Section 2153 (Engine - 3.0L (4V)): Installation: Engine: Installation

All vehicles 

1. Using the special tools, align the engine with the transaxle.
Fig 1: Identifying Special Tools
Courtesy of FORD MOTOR CO.
2. Install the 5 transaxle-to-engine bolts (3 shown).
   • Tighten to 48 Nm (35 lb-ft).
Fig 2: Locating Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
3. Using the special tools, secure the engine and transaxle to the powertrain lift.
Fig 3: Securing Engine & Transaxle To Powertrain Lift Using Special Tool (014-0001)
Courtesy of FORD MOTOR CO.
4. Install the EGR regulator and the 2 stud bolts.
   • Tighten to 6 Nm (53 lb-in).
Fig 4: Identifying Stud Bolts
Courtesy of FORD MOTOR CO.
5. Attach the wiring harness retainer and install the nut.
   • Tighten to 6 Nm (53 lb-in).
Fig 5: Identifying Nut
Courtesy of FORD MOTOR CO.

All wheel drive (AWD) vehicles 

6. Position the power transfer unit (PTU) and install the bolt.
   • Tighten to 45 Nm (33 lb-ft).
Fig 6: Locating Transfer Case Bolt & Transfer Case Unit
Courtesy of FORD MOTOR CO.
7. Install the 3 PTU bolts.
   • Tighten to 45 Nm (33 lb-ft).
Fig 7: Locating PTU Bolts
Courtesy of FORD MOTOR CO.
8. Install the PTU vent tube, the pin-type retainer and the bolt.
   • Tighten to 14 Nm (10 lb-ft).
Fig 8: Locating Pin-Type Retainer & Bolt
Courtesy of FORD MOTOR CO.
9. Install the halfshaft support bracket and the 6 bolts.
   • Tighten to 48 Nm (35 lb-ft).
Fig 9: Locating Half Shaft Support Bracket & Bolts
Courtesy of FORD MOTOR CO.
10. Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
Fig 10: Locating Exhaust Manifold Studs
Courtesy of FORD MOTOR CO.
11. Using a new gasket, install the RH exhaust manifold and 6 new nuts.
    • Tighten in the sequence shown to 20 Nm (15 lb-ft).
Fig 11: Identifying Tightening Sequence Of RH Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
12. Connect the RH heated oxygen sensor (HO2S) electrical connector.
Fig 12: Identifying (HO2S) Connector
Courtesy of FORD MOTOR CO.

