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Section 589 (Engine 4.6 & 5.4L): Installation: Engine

WARNING: This page is about a different car, the 2004 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S) 

Fig 1: Identifying Special Tool
G02763554Courtesy of FORD MOTOR CO.

MATERIAL 

MATERIAL SPECIFICATIONS

Item Specification
SAE 5W-20 Premium Synthetic Blend Engine Oil XO-5W20-QSP or equivalent WSS-M2C153-H

    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 2: Installing Transmission-To-Engine Bolts
    G02763555Courtesy 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 3: Installing RH Lower Transmission-To-Engine Bolt
    G02763556Courtesy of FORD MOTOR CO.

    6. VEHICLES EQUIPPED WITH 4R70E TRANSMISSION 

  6. Install the mounting bracket and connect the shift cable.
    1. Install the bolts.
    2. Connect the clip.
    Fig 4: Installing Mounting Bracket
    G02763557Courtesy of FORD MOTOR CO.

    7. ALL ENGINES 

  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 5: Installing Nuts To Retain Torque Converter To Flexplate
    G02763558Courtesy of FORD MOTOR CO.
  8. Install the cylinder block opening cover.
    Fig 6: Installing Cylinder Block Opening Cover
    G02763559Courtesy of FORD MOTOR CO.
  9. Install the flexplate inspection cover.
    Fig 7: Installing Flexplate Inspection Cover
    G02763560Courtesy of FORD MOTOR CO.
    10. NOTE: RH shown, LH similar.
    Fig 8: Installing Engine Mount Nuts
    G02763561Courtesy 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 9: Installing Starter Motor
    G02763562Courtesy of FORD MOTOR CO.
  12. Connect the starter motor electrical connections.
    Fig 10: Connecting Starter Motor Electrical Connections
    G02763563Courtesy of FORD MOTOR CO.
  13. Install the starter motor solenoid terminal cover.
    Fig 11: Installing Starter Motor Solenoid Terminal Cover
    G02763564Courtesy of FORD MOTOR CO.
  14. Mount the exhaust system to the LH and RH exhaust manifolds.
    Fig 12: Mounting Exhaust System To LH And RH Exhaust Manifolds
    G02763565Courtesy of FORD MOTOR CO.
    15. NOTE: Make sure the tab on the oil filter adapter nests into the notch in the oil cooler.
    Fig 13: Installing Threaded Insert
    G02763566Courtesy of FORD MOTOR CO.
  15. Position the oil cooler on the oil filter adapter and install the threaded insert.
  16. Install a new oil filter.
    Fig 14: Installing Oil Filter
    G02763567Courtesy of FORD MOTOR CO.
  17. Connect the oil cooler hoses.
    Fig 15: Connecting Oil Cooler Hoses
    G02763568Courtesy of FORD MOTOR CO.

    18. ROMEO ENGINE (4.6L) 

  18. Position the transmission fluid cooler tube support bracket and install the nut.
    Fig 16: Positioning Transmission Fluid Cooler Tube Support Bracket
    G02763569Courtesy of FORD MOTOR CO.

    19. WINDSOR ENGINE (5.4L) 

  19. Position the fluid cooler tube support bracket and install the nut.
    Fig 17: Positioning Fluid Cooler Tube Support Bracket
    G02763570Courtesy of FORD MOTOR CO.

