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Section 797 (Engine - 4.6L And 5.4L): Installation: Engine: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

    All Engines 

  1. Position the engine in the vehicle.
  2. Remove the floor crane and the jack supporting the transmission.
  3. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
    4. NOTE: Align the engine-to-transmission dowels before installing the engine-to-transmission bolts.
    Fig 1: Installing Shifter Cable Support Bracket
    G03886111Courtesy of FORD MOTOR CO.
  4. Position the shifter cable support bracket and install the two transmission-to-engine bolts.
  5. Install the RH lower transmission-to-engine bolt.
    Fig 2: Installing RH Lower Transmission-To-Engine Bolt
    G03886112Courtesy of FORD MOTOR CO.
  6. Install the mounting bracket and connect the shift cable.
    1. Install the bolts.
    2. Connect the clip.
      Fig 3: Installing Mounting Bracket And Connecting Shift Cable
      G03886113Courtesy of FORD MOTOR CO.
  7. Install four new nuts to retain the torque converter to the flexplate.
    • Rotate the crankshaft to access all of the torque converter nuts.
      Fig 4: Installing Four New Nuts To Retain Torque Converter To Flexplate
      G03886114Courtesy of FORD MOTOR CO.
  8. Install the cylinder block opening cover.
    Fig 5: Installing Cylinder Block Opening Cover
    G03886115Courtesy of FORD MOTOR CO.
  9. Install the flexplate inspection cover.
    Fig 6: Flywheel Inspection Plate With Torque Specification
    G03885467Courtesy of FORD MOTOR CO.
    10. NOTE: RH shown; LH similar.
    Fig 7: Installing Engine Mount Nuts
    G03886117Courtesy of FORD MOTOR CO.
  10. Install the four engine mount nuts.
  11. Install the starter motor.
    1. Position the starter.
    2. Install the two bolts.
    3. Install the stud bolt.
      Fig 8: Installing Starter Motor
      G03886926Courtesy of FORD MOTOR CO.
  12. Connect the starter motor electrical connections.
    Fig 9: Connecting Starter Motor Electrical Connections
    G03886927Courtesy of FORD MOTOR CO.
  13. Install the starter motor solenoid terminal cover.
    Fig 10: Installing Starter Motor Solenoid Terminal Cover
    G03886928Courtesy of FORD MOTOR CO.
  14. Mount the exhaust system to the LH and RH exhaust manifolds.
    Fig 11: Identifying Three-Way Catalytic Converter To Exhaust Manifold Nuts
    G03886929Courtesy of FORD MOTOR CO.
    15. CAUTION: The oil cooler must be replaced or severe damage to the engine can occur.
    NOTE: Make sure the tab on the oil filter adapter nests into the notch in the oil cooler.
    Fig 12: Installing New Oil Cooler On Oil Filter Adapter
    G03885414Courtesy of FORD MOTOR CO.
  15. Position a new oil cooler on the oil filter adapter and install the threaded insert.
  16. Install a new oil filter.
    Fig 13: Oil Filter With Torque Specification
    G03885415Courtesy of FORD MOTOR CO.
  17. Connect the oil cooler hoses.
    Fig 14: Locating Cooler Hoses
    G03885411Courtesy of FORD MOTOR CO.

    18. Romeo engine (4.6L) 

  18. Position the transmission fluid cooler tube support bracket and install the nut.
    Fig 15: Installing Transmission Fluid Cooler Tube Support Bracket (Romeo Engine -4.6L)
    G03886125Courtesy of FORD MOTOR CO.

    19. Windsor engine (5.4L) 

  19. Position the fluid cooler tube support bracket and install the nut.
    Fig 16: Installing Fluid Cooler Tube Support Bracket (Windsor Engine - 5.4L)
    G03886126Courtesy of FORD MOTOR CO.

    20. All engines 

  20. Using the special tool, install a new Teflon® seal on the power steering pressure tube.
    Fig 17: Installing New Power Steering Seal Using Special Tool
    G03884778Courtesy of FORD MOTOR CO.
  21. Connect the power steering pressure tube and the power steering reservoir hose to the power steering pump.
    Fig 18: Connecting Power Steering Pressure Tube And Power Steering Reservoir Hose To Power Steering Pump
    G03886128Courtesy of FORD MOTOR CO.
  22. Install and tighten the oil drain plug.
    Fig 19: Installing Oil Drain Plug With Torque Specification
    G03885305Courtesy of FORD MOTOR CO.
  23. Position the fuel line and the LH heated oxygen sensor (HO2S) brackets. Install the four upper transmission-to-engine bolts.
    Fig 20: Installing Fuel Line And LH Heated Oxygen Sensor Brackets
    G03886130Courtesy of FORD MOTOR CO.
  24. Connect the transmission wiring harness and the LH and RH HO2S electrical connectors. Install the transmission wiring harness connector retainer in the bracket.
    Fig 21: Connecting Transmission Wiring Harness And LH/RH HO2S Electrical Connectors
    G04612445Courtesy of FORD MOTOR CO.
    25. NOTE: Do not reuse the O-ring seals. Lubricate the new O-ring seals with clean engine coolant before installing the heater outlet tube.
    Fig 22: Installing Heater Outlet Tube Over New Seals
    G03885471Courtesy of FORD MOTOR CO.
  25. Insert the heater outlet tube over the new seals.

