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Home >> Ford >> 2003 >> Explorer 4.0 E, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 845 (Engine - 5.4L (3V) - F250-F550 Super Duty) >> Installation >> Engine

Section 845 (Engine - 5.4L (3V) - F250-F550 Super Duty): Installation: Engine

WARNING: This page is about a different car, the 2005 Ford Pickup and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G03886715
 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
MATERIAL

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) 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

    All vehicles 

  1. Using a suitable floor crane, position the engine assembly into the vehicle.
    2. CAUTION: Only use hand tools when installing the RH engine mount nuts or damage to the engine mount can occur.
    NOTE: Align the engine-to-transmission dowels before installing the engine mount nuts.
    NOTE: RH shown, LH similar.
  2. Install the 6 engine mount nuts.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 1: Identifying Engine Mount Nuts
      G03919938Courtesy of FORD MOTOR CO.
  3. Remove the special tool.
    Fig 2: Identifying Special Tool
    G03920205Courtesy of FORD MOTOR CO.

    4. Manual transmission vehicles 

  4. Install the clutch and pressure plate. For additional information, refer to CLUTCH DISC AND PRESSURE PLATE .

    5. Automatic transmission vehicles 

    NOTE: The upper 2 transmission-to-engine bolts will be installed later.
  5. Install the lower 5 transmission-to-engine bolts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 3: Identifying Lower Transmission-To-Engine Bolts
      G03920193Courtesy of FORD MOTOR CO.
  6. Install 4 new torque converter-to-flexplate nuts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 4: Locating Torque Converter-To-Flexplate Nuts
      G03885557Courtesy of FORD MOTOR CO.
  7. Install the cylinder block opening cover.
    Fig 5: Identifying Access Plug
    G03908385Courtesy of FORD MOTOR CO.
  8. Install the flexplate inspection cover and the 2 bolts.
    • Tighten to 34 Nm (25 lb-ft).
      Fig 6: Locating Flexplate Inspection Cover Bolts
      G03885458Courtesy of FORD MOTOR CO.
  9. Position the transmission fluid filler tube and install the ground strap and the nut.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 7: Installing Ground Strap
      G03920194Courtesy of FORD MOTOR CO.
  10. Install the starter. For additional information, refer to STARTER MOTOR .

    11. All vehicles 

  11. Install a new oil filter.
  12. If equipped, connect the block heater electrical connector.
    Fig 8: Locating Block Heater Electrical Connector
    G03920195Courtesy of FORD MOTOR CO.
  13. Position the starter electrical harness support bracket and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 9: Locating Starter Wiring Harness Support Bracket Bolt
      G03919905Courtesy of FORD MOTOR CO.
  14. Position the ground strap and install the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 10: Positioning Ground Strap
      G03905683Courtesy of FORD MOTOR CO.
  15. Connect the engine oil temperature (EOT) sensor electrical connector.
    Fig 11: Locating Engine Oil Temperature Sensor Electrical Connector
    G03920098Courtesy of FORD MOTOR CO.
  16. Connect the crankshaft position (CKP) sensor electrical connector.
    Fig 12: Connecting Crankshaft Position (CKP) Sensor Electrical Connector
    G03920483Courtesy of FORD MOTOR CO.
  17. Position the A/C compressor and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 13: Locating Bolt Access Holes For A/C Compressor
      G03919912Courtesy of FORD MOTOR CO.
  18. Install the 4 exhaust manifold flange nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 14: Identifying Exhaust Manifold Flange Nuts
      G03885400Courtesy of FORD MOTOR CO.
  19. Connect the 2 heated exhaust gas oxygen sensor (HO2S) electrical connectors.
    Fig 15: Connecting Heated Exhaust Gas Oxygen Sensor (HO2S) Electrical Connectors
    G03920201Courtesy of FORD MOTOR CO.

