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Section 1263 (Engine - 3.9): Installation: Engine

WARNING: This page is about a different car, the 2005 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
ENGINE INSTALLATION SPECIAL TOOLS

G03898369
 Lifting Brackets, Engine 303-050 (T70P-6000)
G03898617
 Spreader Bar 303-D089 (D93P-6001-A3)
G03897842
 Powertrain Lift With Tilting Plate 014-00765
G03996186
 Transmission Support Bracket 014-00341
MATERIAL SPECIFICATION

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
    NOTE: Align the flexplate to converter marks made during engine removal.
    Fig 1: Locating Engine-To-Transmission Bolts
    G03996585Courtesy of FORD MOTOR CO.
  1. Install the engine to the transmission and install the bolts.
    • Tighten to 47 Nm (35 lb-ft).
  2. Position the wiring harness and install the 2 nuts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 2: Identifying Engine Wiring Harness Retainer And Nuts
    G03996270Courtesy of FORD MOTOR CO.
  3. Using the special tool and an engine crane, move the engine and transmission onto the crossmember and cooling system assembly.
    Fig 3: Moving Engine And Transmission Onto Crossmember
    G03996191Courtesy of FORD MOTOR CO.
    4. NOTE: LH shown, RH similar.
    Fig 4: Installing LH And RH Upper Engine Mount Nuts
    G03996582Courtesy of FORD MOTOR CO.
  4. Install the LH and the RH upper engine mount nuts.
    • Tighten to 50 Nm (37 lb-ft).
  5. Connect the transmission cooler tubes.
    • Tighten to 35 Nm (26 lb-ft).
    Fig 5: Identifying Transmission Cooler Tubes
    G03996579Courtesy of FORD MOTOR CO.
  6. Install the transmission cooler tube bracket nut.
    • Tighten to 10 Nm (89 lb-in).
    Fig 6: Locating Transmission Cooler Tube Bracket Nut
    G03996578Courtesy of FORD MOTOR CO.
  7. Install the power steering pump and 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 7: Installing Power Steering Pump Bolts
    G03996577Courtesy of FORD MOTOR CO.
  8. Install the power steering tube bracket nut.
    • Tighten to 18 Nm (13 lb-ft).
    Fig 8: Installing Power Steering Tube Bracket Nut
    G03996425Courtesy of FORD MOTOR CO.
  9. Install the A/C compressor and 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 9: Installing A/C Compressor Bolts
    G03995959Courtesy of FORD MOTOR CO.
  10. Connect the A/C compressor and power steering pressure (PSP) switch electrical connectors.
    Fig 10: Connecting A/C Compressor And Power Steering Pressure Switch Electrical Connectors
    G03996574Courtesy of FORD MOTOR CO.
  11. Install the accessory drive belt.
  12. Connect the 2 oil cooler hoses, if equipped.
    Fig 11: Installing Accessory Drive Belt
    G03996941Courtesy of FORD MOTOR CO.
  13. Connect the lower radiator, upper radiator and heater hose.
    Fig 12: Locating Lower Radiator, Upper Radiator And Heater Hoses
    G03996322Courtesy of FORD MOTOR CO.
  14. Install the lower radiator hose bracket nut.
    • Tighten to 10 Nm (89 lb-in).
    Fig 13: Identifying Lower Radiator Hose Bracket Nut
    G03996321Courtesy of FORD MOTOR CO.
  15. Using the powertrain lift and the transmission support bracket, carefully raise the entire assembly into the vehicle.
    Fig 14: Raising Entire Assembly
    G03996565Courtesy of FORD MOTOR CO.
    16. NOTE: LH shown, RH similar.
    Fig 15: Identifying Front Crossmember And Center Crossmember Bolts
    G03995953Courtesy of FORD MOTOR CO.
  16. Install the 4 front crossmember and the 4 center crossmember bolts.
    • Tighten to 103 Nm (76 lb-ft).
    17. NOTE: RH shown, LH similar.
    Fig 16: Tightening RH And LH Center Crossmember I-Brace Bolts
    G03996567Courtesy of FORD MOTOR CO.
  17. Install the 4 RH and LH center crossmember I-brace bolts.
    • Tighten to 103 Nm (76 lb-ft).
  18. Install the 4 transmission support bolts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 17: Locating Transmission Crossmember Support Bolts
    G03995952Courtesy of FORD MOTOR CO.
  19. Install the 4 torque converter nuts.
    • Tighten to 38 Nm (28 lb-ft).
    Fig 18: Locating Torque Converter Nuts
    G03996211Courtesy of FORD MOTOR CO.
  20. Install the cover.
    Fig 19: Locating Torque Converter Cover
    G03996563Courtesy of FORD MOTOR CO.
