Special tool
 | Neutral Position Switch Alignment Tool 307-350 (16-088) |
 | Engine Lifting Tool 303-122 (21068A) |
 | Radiator Hose Clamp Remover and Installer 303-397 (24-003) |
General equipment:
- Assembly table
- Fixing clamp
- Repair zone crane
- Wooden blocks
| Name | Specification |
| Clamps | |
| High temperature grease | ESD-M1C220-A |
| Transmission fluid | ESDM-2C186-A |
All cars
1. Replace the self-locking nuts and retaining ring.
- If necessary, use special tool 303-397 when installing coolant hoses and ventilation hoses.
- 2. Preparatory operations
- Using the locking clamp, install the gearbox onto the assembly stand.
- Attach the engine to the repair area crane, bring it into the required position in relation to the gearbox and support it using wooden blocks.
3. Tighten the flange bolts.
4. Tighten the flange bolts. Unhook the engine from the crane.
5. Install the starter and ground wire.
6. Raise the vehicle. Refer to Section 100-02 for additional information.
7. Place the engine and gearbox assembly, secured on the assembly stand, under the vehicle. Carefully lower the vehicle.
8.
NOTE: Hand tighten bolts and nuts.
Install the front engine mount.
9.
NOTE: Tighten the nuts by hand.
Install the rear engine mount.
10. Remove the retaining clamp from the gearbox.
11. Raise the vehicle. Refer to Section 100-02 for additional information. Remove the assembly stand.
12. Install the engine roll limiter.
13.
CAUTION: The inner hinge should not be adjusted more than 18 degrees, and the outer hinge should not be adjusted more than 45 degrees.
NOTE: Use new bolts and a new intermediate bearing cap.
Connect the right front axle shaft to the intermediate shaft.
14.
CAUTION: The inner hinge should not be adjusted more than 18 degrees, and the outer hinge should not be adjusted more than 45 degrees.
NOTE: Use a new snap ring.
NOTE: Lock the snap ring in place.
Connect the left front axle shaft.
15. Connect both suspension arms (right side shown).
16. Install both front wheels. For additional information, refer to Section 204-04.
17. Install the flexible exhaust pipe.
18. Lower the vehicle.
19. Tighten the front engine mount nuts/bolts.
20.
NOTE: Tightening sequence.
Install the rear engine mount nuts, but do not tighten them.
- First tighten the M14 nut.
- Then tighten the M10 nuts evenly, working in a criss-cross pattern.
21. Install the power steering pump and tighten the upper bolts.
22. Connect the bracket for the power steering high pressure line.
23. Connect the PAS tank.
24. Install the expansion tank of the cooling system.
25. Raise the vehicle. Refer to Section 100-02 for additional information.
26. Install the two lower power steering pump bolts and connect the coolant hose.
Cars with air conditioning system
27. Install the air conditioning compressor.
All cars
28. Install and tension the drive belt. Vehicle shown without air conditioning. Turn the belt tensioner clockwise.
29. Install the drive belt cover
30. Install the air deflector and radiator fan. Align the air deflector and secure it to the top on both sides (left side shown).
31. Lower the vehicle.
32. Connect the coolant hoses.
33.
NOTE: The adjustment mechanism must be unlocked.
Connect and adjust the shift lever and selector lever cables in the transmission.
- 1. Loosen the support bushings by turning them counterclockwise and install the gear selector cable into the bracket.
- 2.Connect the shift cable to the selector lever.
- 3. Loosen the support bushings by turning them counterclockwise and install the gear shift cable into the bracket.
- 4.Connect the shift cable to the shift lever.
- 5. Lock the adjustment mechanism by tightening the clamp.
34. Connect the fuel lines. Connect the ground wire.
35. Connect the brake booster vacuum hose.
36. Connect the vacuum hoses.
37. Connect the plug connectors of the reverse light switch and the SCR. Fix the wiring harness in the required position.
38. Connect the engine wiring harness connector.
39. Connect the VSS plug connector.
40.
CAUTION: Brake fluid leakage. Observe brake fluid precautions. Refer to Section 206-00 for additional information.
Connect the high pressure line to the clutch slave cylinder. Install the spring clamp.
41. Connect the heated oxygen sensor (HO2S) connector and the power steering pump pressure switch connector.
42. Connect the radiator fan plug. Install the clamps.
43. Connect the PCM connector.
44. Connect the generator plug.
45. Connect the connectors of the EI coil and the radio interference suppression filter.
46. Install the accelerator cable.
- 1. Attach the accelerator cable.
- 2. Fix the plastic clamp.
47.
NOTE: The resonator is a tight fit.
Install the air cleaner intake manifold together with the resonator.
48. Install the intake manifold.
49. Connect the ground cable.
50. Install the air filter housing.
- Insert the air filter housing into the rubber grommets.
- 1. Connect the mass air flow sensor (MAF sensor) connector.
- 2.Connect the crankcase ventilation hose.
- 3.Connect the inlet hose.
51.
NOTE: Lock against rotation with Allen key.
Tighten the nuts of the right and left suspension struts.
- • Tighten finger tight using a spanner.
- • Use a torque wrench to tighten to the specified torque.
52. Install the battery tray.
- 1.Connect the ground wire and the positive wire.
- 2. Screw in the bolts.
- 3. Fix the wiring harness in the required position.
- 4. Connect and secure the plug connector.
53. Install the battery.
54. Remove the special tool. Secure the covers.
55. Tighten the wheel nuts.
56. Standard finishing operations:
- Fill with coolant. Refer to Section 303-03 for additional information.
- Bleed the clutch hydraulic system. Refer to Section 308-00 for additional information.
- Enter the radio key code.
- Reprogram preset radio stations.
- Perform a road test to allow the PCM to collect data.
(The material was copied from an information website: «Fordbook.ru»)