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Section 458 (Engine - 3.0L 4V): Installation: Engine: Installation

WARNING: This page is about a different car, the 2003 Mercury Sable and 2003 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: The studs from the torque converter must align with the engine flexplate holes to assemble the engine/transaxle. Install the indexed stud to the indexed hole in the flexplate.
    Fig 1: Supporting Engine And Assembling With Transaxle
    G01593228Courtesy of FORD MOTOR CO.
  1. Using the special tools, support the engine and assemble with the transaxle.
  2. Install the five engine-to-transaxle bolts.
    Fig 2: Installing Engine-To-Transaxle Bolts
    G01593229Courtesy of FORD MOTOR CO.
  3. Install the LH engine mount nut.
    Fig 3: Installing LH Engine Mount Nut
    G01593230Courtesy of FORD MOTOR CO.
  4. Install the RH engine mount nut.
    Fig 4: Installing RH Engine Mount Nut
    G01593231Courtesy of FORD MOTOR CO.
  5. Using the special tool, install new seals on the power steering hose fittings.
    Fig 5: Installing Seals On Power Steering Hose Fittings
    G01593232Courtesy of FORD MOTOR CO.
  6. Connect the power steering pressure line and install the clamp bolt.
    Fig 6: Connecting Power Steering Pressure Line And Installing Clamp Bolt
    G01593233Courtesy of FORD MOTOR CO.
  7. Remove the special tools from the engine.
    Fig 7: Removing Special Tools From Engine
    G01593234Courtesy of FORD MOTOR CO.
  8. Install the engine support brace.
    Fig 8: Installing Engine Support Brace
    G01593235Courtesy of FORD MOTOR CO.
  9. Position the coolant tube to the head, and install the coolant tube mounting bolt.
    Fig 9: Positioning Coolant Tube To Head, And Installing Coolant Tube Mounting Bolt
    G01593236Courtesy of FORD MOTOR CO.
  10. Install the coolant tube lower mounting bolt.
    Fig 10: Installing Coolant Tube Lower Mounting Bolt
    G01593237Courtesy of FORD MOTOR CO.
  11. Using the special tool, raise the engine/transaxle assembly into the vehicle and loosely install the four subframe bolts.
    Fig 11: Raising Engine/Transaxle Assembly Into Vehicle And Installing Subframe Bolts
    G01593238Courtesy of FORD MOTOR CO.
  12. Align the subframe with the body.
    1. Install a 19 mm (0.75 in) rod into the front LH sub frame-to-body alignment hole.
    2. Hand-tighten the bolt.
    Fig 12: Aligning Subframe With Body
    G01593239Courtesy of FORD MOTOR CO.
  13. Align the subframe with the body.
    1. Install a 19 mm (0.75 in) rod into the front RH sub frame-to-body alignment hole.
    2. Hand-tighten the bolt.
    Fig 13: Aligning Subframe With Body
    G01593240Courtesy of FORD MOTOR CO.
  14. Verify the subframe-to-body alignment at both of the alignment holes.
  15. Tighten the four subframe bolts.
    Fig 14: Tightening Subframe Bolts
    G01593241Courtesy of FORD MOTOR CO.
  16. Remove the special tool.
    Fig 15: Removing Special Tool
    G01593242Courtesy of FORD MOTOR CO.
    17. NOTE: Clean and degrease all sealing surfaces with metal surface cleaner.
    NOTE: The oil pan must be installed and the bolts tightened within four minutes of the sealant application.
    Fig 16: Identifying Locations For Applying Silicone Gasket And Sealant
    G01593243Courtesy of FORD MOTOR CO.
  17. Apply a 10 mm (0.4 in) dot of silicone gasket and sealant to the front cover-to- cylinder block mating surface.
  18. Position the oil pan and gasket and loosely install the bolts and the studs in the indicated sequence.
    Fig 17: Positioning Oil Pan And Gasket And Installing Bolts
    G01593244Courtesy of FORD MOTOR CO.
  19. Install the oil pan to transaxle housing bolts.
    Fig 18: Installing Oil Pan To Transaxle Housing Bolts
    G01593245Courtesy of FORD MOTOR CO.
  20. Tighten the oil pan bolts and studs in the sequence shown.
    Fig 19: Tightening Sequence Of Oil Pan Bolts
    G01593246Courtesy of FORD MOTOR CO.
