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Section 1415 (Engine -- 4.0L SOHC): Installation: Engine: Installation

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

    CAUTION: If used as a leverage device, the fuel rail can be damaged. Care must be taken when working around the fuel rail.
    Fig 1: Removing Floor Crane And Special Tools
    G03947212Courtesy of FORD MOTOR CO.
  1. Position the engine in the vehicle and remove the floor crane and the special tools.
  2. Install the RH engine support insulator nuts.
    • Tighten to 80 Nm (59 lb-ft).
      Fig 2: Installing RH Engine Support Insulator Nuts
      G03947206Courtesy of FORD MOTOR CO.
  3. Install the radiator and A/C condenser as an assembly.
    Fig 3: Installing Radiator And A/C Condenser Assembly
    G03947209Courtesy of FORD MOTOR CO.
  4. Position the RH radiator support bracket and the bolts.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 4: Positioning RH Radiator Support Bracket And Bolts
      G03947471Courtesy of FORD MOTOR CO.
  5. Position the LH radiator support bracket and the bolts.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 5: Positioning LH Radiator Support Bracket And Bolts
      G03947207Courtesy of FORD MOTOR CO.
  6. Remove the special tool from the RH side of the engine.
    Fig 6: Removing Special Tool From RH Side Of Engine
    G03947211Courtesy of FORD MOTOR CO.
  7. Remove the special tool from the LH cylinder head.
    Fig 7: Removing Special Tool From LH Cylinder Head
    G03947210Courtesy of FORD MOTOR CO.
  8. Using the special tool, install a new seal on the power steering pressure (PSP) hose fitting.
    Fig 8: Installing Seal On Power Steering Pressure Hose Fitting Using Special Tool
    G03947475Courtesy of FORD MOTOR CO.
  9. Connect the PSP hose to the power steering pump.
    • Tighten to 65 Nm (48 lb-ft).
      Fig 9: Connecting PSP Hose To Power Steering Pump
      G03947205Courtesy of FORD MOTOR CO.
  10. Install the PSP hose support bracket and the bolt.
    • Tighten to 11 Nm (8 lb-ft).
      Fig 10: Installing PSP Hose Support Bracket And Bolt
      G03947477Courtesy of FORD MOTOR CO.
  11. Install the LH support insulator through bolt.
    • Tighten to 110 Nm (81 lb-ft).
      Fig 11: Installing LH Support Insulator Through Bolt
      G03947202Courtesy of FORD MOTOR CO.
  12. Connect the power steering return hose.
    Fig 12: Connecting Power Steering Return Hose
    G03947479Courtesy of FORD MOTOR CO.
  13. Remove the special tool.
    Fig 13: Removing Special Tool
    G03947200Courtesy of FORD MOTOR CO.
    14. NOTE: Make sure the stud and flexplate marks made during removal line up.
    Fig 14: Supporting Transmission With Transmission Jack
    G03947197Courtesy of FORD MOTOR CO.
  14. Position the transmission in the vehicle.
  15. Install the 8 engine-to-transmission bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 15: Locating Engine-To-Transmission Retaining Bolts
      G03947199Courtesy of FORD MOTOR CO.
  16. Position the transmission cooler tubes, and the bracket and install the nut.
    • Tighten to 19 Nm (14 lb-ft).
      Fig 16: Installing Nut
      G03947196Courtesy of FORD MOTOR CO.
  17. Connect the transmission cooler tubes.
    Fig 17: Connecting Transmission Cooler Tubes
    G03947484Courtesy of FORD MOTOR CO.
  18. Install the transmission cooler tube clips.
    Fig 18: Installing Transmission Cooler Tube Clips
    G03947194Courtesy of FORD MOTOR CO.
    19. CAUTION: Use care not to bend or force the transmission cooler tubes. Damage to the tubes or the transmission can occur. Use a wrench to hold the fittings mounted in the transmission.
  19. Connect the cooler tubes to the transmission.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 19: Locating Transmission Cooler Tubes
      G03947193Courtesy of FORD MOTOR CO.
  20. Connect the harness retainers.
    Fig 20: Connecting Harness Retainers
    G03948792Courtesy of FORD MOTOR CO.
    21. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification.
    NOTE: Always install new O-ring seals on the vehicle harness connector.
    NOTE: Clean the area around the connector to prevent contamination of the solenoid body connector.
    NOTE: Use petroleum jelly to lubricate the O-ring seals to aid the installation process.
  21. Lubricate and install new O-ring seals on the transmission body electrical connector, connect the electrical connector and tighten the screw.
    • Tighten to 5 Nm (44 lb-in).
      Fig 21: Identifying Solenoid Body Electrical Connector
      G03947191Courtesy of FORD MOTOR CO.
  22. Connect the electrical connectors.
    Fig 22: Locating Electrical Connectors
    G03947190Courtesy of FORD MOTOR CO.
  23. Connect the digital transmission range (TR) sensor.
    Fig 23: Locating Transmission Range (TR) Sensor Electrical Connector
    G03947189Courtesy of FORD MOTOR CO.
  24. Move the rubber boot back into position.
    Fig 24: Moving Rubber Boot Back Into Position
    G03947188Courtesy of FORD MOTOR CO.
    25. NOTE: Match the identifying mark on the nut, stud and flexplate to allow for correct installation.
  25. Install the 4 torque converter nuts.
    • Rotate the crankshaft to access all the nuts.
    • Tighten to 38 Nm (28 lb-ft).
      Fig 25: Installing Torque Converter Nuts
      G03948782Courtesy of FORD MOTOR CO.
  26. Connect the LH catalyst monitor connector to the transmission.
    Fig 26: Identifying LH Catalyst Monitor Connector Retainer At Transmission
    G03947871Courtesy of FORD MOTOR CO.
  27. Connect the LH heated oxygen sensor (HO2S) electrical connector retainer and the harness clip to the transmission.
    Fig 27: Identifying Wire Harness Retainers
    G03948290Courtesy of FORD MOTOR CO.
  28. If equipped, connect the shift motor electrical connector.
    Fig 28: Locating Shift Motor Electrical Connector And Wiring Harness Pin-Type Retainer
    G03947184Courtesy of FORD MOTOR CO.
  29. Connect the RH HO2S electrical connector to the transmission.
    Fig 29: Connecting RH HO2S Electrical Connector To Transmission
    G03948785Courtesy of FORD MOTOR CO.
  30. Connect the RH catalyst monitor connector and the fuel tubes to the bracket.
    Fig 30: Locating Fuel Lines And RH Catalyst Monitor Connector Bracket
    G03947872Courtesy of FORD MOTOR CO.
    31. CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with threadlock and sealer.
    CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in the sequence shown in Fig 31.
    NOTE: Align the marks made on the flange and driveshaft during removal.
    NOTE: On 2-wheel drive vehicles, align the marks on the transmission output shaft.
  31. Position the driveshaft and install the driveshaft-to-pinion flange bolts in the sequence shown in Fig 31.
    • Tighten to 112 Nm (83 lb-ft).
      Fig 31: Identifying Installing Sequence Of Driveshaft-To-Pinion Flange Bolts
      G03947498Courtesy of FORD MOTOR CO.

