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Section 959 (Engine): Installation: Engine: Installation

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
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: Aligning Engine With Transaxle
    G03990500Courtesy of FORD MOTOR CO.

    2. Vehicles with 6-speed transaxle 

  2. Install the 4 transaxle-to-engine bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 2: Installing Transaxle-To-Engine Bolts
      G03990501Courtesy of FORD MOTOR CO.

    3. Vehicles with CVT transaxle 

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

    4. All vehicles 

  4. Install the engine-to-transaxle bolt.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 4: Installing Engine-To-Transaxle Bolt
      G03990667Courtesy of FORD MOTOR CO.
  5. Position the knock sensor (KS), install the bolt and connect the electrical connector.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 5: Installing Bolt And Connect Electrical Connector
      G03990504Courtesy of FORD MOTOR CO.
  6. Attach the heat shield to the KS.
    Fig 6: Identifying Heat Shield Over Knock Sensor
    G03990937Courtesy of FORD MOTOR CO.
    7. NOTE: A third lift chain should be used to allow for level lifting of the engine.
    Fig 7: Installing Special Tools And Suitable Engine Crane
    G03990284Courtesy 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 Nm (62 lb-ft).
      Fig 8: Installing LH Engine Insulator Upper Nut
      G03990280Courtesy of FORD MOTOR CO.
  9. Install the RH engine insulator upper nut.
    • Tighten to 70 Nm (62 lb-ft).
      Fig 9: Installing RH Engine Insulator Upper Nut
      G03990279Courtesy of FORD MOTOR CO.
  10. Position the RH exhaust manifold heat shield and install the 3 bolts.
    • Tighten to 11 Nm (8 lb-ft).
      Fig 10: Installing Bolts
      G03990278Courtesy of FORD MOTOR CO.
  11. Install the front transaxle stabilizer bolt.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 11: Installing Front Transaxle Stabilizer Bolt
      G03990196Courtesy of FORD MOTOR CO.
  12. If equipped, install the upper power transfer unit (PTU) bracket and the bolts.
    • Tighten to 55 Nm (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 Nm (41 lb-ft).
      Fig 13: Installing Rear Transaxle Insulator Bracket Bolts
      G03990283Courtesy of FORD MOTOR CO.
  15. Position the ground cable and install the bolt.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 14: Installing Bolt
      G03991887Courtesy of FORD MOTOR CO.
  16. Position the starter motor and install the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 15: Positioning Starter Motor
      G03990270Courtesy of FORD MOTOR CO.
  17. Position the starter motor wiring and install the nuts.
    • Tighten the larger nut to 12 Nm (9 lb-ft).
    • Tighten the smaller nut to 9 Nm (80 lb-in).
      Fig 16: Installing Nuts
      G03990269Courtesy of FORD MOTOR CO.
  18. Install the starter motor terminal cover.
    Fig 17: Installing Starter Motor Terminal Cover
    G03990268Courtesy 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 Nm (41 lb-ft).
      Fig 18: Installing Bolts
      G03990517Courtesy 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 Nm (41 lb-ft).
      Fig 19: Installing Bolts
      G03990266Courtesy of FORD MOTOR CO.
  23. Connect the transmission control unit (TCU) wire harness.
    Fig 20: Connecting Transmission Control Unit (TCU) Wire Harness
    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 Nm (41 lb-ft).
      Fig 21: Installing Rear Transaxle Insulator Bracket Bolts
      G03990520Courtesy of FORD MOTOR CO.
  26. Position the ground cable and install the bolt.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 22: Installing Bolt
      G03991001Courtesy of FORD MOTOR CO.
  27. Position the starter motor and install the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 23: Positioning Starter Motor
      G03990522Courtesy of FORD MOTOR CO.
  28. Position the starter motor wiring and install the nuts.
    • Tighten the larger nut to 12 Nm (9 lb-ft).
    • Tighten the smaller nut to 9 Nm (80 lb-in).
      Fig 24: Positioning Starter Motor Wiring & Installing Nuts
      G03990920Courtesy of FORD MOTOR CO.
  29. Install the starter motor terminal cover.
    Fig 25: Installing Starter Motor Terminal Cover
    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 Nm (41 lb-ft).
      Fig 26: Installing Bolts
      G03990260Courtesy of FORD MOTOR CO.
  32. Attach the wiring harness to the roll restrictor.
    Fig 27: Attaching Wiring Harness To Roll Restrictor
    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 Nm (41 lb-ft).
      Fig 28: Installing Bolts
      G03990258Courtesy of FORD MOTOR CO.
  35. Attach the lower wiring harness retainers to the transaxle.
    Fig 29: Attaching Lower Wiring Harness Retainers To Transaxle
    G03990257Courtesy of FORD MOTOR CO.
  36. Attach the wiring harness retainers to the transaxle.
    Fig 30: Attaching Wire Harness Retainers To Transaxle
    G03990911Courtesy of FORD MOTOR CO.
  37. Attach the wiring harness retainer to the transaxle.
    Fig 31: Attaching Wiring Harness Retainer To Transaxle
    G03990255Courtesy of FORD MOTOR CO.
  38. Connect the transaxle bulkhead electrical connector.
    Fig 32: Connecting Transaxle Bulkhead Electrical Connector
    G03990860Courtesy of FORD MOTOR CO.

