Section 1209 (Engine): Installation: Engine

WARNING: This page is about a different car, the 2008 Mercury Sable, 2008 Ford Taurus X, and 2008 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools

Illustration	Tool Name	Tool Number
	Heavy Duty Floor Crane	014-00071 or equivalent
	Powertrain Lift	014-00765
	Spreader Bar	303-D089 (D93P-6001-A3) or equivalent
	Universal Adapter Brackets	014-0001

Material

Item	Specification
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 vehicles

Using the special tools, align the transaxle to the engine.

Fig 1: Removing Engine & Transaxle From Lift Table Using Special Tools (303-D089, 014-00071) & Suitable Engine Crane

Courtesy of FORD MOTOR CO.

Install the 5 transaxle-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).

Fig 2: Locating Transaxle-To-Engine Bolts

Courtesy of FORD MOTOR CO.

Install the 2 engine-to-transaxle bolts.
- Tighten to 48 Nm (35 lb-ft).

Fig 3: Locating Engine-To-Transaxle Bolts

Courtesy of FORD MOTOR CO.

Using the special tools, position the engine and transaxle onto the lift table.

Fig 4: Removing Engine & Transaxle From Lift Table Using Special Tools (303-D089, 014-00071) & Suitable Engine Crane

Courtesy of FORD MOTOR CO.

NOTE: Position a block of wood under the transaxle.

Install the special tools.

Fig 5: Positioning Block Of Wood Under Transaxle Using Special Tools (014-0001) & (014-00765)

Courtesy of FORD MOTOR CO.

Install the starter, the stud bolt and bolt.
- Tighten to 27 Nm (20 lb-ft).

Fig 6: Identifying Bolt, Stud Bolt & Starter

Courtesy of FORD MOTOR CO.

Connect the wiring harness retainer to the starter motor stud bolt.

Fig 7: Identifying Wiring Harness Retainer From Starter Motor Stud Bolt

Courtesy of FORD MOTOR CO.

Attach the starter wire terminals and install the 2 nuts.
1. Tighten to 12 Nm (9 lb-ft).
2. Tighten to 5 Nm (44 lb-in).

Fig 8: Identifying Starter Motor Wire Terminals & Nuts

Courtesy of FORD MOTOR CO.

If equipped, install the starter motor solenoid cover.

Fig 9: Identifying Starter Motor Solenoid Cover

Courtesy of FORD MOTOR CO.

Raise the engine and transaxle assembly into the vehicle.
Install the engine mount and the 3 bolts.
- Tighten to 90 Nm (66 lb-ft).

Fig 10: Identifying Engine Mount And Bolts

Courtesy of FORD MOTOR CO.

Install the 4 engine mount nuts.
- Tighten to 63 Nm (46 lb-ft).

Fig 11: Identifying Mounting Nuts

Courtesy of FORD MOTOR CO.

Install the engine mount brace, nut and bolt.
- Tighten to 20 Nm (15 lb-ft).

Fig 12: Identifying Nut, Bolt And Brace

Courtesy of FORD MOTOR CO.

Install the transaxle mount bracket and the 4 nuts.
- Tighten to 80 Nm (59 lb-ft).

Fig 13: Identifying Bolt, Nuts And Mount Bracket

Courtesy of FORD MOTOR CO.

Install the transaxle mount through bolt and nut.
- Tighten to 175 Nm (129 lb-ft).

Fig 14: Identifying Bolt And Nut

Courtesy of FORD MOTOR CO.

All wheel drive (AWD) vehicles

Position the power transfer unit (PTU) in place and install the 5 bolts.
- Tighten to 90 Nm (66 lb-ft).

Fig 15: Locating PTU Bolts

Courtesy of FORD MOTOR CO.

Position the PTU support bracket in place and install the 5 bolts.
- Tighten to 70 Nm (52 lb-ft).

Fig 16: Identifying Bolts

Courtesy of FORD MOTOR CO.

NOTE: A new PTU seal must be installed whenever the intermediate shaft is removed.

Install a new PTU seal. For additional information, refer to TRANSFER CASE - POWER TRANSFER UNIT (PTU) article.
Using a new gasket, install the RH catalytic converter and 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).

Fig 17: Identifying Nuts

Courtesy of FORD MOTOR CO.

Connect the RH catalyst monitor electrical connector.

Fig 18: Locating RH Catalyst Monitor Electrical Connector

Courtesy of FORD MOTOR CO.

All vehicles

Install the RH halfshaft support bracket and the 4 bolts.
- Tighten the halfshaft support-to-cylinder block bolts to 40 Nm (30 lb-ft).
- Tighten the catalytic converter-to-halfshaft support bolts to 20 Nm (15 lb-ft).

Fig 19: Separating LH Halfshaft From Transaxle

Courtesy of FORD MOTOR CO.

