Section 2294 (Engine Mechanical - 3.5L): Installation: Engine: Material

All vehicles 

1. Align the transaxle to the engine.
2. Install the 4 transaxle-to-engine bolts and the transaxle-to-engine stud bolt.
   • Tighten to 48 Nm (35 lb-ft).
   Fig 1: Locating Transaxle-To-Engine Bolts

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

   Courtesy of FORD MOTOR CO.
4. Using the Heavy Duty Floor Crane and the Spreader Bar, position the engine and transaxle onto the lift table.
   Fig 3: Identifying Heavy Duty Floor Crane And Spreader Bar

   Courtesy of FORD MOTOR CO.
5. Install the Powertrain Lift and Universal Adapter Brackets.
   NOTE: Position a block of wood under the transaxle.
   Fig 4: Identifying Powertrain Lift & Universal Adapter Brackets

   Courtesy of FORD MOTOR CO.
6. Install the starter and the 2 bolts.
   • Tighten to 26 Nm (19 lb-ft).
   Fig 5: Locating Starter & Bolts

   Courtesy of FORD MOTOR CO.
7. Attach the starter wire terminals and install the 2 nuts.
   1. Tighten to 12 Nm (106 lb-in).
   2. Tighten to 5 Nm (44 lb-in).
      • Position the starter terminal boot over the starter terminal.
      Fig 6: Identifying Starter Motor Electrical Connectors

      Courtesy of FORD MOTOR CO.
8. Connect the Transmission Control Module (TCM) electrical connector.
   Fig 7: Locating Transmission Control Module Electrical Connector

   Courtesy of FORD MOTOR CO.
9. Install the ground wire and bolt.
   • Tighten to 12 Nm (106 lb-in).
   Fig 8: Locating Ground Wire & Bolt

   Courtesy of FORD MOTOR CO.
10. Connect the wiring harness fasteners to the transaxle-to-engine stud bolt and the starter.
    Fig 9: Locating Transaxle-To-Engine Stud Bolt & Starter

    Courtesy of FORD MOTOR CO.
11. Raise the engine and transaxle assembly into the vehicle.
12. Install the engine mount, the nut and the 2 bolts.
    • Tighten the bolts to 55 Nm (41 lb-ft).
    • Tighten the nut to 63 Nm (46 lb-ft).
    Fig 10: Locating RH Instrument Panel Floor Brace Bolts

    Courtesy of FORD MOTOR CO.
13. Install the 2 engine mount spacers and the 4 engine mount nuts.
    • Tighten in the sequence shown in illustration below to 70 Nm (52 lb-ft).
    Fig 11: Identifying Engine Mount Nut Tightening Sequence

    Courtesy of FORD MOTOR CO.
14. Install the 2 transaxle support insulator bracket nuts and the bolt.
    • Tighten to 80 Nm (59 lb-ft).
    Fig 12: Locating Transaxle Support Insulator Bracket Bolt & Nuts

    Courtesy of FORD MOTOR CO.
15. Install the transaxle support insulator through bolt and nut.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 13: Locating Transaxle Support Insulator Through Bolt & Nut

    Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

16. Using a small screwdriver, remove the compression seal and discard.
    NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is moved from the vehicle.
    Fig 14: Removing Compression Seal Using Small Screwdriver

    Courtesy of FORD MOTOR CO.
17. Using a soft face hammer, install the new compression seal.
    Fig 15: Locating Compression Seal

    Courtesy of FORD MOTOR CO.
18. Position the PTU  in place and install the 5 bolts.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 16: Locating PTU Bolts

    Courtesy of FORD MOTOR CO.
19. Position the PTU  support bracket in place and install the 5 bolts.
    • Tighten to 70 Nm (52 lb-ft).
    Fig 17: Locating Bolts & Power Transfer Unit (PTU) Support Bracket

    Courtesy of FORD MOTOR CO.
20. Using a new gasket, install the RH catalytic converter and 4 new nuts.
    NOTE: Do not tighten the 4 catalytic converter nuts at this time.
    Fig 18: Locating RH Catalytic Converter & Nuts

    Courtesy of FORD MOTOR CO.
21. Install the 2 catalytic converter-to-bracket bolts.
    • Tighten the 4 catalytic converter nuts to 40 Nm (30 lb-ft).
    • Tighten the 2 catalytic converter-to-bracket bolts to 20 Nm (177 lb-in).
    Fig 19: Locating RH Catalytic Converter Bracket Bolts

    Courtesy of FORD MOTOR CO.
22. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 20: Locating RH Catalyst Monitor Sensor (CMS) Electrical Connector

    Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

23. Install the RH catalytic converter support bracket and the 2 bolts.
    NOTE: Do not tighten the 2 catalytic converter support bracket bolts at this time.
    Fig 21: Locating RH Catalytic Converter Bracket Bolts

    Courtesy of FORD MOTOR CO.
24. Install the 2 catalytic converter support bracket nuts.
    • Tighten to 40 Nm (30 lb-ft).
    • Tighten the 2 catalytic converter support bracket bolts to 20 Nm (177 lb-in).
    Fig 22: Locating RH Catalytic Converter Bracket & Nuts

    Courtesy of FORD MOTOR CO.

