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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 2616 (Engine Mechanical - 3.5L) >> Installation >> Engine Front Cover

Engine Front Cover

WARNING: This page is about a different car, the 2011 Lincoln MKZ and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G07785334
Alignment Pins
307-399
G07785335
Handle
205-153 (T80T-4000-W)
G07785336
Installer, Crankshaft Vibration Damper
303-102 (T74P-6316-B)
G07785337
Installer, Front Cover Oil Seal
303-335
G07785338
Installer, Front Crankshaft Seal
303-1251
G07785339
Installer, VCT Spark Plug Tube Seal
303-1247/2
G07785340
Powertrain Lift
300-OTC1585AE
G07785341
Strap Wrench
303-D055 (D85L-6000-A) or equivalent
G07785342
Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool
MATERIAL

Item Specification
Motorcraft® High Performance Engine RTV Silicone
TA-357
WSE-M4G323-A6
Motorcraft® Metal Surface Prep
ZC-31-A
-
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada) XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada) WSS-M2C945-A
Motorcraft® Silicone Gasket Remover
ZC-30
-
Threadlock and Sealer
TA-25
WSK-M2G351-A5
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

All vehicles 

  1. Install the Alignment Pins.
    Fig 1: Identifying Alignment Pins
    G07785343Courtesy of FORD MOTOR CO.
  2. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
    Fig 2: Identifying RTV Silicone To Oil Pan-To-Cylinder Block Joint And Cylinder Head-To-Cylinder Block Joint Areas Of Engine Front Cover
    G07785344Courtesy of FORD MOTOR CO.
  3. Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
    • Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
  4. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
    Fig 3: Identifying Engine Front Cover Bolts 17, 18, 19 And 20
    G07785345Courtesy of FORD MOTOR CO.
  5. Install the engine front cover and bolts 17, 18, 19 and 20.
    • Tighten in sequence to 3 Nm (27 lb-in).
  6. Remove the Alignment Pins.
    Fig 4: Identifying Alignment Pins
    G07785346Courtesy of FORD MOTOR CO.
  7. NOTE: Do not tighten the bolts at this time.
    Fig 5: Locating Engine Mount Bracket And Bolts
    G07785347Courtesy of FORD MOTOR CO.
  8. Install the engine mount bracket and the 3 bolts.
  9. NOTE: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
    Fig 6: Identifying Engine Front Cover Bolts And Engine Mount Bracket Bolts Tightening Sequence
    G07785348Courtesy of FORD MOTOR CO.
  10. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in illustration in 2 stages:
    • Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133 lb-in).
    • Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
  11. NOTE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.
    Fig 7: Locating Engine Mount Studs
    G07785349Courtesy of FORD MOTOR CO.
  12. Install the engine mount studs in the following sequence.
    1. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.
    2. Clean all the thread sealer from the engine mount studs (old and new studs).
    3. Apply new Threadlock and Sealer to the engine mount stud threads.
    4. Install the 2 engine mount studs.
    • Tighten to 20 Nm (177 lb-in).
  13. Install the engine mount bracket and the 2 bolts.
    • Tighten to 24 Nm (18 lb-ft).
    Fig 8: Locating Engine Mount Bracket And Bolts
    G07785350Courtesy of FORD MOTOR CO.
  14. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
    Fig 9: Installing Crankshaft Front Seal Using Front Crankshaft Seal Installer And Crankshaft Vibration Damper Installer
    G07785351Courtesy of FORD MOTOR CO.
  15. Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
  16. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
    Fig 10: Identifying Crankshaft Pulley With Front Cover Oil Seal Installer And Crankshaft Vibration Damper Installer
    G07785352Courtesy of FORD MOTOR CO.
  17. Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the crankshaft pulley.
  18. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 11: Identifying Crankshaft Pulley Washer And Bolt With Strap Wrench
    G07785353Courtesy of FORD MOTOR CO.
  19. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 11 Nm (97 lb-in).
    Fig 12: Locating Accessory Drive Belt Tensioner Bolts
    G07785354Courtesy of FORD MOTOR CO.
  20. Install the power steering pump and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 13: Locating Power Steering Pump Bolts
    G07785355Courtesy of FORD MOTOR CO.
  21. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.
    NOTE: Spark plug tube seal installation shown in illustration, Variable Camshaft Timing (VCT) solenoid seal installation similar.
    Fig 14: Installing VCT Solenoid And/Or Spark Plug Tube Seals Using VCT Spark Plug Tube Seal Installer And Handle
    G07785356Courtesy of FORD MOTOR CO.
  22. Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals.
  23. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
    Fig 15: Locating Motorcraft High Performance Engine RTV Silicone Bead On Engine Front Cover-To-RH Cylinder Head Joints
    G07785357Courtesy of FORD MOTOR CO.
