2003 Ford ZX2 AutomaticFACTORY OEM SERVICE PROCEDURE

Section 1636 (Engine): Installation: Engine

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL TABLE

G04656024Courtesy of FORD MOTOR CO.
 Lifting Brackets, Engine 134-00243 or equivalent
G04656025Courtesy of FORD MOTOR CO.
 Powertrain Lift with Tilting Plate 014-00765
G04656026Courtesy of FORD MOTOR CO.
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
G04656027Courtesy of FORD MOTOR CO.
 Engine Lifting Bracket Set 303-1140
MATERIAL TABLE

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalent WSS-M2C930-A
Threadlock and Sealer TA-25 WSK-M2G351-A5
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: Identifying Special Tools
    G04656028Courtesy of FORD MOTOR CO.

    2. Vehicles with 6-speed transaxle 

  2. Install the 4 transaxle-to-engine bolts.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 2: Locating Transaxle-To-Engine Bolts
    G04656029Courtesy of FORD MOTOR CO.

    3. Vehicles with CVT transaxle 

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

    4. All vehicles 

  4. Install the engine-to-transaxle bolt.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 4: Locating Knock Sensor
    G03990667Courtesy of FORD MOTOR CO.
  5. Position the knock sensor (KS), install the bolt and connect the electrical connector.
    • Tighten to 20 N.m (15 lb-ft).
    Fig 5: Locating Electrical Connector & Bolt
    G04656032Courtesy of FORD MOTOR CO.
  6. Attach the heat shield to the KS.
    Fig 6: Identifying Knock Sensor Heat Shield
    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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