Engine - Vehicles With: Manual Transmission

1. WARNING: Before beginning any service procedure in this manual, refer to health and safety warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. General Equipment: Spreader Bar
   Install Special Service Tool : 300-OTC1819E 2,200# Floor Crane, Fold Away

1. Torque : 48 Nm

1. General Equipment: Adjustable Grip Arm
   Install Special Service Tool : 300-OTC1585AE Powertrain Lift
   General Equipment : Wooden Block

1. General Equipment: Spreader Bar
   Remove Special Service Tool : 300-OTC1819E 2,200# Floor Crane, Fold Away

1. Torque : 48 Nm

1. Torque : 25 Nm

1. NOTE: Tighten the top bolt first.

   Torque : 25 Nm

1. 1. Torque : 6 Nm
   2. Torque : 12 Nm

1. Torque : 10 Nm

1. NOTICE: The engine vehicle studs must be torqued or damage to the powertrain mount may occur.

   Torque : 8 Nm

1. Torque :
   Transmission support insulator nuts   125 Nm
   Transmission support insulator bolts   90 Nm

1. Torque : 48 Nm

1. Torque : 80 Nm

1. General Equipment: Adjustable Grip Arm
   Remove Special Service Tool : 300-OTC1585AE Powertrain Lift

1. Torque : 70 Nm

1. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
   Torque : 15 Nm

1. If equipped.
   

1. NOTE: Failure to tighten the catalytic converter manifold fasteners in 20 Nm increments until reaching final torque of 55 Nm will cause the converter to develop an exhaust leak.

   Torque :
     Stage 1:  20 Nm
     Stage 2:  40 Nm
     Stage 3:  55 Nm

1. Torque : 10 Nm

1. 1. Torque : 50 Nm
   2. Torque : 25 Nm

1. NOTE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.

1. Torque : 48 Nm

1. Refer to: Catalyst Monitor Sensor (303-14A Electronic Engine Controls - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
   

1. Torque : 25 Nm

1. 1. Torque : 48 Nm
   2. Torque : 24 Nm

1. Install the following items:
   1. Refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
      
   2. Refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).
      

1. Torque : 10 Nm

1. WARNING: Carefully read cautionary information on product label. For emergency medical information seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.

   NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

1. General Equipment : Hose Clamp Remover/Installer

1. General Equipment : Hose Clamp Remover/Installer

1. Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, General Procedures).
   

1. Refer to: Heated Oxygen Sensor (HO2S) (303-14A Electronic Engine Controls - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
   

1. General Equipment : Hose Clamp Remover/Installer

1. Refer to: Cooling Fan Motor and Shroud (303-03A Engine Cooling - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
   

1. Refer to: Generator - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma (414-02 Generator and Regulator, Removal and Installation).
   

1. Refer to: Spring Lock Couplings (310-00A Fuel System - General Information - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, General Procedures).
   

1. Torque : 10 Nm

1. Torque : 10 Nm

1. Torque : 5.4 Nm

1. Torque : 10 Nm

1. Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
   

1. Install the following items:
   1. Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
      
   2. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
      

1. Fill the engine with clean engine oil.
   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. Refer to: Degas Bottle (303-03A Engine Cooling - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
   

1. Fill the bleed the cooling system.
   Refer to: Cooling System Draining, Filling and Bleeding (303-03A Engine Cooling - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, General Procedures).
   

1. Refer to: Transmission Fluid Level Check (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, General Procedures).
   

1. Refer to: Clutch System Bleeding (308-02 Clutch Controls - Vehicles With: 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, General Procedures).
   

1. Refer to: Gearshift Cable Adjustment - Vehicles With: 5-Speed Manual Transmission - B5/IB5 (308-06 Manual Transmission External Controls - Vehicles With: 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, General Procedures).
   

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