  21. Install the 6 lower transmission to engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
    Fig 20: Identifying Lower Transmission-To-Engine Bolts
    G03996562Courtesy of FORD MOTOR CO.
  22. Connect the generator electrical connector and pin-type retainer.
    Fig 21: Connecting Generator Electrical Connector
    G03996561Courtesy of FORD MOTOR CO.
  23. Connect the starter motor wiring and install the nuts.
    • Tighten the large nut to 12 Nm (9 lb-ft).
    • Tighten the small nut to 6 Nm (53 lb-in).
    Fig 22: Connecting Starter Motor Wiring
    G03996560Courtesy of FORD MOTOR CO.
  24. Install the cover.
    Fig 23: Identifying Starter Motor Terminal Cover
    G03996559Courtesy of FORD MOTOR CO.
  25. Install the starter motor ground cable and nut.
    • Tighten the large nut to 25 Nm (18 lb-ft).
    Fig 24: Installing Starter Motor Ground Cable Nut
    G03996954Courtesy of FORD MOTOR CO.
    26. CAUTION: Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM .
    Fig 25: Connecting Steering Coupling
    G03995938Courtesy of FORD MOTOR CO.
  26. Connect the steering coupling and install the bolt.
    • Tighten to 35 Nm (26 lb-ft).
  27. Install the steering shaft bolt.
    • Tighten to 30 Nm (22 lb-ft).
    Fig 26: Installing Steering Shaft Bolt
    G03996956Courtesy of FORD MOTOR CO.
  28. Connect the block heater electrical connector, if equipped.
    Fig 27: Locating Block Heater Electrical Connector
    G03995941Courtesy of FORD MOTOR CO.
  29. Install the retaining bolt for the high pressure power steering hose bracket.
    • Tighten to 10 Nm (89 lb-in).
    Fig 28: Installing High Pressure Power Steering Retaining Bolt
    G03995940Courtesy of FORD MOTOR CO.
  30. Attach the power steering return hose to the pressure hose clip.
    Fig 29: Attaching Power Steering Return Hose
    G03995936Courtesy of FORD MOTOR CO.
  31. Connect the variable assist power steering (VAPS) actuator electrical connector.
    Fig 30: Locating Variable Assist Power Steering Actuator Electrical Connector
    G03995935Courtesy of FORD MOTOR CO.
  32. Attach the shift cable pin-type retainer to the exhaust heat shield.
    Fig 31: Attaching Shift Cable Pin-Type Retainer
    G04007506Courtesy of FORD MOTOR CO.
  33. Install the shift cable bracket and 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 32: Locating Shift Cable Bracket-To-Body Bolts
    G03995933Courtesy of FORD MOTOR CO.
  34. Connect the shift cable to the shifter.
    Fig 33: Identifying Shift Cable Connection Point At Shifter
    G03995932Courtesy of FORD MOTOR CO.
  35. Install the 2 strut-to-control arm bolts and nuts.
    • Tighten to 175 Nm (129 lb-ft).
    Fig 34: Identifying Lower Strut-To-Control Arm Bolt And Nut
    G03995931Courtesy of FORD MOTOR CO.
  36. Position the upper ball joints into the wheel knuckles and install the 2 nuts.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 35: Identifying Upper Ball Joint Nut At Wheel Knuckle
    G03995930Courtesy of FORD MOTOR CO.
  37. Position the stabilizer bar links into the lower control arms and install the 2 nuts.
    • Tighten to 55 Nm (41 lb-ft).
    Fig 36: Identifying Stabilizer Bar Link Connection Point At Lower Control Arm
    G03995929Courtesy of FORD MOTOR CO.
  38. Install the front brake calipers and the 4 bolts.
    • Tighten to 35 Nm (26 lb-ft).
    Fig 37: Identifying Brake Caliper Mounting Bolts
    G03995928Courtesy of FORD MOTOR CO.
  39. Attach the RH and LH anti-lock brake sensor harnesses to the brake hose clips.
    Fig 38: Identifying Anti-Lock Brake Sensor Harnesses-To-Hose Clips
    G03995927Courtesy of FORD MOTOR CO.
  40. Connect the RH and LH anti-lock brake sensor electrical connectors.
    Fig 39: Locating Anti-Lock Brake Sensor Electrical Connector
    G03995926Courtesy of FORD MOTOR CO.
  41. Install the RH and LH inner splash shields and pin-type retainers.
  42. Connect the low pressure A/C hose.
    Fig 40: Identifying Low Pressure A/C Hose
    G03996234Courtesy of FORD MOTOR CO.
  43. Connect the A/C high pressure hose and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    Fig 41: Connecting A/C High Pressure Hose
    G03996540Courtesy of FORD MOTOR CO.
    44. NOTE: The top heater hose has a green identifying mark to match the hose on the dual coolant flow valve. This will aid in the correct installation of the hose assemblies.