  24. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
  25. Using a new gasket, install the RH valve cover and tighten the bolt and 8 stud bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
    Fig 16: Identifying RH Valve Cover Bolts Tightening Sequence
    G07785358Courtesy of FORD MOTOR CO.
  26. NOTE: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
    Fig 17: Locating Motorcraft High Performance Engine RTV Silicone Bead On Engine Front Cover-To-LH Cylinder Head Joints
    G07785359Courtesy of FORD MOTOR CO.
  27. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
  28. Using a new gasket, install the RH valve cover and tighten the 9 stud bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
    Fig 18: Identifying RH Valve Cover Bolts Tightening Sequence
    G07785360Courtesy of FORD MOTOR CO.
  29. Install the wiring harness retaining bracket and the 2 nuts.
    • Tighten to 4 Nm (35 lb-in).
    Fig 19: Locating Nuts And Wiring Harness Retaining Bracket
    G07785361Courtesy of FORD MOTOR CO.
  30. Install the Power Steering Pressure (PSP) hose bracket and nut.
    • Tighten to 9 Nm (80 lb-in).
    Fig 20: Locating PSP Hose Bracket Nut
    G07785362Courtesy of FORD MOTOR CO.
  31. Attach the PSP hose retainer to the engine lifting eye.
    Fig 21: Locating PSP Hose Retainer At Engine Lifting Eye
    G07785363Courtesy of FORD MOTOR CO.
  32. NOTE: LH shown in illustration, RH similar.
    Fig 22: Locating Coil-On-Plugs And Bolts
    G07785364Courtesy of FORD MOTOR CO.
  33. Install the 6 coil-on-plug assemblies and the 6 bolts.
    • Tighten to 7 Nm (62 lb-in).
  34. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
  35. Connect the 3 LH coil-on-plug electrical connectors.
    Fig 23: Locating LH Coil-On-Plug Electrical Connectors
    G07785365Courtesy of FORD MOTOR CO.
  36. Connect the LH camshaft VCT solenoid electrical connector.
    Fig 24: Locating LH VCT Solenoid Electrical Connector
    G07785366Courtesy of FORD MOTOR CO.
  37. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
  38. Connect the 3 RH coil-on-plug electrical connectors.
    Fig 25: Locating RH Coil-On-Plug Electrical Connectors
    G07785367Courtesy of FORD MOTOR CO.
  39. Connect the RH VCT solenoid electrical connector.
    Fig 26: Locating RH Variable Camshaft Timing (VCT) Solenoid Electrical Connector
    G07785368Courtesy of FORD MOTOR CO.
  40. Connect the PSP switch electrical connector.
    Fig 27: Locating PSP Switch Electrical Connector
    G07785369Courtesy of FORD MOTOR CO.
  41. Connect the RH Catalyst Monitor Sensor (CMS) sensor electrical connector.
    Fig 28: Identifying RH Catalyst Monitor Sensor Electrical Connector
    G07785370Courtesy of FORD MOTOR CO.
  42. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
    Fig 29: Identifying Upper Intake Manifold Bolts Tightening Sequence
    G07785371Courtesy of FORD MOTOR CO.
  43. Using new gaskets, install the upper intake manifold and the 6 bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
  44. Install the upper intake manifold support bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 30: Locating Upper Intake Manifold Support Bracket Bolt
    G07785372Courtesy of FORD MOTOR CO.
  45. Attach the wiring harness retainers to the upper intake manifold.
    Fig 31: Locating Wiring Harness Retainers At Upper Intake Manifold
    G07785373Courtesy of FORD MOTOR CO.
  46. Connect the Throttle Body (TB) electrical connector.
    Fig 32: Locating Throttle Body (TB) Electrical Connector
    G07785374Courtesy of FORD MOTOR CO.
  47. Connect the PCV hose to the PCV valve.
    Fig 33: Locating PCV Hose
    G07785375Courtesy of FORD MOTOR CO.
  48. If equipped, attach the block heater wiring harness retainer to the PSP tube and the power steering reservoir hose.
    Fig 34: Locating Block Heater Wiring Harness Retainers At PSP Hose And Power Steering Reservoir Hose
    G07785376Courtesy of FORD MOTOR CO.
  49. If equipped, attach the block heater wiring harness retainer to the upper intake manifold.
    Fig 35: Locating Block Heater Wiring Harness Retainer At Upper Intake Manifold
    G07785377Courtesy of FORD MOTOR CO.
  50. Raise the engine and transaxle assembly into the vehicle.
  51. 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 36: Locating Engine Mount Nut And Bolts
    G07785378Courtesy of FORD MOTOR CO.
  52. Install the 2 engine mount spacers and the 4 engine mount nuts.
    • Tighten in the sequence shown in illustration to 70 Nm (52 lb-ft).
    Fig 37: Identifying Engine Mount-To-Engine Nuts Tightening Sequence
    G07785379Courtesy of FORD MOTOR CO.
  53. Install the transaxle support insulator bracket, bolt and the 2 nuts.
    • Tighten to 80 Nm (59 lb-ft).
    Fig 38: Locating Transaxle Support Insulator Bracket Bolt And Nuts
    G07785380Courtesy of FORD MOTOR CO.
  54. Install the transaxle support insulator through bolt and nut.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 39: Locating Transaxle Support Insulator Through Bolt And Nut
    G07785381Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