    20. ALL ENGINES 

  20. Using the special tool, install a new Teflon® seal on the power steering pressure tube.
    Fig 18: Installing Teflon® Seal On Power Steering Pressure Tube Using Special Tool
    G02763571Courtesy of FORD MOTOR CO.
  21. Connect the power steering pressure tube and the power steering reservoir hose to the power steering pump.
    Fig 19: Connecting Power Steering Pressure Tube And Power Steering Reservoir Hose To Power Steering Pump
    G02763572Courtesy of FORD MOTOR CO.
  22. Install and tighten the oil drain plug.
    Fig 20: Tightening Oil Drain Plug
    G02763573Courtesy 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 21: Installing Upper Transmission-To-Engine Bolts
    G02763574Courtesy 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 22: Installing Transmission Wiring Harness Connector Retainer In Bracket
    G02763575Courtesy 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 23: Inserting Heater Outlet Tube Over Seals
    G02763576Courtesy 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 24: Installing Heater Outlet Tube Studs
    G02763577Courtesy of FORD MOTOR CO.
    27. NOTE: Lubricate the O-ring seals with clean transmission fluid before installing the transmission fluid filler tube.
    Fig 25: Installing Transmission Fluid Filler Tube
    G02763578Courtesy of FORD MOTOR CO.
  27. Install the transmission fluid filler tube.

    28. WINDSOR ENGINE (5.4L) 

  28. Install the heater outlet tube studs.
    Fig 26: Installing Heater Outlet Tube Studs
    G02763579Courtesy of FORD MOTOR CO.
    29. NOTE: Lubricate the O-ring seals with clean transmission fluid before installing the transmission fluid filler tube.
    Fig 27: Installing Transmission Fluid Filler Tube
    G02763580Courtesy of FORD MOTOR CO.
  29. Install the transmission fluid filler tube.

