Section 144 (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

Using the special tools and a suitable engine crane, align the engine with the transaxle.

Fig 1: Aligning Engine With Transaxle
Courtesy of FORD MOTOR CO.

Vehicles with 6-speed transaxle

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

Vehicles with CVT transaxle

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

All vehicles

Install the engine-to-transaxle bolt.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 4: Installing Engine-To-Transaxle Bolt
  Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
Attach the heat shield to the KS.

Fig 6: Identifying Heat Shield Over Knock Sensor
Courtesy of FORD MOTOR CO.

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

Courtesy of FORD MOTOR CO.

Using the special tools and a suitable engine crane, position the powertrain on the subframe.
Install the LH engine insulator upper nut.
- Tighten to 70 Nm (62 lb-ft).
  
  Fig 8: Installing LH Engine Insulator Upper Nut
  Courtesy of FORD MOTOR CO.
Install the RH engine insulator upper nut.
- Tighten to 70 Nm (62 lb-ft).
  
  Fig 9: Installing RH Engine Insulator Upper Nut
  Courtesy of FORD MOTOR CO.
Position the RH exhaust manifold heat shield and install the 3 bolts.
- Tighten to 11 Nm (8 lb-ft).
  
  Fig 10: Installing Bolts
  Courtesy of FORD MOTOR CO.
Install the front transaxle stabilizer bolt.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 11: Installing Front Transaxle Stabilizer Bolt
  Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.

Vehicles with 6-speed transaxle

Clean the 3 rear transaxle insulator bracket bolts using a wire brush and apply new threadlock to the threads.
Install the 3 rear transaxle insulator bracket bolts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 13: Installing Rear Transaxle Insulator Bracket Bolts
  Courtesy of FORD MOTOR CO.
Position the ground cable and install the bolt.
- Tighten to 12 Nm (9 lb-ft).
  
  Fig 14: Installing Bolt
  Courtesy of FORD MOTOR CO.
Position the starter motor and install the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 15: Positioning Starter Motor
  Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
Install the starter motor terminal cover.

Fig 17: Installing Starter Motor Terminal Cover
Courtesy of FORD MOTOR CO.
Clean the 2 roll restrictor bolts using a wire brush and apply new threadlock to the threads.
Position the roll restrictor and install the 2 bolts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 18: Installing Bolts
  Courtesy of FORD MOTOR CO.
Clean the 4 roll restrictor bracket bolts using a wire brush and apply new threadlock to the threads.
Position the roll restrictor bracket and install the 4 bolts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 19: Installing Bolts
  Courtesy of FORD MOTOR CO.
Connect the transmission control unit (TCU) wire harness.

Fig 20: Connecting Transmission Control Unit (TCU) Wire Harness
Courtesy of FORD MOTOR CO.

Vehicles with CVT transaxle

Clean the 4 rear transaxle insulator bolts using a wire brush and apply new threadlock to the threads.
Install the 4 rear transaxle insulator bracket bolts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 21: Installing Rear Transaxle Insulator Bracket Bolts
  Courtesy of FORD MOTOR CO.
Position the ground cable and install the bolt.
- Tighten to 12 Nm (9 lb-ft).
  
  Fig 22: Installing Bolt
  Courtesy of FORD MOTOR CO.
Position the starter motor and install the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 23: Positioning Starter Motor
  Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
Install the starter motor terminal cover.

Fig 25: Installing Starter Motor Terminal Cover
Courtesy of FORD MOTOR CO.
Clean the 2 roll restrictor bolts using a wire brush and apply new threadlock to the threads.
Position the roll restrictor and install the 2 bolts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 26: Installing Bolts
  Courtesy of FORD MOTOR CO.
Attach the wiring harness to the roll restrictor.

Fig 27: Attaching Wiring Harness To Roll Restrictor
Courtesy of FORD MOTOR CO.
Clean the 4 roll restrictor bracket bolts using a wire brush and apply new threadlock to the threads.
Position the roll restrictor bracket and install the 4 bolts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 28: Installing Bolts
  Courtesy of FORD MOTOR CO.
Attach the lower wiring harness retainers to the transaxle.

Fig 29: Attaching Lower Wiring Harness Retainers To Transaxle
Courtesy of FORD MOTOR CO.
Attach the wiring harness retainers to the transaxle.

Fig 30: Attaching Wire Harness Retainers To Transaxle
Courtesy of FORD MOTOR CO.
Attach the wiring harness retainer to the transaxle.

Fig 31: Attaching Wiring Harness Retainer To Transaxle
Courtesy of FORD MOTOR CO.
Connect the transaxle bulkhead electrical connector.

Fig 32: Connecting Transaxle Bulkhead Electrical Connector
Courtesy of FORD MOTOR CO.

All vehicles

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
Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
Using the special tool, position the powertrain and subframe in the vehicle.

Fig 36: Positioning Powertrain And Subframe In Vehicle
Courtesy of FORD MOTOR CO.
Install the 2 forward subframe bolts and washers.
- Tighten to 200 Nm (148 lb-ft).
  
