Part 2
Engine Front CoverInstallation (Steps 37-108)
37. Connect the PCV hose to the PCV valve.
38. If equipped, connect the PCV electrical connector.
39. If equipped, attach the block heater wiring harness retainer to the PSP tube and the power steering reservoir hose.
40. If equipped, attach the block heater wiring harness retainer to the upper intake manifold.
41. Raise the engine and transaxle assembly into the vehicle.
42. Install the engine mount, the nut and the 2 bolts.
^ Tighten the bolts to 55 Nm (41 lb-ft).
^ Tighten the nut to 63 Nm (46 lb-ft).
43. Install the 4 engine mount nuts.
^ Tighten to 63 Nm (46 lb-ft).
44. Install the transaxle mount bracket, bolt and the 2 nuts.
^ Tighten to 80 Nm (59 lb-ft).
45. Install the transaxle mount through bolt and nut.
^ Tighten to 90 Nm (66 lb-ft).
Front wheel drive (FWD) vehicles
46. NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new if necessary.
Position the RH halfshaft in the transaxle and install the bolt and the 2 stud bolts.
^ Tighten to 55 Nm (41 lb-ft).
47. NOTE: Do not tighten the 2 catalytic converter support bracket bolts at this time.
Install the RH catalytic converter support bracket and the 2 bolts.
48. Install the 2 catalytic converter support bracket nuts.
^ Tighten to 40 Nm (30 lb-ft).
^ Tighten the 2 catalytic converter support bracket bolts to 20 Nm (15 lb-ft).
All wheel drive (AWD) vehicles
49. NOTE: A new powertrain transfer unit (PTU) seal must be installed whenever the intermediate shaft is removed.
Install a new PTU seal.
50. NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.
Position the RH halfshaft in the transaxle and install the 2 bolts.
^ Tighten to 23 Nm (17 lb-ft).
All vehicles
51. NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.
Install the LH halfshaft into the transaxle.
52. Using the special tool, raise the subframe into the installed position.
53. NOTE: LH shown, RH similar.
Install the 2 front subframe nuts.
^ Tighten to 150 Nm (111 lb-ft).
54. NOTE: LH shown, RH similar.
Position the subframe brackets and install the 4 bolts finger-tight.
55. NOTE: LH shown, RH similar.
Install the 2 rear subframe nuts.
^ Tighten to 150 Nm (111 lb-ft).
56. NOTE: LH shown, RH similar.
Tighten the 2 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
57. NOTE: LH shown, RH similar.
Install the through bolts into the lower control arms.
^ Tighten to 103 Nm (76 lb-ft).
58. NOTE: LH shown, RH similar.
Install the 4 lower ball joint nuts.
^ Tighten to 200 Nm (148 lb-ft).
59. NOTE: LH shown, RH similar.
Install the stabilizer bar links and nuts to the struts.
60. NOTE: LH shown, RH similar.
Install the tie-rod ends and nuts.
^ Tighten to 48 Nm (35 lb-ft).
^ Install new cotter pins.
61. Install the engine roll restrictor-to-subframe through bolt.
^ Tighten to 90 Nm (66 lb-ft).
AWD vehicles
62. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts (3 shown).
^ Tighten to 70 Nm (52 lb-ft).
All vehicles
63. Using new gaskets, install the Y-pipe assembly and the 6 new nuts.
^ Tighten to 40 Nm (30 lb-ft).
64. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
Install a new engine oil filter.
^ Tighten to 5 Nm (44 lb-inch) and then rotate an additional 180 degrees.
65. Connect the 2 transmission fluid cooler hoses.
66. Connect the power steering cooler tube.
67. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body.
^ From under the vehicle, verify that the seal is correctly installed on the steering gear and the retaining clips are fully engaged into the body.
68. If equipped, install the underbody shield and the 6 screws.
69. Install the LH splash shield and the 6 pin-type retainers (4 shown).
70. Position the LH fender splash shield and install the 4 screws.
71. NOTE: Align the index marks made during removal.
Install the steering intermediate shaft onto the steering gear and install a new bolt.
^ Tighten to 23 Nm (17 lb-ft).
72. Install the steering joint cover and the 2 nuts.
73. Using a new banjo bolt and 2 new seals, install the PSP tube onto the steering gear.
^ Tighten to 37 Nm (27 lb-ft).
74. Install the PSP tube bracket and nut.
^ Tighten to 10 Nm (89 lb-inch).
75. Connect the PCM connectors and pin-type retainers.
76. Install the engine mount brace and the 3 bolts.
^ Tighten to 25 Nm (18 lb-ft).
77. Install the ground wire and the bolt.
^ Tighten to 10 Nm (89 lb-inch).
78. Connect the fuel supply tube to the fuel rail.
79. Attach the power steering reservoir onto the cowl.
80. Connect the hose to the power steering reservoir.
^ Attach the pin-type retainer to the engine mount brace.
81. Install the oil level indicator.
82. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
83. Connect the 2 engine wiring harness electrical connectors.
84. Attach the 2 wiring harness retainers.
85. Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
^ Tighten to 8 Nm (71 lb-inch).
86. Install the A/C tube bracket bolt.
^ Tighten to 8 Nm (71 lb-inch).
87. Install the 2 A/C tube bracket bolts.
^ Tighten to 10 Nm (89 lb-inch).
88. Using a new O-ring seal, connect the A/C tube to the condenser and install the nut.
^ Tighten to 8 Nm (71 lb-inch).
89. Attach the coolant tube retainer clips to the A/C tube.
90. If equipped, attach the engine block heater harness to the radiator support, power steering hose, A/C tube and the engine wiring harness.
91. Install the ground wire and bolt.
^ Tighten to 12 Nm (9 lb-ft).
92. Position the transaxle control cable bracket in place and install the 3 nuts.
^ Tighten to 12 Nm (9 lb-ft).
93. Connect the transaxle control cable to the control lever.
94. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
95. Connect the vacuum hose and the evaporative emissions (EVAP) tube to the upper intake manifold.
96. Install the ground wire and the bolt.
^ Tighten to 10 Nm (89 lb-inch).
97. Connect the power feed to the battery terminal and install the nut.
^ Tighten to 6 Nm (53 lb-inch).
98. Attach the 2 wiring harness retainers to the transmission mount and the battery tray bracket.
99. Connect the 2 engine wiring harness electrical connectors.
100. Install the battery tray.
101. Install the engine air cleaner and the air cleaner outlet pipe.
102. Install the degas bottle.
103. Install the accessory drive belt and the power steering belt.
104. CAUTION: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
Fill the engine with clean engine oil.
105. Fill and bleed the cooling system.
106. Fill the power steering system.
107. Check the transaxle fluid and add fluid if necessary.
108. Recharge the air conditioning system.