Sunday, October 30, 2011

How to replace Manual Transaxle Engine on 2003 Ford Focus?


Engine


Removal & Installation


Manual Transaxle
2.0L Engines (VIN 3 And VIN P)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Loosen the front strut center nuts 5 turns.
  5. Remove or disconnect the following:

    Battery, tray and cables
    Mass Air Flow (MAF) sensor connector
    Air cleaner housing and tubes
    Accelerator cable
    Cruise control cable, if equipped
    Ignition coil connectors
    Power steering pump pressure switch connector
    Heated Oxygen (HO 2 S) sensor connectors
    Fuel injector harness connectors
    Powertrain Control Module (PCM) connectors
    Vehicle Speed (VSS) sensor connector
    Reverse lamp switch connector
    Clutch slave cylinder fluid pipe
    Evaporative Emissions (EVAP) canister vacuum lines
    Power brake booster vacuum line
    Delta Pressure Feedback Electronic (DPFE) system sensor vacuum line
    Exhaust Gas Recirculation (EGR) vacuum line
    Intake manifold vacuum line
    Fuel line
    Coolant bypass hoses
    Radiator hoses
    Coolant expansion tank
    Accessory drive belt
    Power steering pump and reservoir
    Power steering high pressure pipe
    Radiator cooling fan
    Catalytic converter
    Exhaust flex pipe
    Drive belt cover
    Shift cable cover
    Shift cables
    A/C compressor, if equipped
    Right engine mount
    Lower ball joints
    Axle halfshafts
  6. Support the powertrain from below
  7. Remove the front and rear engine mounts.
  8. Raise the vehicle away from the powertrain.
To install:
  1. Lower the vehicle over the powertrain.
  2. Install or connect the following:

