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Section 552 (Engine - 4.6L): Installation: Engine

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tool(s)
G03181683Courtesy of FORD MOTOR CO.
MATERIAL SPECIFICATION CHART

Item Specification
Threadlock and Sealer E0AZ-19554-AA or equivalent WSK-M2G351-A5
Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or -DSP or equivalent WSS-M2C153-H

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Position the engine in the vehicle and remove the special tool and the engine crane.
    Fig 2: Removing Special Tool And Engine Crane
    G03181684Courtesy of FORD MOTOR CO.
  3. Remove the wire tie or mechanic's wire from the fuel hose.
    Fig 3: Removing Wire From Fuel Hose
    G03181685Courtesy of FORD MOTOR CO.
  4. Remove the special tool from the right side of the engine.
    Fig 4: Removing Special Tool
    G03181686Courtesy of FORD MOTOR CO.
  5. Position the ground strap and install the stud bolt.
    Fig 5: Positioning Ground Strap
    G03181687Courtesy of FORD MOTOR CO.
  6. Connect the fuel charging wiring harness electrical connectors.
    Fig 6: Connecting Fuel Charging Wiring Harness Electrical Connectors
    G03181688Courtesy of FORD MOTOR CO.
  7. Attach the harness retaining clip to the ground stud bolt.
    Fig 7: Attaching Harness Retaining Clip
    G03181689Courtesy of FORD MOTOR CO.
  8. Connect the fuel charging wiring harness push pins.
    Fig 8: Connecting Fuel Charging Wiring Harness Push Pins
    G03181690Courtesy of FORD MOTOR CO.
  9. Install the bolt in the left motor mount.
    Fig 9: Installing Bolt In Left Motor Mount
    G03181691Courtesy of FORD MOTOR CO.
  10. Install the washer and nut on the RH motor mount.
    Fig 10: Installing Washer And Nut On RH Motor Mount
    G03181692Courtesy of FORD MOTOR CO.
  11. Using the special tool, install a new seal on the power steering pressure hose fitting.
    Fig 11: Installing Seal On Power Steering Pressure Hose Fitting
    G03181693Courtesy of FORD MOTOR CO.
  12. Connect the power steering pressure (PSP) hose.
    Fig 12: Connecting Power Steering Pressure (PSP) Hose
    G03181694Courtesy of FORD MOTOR CO.
  13. Connect the power steering return hose and position the clamp.
    Fig 13: Connecting Power Steering Return Hose And Position Clamp
    G03181695Courtesy of FORD MOTOR CO.
  14. Position the cooler tubes and install the nut.
    Fig 14: Positioning Cooler Tubes
    G03181696Courtesy of FORD MOTOR CO.
  15. Attach the LH heated oxygen sensor (HO2S) wiring harness.
    Fig 15: Attaching LH Heated Oxygen Sensor (HO2S) Wiring Harness
    G03181697Courtesy of FORD MOTOR CO.
    16. NOTE: Make sure the stud and the flexplate marks made during removal line up.
    Fig 16: Removing Line Up
    G03181698Courtesy of FORD MOTOR CO.
  16. Position the transmission and, if equipped, the transfer case.
  17. Install the seven engine-to-transmission bolts.
    Fig 17: Installing Seven Engine-To-Transmission Bolts
    G03181699Courtesy of FORD MOTOR CO.
  18. Remove the wooden support.
    Fig 18: Removing Wooden Support
    G03181700Courtesy of FORD MOTOR CO.
  19. Install the four torque converter nuts.
    • Turn the crankshaft using the crankshaft pulley bolt.
    Fig 19: Installing Torque Converter Nuts
    G03181701Courtesy of FORD MOTOR CO.
  20. Install the access cover.
    Fig 20: Installing Access Cover
    G03181702Courtesy of FORD MOTOR CO.
  21. Position the cover and install the bolts.
    Fig 21: Positioning Cover And Installing Bolts
    G03181703Courtesy of FORD MOTOR CO.
  22. Position the starter and install the bolts.
    Fig 22: Positioning Starter And Installing Bolts
    G03181704Courtesy of FORD MOTOR CO.
  23. Install the starter wires.
    1. Position the solenoid wire and install the nut.
    2. Position the battery cable and install the nut.
    Fig 23: Installing Starter Wires
    G03181705Courtesy of FORD MOTOR CO.
  24. Install the cap.
    Fig 24: Installing Cap
    G03181706Courtesy of FORD MOTOR CO.
    25. CAUTION: Use care not to bend or force the transmission cooler tube. Damage to the tubes or the transmission can occur. Use a wrench to hold the fittings mounted in the transmission.
    Fig 25: Connecting Transmission Fluid Cooler Tubes
    G03181707Courtesy of FORD MOTOR CO.
  25. Connect the transmission fluid cooler tubes.
  26. Position the front crossmember and install the bolts.
    Fig 26: Positioning Front Crossmember And Install Bolts
    G03181708Courtesy of FORD MOTOR CO.