All vehicles 

13. Connect the turbine speed sensor (TSS) electrical connector.
    • Attach the wiring harness retainer.
Fig 13: Identifying (TSS) Connector And Harness Retainer
Courtesy of FORD MOTOR CO.
14. Attach the transaxle control harness to the bracket.
Fig 14: Identifying Bracket
Courtesy of FORD MOTOR CO.
15. Connect the transaxle wiring harness electronic control switch electrical connector.
Fig 15: Locating Transaxle Wiring Harness Electronic Control Switch Electrical Connector
Courtesy of FORD MOTOR CO.
16. Connect the transmission range (TR) sensor electrical connector.
Fig 16: Locating Transmission Range (TR) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
17. Attach the pin-type retainers to the transaxle support bracket and connect the HO2S and catalyst monitor sensor electrical connectors.
Fig 17: Locating Heated Oxygen & Catalyst Monitor Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
18. Position the powertrain into the vehicle.
Fig 18: Positioning Powertrain Into Vehicle
Courtesy of FORD MOTOR CO.
19. Install the engine support bracket, the bolt and the 3 nuts.
    • Tighten the nuts to 55 Nm (41 lb-ft) and the bolt to 90 Nm (66 lb-ft).
Fig 19: Identifying Bolt And Nuts
Courtesy of FORD MOTOR CO.
20. Install the rear transaxle support through bolt.
    • Tighten to 103 Nm (76 lb-ft).
Fig 20: Locating Transaxle Mount Bolt
Courtesy of FORD MOTOR CO.
21. Position the RH transaxle support insulator and install the bolt and nuts.
    • Tighten to 80 Nm (59 lb-ft).
Fig 21: Locating Transaxle Support Insulator Bolt & Nuts
Courtesy of FORD MOTOR CO.
22. Install the RH transaxle support insulator through bolt.
    • Tighten to 115 Nm (85 lb-ft).
Fig 22: Locating RH Transaxle Support Insulator Bolt
Courtesy of FORD MOTOR CO.
23. Install the transaxle-to-engine stud and 2 nuts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 23: Locating Transaxle Bolt
Courtesy of FORD MOTOR CO.
NOTE: Clean and degrease all sealing surfaces with metal surface cleaner.
NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of the sealant application.
24. Apply a 10 mm (0.39 in) dot of silicone gasket and sealant to the front cover-to-cylinder block sealing surface.
Fig 24: Applying Silicone Gasket And Sealant To Front Cover-To-Cylinder Block
Courtesy of FORD MOTOR CO.
NOTE: Install a new oil pan gasket.
25. Position the oil pan and gasket and loosely install the bolts and stud bolts.
Fig 25: Locating Oil Pan Gasket Bolts & Stud Bolts
Courtesy of FORD MOTOR CO.
26. Install the 2 oil pan-to-transaxle bolts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 26: Locating Oil Pan-To-Transaxle Bolts
Courtesy of FORD MOTOR CO.
27. Tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).
Fig 27: Identifying Tightening Sequence Of Oil Pan-To-Engine Bolts And Stud Bolts
Courtesy of FORD MOTOR CO.
28. Install the 4 torque converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 28: Locating Torque Converter Nuts
Courtesy of FORD MOTOR CO.
29. Install the torque converter inspection cover.
Fig 29: Locating Torque Converter Inspection Cover
Courtesy of FORD MOTOR CO.
30. Install the output shaft speed (OSS) sensor and the bolt and connect the electrical connector.
    • Tighten to 13 Nm (10 lb-ft).
Fig 30: Locating Output Shaft Speed (OSS) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
31. If equipped, connect the engine block heater electrical connector.
Fig 31: Locating Engine Block Heater Electrical Connector
Courtesy of FORD MOTOR CO.
32. Install the ground wire eyelet and nut to the engine mount stud.
    • Tighten to 25 Nm (18 lb-ft).
Fig 32: Identifying Stud
Courtesy of FORD MOTOR CO.
33. Install the wire and nut to the battery cable.
    • Tighten to 10 Nm (89 lb-in).
Fig 33: Locating Battery Cable And Nut
Courtesy of FORD MOTOR CO.
34. Attach the wiring harness retainers from the battery tray bracket.
Fig 34: Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
35. Position the ground strap and the electrical connector and install the bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 35: Locating Ground Strap & Electrical Connector
Courtesy of FORD MOTOR CO.
36. Connect the electrical connector to the power distribution box.
Fig 36: Power Distribution Box Electrical Connector
Courtesy of FORD MOTOR CO.
37. Install the cable and the nut.
    • Tighten to 12 Nm (9 lb-ft).
Fig 37: Identifying Nut
Courtesy of FORD MOTOR CO.