    Front engine mount. Tighten the nuts to 59 ft. lbs. (80 Nm) and the bolts to 35 ft. lbs. (48 Nm).
    Rear engine mount. Tighten the outer nuts to 35 ft. lbs. (48 Nm) and the center nut to 98 ft. lbs. (133 Nm).
    Axle halfshafts
    Lower ball joints. Tighten the pinch bolts to 37 ft. lbs. (50 Nm).
    Right engine mount. Tighten the bolts to 35 ft. lbs. (48 Nm).
    A/C compressor, if equipped
    Shift cables
    Shift cable cover
    Drive belt cover
    Exhaust flex pipe
    Catalytic converter
    Radiator cooling fan
    Power steering high pressure pipe
    Power steering pump and reservoir
    Accessory drive belt
    Coolant expansion tank
    Radiator hoses
    Coolant bypass hoses
    Fuel line
    Intake manifold vacuum line
    EGR vacuum line
    DPFE system sensor vacuum line
    Power brake booster vacuum line
    EVAP canister vacuum lines
    Clutch slave cylinder fluid pipe
    Reverse lamp switch connector
    VSS sensor connector
    PCM connectors
    Fuel injector harness connectors
    HO 2 S sensor connectors
    Power steering pump pressure switch connector
    Ignition coil connectors
    Cruise control cable, if equipped
    Accelerator cable
    Air cleaner housing and tubes
    MAF sensor connector
    Battery, tray and cables
  3. Tighten the strut center nuts to 35 ft. lbs. (48 Nm).
  4. Fill the cooling system.
  5. Start the engine and check for leaks.
2.3L Engine (VIN Z)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. With the vehicle in NEUTRAL, position it on a hoist.
  3. Release the fuel system pressure.
  4. Remove the battery tray.
  5. Recover the A/C system.
  6. Drain the cooling system.
  7. Drain the engine oil. Install the drain plug.
  8. Remove the accessory drive belt.
  9. Remove the catalytic converter.
  10. Remove the air intake resonator.
  11. Disconnect the fuel tube.
  12. Disconnect the vapor tube.
  13. Disconnect the engine emissions hose and the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical connector.
  14. Disconnect the brake booster vacuum hose.
  15. Disconnect the lower radiator hose, the heater hose and the overflow hose from the coolant bypass.
  16. Disconnect the hose, remove the screw and the pin-type retainer.
  17. Remove the snow shield.
  18. Position aside the accelerator cable and speed control cable (if equipped).
  19. Disconnect the accelerator and speed control cable (if equipped) from the throttle body.
  20. Remove the three bolts and position aside the accelerator cable bracket aside.
  21. Disconnect the fuel injection supply manifold wiring harness electrical connector.
  22. Disconnect the EGR valve electrical connector.
  23. Disconnect the gearshift cables from the transaxle.
  24. Disconnect the shifter cable from the shift mast.
  25. Disconnect the selector cable from the selector lever.
  26. Disconnect the gearshift cables from the bracket.
  27. Disconnect the shifter cable from the bracket, turning the abutment sleeves counterclockwise.
  28. Disconnect the selector cable from the bracket, turning the abutment sleeves counterclockwise.
  29. Remove the clutch slave cylinder supply line.
  30. Remove the supply line and secure it to one side using cable tires.
  31. Disconnect the reversing lamp switch electrical connector.
  32. Disconnect the heater hose from the "T" fitting and position it aside.
  33. Remove the coolant expansion tank.
  34. Disconnect the power steering pressure (PSP) switch electrical connector.
  35. Remove the power steering pump pulley.
  36. Disconnect the PSP tube.
  37. Disconnect the three main engine wiring harness electrical connectors.
  38. Remove the wiring harness retainers from the valve cover.
  39. Disconnect the cooling fan electrical connector.
  40. Disconnect the upper radiator hose.
  41. Remove the battery cable bracket nut.
  42. Remove the generator heat shield top nut.
  43. Remove the generator B+ cable nut and disconnect the B+ cable.
  44. Remove the bolt and the ground cable.
  45. Remove the generator cooling tube.
  46. Remove the cooling fan.
  47. Remove the two lower bellhousing bolts.
  48. Remove the two oil pan-to-bellhousing bolts.
  49. Disconnect the starter electrical connections.
  50. Remove the nuts and disconnect the power steering pressure line brackets from the stud bolts.
  51. Remove the three A/C compressor bolts.
  52. Loosen the bolt and remove the A/C compressor.
  53. Lower the A/C compressor to access the manifold bolt. Discard the O-ring seals.
  54. Disconnect the field coil electrical connector.
  55. Disconnect the LH brake hose from the support bracket.
  56. Disconnect the LH caliper.
    CAUTION
    Suspend the caliper to prevent load from being placed on the brake hose.
  57. Support the brake caliper.
  58. Loosen the LH strut and spring assembly top mount nuts by four turns.
  59. Disconnect the LH stabilizer bar at the strut.
  60. Remove the LH tie-rod end nut.
  61. Remove the RH tie-rod end nut.
  62. Disconnect both of the tie-rods from the knuckles.
  63. Disconnect both of the lower control arms from the knuckles.
  64. Remove the mounting bracket nuts, then remove the bracket from the halfshaft intermediate bearing.
  65. Remove the RH front drive halfshaft. Position the halfshaft aside and support with mechanic's wire.
  66. Install a plug into the transaxle opening.
  67. Remove the LH front drive halfshaft from the transaxle.
  68. Install a plug into the transaxle opening.
  69. Support the halfshaft using mechanic's wire.
  70. Remove the lower engine mount.
  71. Remove the three bolts and the starter.
  72. Remove the starter isolator.
  73. Disconnect the vehicle speed sensor (VSS) electrical connector.
  74. Fasten the engine to the lift table.
  75. Remove the RH motor mount nuts.
  76. Remove the LH motor mount nut.
  77. Lower the engine and transaxle assembly from the vehicle.
  78. Separate the transaxle from the engine.
To install:
  1. Install the transaxle. Make sure the transaxle is flush to the engine.
    CAUTION
    Failure to follow these steps will result in gear rattle at idle.
  2. Install the two bolts at the dowels first. Tighten to 35 ft. lbs. (48 Nm).
  3. Install the remaining transaxle RH flange bolts. Tighten to 35 ft. lbs. (48 Nm).
  4. Connect the vehicle speed sensor (VSS) electrical connector.
  5. Using the lift table, position the engine and transaxle assembly in the vehicle.
  6. Install the RH motor mount nuts and tighten them to 59 ft. lbs. (80 Nm).
  7. Install the LH motor mount nut and tighten it to 98 ft. lbs. (133 Nm).
  8. Remove the lift table.
  9. Install the lower motor mount. Tighten the bolts to 35 ft. lbs. (48 Nm).
  10. Install the two lower engine-to-bellhousing bolts and tighten them to 35 ft. lbs. (48 Nm).
  11. Install the remaining engine-to-bellhousing bolts and tighten them to 35 ft. lbs. (48 Nm).
  12. Install the starter motor isolator.
  13. Install the starter motor and tighten the bolts to 18 ft. lbs. (25 Nm).
  14. Install the generator heat shield and the lower nut.
    NOTE
    Install new O-ring seals.
  15. Position the A/C compressor to the manifold and tube assembly and tighten the bolt to 15 ft. lbs. (21 Nm).
  16. Install the A/C compressor and tighten the three bolts to 18 ft. lbs. (21 Nm).
  17. Connect the field coil electrical connector.
  18. Attach the power steering pressure tube brackets to the stud bolts and install the nuts.
  19. Connect the starter motor electrical connections.
  20. Install the cooling fan.
  21. Position the battery cable and install the cable bracket nut.
  22. Install the generator cooling tube.
  23. Install the generator heat shield top nut.
  24. Install the generator B+ cable and install the cable nut.
  25. Install the upper radiator hose.
  26. Position the ground cable and install the bolt.
  27. Connect the cooling fan electrical connector.
  28. Connect the cooling fan electrical connector.
  29. Connect the wiring harness retainers to the valve cover studs.
  30. Position the power steering pump (PSP) and install the bolts.
  31. Connect the PSP tube.
    NOTE
    Make sure the pulley is flush with the end of the power steering pump shaft.
  32. Install the power steering pump pulley.
  33. Connect the PSP switch electrical connector.
  34. Connect the three main engine wiring harness connectors.
  35. Install the coolant expansion tank.
  36. Connect the heater hose to the "T" fitting.
  37. Connect the exhaust gas recirculation (EGR) valve electrical connector.
  38. Connect the fuel injection supply manifold wiring harness electrical connector.
  39. Position the accelerator cable bracket.
  40. Install the speed control cable (if equipped) and the throttle cable.
  41. Attach the hose and install the screw and the pin-type retainer.
  42. Install the snow shield.
  43. Install the catalytic converter.
  44. Connect the lower radiator hose, the heater hose and the overflow hose to the coolant bypass.
  45. Connect the engine emissions hose and EGR vacuum regulator solenoid electrical connector.
  46. Install the vapor tube.
  47. Connect the fuel tube.
  48. Install the brake booster vacuum hose.
  49. Fill the engine with clean engine oil.
    NOTE
    Install a new snap ring.
  50. Install the LH front drive halfshaft.
    NOTE
    Install new nuts and a new center bearing cap.
  51. Install the RH front halfshaft together with the intermediate shaft.
  52. Install the mounting bracket for the front drive halfshaft intermediate bearing.
  53. Install both of the lower control arms to the knuckles. Tighten the bolts to 37 ft. lbs. (50 Nm).
  54. Install both of the tie-rod ends to the knuckles. Tighten the nuts to 35 ft. lbs. (47 Nm).
  55. Connect the stabilizer bar at the strut.
  56. Tighten the LH strut and spring assembly top mount nuts to 18 ft. lbs. (25 Nm).
  57. Install the brake caliper. Tighten the bolts to 21 ft. lbs. (28 Nm).
  58. Install the brake hose onto the support bracket.
  59. Install the accessory drive belt.
  60. Connect the reversing lamp switch electrical connector.
  61. Connect the clutch slave cylinder supply line. Insert the clip.
    NOTE
    The shift cable abutment sleeve is colored white.


