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Engine Mechanical: Mechanical: Engine: Installation: Engine

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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