  21. Position the engine-to-transaxle bracket and install the nuts and the bolt.
    Fig 20: Positioning Engine-To-Transaxle Bracket And Installing Nuts And Bolt
    G01593247Courtesy of FORD MOTOR CO.
  22. Install the four torque converter-to-flexplate nuts.
    Fig 21: Installing Torque Converter-To-Flexplate Nuts
    G01593248Courtesy of FORD MOTOR CO.
  23. Install the torque converter inspection cover.
    Fig 22: Installing Torque Converter Inspection Cover
    G01593249Courtesy of FORD MOTOR CO.
  24. Clip the engine block heater harness to the engine block.
    Fig 23: Installing Engine Block Heater Harness To Engine Block
    G01593250Courtesy of FORD MOTOR CO.
  25. Connect the engine block heater electrical connector.
    Fig 24: Connecting Engine Block Heater Electrical Connector
    G01593251Courtesy of FORD MOTOR CO.
  26. Connect the lower radiator hose and reservoir supply hose.
    Fig 25: Connecting Lower Radiator Hose And Reservoir Supply Hose
    G01593252Courtesy of FORD MOTOR CO.
  27. Install the radiator support bracket and bolts.
    Fig 26: Installing Radiator Support Bracket And Bolts
    G01593253Courtesy of FORD MOTOR CO.
  28. Connect the A/C high pressure tube to the condenser and install the nut.
    Fig 27: Connecting A/C High Pressure Tube To Condenser And Installing Nut
    G01593254Courtesy of FORD MOTOR CO.
  29. Connect the transaxle cooler hose.
    Fig 28: Connecting Transaxle Cooler Hose
    G01593255Courtesy of FORD MOTOR CO.
  30. Connect the power steering and transaxle hoses to the cooler.
    Fig 29: Connecting Power Steering And Transaxle Hoses To Cooler
    G01593256Courtesy of FORD MOTOR CO.
  31. Position the dual converter Y-pipe and install the nuts.
    Fig 30: Positioning Dual Converter Y-Pipe And Installing Nuts
    G01593257Courtesy of FORD MOTOR CO.
  32. Install the RH exhaust manifold-to-pipe bolts.
    Fig 31: Installing RH Exhaust Manifold-To-Pipe Bolts
    G01593258Courtesy of FORD MOTOR CO.
    33. NOTE: RH shown, LH similar.
    Fig 32: Connecting Tie Rod Ends
    G01593259Courtesy of FORD MOTOR CO.
  33. Connect the RH and LH tie rod ends.
    1. Install the castle nut.
    2. Install the cotter pin.
    34. NOTE: RH shown, LH similar.
    Fig 33: Installing Ball Joint Nuts
    G01593260Courtesy of FORD MOTOR CO.
  34. Install the RH and LH ball joint nuts.
    35. NOTE: RH shown, LH similar.
    Fig 34: Installing Sway Bar End Link Nuts
    G01593261Courtesy of FORD MOTOR CO.
  35. Install the RH and LH sway bar end link nuts.
    36. NOTE: Install a steel rod to prevent the rotor from turning.
    Fig 35: Positioning Halfshaft In Hub And Installing Washer And Nut
    G01593262Courtesy of FORD MOTOR CO.
  36. Position the halfshaft in the hub and install the washer and a new nut.
  37. Position the starter cable and install the nut.
    Fig 36: Positioning Starter Cable And Installing Nut
    G01593263Courtesy of FORD MOTOR CO.
  38. Install the starter cable cover.
    Fig 37: Installing Starter Cable Cover
    G01593264Courtesy of FORD MOTOR CO.
  39. Position the inner fender splash shield and install the pin-type retainers.
    Fig 38: Positioning Inner Fender Splash Shield And Installing Pin-Type Retainers
    G01593265Courtesy of FORD MOTOR CO.
  40. Position the front splash shield and install the bolts and pin-type retainers.
    Fig 39: Positioning Front Splash Shield And Installing Bolts And Pin-Type Retainers
    G01593266Courtesy of FORD MOTOR CO.
  41. Install the LH and RH wheels. For additional information, refer to WHEELS & TIRES .
  42. Install the two LH exhaust manifold-to-pipe nuts.
    Fig 40: Installing LH Exhaust Manifold-To-Pipe Nuts
    G01593267Courtesy of FORD MOTOR CO.