38. Attach the ground wire and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 38: Locating Ground Wire & Bolt
Courtesy of FORD MOTOR CO.
39. Position the wiring and install the nut. Connect the PCM electrical connectors.
    • Tighten to 8 Nm (71 lb-in).
Fig 39: Locating Powertrain Control Module (PCM) Electrical Connectors
Courtesy of FORD MOTOR CO.
40. Connect the manifold absolute pressure (MAP) sensor electrical connector and vacuum tube.
Fig 40: Locating Manifold Absolute Pressure (MAP) Sensor Vacuum Tube & Electrical Connector
Courtesy of FORD MOTOR CO.
41. Connect the brake booster vacuum tube.
Fig 41: Identifying Vacuum Tube
Courtesy of FORD MOTOR CO.
42. Connect the evaporative emissions (EVAP) purge valve tube to the intake manifold.
Fig 42: Locating Vacuum Tube Retainer
Courtesy of FORD MOTOR CO.
43. Position the EGR tube and loosely install the fittings.
    • Tighten the EGR tube-to-EGR valve fitting to 40 Nm (30 lb-ft).
Fig 43: Locating Exhaust Gas Recirculation (EGR) Tube
Courtesy of FORD MOTOR CO.
44. Connect the differential pressure feedback EGR sensor electrical connector and attach the pin-type retainer.
Fig 44: Locating EGR Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
45. Position the shift cable and bracket in place, install the bolts and install the wiring harness retainer.
    • Tighten to 23 Nm (17 lb-ft).
Fig 45: Identifying Bolts And Retainer
Courtesy of FORD MOTOR CO.
46. Connect the gearshift cable to the transaxle.
Fig 46: Identifying Gearshift Cable
Courtesy of FORD MOTOR CO.
47. Attach the wiring harness pin-type retainer to the gearshift cable bracket.
Fig 47: Locating Pin-Type Retainer
Courtesy of FORD MOTOR CO.
48. Connect the fuel supply tube quick connect coupling at the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
49. Attach the transaxle vent tube retainer to the throttle body.
Fig 48: Identifying Retainer
Courtesy of FORD MOTOR CO.
50. Connect the heater hoses and the throttle body coolant hose.
Fig 49: Locating Heater Hoses & Throttle Body Coolant Hose
Courtesy of FORD MOTOR CO.
51. Connect the upper and lower radiator hoses.
Fig 50: Locating Hoses
Courtesy of FORD MOTOR CO.
52. Position the accelerator and speed control cables and bracket. Install the nut.
    • Tighten to 10 Nm (89 lb-in).
Fig 51: Cable Bracket
Courtesy of FORD MOTOR CO.
53. Position the bracket and install the bolts.
    • Tighten to 10 Nm (89 lb-in).
    • Connect the accelerator cable and the speed control actuator cable.
Fig 52: Accelerator Cable, Speed Control Actuator Cable & Cable Bracket Bolts
Courtesy of FORD MOTOR CO.
54. Position the accelerator cable snow shield and install the bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 53: Locating Accelerator Cable Snow Shield Bolts
Courtesy of FORD MOTOR CO.
55. Tighten the EGR tube-to-RH catalytic converter fitting to 40 Nm (30 lb-ft).
Fig 54: Locating EGR Tube-To-RH Catalytic Converter Fitting
Courtesy of FORD MOTOR CO.
56. Install the transaxle cooler tube and the bracket bolt.
    • Tighten the bolt to 13 Nm (10 lb-ft), tighten the fitting to 23 Nm (17 lb-ft).
Fig 55: Identifying Cooler Tube And Bolt
Courtesy of FORD MOTOR CO.
57. Connect the 2 transmission cooler tubes (1 shown).
Fig 56: Locating Transmission Cooler Tubes
Courtesy of FORD MOTOR CO.
58. Install the cross brace and the new nut finger tight.
Fig 57: Identifying Cross Brace And Rear Nut
Courtesy of FORD MOTOR CO.
59. Install the 2 bolts for the cross brace and the bolt for the front roll restrictor.
    • Tighten the 2 cross brace bolts to 90 Nm (66 lb-ft).
    • Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
Fig 58: Identifying Front Roll Restrictor Bolt & Bolts For Engine Support Crossmember
Courtesy of FORD MOTOR CO.
60. Tighten the cross brace nut to 175 Nm (129 lb-ft).
Fig 59: Identifying Nut
Courtesy of FORD MOTOR CO.
61. Position the RH accessory drive belt idler pulley and bracket and attach the wiring harness retainer.
    • Install the 3 bolts and tighten to 25 Nm (18 lb-ft).
Fig 60: Identifying Bolts
Courtesy of FORD MOTOR CO.
62. Install the A/C compressor and the bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 61: Identifying Bolts
Courtesy of FORD MOTOR CO.
63. Connect the A/C clutch field coil electrical connector.
Fig 62: Identifying Connector
Courtesy of FORD MOTOR CO.
64. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
Fig 63: Rotating Drive Belt Tensioner
Courtesy of FORD MOTOR CO.