Install the 2 halfshaft support bracket studs.
- Tighten to 10 Nm (89 lb-in).

Fig 20: Identifying Studs

Courtesy of FORD MOTOR CO.

Install the RH halfshaft into the transaxle and the wheel hub and install the 2 carrier bearing nuts.
- Tighten to 40 Nm (30 lb-ft).

Fig 21: Identifying Nuts

Courtesy of FORD MOTOR CO.

Install the 4 oil pan-to-transaxle bolts.
- Tighten to 48 Nm (35 lb-ft).

Fig 22: Locating Oil Pan-To-Transaxle Bolts

Courtesy of FORD MOTOR CO.

Install 3 new torque converter bolts.
- Tighten to 55 Nm (41 lb-ft).

Fig 23: Identifying Bolt

Courtesy of FORD MOTOR CO.

Install the inspection cover and the 2 fasteners.

Fig 24: Identifying Inspection Cover & Fasteners

Courtesy of FORD MOTOR CO.

Connect the transaxle cooling tubes and install the safety clips.

Fig 25: Identifying Cooling Tubes

Courtesy of FORD MOTOR CO.

NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.

Install the LH halfshaft into the transaxle.

Fig 26: Identifying LH Halfshaft

Courtesy of FORD MOTOR CO.

Using the special tool, raise the subframe into the installed position.

Fig 27: Positioning Special Tool (014-00765) Under Subframe Assembly

Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Install the 2 front subframe bolts.
- Tighten to 150 Nm (111 lb-ft).

Fig 28: Identifying Bolt

Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Position the subframe brackets and install the 4 bolts finger-tight.

Fig 29: Identifying Bracket And Bolts

Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Install the 2 rear subframe bolts.
- Tighten to 150 Nm (111 lb-ft).

Fig 30: Identifying Bolt And Bracket

Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).

Fig 31: Identifying Bracket-To-Body Bolts

Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Install new lower ball joint-to-wheel knuckle nuts.
- Tighten to 115 Nm (85 lb-ft).

Fig 32: Identifying Nut And Wheel Knuckles

Courtesy of FORD MOTOR CO.

NOTE: The hex holding feature can be used to prevent turning of the stud while removing the nuts.

NOTE: RH shown, LH similar.

Install new tie-rod end nuts.
- Tighten to 115 Nm (85 lb-ft).

Fig 33: Identifying Tie-Rod End Nut And Wheel Knuckles

Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Install new upper stabilizer bar link nuts.
- Tighten to 55 Nm (41 lb-ft).

Fig 34: Identifying Nut

Courtesy of FORD MOTOR CO.

CAUTION: Install and tighten the new front axle wheel end nut to specification in a continuous rotation. Stopping the rotation during installation will cause the nylon lock to seat incorrectly. This will cause incorrect torque readings while tightening the front axle wheel end nut and lead to bearing failure. Always install a new front axle wheel end nut after loosening or when not tightened to specifications in a continuous rotation.

NOTE: Never use power tools to tighten the front axle wheel end nut.

NOTE: Apply the brake to keep the halfshaft from rotating.

Install the new halfshaft nut.
- Tighten to 350 Nm (258 lb-ft).

Fig 35: Identifying RH Halfshaft Nut

Courtesy of FORD MOTOR CO.

Install the 2 engine roll restrictor-to-transaxle bolts.
- Tighten to 103 Nm (76 lb-ft).

Fig 36: Identifying Bolts

Courtesy of FORD MOTOR CO.

Using a new O-ring seal, install the PSP tube onto the steering gear, rotate the clamp plate and install the bolt.
- Tighten to 25 Nm (18 lb-ft).

Fig 37: Identifying Bolt, Clamp Plate And PSP Tube

Courtesy of FORD MOTOR CO.

Install the PSP tube bracket-to-steering gear bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 38: Identifying PSP Bracket-To-Steering Gear Bolt

Courtesy of FORD MOTOR CO.

NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.

Install a new engine oil filter.
- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.

Fig 39: Identifying Engine Oil Filter

Courtesy of FORD MOTOR CO.

AWD vehicles

Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts (3 shown).
- Tighten to 70 Nm (52 lb-ft).

Fig 40: Identifying Drive Shaft Bolts

Courtesy of FORD MOTOR CO.

All vehicles

Using a new gasket, install the Y-pipe and install the 2 new nuts.
- Tighten to 40 Nm (30 lb-ft).
- Attach the exhaust hanger.

Fig 41: Identifying Nuts And Exhaust Hanger

Courtesy of FORD MOTOR CO.

Install the Y-pipe assembly and 4 new nuts.
- Tighten to 40 Nm (30 lb-ft).

Fig 42: Identifying Nuts

Courtesy of FORD MOTOR CO.

CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM article.

NOTE: Align the index marks made during removal.

