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Section 457 (Engine - 3.0L 2V): Installation: Engine

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.
Fig 1: Identifying Special Tools (1 Of 2)
G01592582Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tools (2 Of 2)
G01592583Courtesy of FORD MOTOR CO.
Fig 3: Identifying Material Specifications
G01592584Courtesy of FORD MOTOR CO.
  1. Install the flexplate and the bolts. Tighten the bolts in a criss-cross pattern.
    Fig 4: Installing Flexplate And Bolts
    G01592585Courtesy of FORD MOTOR CO.
  2. Position the engine on the subframe and transmission assembly.
    Fig 5: Positioning Engine On Subframe And Transmission Assembly
    G01592586Courtesy of FORD MOTOR CO.
  3. Install the transmission-to-engine bolts.
    • Install five bolts.
    • Install one stud bolt.
    Fig 6: Installing Transmission-To-Engine Bolts
    G01592587Courtesy of FORD MOTOR CO.
  4. Connect the lower radiator hose to the water pump.
    Fig 7: Connecting Lower Radiator Hose To Water Pump
    G01592588Courtesy of FORD MOTOR CO.
  5. Install the RH engine support insulator through bolt.
    Fig 8: Installing RH Engine Support Insulator Through Bolt
    G01592589Courtesy of FORD MOTOR CO.
  6. Install the dual converter Y-pipe and the bolts.
    Fig 9: Installing Dual Converter Y-Pipe And Bolts
    G01592590Courtesy of FORD MOTOR CO.
  7. Connect the catalyst monitor sensor electrical connector.
    Fig 10: Connecting Catalyst Monitor Sensor Electrical Connector
    G01592591Courtesy of FORD MOTOR CO.
  8. Connect the catalyst monitor sensor electrical connector.
    Fig 11: Connecting Catalyst Monitor Sensor Electrical Connector
    G01592592Courtesy of FORD MOTOR CO.
  9. Install the LH engine support insulator-to-subframe nut.
    Fig 12: Installing LH Engine Support Insulator-To-Subframe Nut
    G01592593Courtesy of FORD MOTOR CO.
  10. Install the two RH engine support insulator-to-transmission bolts.
    Fig 13: Installing RH Engine Support Insulator-To-Transmission Bolts
    G01592594Courtesy of FORD MOTOR CO.
  11. Remove the special tools.
    Fig 14: Removing Special Tools
    G01592595Courtesy of FORD MOTOR CO.
  12. Remove the special tool from the RH side of the engine.
    Fig 15: Removing Special Tool From RH Side Of Engine
    G01592596Courtesy of FORD MOTOR CO.
  13. Remove the special tool from the LH side of the engine.
    Fig 16: Removing Special Tool From LH Side Of Engine
    G01592597Courtesy of FORD MOTOR CO.
  14. Install the secondary air injection hose, if equipped.
    Fig 17: Installing Secondary Air Injection Hose
    G01592598Courtesy of FORD MOTOR CO.
  15. Install the RH catalytic converter heat shield.
    • Install the two nuts.
    • Position the ground strap and install the bolt.
    Fig 18: Installing RH Catalytic Converter Heat Shield
    G01592599Courtesy of FORD MOTOR CO.
  16. Position the 42-pin connector on the bracket and connect the transaxle harness electrical connector.
    Fig 19: Connecting Transaxle Harness Electrical Connector
    G01592600Courtesy of FORD MOTOR CO.
  17. Connect the turbine shaft speed (TSS) sensor electrical connector.
    Fig 20: Connecting Turbine Shaft Speed Sensor Electrical Connector
    G01592601Courtesy of FORD MOTOR CO.
  18. Connect the output speed sensor (OSS) electrical connector.
    Fig 21: Connecting Output Speed Sensor Electrical Connector
    G01592602Courtesy of FORD MOTOR CO.
  19. Install the ignition coil and the bolts.
    Fig 22: Installing Ignition Coil And Bolts
    G01592603Courtesy of FORD MOTOR CO.
  20. Connect the ignition coil electrical connector.
    Fig 23: Connecting ignition coil electrical connector
    G01592604Courtesy of FORD MOTOR CO.
  21. Connect the spark plug wires to the ignition coil.
    Fig 24: Connecting Spark Plug Wires To Ignition Coil
    G01592605Courtesy of FORD MOTOR CO.
  22. Install the secondary air injection valve and bracket, if equipped.
    Fig 25: Installing Secondary Air Injection Valve And Bracket
    G01592606Courtesy of FORD MOTOR CO.
  23. Connect the secondary air injection valve vacuum tube, if equipped.
    Fig 26: Connecting Secondary Air Injection Valve Vacuum Tube
    G01592607Courtesy of FORD MOTOR CO.