  55. NOTE: Do not tighten the 2 catalytic converter support bracket bolts at this time.
    Fig 40: Locating RH Catalytic Converter Bracket Bolts
    G07785382Courtesy of FORD MOTOR CO.
  56. Install the RH catalytic converter support bracket and the 2 bolts.
  57. 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 41: Locating Nuts And RH Catalytic Converter Bracket
    G07785383Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

  58. NOTE: A new Power Transfer Unit (PTU) seal must be installed whenever the intermediate shaft is removed.
  59. Install a new PTU seal. For additional information, refer to ENGINE IGNITION - 3.0L (4V) -- FUSION & MILAN article.

    All vehicles 

  60. NOTE: Align the index marks on the subframe to the index marks on the underbody that were made during removal.
    Fig 42: Identifying Powertrain Lift Under Subframe Assembly
    G07785384Courtesy of FORD MOTOR CO.
  61. Using the Powertrain Lift, raise the subframe into the installed position.
  62. NOTE: LH shown in illustration, RH similar.
    Fig 43: Locating Front Subframe Nut
    G07785385Courtesy of FORD MOTOR CO.
  63. Install the 2 front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
  64. NOTE: LH shown in illustration, RH similar.
    Fig 44: Locating Subframe Brackets Bolts
    G07785386Courtesy of FORD MOTOR CO.
  65. Position the subframe brackets and install the 4 bolts finger-tight.
  66. NOTE: LH shown in illustration, RH similar.
    Fig 45: Locating Rear Subframe Nut And Subframe Bracket
    G07785387Courtesy of FORD MOTOR CO.
  67. Install the 2 rear subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
  68. NOTE: LH shown in illustration, RH similar.
    Fig 46: Locating Subframe Bracket-To-Body Bolts
    G07785388Courtesy of FORD MOTOR CO.
  69. Tighten the 2 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
  70. NOTE: LH shown in illustration, RH similar.
    Fig 47: Locating Stabilizer Bar Link Nut
    G07785389Courtesy of FORD MOTOR CO.
  71. Install the stabilizer bar links and nuts to the struts.
  72. NOTE: LH shown in illustration, RH similar.
    Fig 48: Locating Tie-Rod Ends And Nuts
    G07785390Courtesy of FORD MOTOR CO.
  73. Install the tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install new cotter pins.
  74. Install the engine roll restrictor-to-subframe through bolt.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 49: Locating Engine Roll Restrictor-To-Subframe Through Bolt
    G07785391Courtesy of FORD MOTOR CO.