    NOTE
    The selector cable abutment sleeve is colored black.
  62. Attach the gearshift cables to the bracket.
  63. Attach the shifter cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
  64. Attach the selector cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
  65. Attach the shifter cable to the shift mast.
  66. Attach the selector cable to the selector lever.
  67. Check the shift cables at the metal holders. Pull outward on the cables. Cables should remain in the metal.
  68. Adjust the shift cables.
  69. Fill and bleed the clutch hydraulic system
  70. Evacuate and recharge the A/C system.
  71. Install the air intake resonator.
  72. Install the battery tray.
  73. Connect the battery ground cable.
  74. Fill and bleed the cooling system.
  75. Fill and bleed the power steering system.
SVT (VIN 5)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Release the fuel system pressure.
  3. Release the coolant system pressure.
  4. Remove the battery tray.
  5. Remove the air cleaner.
  6. Disconnect the ground cable from the inner fender.
    NOTE
    The resonator is a push fit in the bracket.
  7. Remove the air cleaner intake tube and resonator.
  8. Raise and support the vehicle.
  9. Drain the coolant. Allow the coolant to drain into a suitable container. Install the drain plug after draining.
  10. Drain the engine oil. Allow the oil to drain into a suitable container. Install the drain plug after draining.
  11. Partially lower the vehicle.
  12. Loosen the strut and spring assembly top mount retaining nuts by three turns on both sides.
  13. Remove the splash shield.
  14. Disconnect the accelerator cable and the speed control cable (if equipped) from the throttle body.
  15. Disconnect the intake manifold runner control (IMRC) actuator cable from the IMRC lever.
  16. Remove the electronic ignition (EI) coil cover.
  17. Disconnect the block heater harness (if equipped).
  18. Disconnect the starter field wire electrical connector.
  19. Disconnect the fuel injector wiring harness.
  20. Disconnect the ground cable from the engine lifting eye.
  21. Disconnect the generator electrical connector.
  22. Disconnect the hydraulic line from the clutch slave cylinder.
  23. Disconnect the wiring harness electrical connector.
  24. Raise and support the vehicle.
  25. Disconnect the vehicle speed sensor (VSS) electrical connector.
  26. Disconnect the reversing lamp switch electrical connector.
  27. Partially lower the vehicle.
  28. Disconnect the vacuum hoses from the intake manifold.
  29. Disconnect the brake booster pipe from the intake manifold.
  30. Release the quick release coupling and disconnect the brake booster pipe.
  31. Disconnect the fuel lines.
  32. Disconnect the ground cable.
  33. Disconnect the coolant hoses.
  34. Disconnect the oil cooler hose.
  35. Disconnect the gearshift cables from the transaxle.
  36. Disconnect the gearshift cable and the selector cable from the selector levers.
  37. Disconnect the retaining bracket from the transaxle.
  38. Raise and support the vehicle.
  39. Remove the accessory drive belt.
  40. Disconnect the air conditioning compressor and secure it to the radiator crossmember.
  41. Remove the power steering pump lower retaining bolts and disconnect the radiator lower coolant hose from the water pump housing.
  42. Disconnect the power steering pressure (PSP) switch electrical connector.
  43. Disconnect the crankshaft position (CKP) sensor connector.
  44. Disconnect the coolant hose from the oil cooler.
  45. Lower the vehicle.
  46. Disconnect the coolant expansion tank and position it to one side.
  47. Drain the power assisted steering (PAS) reservoir.
  48. Disconnect the PAS reservoir and position it to one side.
  49. Disconnect the power steering line bracket from the cylinder head.
  50. Disconnect the power steering pump and bracket from the engine and position it to one side.
  51. Raise and support the vehicle.
  52. Remove the flexible exhaust pipe.
  53. Remove the crossmember.
    CAUTION
    Support the halfshaft. The inner joint must not be bent at more than 18 degrees. The outer joint must not be bent at more than 45 degrees.