    27. 4x4 vehicles 

  27. Support the transfer case with a suitable jack stand.
    Fig 27: Supporting Transfer Case With Jack Stand
    G03181709Courtesy of FORD MOTOR CO.
  28. Disconnect the safety chain and remove the transmission jack.
    Fig 28: Removing Transmission Jack
    G03181710Courtesy of FORD MOTOR CO.
  29. If equipped, connect the shift motor electrical connector and wiring harness pin-type retainer(s).
    Fig 29: Shifting Motor Electrical Connector And Wiring Harness Pin-Type Retainer
    G03181711Courtesy of FORD MOTOR CO.

    30. All vehicles 

  30. Attach the RH catalyst monitor sensor electrical connector and the fuel tubes to the bracket.
    Fig 30: Attaching RH Catalyst Monitor Sensor Electrical Connector
    G03181712Courtesy of FORD MOTOR CO.
  31. Attach the LH catalyst monitor sensor electrical connector to the transmission.
    Fig 31: Attaching LH Catalyst Monitor Sensor Electrical Connector
    G03181713Courtesy of FORD MOTOR CO.
    32. NOTE: LH shown, RH similar.
    Fig 32: Attaching RH HO2S Wiring Harness Retainer
    G03181714Courtesy of FORD MOTOR CO.
  32. Attach the RH HO2S wiring harness retainer to the transmission.
  33. Connect the wiring harness retainers.
    Fig 33: Connecting Wiring Harness Retainers
    G03181715Courtesy of FORD MOTOR CO.
  34. Connect the transmission range (TR) sensor electrical connector.
    • Position the rubber boot over the connector.
    Fig 34: Connecting Transmission Range (TR) Sensor Electrical Connector
    G03181716Courtesy of FORD MOTOR CO.
    35. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification.
    NOTE: Always install new O-ring seals on the vehicle harness connector.
    NOTE: Clean the area around the connector to prevent contamination of the solenoid body connector.
    NOTE: Use petroleum jelly to lubricate the O-ring seals to aid the installation process.
    Fig 35: Installing O-Ring Seals
    G03181717Courtesy of FORD MOTOR CO.
  35. Install and lubricate new O-ring seals on the transmission body electrical connector, connect the electrical connector, and tighten the screw.
  36. Connect the turbine shaft speed (TSS) sensor, the output shaft speed (OSS) sensor, and the intermediate shaft speed (ISS) sensor electrical connectors.
    Fig 36: Connecting Turbine Shaft Speed (TSS) Sensor
    G03181718Courtesy of FORD MOTOR CO.
    37. CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with threadlock and sealer.
    CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in the sequence shown.
    NOTE: Align the marks made on the flange and driveshaft during removal.
    NOTE: On 2-wheel drive vehicles, remove the plug placed in the transmission.
    Fig 37: Removing Plug Placed In Transmission
    G03181719Courtesy of FORD MOTOR CO.
  37. Position the driveshaft and install the driveshaft-to-pinion flange bolts.

