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Section 1639 (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.
    Fig 7: Identifying Special Tools
    G04656034Courtesy of FORD MOTOR CO.
  7. Using the special tools and a suitable engine crane, position the powertrain on the subframe.
  8. Install the LH engine insulator upper nut.
    • Tighten to 70 N.m (52 lb-ft).
    Fig 8: Locating LH Engine Insulator Upper Nut
    G04656035Courtesy of FORD MOTOR CO.
  9. Install the RH engine insulator upper nut.
    • Tighten to 70 N.m (52 lb-ft).
    Fig 9: Locating RH Engine Insulator Upper Nut
    G04656036Courtesy of FORD MOTOR CO.
  10. Position the RH exhaust manifold heat shield and install the 3 bolts.
    • Tighten to 11 N.m (8 lb-ft).
    Fig 10: Locating Exhaust Manifold Heat Shield Bolts
    G04656037Courtesy of FORD MOTOR CO.
  11. Install the front transaxle stabilizer bolt.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 11: Locating Front Transaxle Stabilizer Bolt & Nut
    G04656038Courtesy of FORD MOTOR CO.
  12. If equipped, install the upper power transfer unit (PTU) bracket and the bolts.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 12: Identifying Upper PTU Bracket Bolts And Bracket
    G03990281Courtesy of FORD MOTOR CO.

    13. Vehicles with 6-speed transaxle 

  13. Clean the 3 rear transaxle insulator bracket bolts using a wire brush and apply new threadlock to the threads.
  14. Install the 3 rear transaxle insulator bracket bolts.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 13: Identifying Upper Transaxle Mount Retaining Bolts
    G03991478Courtesy of FORD MOTOR CO.
  15. Position the ground cable and install the bolt.
    • Tighten to 12 N.m (9 lb-ft).
    Fig 14: Locating Ground Cable Bolt
    G04656041Courtesy of FORD MOTOR CO.
  16. Position the starter motor and install the 2 bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 15: Locating Starter Motor Bolts
    G04656042Courtesy of FORD MOTOR CO.
  17. Position the starter motor wiring and install the nuts.
    • Tighten the larger nut to 12 N.m (9 lb-ft).
    • Tighten the smaller nut to 9 N.m (80 lb-in).
    Fig 16: Locating Starter Motor Wiring Nuts
    G04656043Courtesy of FORD MOTOR CO.
  18. Install the starter motor terminal cover.
    Fig 17: Locating Starter Motor Terminal Cover
    G04656044Courtesy of FORD MOTOR CO.
  19. Clean the 2 roll restrictor bolts using a wire brush and apply new threadlock to the threads.
  20. Position the roll restrictor and install the 2 bolts.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 18: Locating Roll Restrictor Bolts
    G04656045Courtesy of FORD MOTOR CO.
  21. Clean the 4 roll restrictor bracket bolts using a wire brush and apply new threadlock to the threads.
  22. Position the roll restrictor bracket and install the 4 bolts.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 19: Locating Roll Restrictor Bracket Bolts
    G04656046Courtesy of FORD MOTOR CO.
  23. Connect the transmission control unit (TCU) wire harness.
    Fig 20: Identifying Transmission Control Module Electrical Connector
    G03991767Courtesy of FORD MOTOR CO.