  Fig 37: Installing Forward Subframe Bolts And Washers
  Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
If equipped, connect the driveshaft and install the bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 42: Connecting Driveshaft & Bolts
  Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.

NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of sealant application.

Fig 44: Applying Silicone Sealant

Courtesy of FORD MOTOR CO.

Apply a 10 mm (0.39 in) diameter dot of silicone sealant to the areas indicated.
Position the oil pan and a new gasket. Loosely install the 15 bolts.

Fig 45: Positioning Oil Pan And Gasket
Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
Tighten the 15 oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).

Fig 47: Tightening Oil Pan Bolts In Sequence
Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
Install the 4 new torque converter nuts.
- Tighten to 36 Nm (27 lb-ft).
  
  Fig 49: Installing Torque Converter Nuts
  Courtesy of FORD MOTOR CO.
Position the lower torque converter access plug and install the pin-type retainers.

Fig 50: Installing Pin-Type Retainers
Courtesy of FORD MOTOR CO.
If equipped, connect the block heater electrical connector and attach the wiring retainers.

Fig 51: Locating Engine Block Heater
Courtesy of FORD MOTOR CO.
Connect the power steering cooler hose.

Fig 52: Connecting Power Steering Cooler Hose
Courtesy of FORD MOTOR CO.
Connect the transmission cooler hoses.

Fig 53: Connecting Transmission Cooler Hoses
Courtesy of FORD MOTOR CO.
Position the A/C tube and install the nut.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 54: Installing Nut
  Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
Connect the A/C high-pressure switch electrical connector.

Fig 56: Connecting A/C High-Pressure Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the 10-pin electrical connector and attach the wiring retainers.

Fig 57: Connecting 10-Pin Electrical Connector
Courtesy of FORD MOTOR CO.
Position the coolant tube and secure the tube in the clips.

Fig 58: Positioning Coolant Tube And Secure Tube Clips
Courtesy of FORD MOTOR CO.
Connect the coolant hoses to the thermostat housing.

Fig 59: Connecting Coolant Hoses To Thermostat Housing
Courtesy of FORD MOTOR CO.
Connect the brake booster vacuum hose to the upper intake manifold.

Fig 60: Connecting Brake Booster Vacuum Hose To Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Connect the heater hose and the throttle body coolant hose.

Fig 61: Connecting Heater Hose And Throttle Body Coolant Hose
Courtesy of FORD MOTOR CO.

Vehicles with 6-speed transaxle

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
  Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
Connect the shift cable.

Fig 64: Locating Shift Cable End
Courtesy of FORD MOTOR CO.

Vehicles with CVT transaxle

Position the shift cable bracket and install the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 65: Installing Bolts
  Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
Connect the shift cable.

Fig 67: Disconnecting Shift Cable End
Courtesy of FORD MOTOR CO.

All vehicles

Attach the B+ terminal to the battery cable and install the nut.
- Tighten to 5 Nm (44 lb-in).
  
  Fig 68: Installing Nut
  Courtesy of FORD MOTOR CO.
Position the ground wire on the LH fender and install the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 69: Installing Bolt
  Courtesy of FORD MOTOR CO.
Connect the power steering reservoir hose and attach the retainer.

Fig 70: Connecting Power Steering Reservoir Hose
Courtesy of FORD MOTOR CO.
Connect the 2 powertrain control module (PCM) electrical connectors and attach the wiring conduit.

Fig 71: Connecting Powertrain Control Module (PCM) Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the vapor tube to the purge valve.

Fig 72: Connecting Vapor Tube To Purge Valve
Courtesy of FORD MOTOR CO.

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.

Connect the fuel tube to the fuel rail.
- Connect the fuel tube redundant clip.
  
  Fig 73: Connecting Fuel Tube Redundant Clip
  Courtesy of FORD MOTOR CO.
Attach the fuel tube retainer to the upper intake manifold.

Fig 74: Attaching Fuel Tube Retainer To Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Position the ground strap on the RH fender and install the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 75: Installing Bolt
  Courtesy of FORD MOTOR CO.
Clean the 4 roll restrictor cross brace bolts using a wire brush and apply new threadlock to the threads.
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
  Courtesy of FORD MOTOR CO.
Clean the roll restrictor cross brace-to-roll restrictor bolt using a wire brush and apply new threadlock to the threads.
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
  Courtesy of FORD MOTOR CO.
Install the LH and RH half shafts. For additional information, refer to FRONT DRIVE HALFSHAFTS .
Install the exhaust flex pipe and the LH catalytic converter. For additional information, refer to EXHAUST SYSTEM .
Install the cowl vent screen. For additional information, refer to WIPERS AND WASHERS .
Install the air cleaner outlet pipe and air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
Fill the engine with clean engine oil.
Connect the negative and positive battery cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Evacuate and recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
Fill the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
Fill and bleed the cooling system. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .