Section 2293 (Engine Mechanical - 3.0L (4V)): Installation: Engine: Installation

All vehicles 

1. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, align the transaxle to the engine.
   Fig 1: Removing Engine & Transaxle

   Courtesy of FORD MOTOR CO.
2. Install the 4 transaxle-to-engine bolts.
   • Tighten to 48 Nm (35 lb-ft).
   Fig 2: Locating Transaxle-To-Engine Bolts

   Courtesy of FORD MOTOR CO.
3. Install the transaxle-to-engine bolt.
   • Tighten to 48 Nm (35 lb-ft).
   Fig 3: Locating Transaxle-To-Engine Bolt

   Courtesy of FORD MOTOR CO.
4. Connect the 2 transmission electrical connectors and attach the wiring harness retainer to the stud bolt.
   Fig 4: Locating Wiring Retainer From Stud Bolt

   Courtesy of FORD MOTOR CO.
5. Attach the wiring harness retainer to the transmission indicator tube.
   Fig 5: Locating Wiring Harness Retainer To Transmission Indicator Tube

   Courtesy of FORD MOTOR CO.
6. Install the starter and the 2 stud bolts.
   • Tighten to 27 Nm (20 lb-ft).
   Fig 6: Locating Starter Stud Bolts

   Courtesy of FORD MOTOR CO.
7. Install the starter wiring and the 2 nuts.
   • Tighten the small starter motor solenoid wire nut to 5 Nm (44 lb-in).
   • Tighten the large starter motor solenoid battery cable nut to 12 Nm (106 lb-in).
   Fig 7: Locating Starter Wiring Nut

   Courtesy of FORD MOTOR CO.
8. Use a plastic scraping tool to remove all traces of the oil pan gasket.
   • Clean all sealing surfaces with metal surface prep and install a new oil pan gasket.
   NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
9. Install the starter wiring ground wire and nut.
   • Tighten to 18 Nm (159 lb-in).
   Fig 8: Locating Starter Wiring Ground Nut

   Courtesy of FORD MOTOR CO.
10. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, position the engine and transaxle onto the lift table.
    Fig 9: Removing Engine & Transaxle

    Courtesy of FORD MOTOR CO.
11. Install the Universal Adapter Brackets and the Powertrain Lift to the engine.
    NOTE: Position a suitable block of wood under the transaxle.
    Fig 10: Installing Powertrain Lift & Universal Adapter Brackets Onto Engine

    Courtesy of FORD MOTOR CO.
12. Raise the engine and transaxle up into the vehicle.
13. Install the engine support insulator bracket, 3 nuts and the bolt.
    • Tighten the nuts to 63 Nm (46 lb-ft).
    • Tighten the bolt to 115 Nm (85 lb-ft).
    Fig 11: Locating Engine Mount Bracket With Bolt & Nuts

    Courtesy of FORD MOTOR CO.
14. Install the damper and bolt.
    • Tighten to 23 Nm (17 lb-ft).
    Fig 12: Locating Damper & Bolt

    Courtesy of FORD MOTOR CO.
15. Install the ground strap and bolt on the engine mount bracket.
    • Tighten to 10 Nm (89 lb-in).
    Fig 13: Locating Ground Strap From Engine Mount Bracket & Bolt

    Courtesy of FORD MOTOR CO.
16. Install the rear transaxle support through bolt.
    • Tighten to 103 Nm (76 lb-ft).
    Fig 14: Locating Rear Transaxle Support Through Bolt
    Courtesy of FORD MOTOR CO.
17. Install the transaxle-to-engine stud and 2 nuts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 15: Locating Nuts & Transaxle-To-Engine Stud
    Courtesy of FORD MOTOR CO.
18. Apply a 10 mm (0.39 in) dot of silicone gasket and sealant to the front cover-to-cylinder block sealing surface.
    NOTE: Clean and degrease all sealing surfaces with metal surface prep.
    NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of the sealant application.
    Fig 16: Identifying Evaporative Emission Canister Purge Valve