    AWD vehicles 

  75. 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 (3 shown in illustration).
    • Tighten to 70 Nm (52 lb-ft).
    Fig 50: Locating Driveshaft Bolts
    G07785392Courtesy of FORD MOTOR CO.

    All vehicles 

  76. Using new gaskets, install the Y-pipe assembly and the 6 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 51: Locating Nuts And Y-Pipe Assembly
    G07785393Courtesy of FORD MOTOR CO.
  77. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
  78. Connect the 2 transmission fluid cooler hoses.
    Fig 52: Locating Transaxle Cooler Hoses
    G07785394Courtesy of FORD MOTOR CO.
  79. Connect the power steering cooler tube.
    Fig 53: Locating Power Steering Cooler Tube
    G07785395Courtesy of FORD MOTOR CO.
  80. 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 correctly installed on the steering gear and the retaining clips are fully engaged into the body.
    Fig 54: Locating Clips And Steering Gear-To-Dash Seal
    G07785396Courtesy of FORD MOTOR CO.
  81. If equipped, install the underbody shield and the 6 screws.
    Fig 55: Locating Underbody Shield Screws
    G07785397Courtesy of FORD MOTOR CO.
  82. Install the LH splash shield and the 6 pin-type retainers (4 shown in illustration).
    Fig 56: Locating Pin-Type Retainers And LH Splash Shield
    G07785398Courtesy of FORD MOTOR CO.
  83. Position the LH fender splash shield and install the 4 screws.
    Fig 57: Locating LH Fender Splash Shield Screws
    G07785399Courtesy of FORD MOTOR CO.
  84. NOTE: Align the index marks made during removal.
    Fig 58: Locating Steering Intermediate Shaft Bolt
    G07785400Courtesy of FORD MOTOR CO.
  85. Install the steering intermediate shaft onto the steering gear and install a new bolt.
    • Tighten to 25 Nm (18 lb-ft).
  86. Install the steering joint cover and the 2 nuts.
    Fig 59: Locating Nuts And Steering Joint Cover
    G07785401Courtesy of FORD MOTOR CO.
  87. Using a new banjo bolt and 2 new seals, install the PSP tube onto the steering gear.
    • Tighten to 37 Nm (27 lb-ft).
    Fig 60: Locating PSP Hose Banjo Bolt
    G07785402Courtesy of FORD MOTOR CO.
  88. Install the PSP tube bracket and bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 61: Locating Power Steering Pressure Hose Bracket Bolt
    G07785403Courtesy of FORD MOTOR CO.
  89. Connect the PCM connectors and pin-type retainers.
    Fig 62: Locating PCM Electrical Connectors And Pin-Type Retainers
    G07785404Courtesy of FORD MOTOR CO.
  90. Install the engine mount brace and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 63: Identifying Bolts And Engine Mount Brace
    G07785405Courtesy of FORD MOTOR CO.
  91. Install the ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 64: Locating Bolt And Ground Wire On Engine Mount Brace
    G07785406Courtesy of FORD MOTOR CO.
  92. Connect the fuel supply tube to the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
    Fig 65: Locating Fuel Supply Tube
    G07785407Courtesy of FORD MOTOR CO.
  93. Attach the power steering reservoir onto the cowl.
    Fig 66: Locating Power Steering Reservoir
    G07785408Courtesy of FORD MOTOR CO.
  94. Connect the hose to the power steering reservoir.
    • Attach the pin-type retainer to the engine mount brace.
    Fig 67: Locating Pin-Type Retainer At Engine Mount Brace
    G07785409Courtesy of FORD MOTOR CO.
  95. Install the oil level indicator.
    Fig 68: Identifying Oil Level Indicator
    G07785410Courtesy of FORD MOTOR CO.
  96. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
    Fig 69: Locating Wiring Harness Retainers At LH Valve Cover Stud Bolts
    G07785411Courtesy of FORD MOTOR CO.
  97. Connect the 2 engine wiring harness electrical connectors.
    Fig 70: Locating Engine Control Wiring Harness Electrical Connectors
    G07785412Courtesy of FORD MOTOR CO.
  98. Attach the 2 wiring harness retainers.
