LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2004 >> Excursion 5.4 L, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1848 (Engine - 4.6L And 5.4L) >> Installation >> Engine
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Section 1848 (Engine - 4.6L And 5.4L): Installation: Engine

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0005877
 Holding Wrench, Fan Pulley 303-239 (T84T-6312-C)
GF0000628
 Installer Set, Teflon Seal 211-D027 (D90P-3517-A) or equivalent
GF0000339
 Lifting Bracket, Engine 303-F047 (014-00073) or equivalent
GF0009499
 Wrench, Fan Clutch Nut 303-240 (T84T-6312-D)
Material

Item Specification
Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only)
VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)		 WSS-M97B51-A1
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent		 WSS-M2C930-A

All engines 

  1. Position the engine in the vehicle.
  2. Remove the floor crane and the jack supporting the transmission.
    3. NOTE: Align the engine-to-transmission dowels before installing the engine-to-transmission bolts.
  3. Position the shifter cable support bracket and install the 2 transmission-to-engine bolts.
    • Tighten to 60 Nm (44 lb-ft).
    4. Fig 1: Transmission-To-Engine Bolts
    G03885559Courtesy of FORD MOTOR CO.
  4. Install the RH lower transmission-to-engine bolt.
    • Tighten to 60 Nm (44 lb-ft).
    5. Fig 2: Lower Right Transmission-To-Engine Bolt
    GF0011683Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  5. Install the 4 engine support insulator-to-crossmember nuts.
    • Tighten to 90 Nm (66 lb-ft).
    6. Fig 3: Engine Support Insulator-To-Crossmember Nuts
    G03885561Courtesy of FORD MOTOR CO.
  6. Position the mounting bracket, install the 2 bolts and connect the shift cable.
    • Tighten to 25 Nm (18 lb-ft).
    7. Fig 4: Shift Cable & Bracket At Transmission
    GF0011726Courtesy of FORD MOTOR CO.
  7. Install 4 new torque converter nuts.
    • Rotate the crankshaft to access all of the torque converter nuts.
    • Tighten to 35 Nm (26 lb-ft).
    8. Fig 5: Locating Torque Converter-To-Flexplate Nuts
    GF0002674Courtesy of FORD MOTOR CO.
  8. Install the cylinder block opening cover.
    9. Fig 6: Cylinder Block Opening Cover
    GF0011681Courtesy of FORD MOTOR CO.
  9. Position the flexplate inspection cover and install the 2 bolts.
    • Tighten to 34 Nm (25 lb-ft).
    10. Fig 7: Locating Flexplate Inspection Cover Bolts
    GF0002672Courtesy of FORD MOTOR CO.
  10. If equipped, install the A/C compressor and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    11. Fig 8: A/C Compressor Bolts
    G04612406Courtesy of FORD MOTOR CO.
  11. Position the exhaust Y-pipe and install the 4 nuts.
    • Tighten to 40 Nm (30 lb-ft).
    12. Fig 9: Locating Exhaust Manifold-To-Catalytic Converter Nuts
    GF0002678Courtesy of FORD MOTOR CO.
    CAUTION: The oil cooler must be replaced or severe damage to the engine can occur.
    NOTE: Make sure the tab on the oil filter adapter nests into the notch in the oil cooler.
  12. Position a new oil cooler on the oil filter adapter and install the threaded insert.
    • Tighten to 58 Nm (43 lb-ft).
    13. Fig 10: Identifying Oil Cooler
    G03885413Courtesy of FORD MOTOR CO.
  13. Install a new oil filter.
    • Tighten to 16 Nm (12 lb-ft).
    14. Fig 11: Locating Oil Filter
    G03885412Courtesy of FORD MOTOR CO.
  14. Connect the 2 oil cooler coolant hoses.
    15. Fig 12: Locating Oil Cooler Coolant Hoses
    G03885411Courtesy of FORD MOTOR CO.

    4.6L (2V) engine 

  15. Position the transmission fluid cooler tube support bracket and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    16. Fig 13: Identifying Transmission Fluid Cooler Tube Support Bracket Nut
    G03885563Courtesy of FORD MOTOR CO.