    All vehicles 

25. Using the Powertrain Lift, raise the subframe into the installed position.
    Fig 23: Positioning Powertrain Lift Under Subframe Assembly

    Courtesy of FORD MOTOR CO.
26. Install the 2 front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    NOTE: LH shown in illustration, RH similar.
    Fig 24: Locating Front Subframe Nuts

    Courtesy of FORD MOTOR CO.
27. Position the subframe brackets and install the 4 bolts finger-tight.
    NOTE: LH shown in illustration, RH similar.
    Fig 25: Locating Subframe Brackets & Bolts

    Courtesy of FORD MOTOR CO.
28. Install the 2 rear subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    NOTE: LH shown in illustration, RH similar.
    Fig 26: Locating Rear Subframe Nuts & Subframe Brackets

    Courtesy of FORD MOTOR CO.
29. Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
    NOTE: LH shown in illustration, RH similar.
    Fig 27: Locating Subframe Bracket-To-Body Bolts

    Courtesy of FORD MOTOR CO.
30. Install the stabilizer bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
    NOTE: LH shown in illustration, RH similar.
    Fig 28: Locating Stabilizer Bar Links & Nuts

    Courtesy of FORD MOTOR CO.
31. Install the tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install new cotter pins.
    NOTE: LH shown in illustration, RH similar.
    Fig 29: Locating Tie-Rod Ends & Nuts

    Courtesy of FORD MOTOR CO.
32. Install the engine roll restrictor-to-subframe through bolt.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 30: Locating Engine Roll Restrictor-To-Subframe Through Bolt

    Courtesy of FORD MOTOR CO.

    AWD vehicles 

33. Line up the index marks on the rear driveshaft to the index marks on the PTU  flange made during removal and install the 4 new bolts.
    • Tighten to 70 Nm (52 lb-ft).
    Fig 31: Locating PTU Flange & Bolts

    Courtesy of FORD MOTOR CO.

    All vehicles 

34. Install 4 new torque converter nuts.
    • Tighten to 36 Nm (27 lb-ft).
    Fig 32: Locating Torque Converter Nuts

    Courtesy of FORD MOTOR CO.
35. Install the inspection cover and the 2 fasteners.
    Fig 33: Locating Inspection Cover & Fasteners

    Courtesy of FORD MOTOR CO.
36. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 34: Locating Oil Pan-To-Transaxle Bolts

    Courtesy of FORD MOTOR CO.
37. Using new gaskets, install the Y-pipe assembly and 6 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 35: Locating Transaxle Support Insulator Through Bolt & Nut

    Courtesy of FORD MOTOR CO.
38. Install a new engine oil filter.
    NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
39. Connect the 2 transmission fluid cooler hoses.
    Fig 36: Locating Transaxle Cooler Hoses

    Courtesy of FORD MOTOR CO.
40. Connect the power steering cooler tube.
    Fig 37: Locating Power Steering Cooler Tube

    Courtesy of FORD MOTOR CO.
41. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips 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 38: Locating Steering Gear Clips

    Courtesy of FORD MOTOR CO.
42. If equipped, install the underbody shield and the 6 screws.
    Fig 39: Locating Underbody Shield Screws

    Courtesy of FORD MOTOR CO.
43. Install the LH splash shield and the 6 pin-type retainers (4 shown in illustration).
    Fig 40: Identifying Pin-Type Retainers & LH Splash Shield

    Courtesy of FORD MOTOR CO.
44. Position the LH fender splash shield and install the 4 screws.
    Fig 41: Locating LH Fender Splash Shield & Screws

    Courtesy of FORD MOTOR CO.
45. Install the steering intermediate shaft onto the steering gear and install a new bolt.
    • Tighten to 25 Nm (18 lb-ft).
    NOTE: Align the index marks made during removal.
    Fig 42: Locating Steering Intermediate Shaft Onto Steering Gear

    Courtesy of FORD MOTOR CO.
46. Install the steering joint cover and the 2 nuts.
    Fig 43: Locating Steering Joint Cover & Nuts

    Courtesy of FORD MOTOR CO.
47. Using a new banjo bolt and 2 new seals, install the Power Steering Pressure (PSP) tube onto the steering gear.
    • Tighten to 37 Nm (27 lb-ft).
    Fig 44: Locating PSP Hose Banjo Bolt

    Courtesy of FORD MOTOR CO.
48. Install the PSP  tube bracket and bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 45: Locating Power Steering Pressure Hose Bracket Bolt