    20. Automatic transmission vehicles 

  20. Install the transmission cooler tube support bracket and the nut.
    • Tighten to 10 Nm (89 lb-in).
      Fig 16: Identifying Transmission Cooler Tube Support Bracket And Nut
      G03905682Courtesy of FORD MOTOR CO.
  21. Install the upper 2 transmission-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 17: Installing Upper Transmission-To-Engine Bolts
      G03920204Courtesy of FORD MOTOR CO.

    22. All vehicles 

  22. Position the degas bottle support bracket and install the 3 nuts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 18: Positioning Degas Bottle Support Bracket
      G03920186Courtesy of FORD MOTOR CO.
  23. Connect the body wiring harness retainer to the degas bottle support bracket.
    Fig 19: Connecting Body Wiring Harness Retainer
    G03920185Courtesy of FORD MOTOR CO.
  24. Connect the heater hose.
    Fig 20: Connecting Heater Hose
    G03910394Courtesy of FORD MOTOR CO.
  25. Position the evaporative emissions (EVAP) canister purge valve and bracket assembly, and install the 3 nuts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 21: Positioning Evaporative Emissions Canister Purge Valve And Bracket Assembly
      G03919862Courtesy of FORD MOTOR CO.
  26. Connect the electrical connector and the EVAP tube quick connect couplings to the EVAP canister purge valve. For additional information, refer to QUICK CONNECT COUPLING .
    Fig 22: Connecting Electrical Connector And EVAP Tube Quick Connect Couplings
    G03919866Courtesy of FORD MOTOR CO.
  27. Connect the engine wiring harness retainer to the EVAP canister purge valve bracket.
    Fig 23: Connecting Engine Wiring Harness Retainer To EVAP Canister Purge
    G03919860Courtesy of FORD MOTOR CO.
  28. Connect the CKP sensor wiring harness retainer to the starter motor wiring harness.
    Fig 24: Connecting CKP Sensor Wiring Harness Retainer
    G03920181Courtesy of FORD MOTOR CO.
  29. Connect the generator wiring harness retainer to the RH cylinder head.
    Fig 25: Connecting Generator Wiring Harness Retainer
    G03920180Courtesy of FORD MOTOR CO.
  30. Connect the A/C compressor and the A/C high pressure cut-off switch electrical connectors.
    Fig 26: Connecting A/C Compressor And The A/C High Pressure Cut-Off Switch Electrical Connectors
    G03920179Courtesy of FORD MOTOR CO.
  31. Connect the generator wiring harness retainer to the RH cylinder head.
    Fig 27: Connecting Generator Wiring Harness Retainer
    G03920178Courtesy of FORD MOTOR CO.
  32. Position the power steering pump and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 28: Identifying Power Steering Pump Bolts
      G03886436Courtesy of FORD MOTOR CO.
  33. Position the air cleaner outlet tube support bracket and install the 2 nuts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 29: Positioning Air Cleaner Outlet Tube Support Bracket
      G03919911Courtesy of FORD MOTOR CO.
  34. Connect the 2 electrical connectors on the LH fender splash shield.
    Fig 30: Connecting Electrical Connectors
    G03920176Courtesy of FORD MOTOR CO.
  35. Connect the degas bottle coolant hose.
    Fig 31: Connecting Degas Bottle Coolant Hose
    G03920175Courtesy of FORD MOTOR CO.
  36. Position the accessory drive bolt onto the engine.
  37. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  38. Install the radiator. For additional information, refer to RADIATOR -- GASOLINE ENGINES .
  39. Install the degas bottle. For additional information, refer to DEGAS BOTTLE -- 5.4L, 6.8L .
  40. Install the powertrain control module (PCM). For additional information, refer to POWERTRAIN CONTROL MODULE (PCM) .
  41. Install the cowl vent grille. For additional information, refer to COWL PANEL GRILLE .
  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 AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING .
  45. Fill and bleed the power steering system. For additional information, refer to POWER STEERING SYSTEM FILLING and POWER STEERING SYSTEM PURGING .
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