    CAUTION
    Do not damage the halfshaft oil seal.


    NOTE
    Plug the transaxle to prevent oil loss or dirt ingress.
  54. Remove the RH halfshaft and the intermediate shaft.
  55. Allow the oil to drain into a suitable container.
  56. Disconnect the LH halfshaft from the transaxle and secure it to one side. Allow the oil to drain into a suitable container. Discard the snap ring.
  57. Position the workshop table with suitable wooden blocks under the engine and transmission assembly.
  58. Carefully lower the vehicle until the engine and transmission assembly is positioned on the workshop table.
  59. Secure the engine and transmission assembly to the assembly stand table with a retaining strap.
  60. Remove the engine rear mount.
  61. Remove the engine front mount.
  62. Carefully raise the vehicle.
  63. Pull the assembly stand forward.
  64. Secure the engine and transmission assembly on an engine hoist.
    CAUTION
    The catalytic converter must be supported while the support bracket is removed.
  65. Remove the catalytic converter support bracket.
  66. Remove the catalyst monitor sensor.
  67. Disconnect the catalytic converter from the exhaust manifold. Discard the gasket and nuts.
  68. Remove the heated oxygen (HO2S) sensor.
  69. Remove the transaxle upper retaining bolts.
  70. Disconnect the starter motor.
  71. Remove the starter motor.
  72. Disconnect the ground cable from the transaxle.
  73. Remove the transaxle RH retaining bolts.
  74. Remove the transaxle LH retaining bolts.
  75. Separate the engine from the transaxle.
To install:
  1. Install the transaxle. Tighten the bolts to 35 ft. lbs. (48 Nm).
  2. Install the starter motor. Tighten the bolts to 26 ft. lbs. (35 Nm).
  3. Attach the ground cable to the transaxle.
  4. Connect the starter motor electrical connectors.
    NOTE
    Install a new exhaust flange gasket and new nuts.
  5. Attach the catalytic converter to the exhaust manifold. Tighten the nuts to 35 ft. lbs. (47 Nm).
  6. Install the heated oxygen (HO2S) sensor.
  7. Install the catalytic converter bracket. Tighten the bolts to 18 ft. lbs. (25 Nm).
  8. Install the catalyst monitor sensor (CMS).
  9. Raise and support the vehicle.
  10. Position the engine and transmission assembly under the vehicle.
  11. Carefully lower the vehicle.
  12. Install the engine front mount. Do not tighten the bolts and nuts at this stage.
  13. Install the engine rear mount. Do not tighten the bolts and nuts at this stage.
  14. Remove the retaining strap from the engine and transmission assembly, and remove the assembly stand.
  15. Raise and support the vehicle.
    CAUTION
    Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.