    24. Vehicles with CVT transaxle 

  24. Clean the 4 rear transaxle insulator bolts using a wire brush and apply new threadlock to the threads.
  25. Install the 4 rear transaxle insulator bracket bolts.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 21: Locating Transaxle Mount Bolts
    G03990282Courtesy of FORD MOTOR CO.
  26. Position the ground cable and install the bolt.
    • Tighten to 12 Nm (9 lb-ft).
    Fig 22: Locating Ground Wire
    G03991001Courtesy of FORD MOTOR CO.
  27. Position the starter motor and install the 2 bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 23: Identifying Starter Motor Mounting Bolts
    G03990263Courtesy of FORD MOTOR CO.
  28. Position the starter motor wiring and install the nuts.
    • Tighten the larger nut to 12 N.m (9 lb-ft).
    • Tighten the smaller nut to 9 N.m (80 lb-in).
      Fig 24: Identifying Starter Motor Electrical Connectors
      G03990920Courtesy of FORD MOTOR CO.
  29. Install the starter motor terminal cover.
    Fig 25: Identifying Electrical Cover For Starter Motor Electrical Connectors
    G03990919Courtesy of FORD MOTOR CO.
  30. Clean the 2 roll restrictor bolts using a wire brush and apply new threadlock to the threads.
  31. Position the roll restrictor and install the 2 bolts.
    • Tighten to 55 N.m (41 lb-ft).
      Fig 26: Locating Roll Restrictor Bolts
      G04656053Courtesy of FORD MOTOR CO.
  32. Attach the wiring harness to the roll restrictor.
    Fig 27: Locating Wiring Harness At Roll Restrictor Bolts
    G03990915Courtesy of FORD MOTOR CO.
  33. Clean the 4 roll restrictor bracket bolts using a wire brush and apply new threadlock to the threads.
  34. Position the roll restrictor bracket and install the 4 bolts.
    • Tighten to 55 N.m (41 lb-ft).
      Fig 28: Locating Roll Restrictor Bracket Bolts
      G04656055Courtesy of FORD MOTOR CO.
  35. Attach the lower wiring harness retainers to the transaxle.
    Fig 29: Locating Lower Wiring Harness Retainers
    G04656056Courtesy of FORD MOTOR CO.
  36. Attach the wiring harness retainers to the transaxle.
    Fig 30: Locating Wire Harness Retainers At Transaxle
    G03990911Courtesy of FORD MOTOR CO.
  37. Attach the wiring harness retainer to the transaxle.
    Fig 31: Locating Wiring Harness Retainer
    G04656058Courtesy of FORD MOTOR CO.
  38. Connect the transaxle bulkhead electrical connector.

