift cable. Refer to Section 308-00 for additional information.
22. Using the special tool, connect the coolant hose.
23. Lower the vehicle.
24. Tighten the front engine mount mounting nuts.
25.
NOTE: Install new rear engine mount nuts.
Tighten the rear engine mount mounting nuts.
26. Secure the power steering pump to the appropriate bracket.
27. Using the special tool, connect the coolant hose.
28. Install the accessory drive belt. Refer to Section 303-05 for additional information.
29. Secure the power steering line mounting bracket and ground cable to the transaxle.
30. Connect the power steering pressure (PSP) switch connector.
31. Connect the transmission wiring harness plug connector to the drive axle block.
32. Connect the ground cable to the cylinder head.
33. Connect the vacuum hose to the EVAP canister purge valve.
34. Connect the engine wiring harness plug connector.
35. Connect the accelerator cable to the throttle body.
- 1.Connect the inner accelerator cable to the throttle body lever.
- 2.Connect the outer casing of the accelerator cable to the throttle body bracket.
36. Connect the plug connector of the electronic ignition (EI) unit.
37. Connect the brake booster vacuum line to the intake manifold.
38. Using the special tool, connect the coolant hoses to the coolant circulation control housing.
39. Connect the fuel supply and return line quick release couplings. Refer to Section 310-00 for additional information.
40. Tighten the nuts of the upper support of the suspension strut assembly with the spring (on both sides).
41. Check the transmission fluid level and add manual transmission fluid if necessary. Refer to Section 308-00 for additional information.
42. Install the air cleaner. Refer to Section 303-12 for additional information.
43. Connect the battery. For additional information, refer to Section 414-01.
44. Fill the engine cooling system. For additional information, refer to Section 303-03.
45. Bleed the clutch hydraulic system. Refer to Section 308-00 for additional information.
(The original can be found on the specified resource: FordBook.ru)