    CAUTION
    Do not damage the halfshaft oil seal.


    NOTE
    Install a new halfshaft center bearing cap and locknuts.
  16. Attach the RH halfshaft and the intermediate shaft to the transaxle.
  17. Install the center bearing cap. Tighten the nuts to 18 ft. lbs. (25 Nm).
  18. Attach the LH halfshaft to the transaxle.
  19. Install the crossmember.
  20. Install the flexible exhaust pipe.
  21. Lower the vehicle.
  22. Tighten the engine rear mount nuts and bolts. Tighten the bolts to 35 ft. lbs. (48 Nm), and the nuts to 59 ft. lbs. (80 Nm).
  23. Tighten the engine front mount nuts. Tighten the small nuts to 35 ft. lbs. (48 Nm), and the large nut to 98 ft. lbs. (133 Nm).
  24. Attach the power steering pump and the bracket to the engine. Tighten the bolts to 35 ft. lbs. (48 Nm).
  25. Attach the power steering line bracket to the cylinder head. Tighten to 15 ft. lbs. (20 Nm).
  26. Install the power assisted steering (PAS) reservoir.
  27. Install the coolant expansion tank.
  28. Raise and support the vehicle.
  29. Connect the power steering pressure switch electrical connector.
  30. Connect the crankshaft position sensor electrical connector.
  31. Connect the radiator lower coolant hose to the coolant pump housing.
  32. Connect the radiator lower coolant hose to the oil cooler.
  33. Attach the air conditioning compressor. Tighten the bolts to 18 ft. lbs. (25 Nm).
  34. Install the accessory drive belt.
  35. Lower the vehicle.
  36. Connect the oil cooler hose.
  37. Attach the gearshift cables to the transaxle.
  38. Attach the retaining bracket to the transaxle.
  39. Attach the gearshift cable and the selector cable to the selector levers.
  40. Connect the starter field wire electrical connector.
  41. Attach the coolant hoses to the thermostat housing.
  42. Attach the fuel pipes to the fuel rail.
  43. Attach the brake servo vacuum hose to the intake manifold.
  44. Attach the vacuum hoses to the throttle body.
  45. Connect the reversing lamp switch electrical connector.
  46. Clip on the wiring loom.
  47. Connect the vehicle speed sensor (VSS) electrical connector.
  48. Connect the wiring harness connectors.
  49. Attach the clutch supply line to the clutch slave cylinder. Install the clip.
  50. Connect the generator electrical connector.
  51. Connect the fuel injector wiring harness.
  52. Install the electronic ignition (EI) coil cover.
  53. Attach the accelerator cable and the speed control cable (if equipped) to the throttle body.
  54. Install the splash shield.
  55. Connect the engine block heater (if equipped).
  56. Connect the intake manifold runner control (IMRC).
  57. Install the air cleaner intake tube and resonator.
  58. Tighten the strut and spring assembly upper mounting retaining nuts to 18 ft. lbs. (25 Nm).
  59. Attach the ground cable to the inner fender.
  60. Install the air cleaner.
  61. Install the battery tray.
    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.
  62. Install and connect the battery.
  63. Fill the cooling system.
  64. Fill the transaxle.
  65. Fill the engine with engine oil.
  66. Bleed the hydraulic clutch operating system.
  67. Fill and bleed the PAS system.