    39. All vehicles 

  39. Attach the pin-type retainers to the subframe and connect the RH catalyst monitor sensor electrical connector.
    Fig 33: Connecting RH Catalyst Monitor Sensor Electrical Connector
    G03990253Courtesy of FORD MOTOR CO.
  40. Connect the power steering fluid tubes and install the bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 34: Connecting Power Steering Fluid Tubes & Bolt
      G03990533Courtesy of FORD MOTOR CO.
  41. Install the power steering pressure (PSP) tube bracket bolt and connect the PSP switch electrical connector.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 35: Installing Power Steering Pressure (PSP) Tube Bracket Bolt
      G03990251Courtesy of FORD MOTOR CO.
  42. Using the special tool, position the powertrain and subframe in the vehicle.
    Fig 36: Positioning Powertrain And Subframe In Vehicle
    G03990244Courtesy of FORD MOTOR CO.
  43. Install the 2 forward subframe bolts and washers.
    • Tighten to 200 Nm (148 lb-ft).
      Fig 37: Installing Forward Subframe Bolts And Washers
      G03990250Courtesy of FORD MOTOR CO.
  44. Position the rear subframe brackets and install the 6 bolts.
    • Tighten the 2 larger bolts to 150 Nm (111 lb-ft).
    • Tighten the 4 smaller bolts to 55 Nm (41 lb-ft).
      Fig 38: Installing Bolts
      G03990249Courtesy of FORD MOTOR CO.
  45. Attach the steering column intermediate shaft and install a new bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 39: Attaching Steering Column Intermediate Shaft
      G03990247Courtesy of FORD MOTOR CO.
  46. Attach the outer tie rods to the wheel knuckles and install new nuts.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 40: Attaching Outer Tie Rods To Wheel Knuckles
      G03990246Courtesy of FORD MOTOR CO.
  47. Attach the stabilizer bar links to the struts and install new nuts.
    • Tighten to 55 Nm (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 Nm (18 lb-ft).
      Fig 42: Connecting Driveshaft & Bolts
      G03990243Courtesy of FORD MOTOR CO.
  49. If equipped, position the driveshaft support bracket and install the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 43: Positioning Driveshaft Support Bracket
      G03990242Courtesy of FORD MOTOR CO.
    50. NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of sealant application.
    Fig 44: Applying Silicone Sealant
    G03990183Courtesy 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: Positioning Oil Pan And Gasket
    G03990346Courtesy of FORD MOTOR CO.
  52. Position the LH catalytic converter bracket and install the 3 engine-to-transaxle bolts.
    • Tighten to 40 Nm (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 Nm (18 lb-ft).
    Fig 47: Tightening Oil Pan Bolts In Sequence
    G03990184Courtesy of FORD MOTOR CO.
  54. Install the oil filter adapter-to-oil pan bolt.
    • Tighten to 40 Nm (30 lb-ft) and then tighten an additional 90 degrees.
      Fig 48: Installing Oil Filter Adapter-To-Oil Pan Bolt
      G03990547Courtesy of FORD MOTOR CO.
  55. Install the 4 new torque converter nuts.
    • Tighten to 36 Nm (27 lb-ft).
      Fig 49: Installing Torque Converter Nuts
      G03990548Courtesy of FORD MOTOR CO.
  56. Position the lower torque converter access plug and install the pin-type retainers.
    Fig 50: Installing Pin-Type Retainers
    G03990239Courtesy of FORD MOTOR CO.
  57. If equipped, connect the block heater electrical connector and attach the wiring retainers.
    Fig 51: Locating Engine Block Heater
    G03990550Courtesy of FORD MOTOR CO.
  58. Connect the power steering cooler hose.
    Fig 52: Connecting Power Steering Cooler Hose
    G03990236Courtesy of FORD MOTOR CO.
  59. Connect the transmission cooler hoses.
    Fig 53: Connecting Transmission Cooler Hoses
    G03990235Courtesy of FORD MOTOR CO.
  60. Position the A/C tube and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 54: Installing Nut
      G03990234Courtesy of FORD MOTOR CO.
  61. Position the A/C manifold assembly tubes and install the bolt.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 55: Positioning A/C Manifold Assembly Tubes & Installing Bolt
      G03990554Courtesy of FORD MOTOR CO.
  62. Connect the A/C high-pressure switch electrical connector.
    Fig 56: Connecting A/C High-Pressure Switch Electrical Connector
    G03990232Courtesy of FORD MOTOR CO.
  63. Connect the 10-pin electrical connector and attach the wiring retainers.
    Fig 57: Connecting 10-Pin Electrical Connector
    G03990231Courtesy of FORD MOTOR CO.
  64. Position the coolant tube and secure the tube in the clips.
    Fig 58: Positioning Coolant Tube And Secure Tube Clips
    G03990230Courtesy of FORD MOTOR CO.
  65. Connect the coolant hoses to the thermostat housing.
    Fig 59: Connecting Coolant Hoses To Thermostat Housing
    G03990229Courtesy of FORD MOTOR CO.
  66. Connect the brake booster vacuum hose to the upper intake manifold.
    Fig 60: Connecting Brake Booster Vacuum Hose To Upper Intake Manifold
    G03990228Courtesy of FORD MOTOR CO.
  67. Connect the heater hose and the throttle body coolant hose.
    Fig 61: Connecting Heater Hose And Throttle Body Coolant Hose
    G03990227Courtesy of FORD MOTOR CO.