  24. Connect the control valve solenoid to the bracket, if equipped.
    Fig 27: Connecting Control Valve Solenoid To Bracket
    G01592608Courtesy of FORD MOTOR CO.
  25. Install the LH secondary air injection tube, if equipped.
    Fig 28: Installing LH Secondary Air Injection Tube
    G01592609Courtesy of FORD MOTOR CO.
  26. Connect the power steering pressure tube to the power steering pump.
    Fig 29: Connecting Power Steering Pressure Tube To Power Steering Pump
    G01592610Courtesy of FORD MOTOR CO.
  27. Install the power steering pressure tube bracket and the nut.
    Fig 30: Installing Power Steering Pressure Tube Bracket And Nut
    G01592611Courtesy of FORD MOTOR CO.
  28. Install the power steering pressure tube bracket and the nut.
    Fig 31: Installing Power Steering Pressure Tube Bracket And Nut
    G01592612Courtesy of FORD MOTOR CO.
  29. Using the special tool, raise the engine, transmission and subframe into the vehicle.
    Fig 32: Raising Engine, Transmission And Subframe Into Vehicle
    G01592613Courtesy of FORD MOTOR CO.
  30. Install the four front subframe-to-body bolts.
    Fig 33: Installing Front Subframe-To-Body Bolts
    G01592614Courtesy of FORD MOTOR CO.
  31. Lower the special tool and position it aside.
    Fig 34: Removing Special Tool
    G01592615Courtesy of FORD MOTOR CO.
  32. Install the LH and RH half shafts to the steering knuckles.
    Fig 35: Installing LH And RH Half Shafts To Steering Knuckles
    G01592616Courtesy of FORD MOTOR CO.
  33. Connect the LH and RH tie rod ends to the steering knuckles.
    Fig 36: Connecting LH And RH Tie Rod Ends To Steering Knuckles
    G01592617Courtesy of FORD MOTOR CO.
  34. Connect the LH and RH lower control arms to the steering knuckles.
    Fig 37: Connecting LH And RH Lower Control Arms To Steering Knuckles
    G01592618Courtesy of FORD MOTOR CO.
  35. Connect the LH and RH stabilizer links to the stabilizer bar.
    Fig 38: Connecting LH And RH Stabilizer Links To Stabilizer Bar
    G01592619Courtesy of FORD MOTOR CO.
  36. Install the four torque converter nuts.
    Fig 39: Installing Torque Converter Nuts
    G01592620Courtesy of FORD MOTOR CO.
  37. Install the engine rear plate.
    Fig 40: Installing Engine Rear Plate
    G01592621Courtesy of FORD MOTOR CO.
  38. Install the starter motor.
    Fig 41: Installing Starter Motor
    G01592622Courtesy of FORD MOTOR CO.
  39. Connect the starter motor electrical connectors.
    Fig 42: Connecting Starter Motor Electrical Connectors
    G01592623Courtesy of FORD MOTOR CO.
  40. Install the starter motor electrical connector cover.
    Fig 43: Installing Starter Motor Electrical Connector Cover
    G01592624Courtesy of FORD MOTOR CO.
  41. Connect the auxiliary oil cooler assembly.
    • Connect the transmission oil cooler hose, if equipped.
    • Connect the power steering return hose.
    Fig 44: Connecting Auxiliary Oil Cooler Assembly
    G01592625Courtesy of FORD MOTOR CO.
  42. Connect the wiring harness electrical connector, if equipped.
    Fig 45: Connecting Wiring Harness Electrical Connector
    G01592626Courtesy of FORD MOTOR CO.
  43. Connect the transmission oil cooler hose.
    Fig 46: Connecting Transmission Oil Cooler Hose
    G01592627Courtesy of FORD MOTOR CO.
  44. Connect the lower radiator hose to the radiator and the degas bottle supply hose.
    Fig 47: Connecting Lower Radiator Hose To Radiator And Degas Bottle Supply Hose
    G01592628Courtesy of FORD MOTOR CO.
  45. Install the radiator support bracket.
    Fig 48: Installing Radiator Support Bracket
    G01592629Courtesy of FORD MOTOR CO.
  46. Connect the A/C discharge tube.
    Fig 49: Connecting A/C Discharge Tube
    G01592630Courtesy of FORD MOTOR CO.
  47. Install a new gasket into the Y-pipe flange.
  48. Connect the three-way converter to the dual converter Y-pipe and the muffler pipe.
    Fig 50: Connecting Three-Way Converter To Dual Converter Y-Pipe And Muffler Pipe
    G01592631Courtesy of FORD MOTOR CO.