    All vehicles 

    Fig 32: Locating Transaxle Bulkhead Electrical Connector
    G03990860Courtesy of FORD MOTOR CO.
  39. Attach the pin-type retainers to the subframe and connect the RH catalyst monitor sensor electrical connector.
    Fig 33: Locating Pin-Type Retainers & Catalyst Monitor Sensor Electrical Connector
    G04656060Courtesy of FORD MOTOR CO.
  40. Connect the power steering fluid tubes and install the bolt.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 34: Locating Power Steering Fluid Tubes & Bolt
    G04656061Courtesy of FORD MOTOR CO.
  41. Install the power steering pressure (PSP) tube bracket bolt and connect the PSP switch electrical connector.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 35: Locating Power Steering Pressure Tube Bracket Bolt & PSP Switch Electrical Connector
    G04656062Courtesy of FORD MOTOR CO.
  42. Using the special tool, position the powertrain and subframe in the vehicle.
    Fig 36: Identifying Special Tool
    G04656063Courtesy of FORD MOTOR CO.
  43. Install the 2 forward subframe bolts and washers.
    • Tighten to 200 Nm (148 lb-ft).
    Fig 37: Locating Forward Subframe Bolt & Washer
    G04656064Courtesy of FORD MOTOR CO.
  44. Position the rear subframe brackets and install the 6 bolts.
    • Tighten the 2 larger bolts to 150 N.m (111 lb-ft).
    • Tighten the 4 smaller bolts to 55 N.m (41 lb-ft).
    Fig 38: Locating Rear Subframe Bracket Bolts
    G04656065Courtesy of FORD MOTOR CO.
  45. Attach the steering column intermediate shaft and install a new bolt.
    • Tighten to 23 N.m (17 lb-ft).
    Fig 39: Locating Steering Column Intermediate Shaft Bolt
    G04656066Courtesy of FORD MOTOR CO.
  46. Attach the outer tie rods to the wheel knuckles and install new nuts.
    • Tighten to 115 N.m (85 lb-ft).
    Fig 40: Locating Outer Tie Rod Nut
    G04656067Courtesy of FORD MOTOR CO.
  47. Attach the stabilizer bar links to the struts and install new nuts.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 41: Identifying Stabilizer Bar Link Nuts
    G03990245Courtesy of FORD MOTOR CO.
  48. If equipped, connect the driveshaft and install the bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 42: Locating Driveshaft Bolt
    G04656069Courtesy of FORD MOTOR CO.
  49. If equipped, position the driveshaft support bracket and install the 2 bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 43: Identifying Driveshaft Cross Brace Mounting Bolts
    G03990728Courtesy of FORD MOTOR CO.
    50. NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of sealant application.
    Fig 44: Identifying Silicone Sealant Areas
    G04656071Courtesy of FORD MOTOR CO.
  50. Apply a 10 mm (0.39 in) diameter dot of silicone sealant to the areas indicated.
  51. Position the oil pan and a new gasket. Loosely install the 15 bolts.
    Fig 45: Locating Oil Pan Bolt
    G04656072Courtesy of FORD MOTOR CO.
  52. Position the LH catalytic converter bracket and install the 3 engine-to-transaxle bolts.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 46: Locating Transaxle-To-Engine Bolts
    G03990545Courtesy of FORD MOTOR CO.
  53. Tighten the 15 oil pan bolts in the sequence shown to 25 N.m (18 lb-ft).
    Fig 47: Identifying Oil Pan Bolts Tightening Sequence
    G04656074Courtesy of FORD MOTOR CO.
  54. Install the oil pan-to-oil filter adapter bolt.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 48: Locating Oil Pan-To-Oil Filter Adapter Bolt
    G04656075Courtesy of FORD MOTOR CO.
  55. Install the 4 new torque converter nuts.
    • Tighten to 36 N.m (27 lb-ft).
    Fig 49: Locating Torque Converter Nut
    G04656076Courtesy of FORD MOTOR CO.
  56. Position the lower torque converter access plug and install the pin-type retainers.
    Fig 50: Locating Pin-Type Retainers
    G04656077Courtesy of FORD MOTOR CO.
  57. If equipped, connect the block heater electrical connector and attach the wiring retainers.
    Fig 51: Locating Block Heater Electrical Connector
    G03990550Courtesy of FORD MOTOR CO.
  58. Connect the power steering cooler hose.
    Fig 52: Locating Power Steering Cooler Hose
    G04656079Courtesy of FORD MOTOR CO.
  59. Connect the transmission cooler hoses.
    Fig 53: Locating Transmission Cooler Hoses
    G04656080Courtesy of FORD MOTOR CO.
  60. Position the A/C tube and install the nut.
    • Tighten to 8 N.m (71 lb-in).
    Fig 54: Locating A/C Tube Nut
    G04656081Courtesy of FORD MOTOR CO.
  61. Position the A/C manifold assembly tubes and install the bolt.
    • Tighten to 20 N.m (15 lb-ft).
    Fig 55: Locating A/C Manifold Assembly Tubes Bolt
    G04656082Courtesy of FORD MOTOR CO.
  62. Connect the A/C high-pressure switch electrical connector.
    Fig 56: Locating A/C High-Pressure Switch Electrical Connector
    G04656083Courtesy of FORD MOTOR CO.
  63. Connect the 10-pin electrical connector and attach the wiring retainers.
    Fig 57: Locating 10-Pin Electrical Connector & Wiring Retainer
    G04656084Courtesy of FORD MOTOR CO.
  64. Position the coolant tube and secure the tube in the clips.
    Fig 58: Locating Coolant Tube Position
    G04656085Courtesy of FORD MOTOR CO.
  65. Connect the coolant hoses to the thermostat housing.
    Fig 59: Locating Coolant Hoses To Thermostat Housing
    G04656086Courtesy of FORD MOTOR CO.
  66. Connect the brake booster vacuum hose to the upper intake manifold.
    Fig 60: Locating Brake Booster Vacuum Hose To Upper Intake Manifold
    G04656087Courtesy of FORD MOTOR CO.
  67. Connect the heater hose and the positive crankcase ventilation (PCV) coolant hose.
    Fig 61: Locating Heater Hose And Positive Crankcase Ventilation (PCV) Coolant Hose
    G04656088Courtesy of FORD MOTOR CO.

    68. Vehicles with 6-speed transaxle 

  68. Position the shift cable bracket and install the 3 bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 62: Locating Shift Cable Bracket Bolts
    G04656089Courtesy of FORD MOTOR CO.
  69. Connect the 16-pin electrical connector and attach the wiring retainer.
    • Connect the electrical connector to the shift cable bracket.
    Fig 63: Locating 16-Pin Electrical Connector & Wiring Retainer
    G04656090Courtesy of FORD MOTOR CO.
  70. Connect the shift cable.
    Fig 64: Locating Shift Cable End
    G03991743Courtesy of FORD MOTOR CO.