    32. 4x4 vehicles 

    CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with threadlock and sealer.
    CAUTION: The driveshaft flange fits tightly on the transfer case flange. To make sure that the driveshaft flange seats squarely on the transfer case flange, tighten the bolts evenly in a criss-cross pattern.
    NOTE: Align the marks made on the flange and driveshaft during removal.
  32. Install the rear driveshaft-to-transfer case flange bolts in the sequence shown in Fig 32.
    • Tighten to 112 Nm (83 lb-ft).
      Fig 32: Identifying Installing Sequence Of Rear Driveshaft-To-Transfer Case Flange Bolts
      G03947498Courtesy of FORD MOTOR CO.
    33. NOTE: Install new flange bolts and washers.
    Fig 33: Identifying Index-Mark On Front Output Shaft Assembly
    G03912439Courtesy of FORD MOTOR CO.
  33. Position the front driveshaft flange with the location marks aligned and install the retaining bolts finger-tight.
    34. NOTE: Use new bolts and U-joint straps.
  34. Connect the front driveshaft to the front differential and install new bolts.
    • Tighten to 18 Nm (13 lb-ft).
      Fig 34: Locating Universal Joint Retainers
      G03971114Courtesy of FORD MOTOR CO.
  35. Tighten the front driveshaft flange bolts in the sequence shown in Fig 35.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 35: Identifying Tightening Sequence Of Front Driveshaft Flange Bolts
      G03947502Courtesy of FORD MOTOR CO.

    36. All vehicles 

  36. Position the bracket and install the bolts, Connect the shift cable.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 36: Identifying Shift Cable And Bracket
      G03947170Courtesy of FORD MOTOR CO.