    5.4L (2V) engine 

  16. Position the fluid cooler tube support bracket and install the nut.
    • Tighten to 28 Nm (21 lb-ft).
    17. Fig 14: Identifying Transmission Fluid Cooler Tube Support Bracket Nut
    G03885563Courtesy of FORD MOTOR CO.

    All engines 

  17. Using the special tool, install a new Teflon® seal on the power steering pressure tube.
    18. Fig 15: Installing Teflon(R) Seal Using Special Tool 211-D027
    G03950191Courtesy of FORD MOTOR CO.
  18. Connect the power steering pressure tube and the power steering reservoir hose to the power steering pump.
    • Tighten to 20 Nm (15 lb-ft).
    19. Fig 16: Power Steering Reservoir Hose And Pressure Tube Retainers
    G03885562Courtesy of FORD MOTOR CO.
  19. Install the oil drain plug.
    • Tighten to 23 Nm (17 lb-ft).
    20. Fig 17: Engine Oil Drain Plug
    GF0002670Courtesy of FORD MOTOR CO.
  20. Position the fuel line and the LH heated oxygen sensor (HO2S) brackets and install the 4 upper transmission-to-engine bolts.
    • Tighten to 60 Nm (44 lb-ft).
    21. Fig 18: Upper Transmission-To-Engine Bolts
    G03886655Courtesy of FORD MOTOR CO.
  21. Connect the transmission wiring harness and the LH and RH HO2S electrical connectors. Install the transmission wiring harness connector retainer in the bracket.
    22. Fig 19: View Of Transmission And Heated Oxygen Sensor (HO2S) Electrical Connectors
    G04612445Courtesy of FORD MOTOR CO.
    NOTE: Do not reuse the O-ring seals. Lubricate the new O-ring seals with clean engine coolant prior to installing the heater outlet tube.
  22. Insert the heater outlet tube over the new seals.
    23. Fig 20: Sliding Coolant Tube Forward With O-Ring Seals Into Cylinder Block
    GF0000368Courtesy of FORD MOTOR CO.

    5.4L (2V) engine 

  23. Install the heater outlet tube studs.
    • Tighten to 40 Nm (30 lb-ft).
    24. Fig 21: Identifying Heater Outlet Tube Studs
    G03885600Courtesy of FORD MOTOR CO.
  24. Connect the coolant hose to the heater outlet tube.
    25. Fig 22: View Of Hose To Heater Outlet Tube
    G03886137Courtesy of FORD MOTOR CO.
  25. Install the wiring retainers in the heater outlet tube bracket.
    1. Install the knock sensor (KS) electrical connector retainer.
    2. Install the engine harness routing clip retainer.
    26. Fig 23: Locating Engine Harness Routing Clip Retainers
    G04612441Courtesy of FORD MOTOR CO.