    38. 4x4 vehicles 

    CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with threadlock and sealer.
    CAUTION: The driveshaft flange fits tightly on the transfer case flange. To make sure that the driveshaft flange seats squarely on the transfer case flange, tighten the bolts evenly in a criss-cross pattern.
    NOTE: Align the marks made on the flange and driveshaft during removal.
    Fig 38: Installing Rear Driveshaft-To-Transfer Case Flange Bolts
    G03181720Courtesy of FORD MOTOR CO.
  38. Install the rear driveshaft-to-transfer case flange bolts.
    39. CAUTION: The can (domed CV joint housing cover) is pressed into the CV joint housing at the factory. When housed correctly, the can will appear as shown in the cut-away illustration, top box. Do not reseat the can in the CV joint housing if the can's flange is above the CV joint housing shown in the cut-away illustration, bottom box. Install a new driveshaft.
    Fig 39: Identifying CV Joint Housing
    G03181721Courtesy of FORD MOTOR CO.
  39. Verify the can flange is housed correctly in the CV joint housing as shown in the cut-away illustration, top box. Install a new driveshaft if the can flange is not housed correctly.
    40. CAUTION: Always connect the front driveshaft to the axle first. The weight of the driveshaft can pinch the boot, causing the boot to tear.
    CAUTION: Tighten the bolts evenly in a criss-cross pattern or damage to the CV joint can occur.
    CAUTION: Install new bolts and washers. If new bolts and washers are not available, coat the original bolts with threadlock and sealer.
    NOTE: Align the marks made on the front axle flange and the driveshaft during removal.
    Fig 40: Installing New Bolts And Washers
    G03181722Courtesy of FORD MOTOR CO.
  40. Install new bolts and washers. Tighten the bolts in the sequence shown.
    41. CAUTION: Install new universal joint retainers and bolts. If new retainers and bolts are not available, coat the original bolts with threadlock and sealer.
    Fig 41: Installing New Universal Joint Retainers And Bolts
    G03181723Courtesy of FORD MOTOR CO.
  41. Install new universal joint retainers and bolts.

    42. All vehicles 

  42. Place the manual shift lever in the park position.
    Fig 42: Placing Manual Shift Lever In Park Position
    G03181724Courtesy of FORD MOTOR CO.
  43. Position the shift cable and bracket, install the bolts, and connect the cable to the manual shift lever.
    Fig 43: Positioning Shift Cable And Bracket
    G03181725Courtesy of FORD MOTOR CO.
  44. Position the dual converter Y-pipe with the heat shields on a jack stand and loosely install the four bolts.
    Fig 44: Positioning Dual Converter Y-Pipe With Heat Shields
    G03181726Courtesy of FORD MOTOR CO.
  45. Position the transmission rear mount and loosely install the bolts.
    Fig 45: Positioning Transmission Rear Mount
    G03181727Courtesy of FORD MOTOR CO.
  46. Position a new gasket, connect the dual converter Y-pipe to the muffler, and install the bolts, springs and flag nuts.
    Fig 46: Connecting Dual Converter Y-Pipe To Muffler
    G03181728Courtesy of FORD MOTOR CO.
  47. Tighten the four dual converter Y-pipe-to-exhaust manifold nuts.
    Fig 47: Tightening Dual Converter
    G03181729Courtesy of FORD MOTOR CO.
  48. Tighten the transmission rear mount bolts.
    Fig 48: Tightening Transmission Rear Mount Bolts
    G03181730Courtesy of FORD MOTOR CO.
  49. Remove the jack stand from the dual converter Y-pipe.
    Fig 49: Removing Jack Stand From Dual Converter Y-Pipe
    G03181731Courtesy of FORD MOTOR CO.
    50. NOTE: LH shown, RH similar.
    Fig 50: Connecting HO2S Electrical Connectors
    G03181732Courtesy of FORD MOTOR CO.
  50. Connect the two HO2S electrical connectors.
    51. NOTE: RH shown, LH similar.
    Fig 51: Connecting Catalyst Monitor Sensor Electrical Connectors
    G03181733Courtesy of FORD MOTOR CO.
  51. Connect the two catalyst monitor sensor electrical connectors.
  52. Position the crossmember and loosely install the nuts.
    Fig 52: Positioning Crossmember And Loosely Install Nuts
    G03181734Courtesy of FORD MOTOR CO.
    53. NOTE: RH shown, LH similar.
    Fig 53: Installing Crossmember Lower Bolts
    G03181735Courtesy of FORD MOTOR CO.
  53. Install the four crossmember lower bolts.
    54. NOTE: RH shown, LH similar.
    Fig 54: Installing Crossmember Upper Bolts
    G03181736Courtesy of FORD MOTOR CO.
  54. Install the four crossmember upper bolts.