Install the steering intermediate shaft onto the steering gear and install a new bolt.
- Tighten to 23 Nm (17 lb-ft).

Fig 43: Locating Steering Column Shaft Index Mark And Bolt

Courtesy of FORD MOTOR CO.

Connect the transaxle control electrical connector.

Fig 44: Identifying Connector

Courtesy of FORD MOTOR CO.

Attach the transaxle control wire harness retainer to the transaxle stud bolt.

Fig 45: Identifying Transaxle Control Wire Harness Retainer

Courtesy of FORD MOTOR CO.

Connect the hose to the power steering reservoir.

Fig 46: Disconnecting Hose From Power Steering Reservoir

Courtesy of FORD MOTOR CO.

Install the oil level indicator.

Fig 47: Identifying Oil Level Indicator

Courtesy of FORD MOTOR CO.

Install the ground cable and bolt.
- Tighten to 12 Nm (9 lb-ft).

Fig 48: Identifying Bolt And Ground Cable

Courtesy of FORD MOTOR CO.

Attach the wire to the RH valve cover stud bolt.

Fig 49: Identifying Wire Harness Retainer

Courtesy of FORD MOTOR CO.

Connect the 2 engine wiring harness electrical connectors.
- Attach the electrical connector to the LH valve cover.

Fig 50: Identifying Engine Wiring Harness Electrical Connectors

Courtesy of FORD MOTOR CO.

Connect the fuel supply tube to the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.

Fig 51: Identifying Fuel Supply Tube

Courtesy of FORD MOTOR CO.

Using a new O-ring seal, install the A/C tube and the nut.
- Tighten to 15 Nm (11 lb-ft).

Fig 52: Identifying Nut

Courtesy of FORD MOTOR CO.

Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
- Tighten to 15 Nm (11 lb-ft).

Fig 53: Identifying Nuts

Courtesy of FORD MOTOR CO.

Using a new O-ring seal, connect the upper A/C tube to the condenser and install the nut and connect the A/C pressure switch electrical connector.
- Tighten to 15 Nm (11 lb-ft).

Fig 54: Identifying A/C Pressure Switch And Nut

Courtesy of FORD MOTOR CO.

If equipped, attach the engine block heater harness to the radiator support and the power steering tube.
Connect the transaxle control cable to the shift cable bracket and attach the 2 wiring harness pin-type retainers.

Fig 55: Identifying Control Cable And Pin-Type Retainers

Courtesy of FORD MOTOR CO.

Connect the transaxle control cable to the control lever.

Fig 56: Locating Selector Lever Cable End From Manual Lever

Courtesy of FORD MOTOR CO.

Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.

Fig 57: Locating Upper Radiator Hose, Lower Radiator Hose & Heater Hoses

Courtesy of FORD MOTOR CO.

Disconnect the vacuum hose and the evaporative emissions (EVAP) tube from the upper intake manifold.

Fig 58: Locating Vacuum Hose & Evaporative Emissions (EVAP) Tube From Upper Intake Manifold

Courtesy of FORD MOTOR CO.

Attach the EVAP tube pin-type retainer to the upper intake manifold.

Fig 59: Identifying pin-Type Retainer

Courtesy of FORD MOTOR CO.

Connect the ground cable to the negative battery terminal and install the nut.
- Tighten to 6 Nm (53 lb-in).

Fig 60: Identifying Nut And Ground Cable

Courtesy of FORD MOTOR CO.

Connect the power feed wire to the positive battery terminal and install the nut.
- Tighten to 6 Nm (53 lb-in).

Fig 61: Identifying Nut

Courtesy of FORD MOTOR CO.

Connect the engine wiring harness electrical connector.

Fig 62: Identifying Connector

Courtesy of FORD MOTOR CO.

Install the battery tray and bracket and the nut and bolt.
- Tighten to 9 Nm (80 lb-in).

Fig 63: Identifying Bolt, Nut And Bracket

Courtesy of FORD MOTOR CO.

Install the 2 lower battery tray bracket bolts.
- Tighten to 9 Nm (80 lb-in).

Fig 64: Identifying Bolts

Courtesy of FORD MOTOR CO.

Attach the 2 pin-type wiring harness fasteners to the front of the battery tray.

Fig 65: Identifying Fasteners

Courtesy of FORD MOTOR CO.

Attach the 4 pin-type wiring harness fasteners to the side of the battery tray.

Fig 66: Identifying Fasteners

Courtesy of FORD MOTOR CO.

Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
Install the degas bottle. For additional information, refer to ENGINE COOLING article.
Connect the power steering cooler tube.

Fig 67: Identifying Power Steering Cooler Tube

Courtesy of FORD MOTOR CO.

Install the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE article.
Install the front wheels and tires. For additional information, refer to WHEELS AND TIRES article.
Fill the engine with clean engine oil.
Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING article.
Fill the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL INFORMATION article.
Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.