    All engines 

  26. Connect the evaporative emission (EVAP) canister purge valve electrical connector.
    27. Fig 24: Locating Evaporative Emission (EVAP) Canister Purge Valve Electrical Connector
    G03885596Courtesy of FORD MOTOR CO.
  27. Connect the attachments to the transmission fluid filler tube and install the fluid level indicator.
    1. Connect the rear heater hose hanger.
    2. Install the fluid level indicator.
    28. Fig 25: Transmission Fluid Level Indicator & Rear Heater Hose Hanger
    GF0011692Courtesy of FORD MOTOR CO.
  28. Install the engine oil filler tube support strap bolt.
    • Tighten to 9 Nm (80 lb-in).
    29. Fig 26: Engine Oil Filler Tube Support Strap Bolt
    G03885594Courtesy of FORD MOTOR CO.
  29. Position the mounting bracket, install the ground strap and nut, and connect the electrical connectors to the bracket.
    • Tighten to 25 Nm (18 lb-ft).
    30. Fig 27: Electrical Connectors And Ground Strap Bracket Retaining Nut
    G03885234Courtesy of FORD MOTOR CO.
  30. Connect the engine wiring harness electrical connectors.
    31. Fig 28: Identifying Engine Wiring Harness Electrical Connectors
    G03885233Courtesy of FORD MOTOR CO.
  31. Connect the PCM electrical connectors.
    32. Fig 29: Powertrain Control Module (PCM) Electrical Connectors
    G03885591Courtesy of FORD MOTOR CO.
  32. Connect the engine wiring harness to the PCM bracket.
    33. Fig 30: Identifying Engine Wiring Harness To PCM Bracket Retainer
    G03885211Courtesy of FORD MOTOR CO.
  33. Position the generator and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    34. Fig 31: Locating Generator Bolts
    G03885512Courtesy of FORD MOTOR CO.
  34. Connect the generator electrical connections.
    1. Tighten the B+ terminal nut to 8 Nm (71 lb-in).
    2. Connect the S electrical connector.
    3. Connect the ASI electrical connector.
    35. Fig 32: Generator Electrical Connections
    GF0011691Courtesy of FORD MOTOR CO.
  35. Rotate the tensioner clockwise and install the accessory drive belt. Refer to the decal on the upper radiator air deflector for belt routing.
    36. Fig 33: Rotating Tensioner Clockwise
    GF0000336Courtesy of FORD MOTOR CO.
  36. Connect the lower radiator coolant hose to the oil filter adapter coolant inlet.
    37. Fig 34: Identifying Lower Radiator Hose
    G03886149Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  37. Position the lower radiator support and install the 12 bolts.
    • Tighten to 20 Nm (15 lb-ft).
    38. Fig 35: Identifying Lower Radiator Support Bolts
    G03886640Courtesy of FORD MOTOR CO.
  38. Position the RH side of the headlamp dash panel junction wiring harness.
    1. Connect the electrical connector.
    2. Tighten the ground cable nut to 10 Nm (89 lb-in).
    3. Connect the routing clips.
    39. Fig 36: Right Side Of Headlamp Dash Panel Junction Wiring Harness
    GF0011690Courtesy of FORD MOTOR CO.
  39. Position the LH side of the headlamp dash panel junction wiring harness.
    1. Tighten the ground cable nut to 10 Nm (89 lb-in).
    2. Connect the routing clips.
    40. Fig 37: Left Side Of Headlamp Dash Panel Junction Wiring Harness
    GF0011689Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  40. Position the RH and LH air deflectors and install the pin-type retainers.
    41. Fig 38: Locating Pin-Type Retainers
    G03886637Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  41. Position the upper radiator support and install the 8 bolts.
    • Tighten to 20 Nm (15 lb-ft).
    42. Fig 39: Identifying Upper Radiator Support Bolts
    G03886636Courtesy of FORD MOTOR CO.
  42. Connect the horn electrical connector.
    43. Fig 40: Horn Electrical Connector
    G03885580Courtesy of FORD MOTOR CO.
  43. Connect the front impact severity sensor electrical connector.
    44. Fig 41: Front Impact Severity Sensor Electrical Connector
    G03885579Courtesy of FORD MOTOR CO.
  44. If equipped, connect the air temperature sensor electrical connector.
    45. Fig 42: Air Temperature Sensor Electrical Connector
    G03885578Courtesy of FORD MOTOR CO.
  45. Route the battery feed wiring harness to the power distribution box and insert the routing clips.
    46. Fig 43: Routing Battery Feed Wiring Harness
    G03886632Courtesy of FORD MOTOR CO.
    NOTE: Cover removed for clarity.