    37. 4x4 vehicles 

  37. Support the transfer case with a suitable jack stand.
    Fig 37: Supporting Transfer Case With Suitable Jack Stand
    G03947504Courtesy of FORD MOTOR CO.
  38. Disconnect the safety chain and remove the transmission jack.
    Fig 38: Supporting Transmission With Transmission Jack
    G03947197Courtesy of FORD MOTOR CO.

    39. All vehicles 

    NOTE: The assistance of another technician may be required.
  39. Position the transmission-mounted exhaust hanger, the 3-way converter system and RH heat shield.
    1. If removed, position the mount and install the bolt.
      • Tighten to 90 Nm (66 lb-ft).
    2. Position the exhaust hanger and the converter assembly and install the bolt.
      • Tighten to 90 Nm (66 lb-ft).
        Fig 39: Installing Bolt
        G03947506Courtesy of FORD MOTOR CO.
    40. NOTE: LH shown, RH similar.
  40. Install the 4 converter-to-manifold nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 40: Locating Catalytic Converter-To-Manifold Nuts
      G03946966Courtesy of FORD MOTOR CO.
    41. NOTE: Use a new gasket and new flag nuts.
  41. Connect the muffler to the converter and install the 2 bolts, 2 springs and 2 flag nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 41: Installing Bolts, Springs And Flag Nuts
      G03947167Courtesy of FORD MOTOR CO.
    42. NOTE: RH shown, LH similar.
  42. Install the crossmember and the 4 lower bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 42: Locating RH Side Crossmember Bolts
      G03947164Courtesy of FORD MOTOR CO.
    43. NOTE: RH shown, LH similar.
  43. Install the 4 upper crossmember bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 43: Installing Upper Crossmember Bolts
      G03947163Courtesy of FORD MOTOR CO.

    44. 4x2 vehicles 

  44. Remove the transmission jack from the transmission.
    Fig 44: Supporting Transmission With Transmission Jack
    G03947197Courtesy of FORD MOTOR CO.
  45. Install the cable bracket and the bolts to the transmission.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 45: Installing Cable Bracket And Bolts To Transmission
      G03947512Courtesy of FORD MOTOR CO.

    46. 4x4 vehicles 

  46. Remove the jack stand from under the transfer case.
    Fig 46: Supporting Transfer Case With Suitable Jack Stand
    G03947504Courtesy of FORD MOTOR CO.