    30. ALL ENGINES 

  30. Connect the hose to the heater outlet tube.
    Fig 28: Connecting Hose To Heater Outlet Tube
    G02763581Courtesy 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 29: Installing Wiring Retainers In Heater Outlet Tube Bracket
    G02763582Courtesy of FORD MOTOR CO.
  32. Connect the evaporative emission canister purge valve electrical connector.
    Fig 30: Connecting Evaporative Emission Canister Purge Valve Electrical Connector
    G02763583Courtesy 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 31: Installing Fluid Level Indicator
    G02763584Courtesy of FORD MOTOR CO.
  34. Install the engine oil filler tube support strap bolt.
    Fig 32: Installing Engine Oil Filler Tube Support Strap Bolt
    G02763585Courtesy of FORD MOTOR CO.
    35. NOTE: Windsor engine shown, Romeo engine similar.
    Fig 33: Connecting Electrical Connectors
    G02763586Courtesy of FORD MOTOR CO.
  35. Position the mounting bracket, install the ground strap and nut, and connect the electrical connectors.
  36. Position the generator and install the bolts.
    Fig 34: Positioning Generator And Installing Bolts
    G02763587Courtesy of FORD MOTOR CO.
  37. 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 35: Connecting Generator Electrical Connections
    G02763588Courtesy of FORD MOTOR CO.
    38. NOTE: Typical shown.
    Fig 36: Installing Drive Belt
    G02763589Courtesy of FORD MOTOR CO.
  38. Rotate the tensioner clockwise and install the drive belt. Refer to the decal on the upper radiator air deflector for belt routing.
  39. Connect the lower radiator hose to the oil filter adapter coolant inlet.
    Fig 37: Connecting Lower Radiator Hose To Oil Filter Adapter Coolant Inlet
    G02763590Courtesy of FORD MOTOR CO.
    40. NOTE: LH shown, RH similar.
    Fig 38: Positioning Lower Radiator Support
    G02763591Courtesy of FORD MOTOR CO.
  40. Position the lower radiator support and install the twelve bolts.
  41. 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 39: Connecting Electrical Connector
    G02763592Courtesy of FORD MOTOR CO.
  42. Install the LH side of the headlamp dash panel junction wiring harness.
    1. Install the screw.
    2. Insert the routing clips.
    Fig 40: Installing LH Side Of Headlamp Dash Panel Junction Wiring Harness
    G02763593Courtesy of FORD MOTOR CO.
    43. NOTE: RH shown, LH similar.
    Fig 41: Installing Pin-Type Retainers
    G02763594Courtesy of FORD MOTOR CO.
  43. Position the RH and LH air deflectors and install the pin-type retainers.
    44. NOTE: RH shown, LH similar.
    Fig 42: Positioning Upper Radiator Support
    G02763595Courtesy of FORD MOTOR CO.
  44. Position the upper radiator support and install the eight bolts.
  45. Route the battery feed wiring harness to the power distribution box and insert the routing clips.
    Fig 43: Inserting Routing Clips
    G02763596Courtesy of FORD MOTOR CO.
    46. NOTE: Cover removed for clarity.
    Fig 44: Installing Battery Feed Cable To Power Distribution Box
    G02763597Courtesy of FORD MOTOR CO.
  46. Install the battery feed cable to the power distribution box.
  47. Install the power steering reservoir.
    Fig 45: Installing Power Steering Reservoir
    G02763598Courtesy of FORD MOTOR CO.
  48. Install the hood latch.
    1. Install the hood latch.
    2. Insert the cable routing clip.
    Fig 46: Installing Hood Latch
    G02763599Courtesy of FORD MOTOR CO.
  49. 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 47: Installing A/C Condenser Core
    G02763600Courtesy of FORD MOTOR CO.
    50. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.
    Fig 48: Connecting Condenser Core Refrigerant Tubes
    G02763601Courtesy of FORD MOTOR CO.
  50. Connect the condenser core refrigerant tubes.
    1. Connect the condenser to evaporator tube.
    2. Connect the compressor discharge tube.
    51. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.
    Fig 49: Connecting Compressor Suction Tube
    G02763602Courtesy of FORD MOTOR CO.
  51. Connect the compressor suction tube.
  52. Connect the A/C pressure setoff switch electrical connector.
    Fig 50: Connecting A/C Pressure Setoff Switch Electrical Connector
    G02763603Courtesy of FORD MOTOR CO.
  53. Position the radiator in the vehicle.
    Fig 51: Positioning Radiator In Vehicle
    G02763604Courtesy of FORD MOTOR CO.
    54. NOTE: LH shown, RH similar.
    Fig 52: Positioning Radiator Support Brackets
    G02763605Courtesy of FORD MOTOR CO.
  54. Position the radiator support brackets and install the bolts.
  55. Position the fan shroud and the fan and fan clutch in the vehicle, and install the bolts.
    Fig 53: Positioning Fan Shroud, Fan And Fan Clutch In Vehicle
    G02763606Courtesy of FORD MOTOR CO.
  56. Insert the degas hose retainer in the fan shroud.
    Fig 54: Inserting Degas Hose Retainer In Fan Shroud
    G02763607Courtesy of FORD MOTOR CO.
  57. Install the fan blade assembly and fan clutch.
    1. Install the fan blade and the fan clutch.
    2. Use the special tool to hold the coolant pump pulley.
    3. Using the special tool, tighten the fan clutch nut.
    Fig 55: Installing Fan Blade Assembly And Fan Clutch
    G02763608Courtesy of FORD MOTOR CO.
  58. Connect the upper radiator hose and the degas hose to the radiator.
    Fig 56: Connecting Upper Radiator Hose And Degas Hose To Radiator
    G02763609Courtesy of FORD MOTOR CO.
  59. Install the valance panel. For additional information, refer to FRONT END BODY PANELS .
  60. Connect the transmission cooler tubes.
    Fig 57: Connecting Transmission Cooler Tubes
    G02763610Courtesy of FORD MOTOR CO.
  61. Position the splash shield and install the pushpin retainers.
    Fig 58: Installing Pushpin Retainers
    G02763611Courtesy of FORD MOTOR CO.
  62. Connect the lower radiator hose to the radiator.
    • Connect the hose.
    • Connect the hose hanger.
    Fig 59: Connecting Lower Radiator Hose To Radiator
    G02763612Courtesy of FORD MOTOR CO.
  63. Install the front bumper. For additional information, refer to BUMPERS .
    64. CAUTION: The oil pump must be primed prior to starting the engine.
  64. Fill the engine with clean engine oil.
  65. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD - 4.6L  or INTAKE MANIFOLD - 5.4L .
  66. Fill all fluids to the correct levels.
  67. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.

    68. VEHICLES EQUIPPED WITH A/C 

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