Removal & Installation



2.0L Engine (VIN N)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the engine oil. Reinstall the drain plug.
  3. Drain the cooling system.
  4. Relieve the fuel system pressure.
  5. Recover the A/C refrigerant, if equipped.
  6. Remove or disconnect the following:

    Battery and battery tray
    Accessory drive belt splash guard
    Accessory drive belt
    Catalytic converter from the muffler assembly
    Catalytic converter support bracket
    Catalytic convert heat shield, if equipped
    Exhaust sensor electrical connectors
    Upper exhaust sensor electrical connector and retainer, if equipped
    Secondary air injection (AIR) hose, if equipped
    Catalytic converter-to-engine nuts
    Vent tube from the air cleaner outlet pipe
    Air intake resonator
    Accelerator control snow shield
    Throttle cable
    Cruise control cable, if equipped
    Fuel supply hose quick release coupling from the fuel rail. Position the fuel hose aside.
    Evaporative emissions hose
    AIR hose, if equipped
    AIR vacuum regulator electrical connector, if equipped
    Power brake booster vacuum hose
    Exhaust Gas Recirculation (EGR) valve electrical connector
    Upper radiator hose
    Ground strap (near shock tower)
    Heater hoses
    Fuel charging wiring harness
    Power distribution wiring harness electrical connector
    Wiring harness retainers
    Power distribution wiring harness eyelet
    Three main engine wiring harness electrical connectors
    Gearshift cables from transmission and retaining bracket (M/T)
    Clutch slave cylinder supply hose (M/T)
    Reverse lamp switch electrical connector
    Transmission shifter cable and position it out of the way (A/T)
    Transmission cooler hoses (A/T)
    Heater hose from the "T" fitting and position it out of the way
    Coolant expansion tank
    Power steering pump pulley, using Special Tool 211-016

    Click image to see an enlarged view
    Fig. Removing the power steering pump pulley using Special Tool 211-016-2.0L (VIN N).
    Power steering pump (position out of the way)
    Cooling fan
    Lower radiator hose
    Ground strap connection at engine
    Alternator cooling pipe
    Starter motor electrical connectors
    Power steering pressure hose
    A/C compressor, if equipped
    Left hand brake hose support bracket
    Left hand brake caliper and support aside
  7. Loosen the left hand strut and spring assembly top mounting bolts by four turns.
  8. Disconnect the left hand stabilizer bar at the strut.
  9. Remove the left and right tie rod end nuts.
  10. Disconnect the both tie rods from the knuckles using special tool 211-001

    Click image to see an enlarged view
    Fig. Disconnecting the tie rods using Special Tool 211-001-2.0L (VIN N)
  11. Disconnect the lower control arms from the knuckles.
  12. Remove the intermediate shaft and right hand half shaft assembly from the transmission.
  13. Remove the left hand halfshaft from the transmission using Special Tools 100-001 and 205-241.
    NOTE
    Support both halfshafts to one side with mechanic-s wire or suitable equivalent.


    NOTE
    Install a plug into the transmission openings.



    Click image to see an enlarged view
    Fig. Removing the left hand halfshaft from the transaxle using Removal Tools 100-001 and 205-241.
  14. Remove or disconnect the following:

    Transmission roll restrictor
    Starter and starter isolator
    Two lower bell housing bolts
    Two oil pan-to-bell housing bolts
  15. Using Special Tool 014-0000, fasten the engine to the lift table

    Click image to see an enlarged view
    Fig. Fastening the engine to the lift table to secure the assembly-2.0L (VIN N)
  16. Remove or disconnect the following:

    Motor mount nuts
    Transmission mount center nut
  17. Lower the engine and transmission assembly from the vehicle.
  18. Disconnect the vehicle speed sensor (VSS) connector.
  19. Heater hose from the "T" fitting and position it out of the way; mark one of the bolt to flexplate location for replacement reference (A/T).
  20. Disconnect the output shaft speed (OSS) sensor, turbine shaft speed (TSS) sensor, the solenoid body and the transmission range (TR) sensor electrical connectors (A/T).
  21. Lower the engine on the lifting table to within a few inches of the floor. Using the engine crane, remove the engine from the lift table.
  22. Remove the remaining bell housing bolts and separate the engine and transmission (M/T).
  23. Install the flywheel holding tool (307-346) to retain flywheel position (A/T).

