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Section 973 (Engine - 5.4L (3V) - F150 Pickup): Installation: Engine

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S) CHART

G03886715
 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
G03945465
 Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A)
G03879006
 Installer Set, Teflon® Seal 211-D207 (D90P-3517-A) or equivalent
MATERIAL ITEM SPECIFICATION

Item Specification
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalent WSS-M2C930-A
Motorcraft Premium Gold Engine Coolant VC-7-A (in California, Oregon and New Mexico VC-7-B, in Canada CVC-7-A) or equivalent (yellow color) WSS-M97B51-A1
Threadlock 262 TA-26 or equivalent WSK-M2G351-A6

    All vehicles 

  1. Using a suitable floor crane, position the engine assembly into the vehicle.
    2. CAUTION: Only use hand tools when installing the LH engine mount bolt or damage to the engine mount can occur.
    NOTE: Early build vehicles are equipped with an M14 through bolt. Late build vehicles are equipped with an M18 through bolt.
    Fig 1: Installing LH Engine Support Insulator Bolt
    G03962859Courtesy of FORD MOTOR CO.
  2. Apply Threadlock 262 to the bolt threads and install the LH engine support insulator bolt.
    1. If the M14 through bolt engine support insulator nut is missing or damaged, install a new nut using service part number W709375.
    2. If the M14 through bolt engine support insulator nut cage is damaged or missing, install a new nut using service part number W520516-S301.
      • Early build vehicles, tighten to 220 Nm (162 lb-ft).
      • Late build vehicles, tighten to 350 Nm (258 lb-ft).
    3. CAUTION: Make sure the RH engine support insulator mating surfaces and the washer mating surface are free of foreign material and corrosion before installation. Install a new washer.
    CAUTION: Only use hand tools when installing the RH engine mount nuts or damage to the engine mount can occur.
    Fig 2: Installing RH Engine Support Insulator Washer And Nuts
    G03962568Courtesy of FORD MOTOR CO.
  3. Apply Threadlock 262 to the stud threads and install the RH engine support insulator washer and nuts.
    • Tighten to 250 Nm (184 lb-ft).
  4. Remove the special tool.
    Fig 3: Removing Special Tool
    G03920932Courtesy of FORD MOTOR CO.

    5. Manual transmission vehicles 

  5. Install the clutch. For additional information, refer to CLUTCH .

    6. Automatic transmission vehicles 

    NOTE: The upper 2 transmission-to-engine bolts will be installed later.
    Fig 4: Installing Lower 5 Transmission-To-Engine Bolts
    G03920193Courtesy of FORD MOTOR CO.
  6. Install the lower 5 transmission-to-engine bolts.
    • Tighten to 60 Nm (44 lb-ft).
  7. Position the shift cable bracket and install the bolts and connect the shift cable.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 5: Installing Shift Cable Bracket Bolts And Connecting Shift Cable
    G03964050Courtesy of FORD MOTOR CO.
  8. Install 4 new torque converter-to-flexplate nuts.
    • Tighten to 36 Nm (27 lb-ft).
    Fig 6: Installing New Torque Converter-To-Flexplate Nuts
    G03885557Courtesy of FORD MOTOR CO.
  9. Install the cylinder block opening cover.
    Fig 7: Installing Cylinder Block Opening Cover
    G03908385Courtesy of FORD MOTOR CO.
  10. Install the flexplate inspection cover and the 2 bolts.
    • Tighten to 34 Nm (25 lb-ft).
    Fig 8: Installing Flexplate Inspection Cover And Bolts
    G03885458Courtesy of FORD MOTOR CO.
  11. Install the starter. For additional information, refer to STARTING SYSTEM .
  12. Position the transmission cooler tube support bracket and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 9: Installing Cooler Tube Support Bracket Bolt
    G03919905Courtesy of FORD MOTOR CO.

    13. All vehicles 

  13. If equipped, connect the block heater electrical connector.
    Fig 10: Connecting Block Heater Electrical Connector
    G03920195Courtesy of FORD MOTOR CO.
    14. NOTE: LH shown, RH similar.
    Fig 11: Connecting LH And RH Heated Exhaust Gas Oxygen Sensor (HO2S) Electrical Connector
    G03933349Courtesy of FORD MOTOR CO.
  14. Connect the LH and RH heated exhaust gas oxygen sensor (HO2S) electrical connector and attach the electrical connector retainer.
  15. Attach the starter electrical harness support bracket.
    Fig 12: Attaching Starter Electrical Harness Support Bracket
    G03963182Courtesy of FORD MOTOR CO.
  16. Connect the oil temperature sensor electrical connector.
    Fig 13: Connecting Oil Temperature Sensor Electrical Connector
    G03920098Courtesy of FORD MOTOR CO.
  17. Position the A/C compressor and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 14: Installing A/C Compressor Bolts
    G03933941Courtesy of FORD MOTOR CO.
  18. Install the 4 exhaust manifold flange nuts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 15: Installing Exhaust Manifold Flange Nuts
    G03885400Courtesy of FORD MOTOR CO.