    71. Vehicles with CVT transaxle 

  71. Position the shift cable bracket and install the 2 bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 65: Locating Shift Cable Bracket Bolts
    G03990223Courtesy of FORD MOTOR CO.
  72. Connect the 16-pin electrical connector and attach the wiring retainers.
    • Attach the electrical connector to the shift cable bracket.
    Fig 66: Locating 16-Pin Electrical Connector & Wiring Retainers
    G04656093Courtesy of FORD MOTOR CO.
  73. Connect the shift cable.
    Fig 67: Locating Shift Cable End
    G03990221Courtesy of FORD MOTOR CO.

    74. All vehicles 

  74. Attach the B+ terminal to the battery cable and install the nut.
    • Tighten to 5 N.m (44 lb-in).
    Fig 68: Locating Battery Cable Nut
    G04656095Courtesy of FORD MOTOR CO.
  75. Position the ground wire on the LH fender and install the bolt.
    • Tighten to 10 N.m (89 lb-in).
    Fig 69: Locating Ground Wire Bolt
    G04656096Courtesy of FORD MOTOR CO.
  76. Connect the power steering reservoir hose and attach the retainer.
    Fig 70: Locating Power Steering Reservoir Hose & Retainer
    G04656097Courtesy of FORD MOTOR CO.
  77. Connect the 2 powertrain control module (PCM) electrical connectors and attach the wiring conduit.
    Fig 71: Locating Powertrain Control Module Electrical Connectors & Wiring Conduit
    G04656098Courtesy of FORD MOTOR CO.
  78. Connect the vapor tube to the purge valve.
    Fig 72: Locating Vapor Tube
    G03990216Courtesy of FORD MOTOR CO.
    79. CAUTION: Make sure that the fuel tube coupling clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube.
    NOTE: Apply clean engine oil to the end of the tube before inserting a tube into the connector.
    Fig 73: Locating Fuel Tube
    G04656100Courtesy of FORD MOTOR CO.
  79. Connect the fuel tube to the fuel rail.
    • Connect the fuel tube redundant clip.
  80. Attach the fuel tube retainer to the upper intake manifold.
    Fig 74: Locating Fuel Tube Retainer
    G04656101Courtesy of FORD MOTOR CO.
  81. Position the ground strap on the RH fender and install the bolt.
    • Tighten to 10 N.m (89 lb-in).
    Fig 75: Locating Ground Strap Bolt
    G04656102Courtesy of FORD MOTOR CO.
  82. Clean the 4 roll restrictor cross brace bolts using a wire brush and apply new threadlock to the threads.
  83. Position the roll restrictor cross brace and install the 4 new bolts.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 76: Identifying Transaxle Roll Restrictor Bar Bolts
    G03989189Courtesy of FORD MOTOR CO.
  84. Clean the roll restrictor cross brace-to-roll restrictor bolt using a wire brush and apply new threadlock to the threads.
  85. Install a new roll restrictor cross brace-to-roll restrictor bolt.
    • Tighten to 48 N.m (35 lb-ft).
    Fig 77: Locating Upper Roll Restrictor Bolt
    G03989188Courtesy of FORD MOTOR CO.
  86. Install the LH and RH half shafts. For additional information, refer to INSTALLATION and INSTALLATION .
  87. Install the exhaust flex pipe and the LH catalytic converter. For additional information, refer to REMOVAL AND INSTALLATION .
  88. Install the cowl vent panel. For additional information, refer to REMOVAL AND INSTALLATION .
  89. Install the air cleaner outlet pipe and air cleaner. For additional information, refer to REMOVAL AND INSTALLATION .
  90. Fill the engine with clean engine oil.
  91. Connect the negative and positive battery cables. For additional information, refer to REMOVAL AND INSTALLATION .
  92. Evacuate and recharge the A/C system. For additional information, refer to AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING .
  93. Fill the power steering system. For additional information, refer to POWER STEERING SYSTEM FILLING .
  94. Fill and bleed the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
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