2002 Ford ZX2 StandardFACTORY OEM SERVICE PROCEDURE

Section 1153 (Engine): Installation: Engine: Installation

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

    All vehicles 

  1. Using the special tools and a suitable engine crane, align the engine with the transaxle.
    Fig 1: Aligning Engine With Transaxle
    G03990500Courtesy of FORD MOTOR CO.

    2. Vehicles with 6-speed transaxle 

  2. Install the 4 transaxle-to-engine bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 2: Installing Transaxle-To-Engine Bolts
      G03990501Courtesy of FORD MOTOR CO.

    3. Vehicles with CVT transaxle 

  3. Install the 3 transaxle-to-engine bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 3: Installing Transaxle-To-Engine Bolts
      G03990288Courtesy of FORD MOTOR CO.

    4. All vehicles 

  4. Install the engine-to-transaxle bolt.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 4: Installing Engine-To-Transaxle Bolt
      G03990667Courtesy of FORD MOTOR CO.
  5. Position the knock sensor (KS), install the bolt and connect the electrical connector.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 5: Installing Bolt And Connect Electrical Connector
      G03990504Courtesy of FORD MOTOR CO.
  6. Attach the heat shield to the KS.
    Fig 6: Identifying Heat Shield Over Knock Sensor
    G03990937Courtesy of FORD MOTOR CO.
    7. NOTE: A third lift chain should be used to allow for level lifting of the engine.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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