  43. Connect the power steering fluid hose to the reservoir.
    Fig 41: Connecting Power Steering Fluid Hose To Reservoir
    G01593268Courtesy of FORD MOTOR CO.
  44. Connect the upper radiator hose.
    Fig 42: Connecting Upper Radiator Hose
    G01593269Courtesy of FORD MOTOR CO.
  45. Position the starter motor ground cable and install the nut.
    Fig 43: Positioning Starter Motor Ground Cable And Installing Nut
    G01593270Courtesy of FORD MOTOR CO.
  46. Connect the coolant recovery bottle hose.
    Fig 44: Connecting Coolant Recovery Bottle Hose
    G01593271Courtesy of FORD MOTOR CO.
  47. Install the heater hose bracket nut.
    Fig 45: Installing Heater Hose Bracket Nut
    G01593272Courtesy of FORD MOTOR CO.
  48. Connect the heater hoses.
    Fig 46: Connecting Heater Hoses
    G01593273Courtesy of FORD MOTOR CO.
  49. Install the heater hose bracket nut.
    Fig 47: Installing Heater Hose Bracket Nut
    G01593274Courtesy of FORD MOTOR CO.
  50. Connect the low pressure A/C tube spring lock coupling at the accumulator/drier. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 48: Connecting Low Pressure A/C Tube Spring Lock Coupling At Accumulator/Drier
    G01593275Courtesy of FORD MOTOR CO.
  51. Connect the harness and tighten the bolt.
    Fig 49: Connecting Harness And Tightening Bolt
    G01593276Courtesy of FORD MOTOR CO.
  52. Clip the shifter cable to the bracket and install the nut.
    Fig 50: Installing Shifter Cable To Bracket
    G01593277Courtesy of FORD MOTOR CO.
  53. Connect the transaxle range sensor electrical connector.
    Fig 51: Connecting Transaxle Range Sensor Electrical Connector
    G01593278Courtesy of FORD MOTOR CO.
  54. Connect the throttle position (TP) sensor and idle air control (IAC) valve electrical connectors.
    Fig 52: Connecting Throttle Position Sensor And Idle Air Control Valve Electrical Connectors
    G01593279Courtesy of FORD MOTOR CO.
  55. Connect the accelerator and cruise control cables.
    Fig 53: Connecting Accelerator And Cruise Control Cables
    G01593280Courtesy of FORD MOTOR CO.
  56. Position the accelerator cable splash shield and install the pin-type retainers.
    Fig 54: Positioning Accelerator Cable Splash Shield And Installing Pin-Type Retainers
    G01593281Courtesy of FORD MOTOR CO.
  57. Position the air cleaner cover and clamp into place.
    Fig 55: Positioning Air Cleaner Cover
    G01593282Courtesy of FORD MOTOR CO.
  58. Install the air cleaner outlet tube.
    1. Install the tube.
    2. Tighten the clamps.
    3. Connect the crankcase ventilation hoses.
    Fig 56: Installing Air Cleaner Outlet Tube
    G01593283Courtesy of FORD MOTOR CO.
  59. Connect the mass air flow (MAF) sensor electrical connector.
    Fig 57: Connecting Mass Air Flow Sensor Electrical Connector
    G01593284Courtesy of FORD MOTOR CO.
  60. Connect the evaporative emission system hoses.
    Fig 58: Connecting Evaporative Emission System Hoses
    G01593285Courtesy of FORD MOTOR CO.
  61. Connect the powertrain control module (PCM) electrical connector and tighten the bolt.
    Fig 59: Connecting Powertrain Control Module Electrical Connector And Tightening Bolt
    G01593286Courtesy of FORD MOTOR CO.
  62. Position the ground strap and install the bolt.
    Fig 60: Positioning Ground Strap And Installing Bolt
    G01593287Courtesy of FORD MOTOR CO.
  63. Install the cowl vent screen. For additional information, refer to FRONT END BODY PANELS .
  64. Install the steering shaft pinch bolt.
    Fig 61: Installing Steering Shaft Pinch Bolt
    G01593288Courtesy of FORD MOTOR CO.
  65. Fill the engine with clean engine oil.
  66. Connect the battery ground cable.
  67. Fill the cooling system. For additional information, refer to ENGINE COOLING .
  68. Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
  69. Evacuate, Leak Test, and Charge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
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