    26. Romeo engines (4.6L) 

  26. Install the heater outlet tube studs.
    Fig 23: Installing Heater Outlet Tube Studs (Romeo Engines - 4.6L)
    G03885534Courtesy of FORD MOTOR CO.
    27. NOTE: Lubricate the O-ring seals with clean transmission fluid before installing the transmission fluid filler tube.
    Fig 24: Installing Transmission Fluid Filler Tube
    G03886134Courtesy of FORD MOTOR CO.
  27. Install the transmission fluid filler tube.

    28. Windsor engine (5.4L) 

  28. Install the heater outlet tube studs.
    Fig 25: Installing Heater Outlet Tube Studs (Windsor Engines - 5.4L)
    G03886135Courtesy of FORD MOTOR CO.
    29. NOTE: Lubricate the O-ring seals with clean transmission fluid before installing the transmission fluid filler tube.
    Fig 26: Installing Transmission Fluid Filler Tube
    G03886354Courtesy of FORD MOTOR CO.
  29. Install the transmission fluid filler tube.

    30. All engines 

  30. Connect the hose to the heater outlet tube.
    Fig 27: Connecting Hose To Heater Outlet Tube
    G03886137Courtesy of FORD MOTOR CO.
  31. Install the wiring retainers in the heater outlet tube bracket.
    1. Install the knock sensor electrical connector retainer.
    2. Install the engine harness routing clip retainer.
      Fig 28: Installing Knock Sensor Electrical Connector Retainer
      G03886138Courtesy of FORD MOTOR CO.
  32. Connect the evaporative emission canister purge valve electrical connector.
    Fig 29: Connecting Evaporative Emission Canister Purge Valve Electrical Connector
    G03885596Courtesy of FORD MOTOR CO.
  33. Connect the attachments to the transmission fluid filler tube and install the fluid level indicator.
    1. Connect the rear heater hose hanger.
    2. Install the fluid level indicator.
      Fig 30: Installing Fluid Level Indicator
      G03886140Courtesy of FORD MOTOR CO.
  34. Install the engine oil filler tube support strap bolt.
    Fig 31: Installing Engine Oil Filler Tube Support Strap Bolt
    G03886141Courtesy of FORD MOTOR CO.
    35. NOTE: Windsor engine shown; Romeo engine similar.
    Fig 32: Installing Mounting Bracket
    G03885243Courtesy of FORD MOTOR CO.
  35. Position the mounting bracket, install the ground strap and nut, and connect the electrical connectors to the bracket.
  36. Connect the engine wiring harness electrical connectors.
    Fig 33: Identifying Engine Wiring Harness Electrical Connectors
    G03885233Courtesy of FORD MOTOR CO.
  37. Connect the powertrain control module (PCM) electrical connectors.
    Fig 34: Connecting Powertrain Control Module Electrical Connectors
    G03885591Courtesy of FORD MOTOR CO.
  38. Connect the engine wiring harness to the PCM bracket.
    Fig 35: Identifying Engine Wiring Harness To PCM Bracket Retainer
    G03885211Courtesy of FORD MOTOR CO.
  39. Position the generator and install the bolts.
    Fig 36: Installing Generator
    G03885539Courtesy of FORD MOTOR CO.
  40. Connect the generator electrical connections.
    1. Install the B+ terminal and disconnect the terminal.
    2. Connect the S electrical connector.
    3. Connect the ASI electrical connector.
      Fig 37: Connecting Generator Electrical Connections
      G03885540Courtesy of FORD MOTOR CO.
    41. NOTE: Typical shown.
    Fig 38: Rotating Accessory Drive Belt Tensioner Clockwise
    G03886148Courtesy of FORD MOTOR CO.
  41. Rotate the tensioner clockwise and install the drive belt. Refer to decal on the upper radiator air deflector for belt routing.
  42. Connect the lower radiator hose to the oil filter adapter coolant inlet.
    Fig 39: Connecting Lower Radiator Hose To Oil Filter Adapter Coolant Inlet
    G03886149Courtesy of FORD MOTOR CO.
    43. NOTE: LH shown; RH similar.
    Fig 40: Installing Lower Radiator Support
    G03886952Courtesy of FORD MOTOR CO.
  43. Position the lower radiator support and install the twelve bolts.
  44. Install the RH side of the headlamp dash panel junction wiring harness.
    1. Connect the electrical connector.
    2. Install the screw.
    3. Insert the routing clips.
      Fig 41: Installing RH Side Of Headlamp Dash Panel Junction Wiring Harness
      G03886151Courtesy of FORD MOTOR CO.
  45. Install the LH side of the headlamp dash panel junction wiring harness.
    1. Install the screw.
    2. Insert the routing clips.
      Fig 42: Installing LH Side Of Headlamp Dash Panel Junction Wiring Harness
      G03886954Courtesy of FORD MOTOR CO.
    46. NOTE: RH shown; LH similar.
    Fig 43: Installing RH And LH Air Deflectors
    G03886637Courtesy of FORD MOTOR CO.
  46. Position the RH and LH air deflectors and install the pin-type retainers.