    68. Vehicles with 6-speed transaxle 

  68. Position the shift cable bracket and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 62: Positioning Shift Cable Bracket & Installing Bolts
      G03990226Courtesy 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: Connecting Electrical Connector To Shift Cable Bracket
      G03990225Courtesy 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 Nm (18 lb-ft).
      Fig 65: Installing 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: Attaching Electrical Connector To Shift Cable Bracket
      G03990222Courtesy of FORD MOTOR CO.
  73. Connect the shift cable.
    Fig 67: Disconnecting 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 Nm (44 lb-in).
      Fig 68: Installing Nut
      G03990567Courtesy of FORD MOTOR CO.
  75. Position the ground wire on the LH fender and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 69: Installing Bolt
      G03990219Courtesy of FORD MOTOR CO.
  76. Connect the power steering reservoir hose and attach the retainer.
    Fig 70: Connecting Power Steering Reservoir Hose
    G03990218Courtesy of FORD MOTOR CO.
  77. Connect the 2 powertrain control module (PCM) electrical connectors and attach the wiring conduit.
    Fig 71: Connecting Powertrain Control Module (PCM) Electrical Connectors
    G03990217Courtesy of FORD MOTOR CO.
  78. Connect the vapor tube to the purge valve.
    Fig 72: Connecting Vapor Tube To Purge Valve
    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.
  79. Connect the fuel tube to the fuel rail.
    • Connect the fuel tube redundant clip.
      Fig 73: Connecting Fuel Tube Redundant Clip
      G03990214Courtesy of FORD MOTOR CO.
  80. Attach the fuel tube retainer to the upper intake manifold.
    Fig 74: Attaching Fuel Tube Retainer To Upper Intake Manifold
    G03990215Courtesy of FORD MOTOR CO.
  81. Position the ground strap on the RH fender and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 75: Installing Bolt
      G03990213Courtesy 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 Nm (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 Nm (35 lb-ft).
      Fig 77: Installing New Roll Restrictor Cross Brace-To-Roll Restrictor Bolt
      G03989188Courtesy of FORD MOTOR CO.
  86. Install the LH and RH half shafts. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  87. Install the exhaust flex pipe and the LH catalytic converter. For additional information, refer to EXHAUST SYSTEM .
  88. Install the cowl vent screen. For additional information, refer to WIPERS AND WASHERS .
  89. Install the air cleaner outlet pipe and air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  90. Fill the engine with clean engine oil.
  91. Connect the negative and positive battery cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  92. Evacuate and recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  93. Fill the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
  94. Fill and bleed the cooling system. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
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