    Courtesy of FORD MOTOR CO.
19. Position the oil pan and gasket and loosely install the bolts and stud bolts.
    NOTE: Install a new oil pan gasket.
    Fig 17: Identifying Oil Pan Bolts & Stud Bolts

    Courtesy of FORD MOTOR CO.
20. Install the 2 oil pan-to-transaxle bolts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 18: Locating Oil Pan-To-Transaxle Bolts

    Courtesy of FORD MOTOR CO.
21. Tighten the oil pan bolts in the sequence shown below to 25 Nm (18 lb-ft).
    Fig 19: Identifying Oil Pan Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
22. Install the 4 torque converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 20: Locating Torque Converter Nuts

    Courtesy of FORD MOTOR CO.
23. Install the access cover.
    Fig 21: Locating Access Cover

    Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

24. Install the Power Transfer Unit (PTU) and the 5 bolts.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 22: Locating PTU Bolts

    Courtesy of FORD MOTOR CO.
25. Install the PTU  support bracket and the 5 bolts.
    • Tighten to 55 Nm (41 lb-ft).
    Fig 23: Locating PTU Support Bracket And Bolts

    Courtesy of FORD MOTOR CO.
26. Install a new PTU  seal. For additional information, refer to POWER TRANSFER UNIT (PTU) .
    NOTE: A new PTU  seal must be installed whenever the intermediate shaft is removed.
27. Using a new gasket, install the RH catalytic converter and 3 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 24: Locating RH Catalytic Converter & Nuts

    Courtesy of FORD MOTOR CO.
28. Install the RH exhaust heat shield bracket (inboard half) and the 2 bolts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 25: Locating RH Exhaust Heat Shield Bracket & Bolts

    Courtesy of FORD MOTOR CO.
29. Install the RH exhaust heat shield bracket (outboard half) and the 3 nuts.
    • Tighten to 20 Nm (177 lb-in).
    Fig 26: Locating RH Exhaust Heat Shield Bracket & Nuts

    Courtesy of FORD MOTOR CO.
30. Install the RH exhaust heat shield and the 6 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 27: Locating Solenoid Bracket Bolts

    Courtesy of FORD MOTOR CO.
31. Using the Exhaust Gas Oxygen Sensor Socket, install the RH Heated Oxygen Sensor (HO2S).
    • Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas shown below.
      Fig 28: Identifying Torque Wrench Adapter Formulas

      Courtesy of FORD MOTOR CO.
    • To install, tighten to 48 Nm (35 lb-ft).
    Fig 29: Installing RH Heated Oxygen Sensor (HO2S)

    Courtesy of FORD MOTOR CO.
32. Connect the RH HO2S  electrical connector.
    Fig 30: Locating RH Heated Oxygen Sensor (HO2S) Electrical Connector

    Courtesy of FORD MOTOR CO.
33. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 31: Locating RH CMS Electrical Connector

    Courtesy of FORD MOTOR CO.

    All vehicles 

34. Position the A/C manifold onto the A/C compressor and install the bolt.
    • Install a new gasket.
    • Tighten to 15 Nm (133 lb-in).
    Fig 32: Locating A/C Manifold From A/C Compressor & Bolt

    Courtesy of FORD MOTOR CO.
35. Install 6 new LH catalytic converter studs.
    • Tighten to 12 Nm (106 lb-in).
    Fig 33: Locating LH Catalytic Converter Manifold Studs

    Courtesy of FORD MOTOR CO.
36. Install a new gasket, the LH catalytic converter and 6 new nuts.
    • Tighten to 20 Nm (177 lb-in) in the sequence shown.
    Fig 34: Locating LH Catalytic Converter & Nuts

    Courtesy of FORD MOTOR CO.
37. Install the heat shield and the 4 bolts (3 shown).
    • Tighten to 10 Nm (89 lb-in).
    Fig 35: Locating Heat Shield & Bolts

    Courtesy of FORD MOTOR CO.
38. Connect the LH CMS  electrical connector.
    Fig 36: Locating LH Catalyst Monitor Sensor (CMS) Electrical Connector