    Fig 71: Locating Wiring Harness Retainers
    G07785413Courtesy of FORD MOTOR CO.
  99. Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
    • Tighten to 8 Nm (71 lb-in).
    Fig 72: Locating A/C Tubes Nuts
    G07785414Courtesy of FORD MOTOR CO.
  100. Install the A/C tube bracket bolt.
    • Tighten to 8 Nm (71 lb-in).
    Fig 73: Locating A/C Tube Bracket Bolt
    G07785415Courtesy of FORD MOTOR CO.
  101. Install the 2 A/C tube retaining clamp bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 74: Locating A/C Tube Bracket Bolts
    G07785416Courtesy of FORD MOTOR CO.
  102. 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 75: Locating A/C Tube Nut
    G07785417Courtesy of FORD MOTOR CO.
  103. Attach the coolant tube retainer clips to the A/C tube.
    Fig 76: Locating Coolant Tube Retainer Clips On A/C Tube
    G07785418Courtesy of FORD MOTOR CO.
  104. If equipped, attach the engine block heater harness to the radiator support, power steering hose, A/C tube and the engine wiring harness.
  105. Install the ground wire and bolt.
    • Tighten to 12 Nm (106 lb-in).
    Fig 77: Locating Ground Wire And Bolt
    G07785419Courtesy of FORD MOTOR CO.
  106. Position the transaxle control cable bracket in place and install the 3 nuts.
    • Tighten to 12 Nm (106 lb-in).
    Fig 78: Locating Transaxle Control Cable Bracket Nuts
    G07785420Courtesy of FORD MOTOR CO.
  107. Connect the transaxle control cable to the control lever.
    Fig 79: Locating Transaxle Control Cable At Control Lever
    G07785421Courtesy of FORD MOTOR CO.
  108. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
    Fig 80: Locating Upper Radiator Hose, Lower Radiator Hose And Heater Hoses At Thermostat Housing
    G07785422Courtesy of FORD MOTOR CO.
  109. Connect the vacuum hose and the Evaporative Emission (EVAP) tube to the upper intake manifold.
    Fig 81: Locating Vacuum Hose And Evaporative Emission (EVAP) Tube
    G07785423Courtesy of FORD MOTOR CO.
  110. Install the ground wire and the bolt.
    • Tighten to 12 Nm (106 lb-in).
    Fig 82: Identifying Ground Wire Bolt
    G07785424Courtesy of FORD MOTOR CO.
  111. Install the 2 battery cables to the positive battery cable and the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
    Fig 83: Locating Nuts, Battery Cables And Positive Battery Cable
    G07785425Courtesy of FORD MOTOR CO.
  112. Attach the 2 wiring harness retainers to the transmission mount and the battery tray bracket.
    Fig 84: Locating Wiring Harness Retainers At Transmission Mount And Battery Tray Bracket
    G07785426Courtesy of FORD MOTOR CO.
  113. Connect the 2 engine wiring harness electrical connectors.
    Fig 85: Locating Engine Wiring Harness Electrical Connectors
    G07785427Courtesy of FORD MOTOR CO.
  114. Install the battery tray. For additional information, refer to BATTERY, MOUNTING & CABLES -- FUSION, MILAN & MKZ article.
  115. Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 3.5L -- FUSION & MKZ article.
  116. Install the degas bottle. For additional information, refer to ENGINE COOLING SYSTEM (EXCEPT HYBRID) article.
  117. Install the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
  118. Install the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE - 3.5L -- FUSION & MKZ article.
  119. NOTE: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
  120. Fill the engine with clean engine oil.
  121. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING SYSTEM (EXCEPT HYBRID) article.
  122. Fill the power steering system. For additional information, refer to STEERING SYSTEM - HYDRAULIC POWER ASSIST STEERING (HPAS) article.
  123. 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 -- FUSION & MKZ article.
  124. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS -- FUSION, MILAN & MKZ (EXCEPT HYBRID) article.
  125. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.