  46. Install the battery feed cable to the power distribution box and the 2 nuts.
    • Tighten to 8 Nm (71 lb-in).
    47. Fig 44: Locating Battery Feed Cable Nuts At Power Distribution Box
    G03885576Courtesy of FORD MOTOR CO.
  47. Position the power steering reservoir and install the 2 bolts.
    • Tighten to 20 Nm (15 lb-ft).
    48. Fig 45: Power Steering Reservoir Bolts
    G03886630Courtesy of FORD MOTOR CO.
  48. Install the hood latch.
    1. Position the hood latch and install the 2 bolts.
    2. Connect the cable position retainer.
      • Tighten to 12 Nm (9 lb-ft).
    49. Fig 46: Hood Latch & Clip
    GF0011688Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  49. If equipped, install the A/C condenser.
    1. Position the A/C condenser core in the vehicle.
    2. Install the A/C condenser brackets.
    3. Install the 2 bolts.
      • Tighten to 12 Nm (9 lb-ft).
    50. Fig 47: A/C Condenser Core, Bracket & Bolt
    GF0011727Courtesy of FORD MOTOR CO.
    CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.
  50. If equipped, connect the condenser core refrigerant tubes.
    1. Connect the condenser-to-evaporator tube.
      • Tighten to 18 Nm (13 lb-ft).
    2. Connect the A/C compressor discharge tube.
      • Tighten to 39 Nm (29 lb-ft).
    51. Fig 48: Condenser Core Refrigerant Tubes
    GF0011686Courtesy of FORD MOTOR CO.
    CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.
  51. If equipped, connect the A/C compressor suction tube.
    • Tighten to 47 Nm (35 lb-ft).
    52. Fig 49: A/C Compressor Suction Tube Fitting
    G03885571Courtesy of FORD MOTOR CO.
  52. If equipped, connect the A/C pressure cutoff switch electrical connector.
    53. Fig 50: A/C Pressure Cutoff Switch Electrical Connector
    G03886625Courtesy of FORD MOTOR CO.
  53. Position the radiator in the vehicle.
    54. Fig 51: Positioning Radiator In Vehicle
    G03886624Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  54. Position the radiator support brackets and install the 4 bolts.
    • Tighten to 20 Nm (15 lb-ft).
    55. Fig 52: Radiator Support Brackets Bolts
    G03886623Courtesy of FORD MOTOR CO.
  55. Position the fan shroud and the fan and fan clutch in the vehicle, and install the 2 bolts.
    • Tighten to 6 Nm (53 lb-in).
    56. Fig 53: Fan Shroud Bolts
    GF0011728Courtesy of FORD MOTOR CO.
  56. Insert the degas bottle coolant hose retainer in the fan shroud.
    57. Fig 54: Degas Bottle Coolant Hose Retainer
    G03885566Courtesy of FORD MOTOR CO.
  57. Using the special tools, install the fan blade assembly and fan clutch.
    • Tighten to 55 Nm (41 lb-ft).
    58. Fig 55: Identifying Special Tools And Cooling Fan Assembly
    GF0002833Courtesy of FORD MOTOR CO.
  58. Connect the upper radiator coolant hose and the degas bottle coolant hose to the radiator.
    59. Fig 56: Radiator Upper Hose & Overflow Hose
    GF0011684Courtesy of FORD MOTOR CO.
  59. Connect the transmission cooler tubes.
    60. Fig 57: Identifying Transmission Cooler Hoses
    G03886172Courtesy of FORD MOTOR CO.
  60. Position the splash shield and install the push pin retainers.
    61. Fig 58: Identifying Push Pin Retainers And Splash Shield
    G03885266Courtesy of FORD MOTOR CO.
  61. Connect the lower radiator hose to the radiator.
    • Connect the hose.
    • Connect the hose hanger.
    62. Fig 59: Lower Radiator Hose And Retainers
    G03886599Courtesy of FORD MOTOR CO.
  62. Install the radiator grille support. For additional information, refer to FRONT END BODY PANELS article.
  63. Install the front bumper. For additional information, refer to BUMPERS article.
  64. Install the starter. For additional information, refer to STARTING SYSTEM - GASOLINE ENGINES article.
  65. Install the intake manifold. For additional information, refer to Intake Manifold - 4.6L  or Intake Manifold - 5.4L .
  66. Fill the transmission with clean transmission fluid. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70E/4R75E article.
  67. Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL INFORMATION article.
  68. Fill the engine with clean engine oil.
  69. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
  70. If equipped, evacuate and recharge the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
scientia non olet · About LEMON Manuals