    Courtesy of FORD MOTOR CO.
39. Connect the A/C tube and install the nut.
    • Install a new gasket.
    • Tighten to 8 Nm (71 lb-in).
    Fig 37: Locating A/C Tube & Nut

    Courtesy of FORD MOTOR CO.
40. Install the A/C tube/windshield washer bottle bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 38: Locating A/C Tube & Windshield Washer Bottle Bracket Bolt

    Courtesy of FORD MOTOR CO.
41. Position the transaxle control cable bracket in place, install the 2 bolts.
    • Tighten to 23 Nm (17 lb-ft).
    Fig 39: Locating Shift Cable Bracket Bolts

    Courtesy of FORD MOTOR CO.
42. Connect the gearshift cable to the transaxle.
    Fig 40: Locating Gearshift Cable

    Courtesy of FORD MOTOR CO.
43. Connect the 2 heater hoses.
    Fig 41: Locating Heater Hoses

    Courtesy of FORD MOTOR CO.
44. Connect the upper and lower radiator hoses.
    Fig 42: Locating Upper & Lower Radiator Hoses

    Courtesy of FORD MOTOR CO.
45. Connect the LH HO2S  electrical connector.
    Fig 43: Locating LH Heated Oxygen Sensor (HO2S) Electrical Connector

    Courtesy of FORD MOTOR CO.
46. Connect the Evaporative Emission (EVAP) tube-to-EVAP  canister purge valve quick connect coupling and the brake booster vacuum tube to the upper intake manifold.
    • Attach the fuel tube and EVAP  tube-to-EVAP  canister purge valve tube retainer to the upper intake manifold.
    Fig 44: Identifying Camshaft Phaser & Sprocket, Camshaft Phaser, Sprocket Bolt & Camshaft

    Courtesy of FORD MOTOR CO.
47. Connect the fuel supply tube to the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
48. Connect the 3 PCM electrical connectors.
    Fig 45: Locating PCM Electrical Connectors

    Courtesy of FORD MOTOR CO.
49. Position the PCM ground wire and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 46: Locating PCM Ground Wire & Bolt

    Courtesy of FORD MOTOR CO.
50. Attach the 2 wiring harness retainers to the battery tray bracket and transaxle mount.
    Fig 47: Locating Wiring Harness Retainers From Battery Tray Bracket & Transaxle Mount

    Courtesy of FORD MOTOR CO.
51. Install the ground wire-to-inner fender and bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 48: Locating Ground Wire-To-Inner Fender & Bolt

    Courtesy of FORD MOTOR CO.
52. Connect the 2 engine wiring harness electrical connectors.
    Fig 49: Locating Engine Wiring Harness Electrical Connectors

    Courtesy of FORD MOTOR CO.
53. Connect the engine wiring harness electrical connector.
    Fig 50: Locating Engine Wiring Harness Electrical Connector

    Courtesy of FORD MOTOR CO.
54. Connect the power feed wires to the battery terminal and install the 2 nuts.
    • Tighten to 6 Nm (53 lb-in).
    Fig 51: Locating Power Feed Wires To Battery Terminal & Nuts
    Courtesy of FORD MOTOR CO.
55. Install the battery tray. For additional information, refer to REMOVAL AND INSTALLATION .
56. Install the engine Air Cleaner (ACL) and ACL  outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION and REMOVAL AND INSTALLATION .
57. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
    NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing.
    Fig 52: Locating Engine Oil Filter

    Courtesy of FORD MOTOR CO.
58. Position the transmission fluid cooler tubes in place. Install the transmission fluid cooler tubes in the transaxle by inserting the tube into the fitting until a click is heard/felt. Pull back to confirm connection is secure and install the secondary latches.
    Fig 53: Locating Transmission Fluid Cooler Tubes

    Courtesy of FORD MOTOR CO.
59. Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position.
    Fig 54: Positioning Powertrain Lift Under Subframe Assembly

    Courtesy of FORD MOTOR CO.
60. Install the front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    NOTE: LH shown, RH similar.
    Fig 55: Locating Front Subframe Nuts