    55. 4x2 vehicles 

  55. Position the cable bracket and install the bolts.
    Fig 55: Positioning Cable Bracket
    G03181737Courtesy of FORD MOTOR CO.
  56. Disconnect the safety chain and remove the transmission jack.
    Fig 56: Removing Transmission Jack
    G03181738Courtesy of FORD MOTOR CO.

    57. 4x4 vehicles 

  57. Remove the jack stand from the transfer case.
    Fig 57: Removing Jack Stand From Transfer Case
    G03181739Courtesy of FORD MOTOR CO.

    58. All vehicles 

  58. Tighten the nuts.
    Fig 58: Tightening Nuts
    G03181740Courtesy of FORD MOTOR CO.
  59. Position the plastic shield on the right side of the crossmember and install the nuts.
    Fig 59: Positioning Plastic Shield On Right Side Of Crossmember
    G03181741Courtesy of FORD MOTOR CO.
  60. Position the RH heat shield and install the bolts.
    Fig 60: Positioning RH Heat Shield And Installing Bolts
    G03181742Courtesy of FORD MOTOR CO.
  61. Install the LH heat shield bolt.
    Fig 61: Installing LH Heat Shield Bolt
    G03181743Courtesy of FORD MOTOR CO.
  62. Position the front RH heat shield and install the two bolts.
    Fig 62: Positioning Front RH Heat Shield And Installing Bolts
    G03181744Courtesy of FORD MOTOR CO.
  63. Position the radiator and A/C condenser assembly in the vehicle.
    Fig 63: Positioning Radiator And A/C Condenser Assembly In Vehicle
    G03181745Courtesy of FORD MOTOR CO.
  64. Position the RH radiator support bracket and install the two bolts.
    Fig 64: Positioning RH Radiator Support Bracket
    G03181746Courtesy of FORD MOTOR CO.
  65. Position the LH radiator support bracket and install the two bolts.
    Fig 65: Positioning LH Radiator Support Bracket
    G03181747Courtesy of FORD MOTOR CO.
  66. Connect the cooler hoses.
    Fig 66: Connecting Cooler Hoses
    G03181748Courtesy of FORD MOTOR CO.
  67. Position the lower air deflector and install the pin-type retainers.
    Fig 67: Positioning Lower Air Deflector
    G03181749Courtesy of FORD MOTOR CO.
  68. Position the lower fan shroud and install the bolts.
    Fig 68: Positioning Lower Fan Shroud
    G03181750Courtesy of FORD MOTOR CO.
  69. Connect the lower radiator hose and position the clamp.
    Fig 69: Connecting Lower Radiator Hose
    G03181751Courtesy of FORD MOTOR CO.
  70. Position the coolant hose in the retainer, connect the hose and position the clamp.
    Fig 70: Positioning Coolant Hose In Retainer
    G03181752Courtesy of FORD MOTOR CO.
  71. Remove the special tool.
    Fig 71: Removing Special Tool
    G03181753Courtesy of FORD MOTOR CO.
  72. Position the bracket and install the bolts.
    Fig 72: Positioning Bracket
    G03181754Courtesy of FORD MOTOR CO.
  73. Connect the evaporative emissions (EVAP) canister purge valve hoses.
    Fig 73: Connecting Evaporative Emissions (EVAP) Canister Purge Valve Hoses
    G03181755Courtesy of FORD MOTOR CO.
  74. Connect the brake booster vacuum hose.
    Fig 74: Connecting Brake Booster Vacuum Hose
    G03181756Courtesy of FORD MOTOR CO.
  75. Connect the heater control vacuum supply hose.
    Fig 75: Connecting Heater Control Vacuum Supply Hose
    G03181757Courtesy of FORD MOTOR CO.
  76. Position the heater control valve bracket and install the bolt.
    Fig 76: Positioning Heater Control Valve Bracket
    G03181758Courtesy of FORD MOTOR CO.
  77. Using the special tools, install the cooling fan.
    Fig 77: Installing Cooling Fan
    G03181759Courtesy of FORD MOTOR CO.
  78. Position the upper fan shroud.
    Fig 78: Positioning Upper Fan Shroud