  49. Install the exhaust clamp.
    Fig 51: Installing Exhaust Clamp
    G01592632Courtesy of FORD MOTOR CO.
  50. Install the front wheels.
  51. Install the front splash shield.
    • Install the three screws.
    • Install the nine pin-type retainers.
    Fig 52: Installing Front Splash Shield
    G01592633Courtesy of FORD MOTOR CO.
  52. Lower the vehicle.
  53. Connect the powertrain control module (PCM) electrical connector.
    Fig 53: Connecting Powertrain Control Module Electrical Connector
    G01592634Courtesy of FORD MOTOR CO.
  54. Connect the evaporative emissions (EVAP) canister purge valve electrical connector.
    Fig 54: Connecting Evaporative Emissions Canister Purge Valve Electrical Connector
    G01592635Courtesy of FORD MOTOR CO.
  55. Connect the ground electrical connectors and install the bolt.
    Fig 55: Connecting Ground Electrical Connectors And Installing Bolt
    G01592636Courtesy of FORD MOTOR CO.
  56. Connect the heater water hose.
    Fig 56: Connecting Heater Water Hose
    G01592637Courtesy of FORD MOTOR CO.
  57. Install the engine roll restrictor and install the bolts.
    Fig 57: Installing Engine Roll Restrictor And Installing Bolts
    G01592638Courtesy of FORD MOTOR CO.
  58. Install the engine roll restrictor brace and install the nut and bolt.
    Fig 58: Installing Engine Roll Restrictor Brace
    G01592639Courtesy of FORD MOTOR CO.
  59. Connect the hoses to the degas bottle.
    Fig 59: Connecting Hoses To Degas Bottle
    G01592640Courtesy of FORD MOTOR CO.
  60. Connect the fuel tube spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  61. Connect the A/C suction tube to the accumulator drier. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  62. Connect the generator electrical connections.
    Fig 60: Connecting Generator Electrical Connections
    G01592641Courtesy of FORD MOTOR CO.
  63. Connect the power steering return hose.
    Fig 61: Connecting Power Steering Return Hose
    G01592642Courtesy of FORD MOTOR CO.
  64. Connect the ground strap electrical connector.
    Fig 62: Connecting Ground Strap Electrical Connector
    G01592643Courtesy of FORD MOTOR CO.
  65. Connect the upper radiator hose and heater water hose to the thermostat housing.
    Fig 63: Connecting Upper Radiator Hose And Heater Water Hose To Thermostat Housing
    G01592644Courtesy of FORD MOTOR CO.
  66. Connect the transmission range (TR) sensor and the 42-pin electrical connectors.
    Fig 64: Connecting Transmission Range Sensor And 42-Pin Electrical Connectors
    G01592645Courtesy of FORD MOTOR CO.
  67. Install the manual control lever cable.
    Fig 65: Installing Manual Control Lever Cable
    G01592646Courtesy of FORD MOTOR CO.
  68. Connect the manual control lever cable to the manual control lever and install the nut.
    Fig 66: Connecting Manual Control Lever Cable To Manual Control Lever And Installing Nut
    G01592647Courtesy of FORD MOTOR CO.
  69. Connect the chassis vacuum hose.
    Fig 67: Connecting Chassis Vacuum Hose
    G01592648Courtesy of FORD MOTOR CO.
  70. Install the accelerator cable bracket and install the bolts.
    Fig 68: Installing Accelerator Cable Bracket And Installing Bolts
    G01592649Courtesy of FORD MOTOR CO.
  71. Connect the accelerator cable, speed control cable and throttle return spring.
    Fig 69: Connecting Accelerator Cable, Speed Control Cable And Throttle Return Spring
    G01592650Courtesy of FORD MOTOR CO.
  72. Install the snow shield.
    Fig 70: Installing Snow Shield
    G01592651Courtesy of FORD MOTOR CO.
  73. Connect the steering column to the steering gear input shaft and install the bolt.
    Fig 71: Connecting Steering Column To Steering Gear Input Shaft And Installing Bolt
    G01592652Courtesy of FORD MOTOR CO.
  74. Position the steering column input shaft coupling boot and install the nuts.
    Fig 72: Positioning Steering Column Input Shaft Coupling Boot And Installing Nuts
    G01592653Courtesy of FORD MOTOR CO.
  75. Install the engine air cleaner and the engine air cleaner outlet tube. For additional information, refer to REMOVAL & INSTALLATION .
  76. Install the cowl extension and cowl vent screen. For additional information, refer to FRONT END BODY PANELS .
  77. Install the battery and connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  78. Fill the engine with clean engine oil.
  79. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
  80. Charge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  81. Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
  82. Inspect the engine and cooling system for leaks.
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