    47. All vehicles 

  47. Install the plastic shield and the 2 nuts on the right side of the crossmember.
    • Tighten to 9 Nm (80 lb-in).
      Fig 47: Locating Plastic Shield On Right Side Of Crossmember Near Fuel Tank
      G03948762Courtesy of FORD MOTOR CO.
  48. Install the crossmember-to-transmission support insulator nuts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 48: Identifying Transmission Support Insulator Nuts
      G03947166Courtesy of FORD MOTOR CO.
  49. Install the LH heat shield bolt.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 49: Locating LH Heat Shield Bolt
      G03947161Courtesy of FORD MOTOR CO.
  50. Install the RH heat shield bolts.
    Fig 50: Installing RH Heat Shield Bolts
    G03947517Courtesy of FORD MOTOR CO.
    51. NOTE: RH shown, LH similar.
    Fig 51: Identifying Catalyst Monitor Sensor Electrical Connector
    G03947158Courtesy of FORD MOTOR CO.
  51. Connect the 2 catalyst monitor sensor electrical connectors.
    52. NOTE: LH shown, RH similar.
    Fig 52: Locating Heated Oxygen Sensor Electrical Connector
    G03947157Courtesy of FORD MOTOR CO.
  52. Connect the 2 heated oxygen sensor electrical connectors.
  53. Install the 2 bolts and the RH heat shield.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 53: Installing RH Heat Shield Bolts
      G03948756Courtesy of FORD MOTOR CO.
  54. Position the battery retainer bracket and install the nut.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 54: Installing Nut
      G03947153Courtesy of FORD MOTOR CO.
  55. Position the lower air shroud and install the pushpins.
    Fig 55: Locating Lower Air Dam Push Pins
    G03947152Courtesy of FORD MOTOR CO.
  56. Install the starter. For additional information, refer to STARTING SYSTEM .
  57. Position the exhaust manifold-to-exhaust gas recirculation (EGR) valve tube and tighten the fittings.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 56: Positioning Exhaust Manifold-To-Exhaust Gas Recirculation Valve Tube
      G03947523Courtesy of FORD MOTOR CO.
  58. Install 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 57: Installing O-Ring Seal, Connect A/C Tube To Condenser
      G03947524Courtesy of FORD MOTOR CO.
  59. Connect the A/C tube to the retainer.
    Fig 58: Connecting A/C Tube To Retainer
    G03947150Courtesy of FORD MOTOR CO.
  60. Connect the A/C high pressure cut-off switch electrical connector.
    Fig 59: Connecting A/C High Pressure Cut-Off Switch Electrical Connector
    G03947148Courtesy of FORD MOTOR CO.
  61. Connect the vacuum hoses.
    Fig 60: Connecting Vacuum Hoses
    G03947147Courtesy of FORD MOTOR CO.
  62. Install 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 61: Connecting A/C Tube To Condenser
      G03947528Courtesy of FORD MOTOR CO.
  63. Install a new O-ring seal, connect the A/C tube to the accumulator and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 62: Connecting A/C Tube To Accumulator
      G03947529Courtesy of FORD MOTOR CO.
  64. Connect the coolant hoses to the degas bottle.
    Fig 63: Connecting Coolant Hoses To Degas Bottle
    G03947530Courtesy of FORD MOTOR CO.
  65. Connect the lower radiator hose at the coolant pump.
    Fig 64: Connecting Lower Radiator Hose At Coolant Pump
    G03947531Courtesy of FORD MOTOR CO.
  66. Connect the upper radiator hose and heater hose.
    Fig 65: Connecting Upper Radiator Hose And Heater Hose
    G03947532Courtesy of FORD MOTOR CO.
  67. Position the heater hose bracket and install the bolts.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 66: Installing Bolts
      G03947533Courtesy of FORD MOTOR CO.
  68. Connect the vacuum and heater hoses.
    Fig 67: Connecting Vacuum And Heater Hoses
    G03947141Courtesy of FORD MOTOR CO.
  69. Install the ground wire and the bolt to the engine.
    • Tighten to 10 Nm (89 lb-in).
      Fig 68: Installing Ground Wire And Bolt To Engine
      G03946958Courtesy of FORD MOTOR CO.
  70. Connect the vacuum hose.
    Fig 69: Connecting Vacuum Hose
    G03947139Courtesy of FORD MOTOR CO.
  71. Connect the evaporative emissions (EVAP) tube.
    Fig 70: Connecting Evaporative Emissions Tube
    G03947138Courtesy of FORD MOTOR CO.
  72. Connect the spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  73. Connect the transmission control wiring harness pin-type retainers to the engine wiring harness.
    Fig 71: Connecting Transmission Control Wiring Harness Pin-Type Retainers To Engine Wiring Harness
    G03947137Courtesy of FORD MOTOR CO.
  74. Install the engine wiring harness in the clips on the bulkhead.
    Fig 72: Installing Engine Wiring Harness In Clips On Bulkhead
    G03947894Courtesy of FORD MOTOR CO.
  75. Connect the powertrain control module (PCM) electrical connectors.
    Fig 73: Connecting Powertrain Control Module Electrical Connectors
    G03947135Courtesy of FORD MOTOR CO.
  76. Install the air cleaner.
    Fig 74: Installing Air Cleaner
    G03947541Courtesy of FORD MOTOR CO.
  77. Connect the mass air flow (MAF) sensor electrical connector.
    Fig 75: Connecting Mass Air Flow Sensor Electrical Connector
    G03947133Courtesy of FORD MOTOR CO.
    78. NOTE: Align the marks made during removal.
  78. Install the hood, the 4 bolts and the hood supports.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 76: Installing Hood, Bolts And Hood Supports
      G03947807Courtesy of FORD MOTOR CO.
  79. Connect the windshield washer hose.
    Fig 77: Connecting Windshield Washer Hose
    G03947806Courtesy of FORD MOTOR CO.
  80. Connect the battery cable to the power distribution box and install the nut.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 78: Connecting Battery Cable To Power Distribution Box
      G03947545Courtesy of FORD MOTOR CO.
  81. Connect the electrical connector and attach the wiring harness retainer.
    Fig 79: Connecting Electrical Connector
    G03947129Courtesy of FORD MOTOR CO.
  82. Install the ground wire and the nut.
    • Tighten to 9 Nm (80 lb-in).
      Fig 80: Installing Ground Wire And Nut
      G03947128Courtesy of FORD MOTOR CO.
  83. Install the cooling fan and shroud. For additional information, refer to ENGINE COOLING .
  84. Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  85. Fill the engine with clean engine oil.
  86. Connect both battery cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  87. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  88. Fill and purge the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
  89. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  90. Start the engine and check for leaks. Stop the engine and check all fluid levels.
  91. Carry out the fluid level check for the transmission. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - 5R55S .
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