    NOTE: Hose assemblies shown with components removed for clarity.
    Fig 42: Identifying Heater Hose Quick Release Couplings
    G03995921Courtesy of FORD MOTOR CO.
  44. Connect the 3 heater hose quick release couplings. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    45. CAUTION: Install the bolts, washers and nuts in their original positions or driveshaft NVH can occur. Install the driveshaft flex coupling bolts with the head of the bolt seated against the flange and the nuts seated against the flex coupling.
    NOTE: The bolt heads are serrated. Hold the bolt and tighten the nut.
    Fig 43: Identifying Flange Nuts & Locating Index Mark
    G03995919Courtesy of FORD MOTOR CO.
  45. Install the bolts, washers and nuts.
    • Coat the nut and bolt threads with sealer.
    • Tighten to 81 Nm (60 lb-ft).
  46. Install the catalytic converters. For addition information, refer to EXHAUST SYSTEM .
  47. Install the inner air deflector.
    Fig 44: Installing Inner Air Deflector
    G03995918Courtesy of FORD MOTOR CO.
  48. Install the center splash shield.
    Fig 45: Installing Center Splash Shield
    G03996975Courtesy of FORD MOTOR CO.
    49. NOTE: LH shown, RH similar.
    Fig 46: Locating Splash Shields
    G03995916Courtesy of FORD MOTOR CO.
  49. Install the LH and the RH splash shields.
  50. Connect the A/C pressure switch electrical connector.
    Fig 47: Locating A/C Pressure Switch & Electrical Connector
    G03996977Courtesy of FORD MOTOR CO.
  51. Connect the cooling fan electrical connector.
    Fig 48: Connecting Cooling Fan Electrical Connector
    G03996532Courtesy of FORD MOTOR CO.
  52. Connect the coolant valve electrical connector and attach the wiring harness clip to the radiator support.
    Fig 49: Connecting Coolant Valve Electrical Connector
    G03995915Courtesy of FORD MOTOR CO.
  53. Connect the bulkhead electrical connectors.
    • Tighten to 6 Nm (53 lb-in).
    Fig 50: Connecting Bulkhead Electrical Connectors
    G03996530Courtesy of FORD MOTOR CO.
    54. NOTE: The connectors are located on the backside of the RH strut tower.
    Fig 51: Identifying Engine Wiring Harness Electrical Connectors
    G04007484Courtesy of FORD MOTOR CO.
  54. Connect the engine wiring harness electrical connectors.
  55. Position the ground strap and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 52: Locating Ground Strap And Bolt
    G03996528Courtesy of FORD MOTOR CO.
  56. Install the power steering reservoir and 2 bolts.
    • Tighten the top bolt to 6 Nm (53 lb-in).
    • Tighten the bottom bolt to 12 Nm (9 lb-ft).
    Fig 53: Installing Power Steering Reservoir Bolts
    G03995902Courtesy of FORD MOTOR CO.
  57. Connect the degas bottle hose.
    Fig 54: Connecting Degas Bottle Hose
    G03996526Courtesy of FORD MOTOR CO.
  58. Connect the vacuum hose.
    Fig 55: Identifying Vacuum Supply Hose/Tube
    G03996268Courtesy of FORD MOTOR CO.
  59. Connect the evaporative emissions (EVAP) hose to the EVAP canister purge valve.
    Fig 56: Connecting Evaporative Emissions Hose To EVAP Canister Purge Valve
    G03995908Courtesy of FORD MOTOR CO.
    60. NOTE: RH shown, LH similar.
    Fig 57: Identifying Upper Radiator Support Bracket & Bolts
    G03995900Courtesy of FORD MOTOR CO.
  60. Install the 2 upper radiator support brackets and the 6 bolts.
    • Tighten to 10 Nm (89 lb-in).
  61. Install the upper radiator sight shield.
    Fig 58: Locating Upper Radiator Sight Shield
    G04007969Courtesy of FORD MOTOR CO.
  62. Connect the fuel supply tube. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  63. Install the fresh air inlet duct. For additional information, refer to AIR DISTRIBUTION & FILTERING .
  64. Install the air cleaner assembly and outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  65. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  66. Fill the engine with clean engine oil.
    67. CAUTION: The coolant fill procedure must be followed exactly or damage to the engine can occur.
  67. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
    68. CAUTION: The engine appearance cover is equipped with a noise suppressor. If the noise suppressor becomes separated from the engine appearance cover it must be positioned on the intake manifold prior to installing the engine appearance cover.
    Fig 59: Identifying Engine Appearance Cover/Noise Suppressor
    G03996267Courtesy of FORD MOTOR CO.
  68. Install the noise suppressor (if detached) and the engine appearance cover.
  69. Evacuate and recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
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