    47. NOTE: RH shown; LH similar.
    Fig 44: Installing Upper Radiator Support
    G03886956Courtesy of FORD MOTOR CO.
  47. Position the upper radiator support and install the eight bolts.
  48. Connect the horn electrical connector.
    Fig 45: Connecting Horn Electrical Connector
    G03885580Courtesy of FORD MOTOR CO.
  49. Connect the front impact severity sensor electrical connector.
    Fig 46: Connecting Front Impact Severity Sensor Electrical Connector
    G03885579Courtesy of FORD MOTOR CO.
  50. If equipped, connect the air temperature sensor electrical connector.
    Fig 47: Connecting Air Temperature Sensor Electrical Connector
    G03885578Courtesy of FORD MOTOR CO.
  51. Route the battery feed wiring harness to the power distribution box and insert the routing clips.
    Fig 48: Routing Battery Feed Wiring Harness To Power Distribution Box
    G03886632Courtesy of FORD MOTOR CO.
    52. NOTE: Cover removed for clarity.
    Fig 49: Installing Battery Feed Cable To Power Distribution Box
    G03886159Courtesy of FORD MOTOR CO.
  52. Install the battery feed cable to the power distribution box.
  53. Install the power steering reservoir.
    Fig 50: Installing Power Steering Reservoir
    G03886962Courtesy of FORD MOTOR CO.
  54. Install the hood latch.
    1. Install the hood latch.
    2. Insert the cable routing clip.
      Fig 51: Installing Hood Latch
      G03886963Courtesy of FORD MOTOR CO.
  55. Install the A/C condenser core.
    1. Position the A/C condenser core in the vehicle.
    2. Position the A/C condenser brackets.
    3. Install the bolts.
      Fig 52: Installing A/C Condenser Core
      G03886964Courtesy of FORD MOTOR CO.
    56. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.
  56. Connect the condenser core refrigerant tubes.
    1. Connect the condenser to evaporator tube.
    2. Connect the compressor discharge tube.
      Fig 53: Connecting Condenser Core Refrigerant Tubes
      G03886965Courtesy of FORD MOTOR CO.
    57. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.
    Fig 54: Connecting Compressor Suction Tube
    G03886164Courtesy of FORD MOTOR CO.
  57. Connect the compressor suction tube.
  58. Connect the A/C pressure cutoff switch electrical connector.
    Fig 55: Connecting A/C Pressure Cutoff Switch Electrical Connector
    G03886625Courtesy of FORD MOTOR CO.
  59. Position the radiator in the vehicle.
    Fig 56: Installing Radiator In Vehicle
    G03886624Courtesy of FORD MOTOR CO.
    60. NOTE: LH shown; RH similar.
    Fig 57: Installing Radiator Support Brackets
    G03886167Courtesy of FORD MOTOR CO.
  60. Position the radiator support brackets and install the bolts.
  61. Position the fan shroud and the fan and fan clutch in the vehicle, and install the bolts.
    Fig 58: Installing Fan Shroud, Fan And Fan Clutch
    G03886168Courtesy of FORD MOTOR CO.
  62. Insert the degas hose retainer in the fan shroud.
    Fig 59: Installing Degas Hose Retainer In Fan Shroud
    G03885566Courtesy of FORD MOTOR CO.
  63. Install the fan blade assembly and fan clutch.
    1. Install the fan blade and the fan clutch.
    2. Using the special tool, hold the coolant pump pulley.
    3. Using the special tool, tighten the fan clutch nut.
      Fig 60: Installing Fan Blade Assembly And Fan Clutch
      G03886170Courtesy of FORD MOTOR CO.
  64. Connect the upper radiator hose and the degas hose to the radiator.
    Fig 61: Connecting Upper Radiator Hose And Degas Hose To Radiator
    G03885564Courtesy of FORD MOTOR CO.
  65. Install the valance panel. For additional information, refer to FRONT END BODY PANELS .
  66. Connect the transmission cooler tubes.
    Fig 62: Connecting Transmission Cooler Tubes
    G03886172Courtesy of FORD MOTOR CO.
  67. Position the splash shield and install the pushpin retainers.
    Fig 63: Identifying Pushpin Retainers And Splash Shield
    G03885266Courtesy of FORD MOTOR CO.
  68. Connect the lower radiator hose to the radiator.
    • Connect the hose.
    • Connect the hose hanger.
      Fig 64: Connecting Lower Radiator Hose To Radiator
      G03886599Courtesy of FORD MOTOR CO.
  69. Install the front bumper. For additional information, refer to BUMPERS .
  70. Fill the engine with clean engine oil.
  71. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD - 4.6L  or INTAKE MANIFOLD - 5.4L .
  72. Fill all fluids to the correct levels.
  73. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.

    74. Vehicles equipped with A/C 

  74. Evacuate and recharge the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
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