    Courtesy of FORD MOTOR CO.
61. Position the subframe brackets and install the bolts finger-tight.
    NOTE: LH shown, RH similar.
    Fig 56: Locating Subframe Brackets & Bolts

    Courtesy of FORD MOTOR CO.
62. Install the subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    NOTE: LH shown, RH similar.
    Fig 57: Locating Subframe Nuts

    Courtesy of FORD MOTOR CO.
63. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
    NOTE: LH shown, RH similar.
    Fig 58: Locating Subframe Bracket-To-Body Bolts

    Courtesy of FORD MOTOR CO.
64. Attach the 3 wiring harness retainers to the LH front of the subframe.
    Fig 59: Locating Wiring Harness Retainers To Front Of Subframe LH

    Courtesy of FORD MOTOR CO.
65. Connect the 2 Electronic Power Assist Steering (EPAS) electrical connector on the front of the subframe.
    Fig 60: Locating EPAS Electrical Connector

    Courtesy of FORD MOTOR CO.
66. Install the intermediate shaft and the LH halfshaft. For additional information, refer to INSTALLATION .
67. Install the stabilizer bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
    NOTE: LH shown, RH similar.
    Fig 61: Locating Stabilizer Bar Links & Nuts

    Courtesy of FORD MOTOR CO.
68. Install the tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install the cotter pin.
    NOTE: LH shown, RH similar.
    Fig 62: Locating Cotter Pins & Nuts From Tie-Rod Ends

    Courtesy of FORD MOTOR CO.
69. Install the engine roll restrictor and the 2 bolts.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 63: Locating Engine Roll Restrictor & Bolts

    Courtesy of FORD MOTOR CO.
70. If equipped, install the heat shield and the 2 bolts.
    Fig 64: Locating Heat Shield & Bolts

    Courtesy of FORD MOTOR CO.
71. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips (2 shown) into the body.
    • From under the vehicle, verify that the seal is properly installed on the steering gear and the retaining clips are fully engaged into the body.
      Fig 65: Locating Steering Gear & Retaining Clips

      Courtesy of FORD MOTOR CO.

    AWD vehicles 

72. 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 66: Locating PTU Flange & Bolts

    Courtesy of FORD MOTOR CO.

    All vehicles 

73. Install the exhaust flexible pipe. For additional information, refer to INSTALLATION .
74. Install the LH splash shield and the 6 pin-type retainers (4 shown).
    Fig 67: Locating LH Splash Shield & Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
75. Position the LH fender splash shield and install the 4 screws.
    Fig 68: Locating LH Fender Splash Shield Aside & Screws

    Courtesy of FORD MOTOR CO.
76. Install the EPAS  ground wire and bolt in the RH front wheel well.
    • Tighten to 10 Nm (89 lb-in).
    Fig 69: Locating EPAS Wiring Ground Wire & Bolt

    Courtesy of FORD MOTOR CO.
77. Install the RH splash shield and the 6 pin-type retainers (4 shown).
    Fig 70: Locating RH Splash Shield & Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
78. Position the RH fender splash shield and install the 4 screws.
    Fig 71: Locating RH Fender Splash Shield Aside & Screws

    Courtesy of FORD MOTOR CO.
79. Install the steering intermediate shaft onto the steering gear and install the bolt.
    • Tighten to 20 Nm (177 lb-in).
    Fig 72: Locating Steering Column Shaft From Steering Gear & Bolt

    Courtesy of FORD MOTOR CO.
80. Install the steering joint cover and the 2 nuts.
    Fig 73: Locating Steering Joint Cover & Nuts

    Courtesy of FORD MOTOR CO.
81. Fill the engine with clean engine oil.
82. Connect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION .
83. Fill and bleed the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
84. Check the transaxle fluid and add fluid if necessary. For additional information, refer to the transmission fluid drain and refill procedure in AUTOMATIC TRANSAXLE/TRANSMISSION - AISIN AW21 .
85. Recharge the A/C system. For additional information, refer to AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING .
86. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.