    G03181760Courtesy of FORD MOTOR CO.
    79. NOTE: LH shown, RH similar.
    NOTE: Do not install the assembly screw holding the upper and lower shrouds.
    Fig 79: Installing Two Bolts
    G03181761Courtesy of FORD MOTOR CO.
  79. Install the two bolts.
  80. Position the tube and install the nut.
    Fig 80: Positioning Tube
    G03181762Courtesy of FORD MOTOR CO.
  81. Position the tube and install the nut. If equipped, position the auxiliary A/C tube and install the nut.
    Fig 81: Positioning Auxiliary A/C Tube
    G03181763Courtesy of FORD MOTOR CO.
  82. Position the tube and install the nut.
    Fig 82: Positioning Tube
    G03181764Courtesy of FORD MOTOR CO.
  83. Position the A/C tube in the clips.
    Fig 83: Positioning A/C Tube
    G03181765Courtesy of FORD MOTOR CO.
  84. Connect the A/C pressure switch electrical connector.
    Fig 84: Connecting A/C Pressure Switch Electrical Connector
    G03181766Courtesy of FORD MOTOR CO.
  85. Connect the heater hose and position the clamp.
    Fig 85: Connecting Heater Hose
    G03181767Courtesy of FORD MOTOR CO.
  86. Connect the upper radiator and degas vent hoses and position the clamps.
    Fig 86: Connecting Upper Radiator And Degas Vent Hoses
    G03181768Courtesy of FORD MOTOR CO.
  87. Connect the hoses and position the clamps.
    Fig 87: Connecting Hoses And Positioning Clamps
    G03181769Courtesy of FORD MOTOR CO.
  88. Install the radiator appearance cover.
    Fig 88: Installing Radiator Appearance Cover
    G03181770Courtesy of FORD MOTOR CO.
  89. Install the air cleaner assembly.
    Fig 89: Installing Air Cleaner Assembly
    G03181771Courtesy of FORD MOTOR CO.
  90. Connect the mass air flow (MAF) sensor.
    Fig 90: Connecting Mass Air Flow (MAF) Sensor
    G03181772Courtesy of FORD MOTOR CO.
  91. Install the air cleaner outlet tube.
    1. Install the air cleaner outlet tube.
    2. Tighten the clamp.
    3. Connect the hose.
    4. Tighten the clamp.
    Fig 91: Installing Air Cleaner Outlet Tube
    G03181773Courtesy of FORD MOTOR CO.
  92. Connect the fuel hose spring lock coupling. For additional information, refer to FUEL SYSTEM .
  93. Connect the wiring harness terminals and install the nut. Close the cover.
    Fig 92: Connecting Wiring Harness Terminals
    G03181774Courtesy of FORD MOTOR CO.
  94. Attach the wiring harness retainers and connect the electrical connector.
    Fig 93: Attaching Wiring Harness Retainers
    G03181775Courtesy of FORD MOTOR CO.
  95. Connect the ground wire and install the nut.
    Fig 94: Connecting Ground Wire
    G03181776Courtesy of FORD MOTOR CO.
  96. Connect the battery cables. For additional information, refer to BATTERY DISCONNECT .
    97. NOTE: Align the hinges to the marks made on the hood during removal.
    Fig 95: Positioning Hood
    G03181777Courtesy of FORD MOTOR CO.
  97. Position the hood and install the four bolts.
  98. Connect the windshield washer hose.
    Fig 96: Connecting Windshield Washer Hose
    G03181778Courtesy of FORD MOTOR CO.
  99. Fill the engine with clean engine oil.
  100. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
  101. Fill the power steering system. For additional information, refer to STEERING SYSTEM .
  102. Charge the A/C system. For additional information, refer to Section CLIMATE CONTROL SYSTEM .
  103. Start the engine and check for leaks. Stop the engine and check all fluid levels.
  104. Check the transmission fluid level. For additional information, refer to AUTOMATIC TRANSMISSION - 5R55S .
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