AWD vehicles 

CAUTION: Do not reuse the driveshaft flange bolts and washers. Install new bolts and washers or damage to the vehicle may occur.
65. Align the index-marks made during removal and install 6 new front driveshaft-to-PTU bolts and washers.
    • Tighten to 37 Nm (27 lb-ft).
Fig 64: Locating Driveshaft-To-Power Take Off Bolts & Washers
Courtesy of FORD MOTOR CO.

All vehicles 

66. Install the intermediate shaft and the 2 nuts.
    • Tighten to 27 Nm (20 lb-ft).
Fig 65: Locating Intermediate Shaft Retaining Nuts
Courtesy of FORD MOTOR CO.
67. Install the RH halfshaft onto the intermediate shaft.
Fig 66: Identifying RH Halfshaft
Courtesy of FORD MOTOR CO.
68. Install the LH halfshaft into the transaxle.
Fig 67: Identifying LH Halfshaft
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
69. Attach the LH and RH lower ball joints to the steering knuckles and install the pinch bolts and nuts.
    • Tighten to 63 Nm (46 lb-ft).
Fig 68: Identifying Bolt And Nut
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
70. Install the LH and RH tie-rod ends and nuts.
    • Tighten to 55 Nm (41 lb-ft).
Fig 69: Identifying Nut
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
71. Install the LH and RH stabilizer link-to-strut nuts.
    • Tighten to 63 Nm (46 lb-ft).
Fig 70: Identifying Nut
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
72. Install the LH and RH brake hose retainers and ABS sensor wiring harness bolts.
    • Tighten to 15 Nm (11 lb-ft).
Fig 71: Identifying Retainer And Bolt
Courtesy of FORD MOTOR CO.
73. Install the Y-pipe and the 2 new exhaust flange-to-RH catalytic converter nuts.
    • Tighten to 29 Nm (21 lb-ft).
Fig 72: Rear Exhaust Pipe Flange & Nuts
Courtesy of FORD MOTOR CO.
74. Install the 2 new exhaust flange-to-LH catalytic converter nuts.
    • Tighten to 29 Nm (21 lb-ft).
Fig 73: Front Exhaust Pipe Flange Nuts
Courtesy of FORD MOTOR CO.
75. Attach the Y-pipe to the rear catalytic converter.
    1. Attach the exhaust hanger.
    2. Install the 2 new exhaust flange-to-rear catalytic converter nuts.
       • Tighten to 29 Nm (21 lb-ft).
Fig 74: Exhaust Hanger & Nuts
Courtesy of FORD MOTOR CO.
76. Install the lateral support crossmember and the 4 bolts.
    • Tighten to 115 Nm (85 lb-ft).
Fig 75: Identifying Lateral Support Crossmember And Bolts
Courtesy of FORD MOTOR CO.
77. Connect the catalyst monitor sensor electrical connector and the 2 wiring harness retainers.
Fig 76: Identifying Connector And Retianers
Courtesy of FORD MOTOR CO.
78. Install the lower splash shields.
Fig 77: Splash Shields
Courtesy of FORD MOTOR CO.
79. Install the front wheels and tires. For additional information, refer to WHEELS AND TIRES article.
80. Install the air cleaner outlet pipe and air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V) article.
81. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
82. Fill the engine with clean engine oil.
83. Fill and bleed the cooling system. For additional information refer to ENGINE COOLING article.