    19. Automatic transmission vehicles 

  19. Install the upper 2 transmission-to-engine bolts.
    • Tighten to 60 Nm (44 lb-ft).
    Fig 16: Installing Upper Transmission-To-Engine Bolts
    G03920204Courtesy of FORD MOTOR CO.
  20. Position the transmission filler tube and install the bolt.
    • Tighten to 20 Nm (15 lb-ft).
    Fig 17: Positioning Transmission Filler Tube And Installing Bolt
    G03963266Courtesy of FORD MOTOR CO.

    21. All vehicles 

  21. Connect the crankshaft position (CKP) sensor wiring harness retainer to the starter motor wiring harness.
    Fig 18: Connecting Crankshaft Position (CKP) Sensor Wiring Harness Retainer To Starter Motor Wiring Harness
    G03920181Courtesy of FORD MOTOR CO.
  22. Connect the generator wiring harness retainer to the RH cylinder head.
    Fig 19: Connecting Generator Wiring Harness Retainer To RH Cylinder Head
    G03920180Courtesy of FORD MOTOR CO.
  23. Connect the A/C compressor and the A/C high pressure cut-off switch electrical connectors.
    Fig 20: Connecting A/C Compressor And A/C High Pressure Cut-Off Switch Electrical Connectors
    G03920179Courtesy of FORD MOTOR CO.
  24. Connect the generator wiring harness retainer to the RH cylinder head.
    Fig 21: Connecting Generator Wiring Harness Retainer To RH Cylinder Head
    G03920178Courtesy of FORD MOTOR CO.
  25. Position the power steering pump assembly and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 22: Installing Power Steering Pump Bolts
    G03962601Courtesy of FORD MOTOR CO.
  26. Using the special tool, install a new O-ring seal on the pressure line fitting.
    Fig 23: Using Special Tool To Install New O-Ring Seal On Pressure Line Fitting
    G03955529Courtesy of FORD MOTOR CO.
  27. Connect the power steering pressure tube.
    • Tighten to 65 Nm (48 lb-ft).
    Fig 24: Connecting Power Steering Pressure Tube
    G03962599Courtesy of FORD MOTOR CO.
  28. Using the special tool, install the power steering pump pulley.
    Fig 25: Using Special Tool To Install Power Steering Pump Pulley
    G03963051Courtesy of FORD MOTOR CO.
  29. Position the power steering pressure hose support bracket and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    Fig 26: Installing Power Steering Pressure Hose Support Bracket Nut
    G03933414Courtesy of FORD MOTOR CO.
  30. Position the power steering reservoir assembly and install the bolt.
    • Tighten to 23 Nm (17 lb-ft).
    Fig 27: Installing Power Steering Reservoir Assembly Bolt
    G03963251Courtesy of FORD MOTOR CO.
  31. Using a new O-ring seal, connect the A/C manifold and tube assembly and install the nut.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 28: Using New O-Ring Seal To Connect A/C Manifold And Tube Assembly And Install Nut
    G03963248Courtesy of FORD MOTOR CO.
  32. Position the A/C manifold and tube assembly support bracket and install the nut.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 29: Installing A/C Manifold And Tube Assembly Support Bracket Nut
    G03962594Courtesy of FORD MOTOR CO.
  33. Connect the heater hose.
    Fig 30: Connecting Heater Hose
    G03933635Courtesy of FORD MOTOR CO.
  34. Disconnect the coolant hose.
    Fig 31: Disconnecting Coolant Hose
    G03933636Courtesy of FORD MOTOR CO.
  35. Connect the electrical connector and position the ground strap and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 32: Connecting Electrical Connector And Installing Bolt
    G03962592Courtesy of FORD MOTOR CO.
  36. Position the cowl extension panel and install the bolts.
    Fig 33: Installing Cowl Extension Panel Bolts
    G03962591Courtesy of FORD MOTOR CO.
  37. Attach the wiring harness and the windshield washer hose retainers to the cowl panel extension.
    Fig 34: Attaching Wiring Harness And Windshield Washer Hose Retainers To Cowl Panel Extension
    G03962091Courtesy of FORD MOTOR CO.
  38. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  39. Install the radiator. For additional information, refer to ENGINE COOLING .
  40. Install the powertrain control module (PCM). For additional information, refer to ELECTRONIC ENGINE CONTROLS .
  41. Install the cowl. For additional information, refer to FRONT END BODY PANELS .
  42. Install the hood.
  43. Fill the crankcase with clean engine oil.
  44. Evacuate and charge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  45. Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
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