    Click image to see an enlarged view
    Fig. Using the engine lifting crane-2.0L (VIN N)


    Click image to see an enlarged view
    Fig. Installing the flywheel holding tool-2.0L (VIN N) with automatic transmission
To install:
  1. On 2.0L with automatic transmission, perform the following:
    1. Lubricate the torque converter pilot hub with multi-purpose grease.
    2. Check the depth of the torque converter position by laying a straightedge on the automatic transaxle flange.
    3. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.

      Click image to see an enlarged view
      Fig. Checking the torque converter installation depth-2.0L with automatic transmission
  2. For all models, install new dowel pins in the engine block on either side of the flywheel.
  3. Install the transmission onto the engine and tighten the bell housing bolts to 35 ft. lbs. (48 Nm).
  4. Using engine crane, raise the engine and transmission assembly onto the lifting table.
  5. Secure the engine assembly to the lift table using Special Tool 014-00001.
  6. On 2.0L models with automatic transmission, perform the following:
    1. Connect the solenoid body and transmission range (TR) sensor connectors.
    2. Connect Turbine shaft speed (TSS) connector.
    3. Connect the output shaft speed (OSS) connector.
    4. Install the four torque converter nuts and tighten to 26 ft. lbs. (35 Nm).
  7. Using the lift table, position the engine and transmission assembly into the vehicle.
  8. Connect the VSS connector (M/T).
  9. Using the lift table, position the engine and transmission assembly into the vehicle.
  10. Install or connect the following:

    Transmission center mount and nut and tighten to 98 ft. lbs. (133 Nm)
    Motor mount nuts and tighten to 59 ft. lbs. (80 Nm)
    Remaining bell housing bolts and tighten to 35 ft. lbs. (48 Nm)
    Starter motor isolator and starter motor. Tighten the bolts to 18 ft. lbs. (25 Nm).
    Transmission roll restrictor and tighten the bolts to 35 ft. lbs. (48 Nm)
    Left hand halfshaft
    Right hand halfshaft and intermediate shaft. Tighten the mounting bracket to 18 ft. lbs. (25 Nm).
    Lower control arms
    Tie rod ends
    Stabilizer bar at the struts
  11. Tighten the left hand strut and spring assembly top mounting nuts to 18 ft. lbs. (25 Nm).
  12. Install or connect the following:
    NOTE
    Use new O-rings when connecting the PSP hose.



    Brake caliper
    Brake hose support bracket
    A/C compressor, if equipped. Tighten the bolts to 18 ft. lbs. (25 Nm).
    PSP tube and tighten the nuts to 10 ft. lbs. (13 Nm)
    Starter motor electrical connections
    Alternator coolant pipe
    Engine ground cable and tighten to 35 ft. lbs. (48 Nm)
    Lower radiator hose
    Cooling fan
    Power steering pump and tighten to 13 ft. lbs. (18 Nm)



    Power steering pump pulley using Special Tool 211-185
    Coolant expansion tank
    Reversing lamp electrical connector
    Clutch slave cylinder supply hose
    Transmission cables
    Transmission cooler hoses (A/T)
    Automatic transmission shifter cable (A/T)
    Three main wiring harness connectors
    Power distribution wiring harness eyelet
    Wiring harness retainers
    Power distribution wiring harness electrical connector
    Fuel charging wiring harness
    Upper radiator hose
    Heater hoses
    Coolant vent hose
    EGR electrical connector
    Power brake booster vacuum hose
    Secondary AIR electrical connector, if equipped
    AIR hose, if equipped
    Evaporative emission hose
    Fuel supply hose
    Throttle cable
    Cruise control cable, if equipped
    Accelerator control snow shield and tighten to 89 inch lbs. (10 Nm)
    Air intake resonator
    Air cleaner outlet pipe
    Catalytic converter, using new gasket and nuts. Tighten to 41 ft. lbs. (55 Nm).
    Upper exhaust sensor electrical connector, if equipped
    Exhaust sensor electrical connectors
    Catalytic converter heat shield, if equipped
    Catalytic converter support bracket
    Catalytic converter to muffler assembly using a new gasket and nuts
    Accessory drive belt
    Accessory drive belt splash shield
    Battery tray
  13. Fill the engine with oil.
  14. Fill and bleed the power steering system.
  15. Fill the engine with coolant to the correct level.
  16. Charge the A/C system.
  17. Start the engine and check for leaks.



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