    Courtesy of FORD MOTOR CO.
49. Connect the PCM electrical connectors and pin-type retainers.
    Fig 46: Locating PCM Electrical Connectors & Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
50. Install the engine mount brace and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 47: Locating Engine Mount Brace & Bolt

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

    Courtesy of FORD MOTOR CO.
52. Connect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 49: Locating Fuel Supply Tube From Fuel Rail

    Courtesy of FORD MOTOR CO.
53. Attach the power steering reservoir onto the cowl.
    Fig 50: Attaching Power Steering Reservoir Onto Cowl

    Courtesy of FORD MOTOR CO.
54. Connect the hose to the power steering reservoir.
    • Attach the pin-type retainer to the engine mount brace.
    Fig 51: Locating Hose

    Courtesy of FORD MOTOR CO.
55. Install the oil level indicator.
    Fig 52: Locating Oil Level Indicator

    Courtesy of FORD MOTOR CO.
56. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
    Fig 53: Locating LH Valve Cover Stud Bolts & Wiring Harness

    Courtesy of FORD MOTOR CO.
57. Connect the 2 engine wiring harness electrical connectors.
    Fig 54: Locating Engine Control Wiring Harness Electrical Connectors

    Courtesy of FORD MOTOR CO.
58. Attach the 2 wiring harness retainers.
    Fig 55: Locating Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
59. Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
    • Tighten to 8 Nm (71 lb-in).
    Fig 56: Locating A/C Tubes & Nuts

    Courtesy of FORD MOTOR CO.
60. Install the A/C tube bracket bolt.
    • Tighten to 8 Nm (71 lb-in).
    Fig 57: Locating A/C Tube Bracket Bolt

    Courtesy of FORD MOTOR CO.
61. Install the 2 A/C tube bracket bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 58: Locating A/C Tube Bracket Bolts

    Courtesy of FORD MOTOR CO.
62. Using a new O-ring seal, connect the A/C tube to the condenser and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    Fig 59: Locating A/C Tube & Nut

    Courtesy of FORD MOTOR CO.
63. Attach the coolant tube retainer clips to the A/C tube.
    Fig 60: Locating Coolant Tube Retainer Clips & A/C Tube

    Courtesy of FORD MOTOR CO.
64. If equipped, attach the engine block heater harness to the radiator support, power steering hose, A/C tube and the engine wiring harness.
65. Install the ground wire and bolt.
    • Tighten to 12 Nm (106 lb-in).
    Fig 61: Locating Ground Wire & Bolt

    Courtesy of FORD MOTOR CO.
66. Position the transaxle control cable bracket in place and install the 3 nuts.
    • Tighten to 12 Nm (106 lb-in).
    Fig 62: Locating Transaxle Control Cable Bracket

    Courtesy of FORD MOTOR CO.
67. Connect the transaxle control cable to the control lever.
    Fig 63: Locating Transaxle Control Cable

    Courtesy of FORD MOTOR CO.
68. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
    Fig 64: Locating Upper Radiator Hose, Lower Radiator Hose & Heater Hoses

    Courtesy of FORD MOTOR CO.
69. Connect the vacuum hose and the Evaporative Emission (EVAP) tube to the upper intake manifold.
    Fig 65: Locating Vacuum Hose & Evaporative Emission (EVAP) Tube

    Courtesy of FORD MOTOR CO.
70. Install the ground wire and the bolt.
    • Tighten to 12 Nm (106 lb-in).
    Fig 66: Locating Ground Wire Bolt

    Courtesy of FORD MOTOR CO.
71. Install the 2 battery cables to the positive battery cable and the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
    Fig 67: Locating Battery Cables & Nuts

    Courtesy of FORD MOTOR CO.
72. Attach the 2 wiring harness retainers to the transmission mount and the battery tray bracket.
    Fig 68: Locating Transmission Mount & Battery Tray Bracket

    Courtesy of FORD MOTOR CO.
73. Connect the 2 engine wiring harness electrical connectors.
    Fig 69: Locating Engine Wiring Harness Electrical Connectors

    Courtesy of FORD MOTOR CO.
74. Install the battery tray. For additional information, refer to REMOVAL AND INSTALLATION .
75. Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION .
76. Install the degas bottle. For additional information, refer to REMOVAL AND INSTALLATION .
77. Install the LH halfshaft and the intermediate shaft. For additional information, refer to INSTALLATION .
78. Install the accessory drive belt and the power steering belt. For additional information, refer to INSTALLATION .
79. Fill the engine with clean engine oil.
80. Fill and bleed the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
81. Fill the power steering system. For additional information, refer to POWER STEERING SYSTEM FILLING .
82. Check the transaxle fluid and add fluid if necessary. For additional information, refer to the TRANSMISSION FLUID DRAIN AND REFILL .
83. Recharge the A/C system. For additional information, refer to AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING .
84. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions