Section 1957 (Engine Mechanical - 3.5L): Installation: Engine: Material

All vehicles 

1. Align the transaxle to the engine.
2. Install the 5 transaxle-to-engine bolts.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 1: Locating Transaxle-To-Engine Bolts

     Courtesy of FORD MOTOR CO.
3. Install the 2 engine-to-transaxle bolts.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 2: Locating Engine-To-Transaxle Bolts

     Courtesy of FORD MOTOR CO.
4. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle onto the lift table.
   Fig 3: Identifying Heavy Duty Floor Crane And Spreader Bar

   Courtesy of FORD MOTOR CO.
NOTE: Position a block of wood under the transaxle.
Fig 4: Identifying Powertrain Lift And Universal Adapter Brackets
Courtesy of FORD MOTOR CO.
5. Install the Powertrain Lift and Universal Adapter Brackets.
6. Install the starter, the bolt and the stud bolt.
   • Tighten to 27 Nm (20 lb-ft).
     Fig 5: Locating Stud Bolt And Starter

     Courtesy of FORD MOTOR CO.
7. Connect the wiring harness retainer to the starter stud bolt.
   Fig 6: Locating Wiring Harness Retainer

   Courtesy of FORD MOTOR CO.
8. Attach the starter motor wire terminals and install the 2 nuts.
   1. Tighten the starter B+ terminal nut to 12 Nm (106 lb-in).
   2. Tighten the starter S-terminal nut to 5 Nm (44 lb-in).
      • Position the starter terminal boot over the starter terminal.
        Fig 7: Identifying Starter Motor Wire Terminals

        Courtesy of FORD MOTOR CO.
9. Raise the engine and transaxle assembly into the vehicle.
10. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 8: Locating Engine Mount Bolts

      Courtesy of FORD MOTOR CO.
11. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
      Fig 9: Locating Engine Mount Nuts

      Courtesy of FORD MOTOR CO.
12. Install the engine mount brace, the nut and the bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 10: Locating Engine Mount Brace Nut And Bolt

      Courtesy of FORD MOTOR CO.
13. Install the transaxle support insulator bracket, the 3 nuts and the bolt.
    • Tighten the 3 nuts to 63 Nm (46 lb-ft).
    • Tighten the bolt to 80 Nm (59 lb-ft).
      Fig 11: Identifying Transaxle Support Insulator Bracket Nuts

      Courtesy of FORD MOTOR CO.
14. Install the transaxle support insulator through bolt and nut.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 12: Locating Transaxle Support Insulator Through Bolt And Nut

      Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is removed from the vehicle.
Fig 13: Removing Compression Seal
Courtesy of FORD MOTOR CO.
15. Using a small screwdriver, remove the compression seal and discard.
16. Using a soft-face hammer, install the new compression seal.
    Fig 14: Locating Compression Seal

    Courtesy of FORD MOTOR CO.
17. Position the PTU  in place and install the 5 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 15: Locating PTU Bolts

      Courtesy of FORD MOTOR CO.
18. Position the PTU  support bracket in place and install the 5 bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 16: Locating Power Transfer Unit Support Bracket Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Do not tighten the 4 catalytic converter nuts at this time.
Fig 17: Locating RH Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.
19. Using a new gasket, install the RH catalytic converter and 4 new nuts.
20. Install the 2 catalytic converter-to-bracket bolts.
    • Tighten the 4 catalytic converter nuts to 40 Nm (30 lb-ft).
    • Tighten the 2 catalytic converter-to-bracket bolts to 20 Nm (177 lb-in).
      Fig 18: Locating RH Catalytic Converter Support Bracket Bolts

      Courtesy of FORD MOTOR CO.
21. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 19: Locating RH Catalyst Monitor Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.

    All vehicles 

22. Using the Powertrain Lift, raise the subframe into the installed position.
    Fig 20: Positioning Powertrain Lift Under Subframe Assembly

    Courtesy of FORD MOTOR CO.
23. Install the 2 middle subframe nuts.
    • Tighten to 133 Nm (98 lb-ft).
      Fig 21: Locating Middle Subframe Nuts

      Courtesy of FORD MOTOR CO.
24. Install the 2 front subframe nuts.
    • Tighten to 133 Nm (98 lb-ft).
      Fig 22: Locating Front Subframe Nuts

      Courtesy of FORD MOTOR CO.
25. Position the subframe support brackets in place and loosely install the 4 bolts.
    Fig 23: Locating Subframe Support Brackets Bolts

    Courtesy of FORD MOTOR CO.
26. Install the 2 rear subframe bracket nuts.
    • Tighten to 133 Nm (98 lb-ft).
      Fig 24: Locating Rear Subframe Bracket Nuts

      Courtesy of FORD MOTOR CO.
27. Tighten the 4 subframe support bracket bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 25: Locating Subframe Support Bracket Bolts

      Courtesy of FORD MOTOR CO.
28. Position the lower bumper on the subframe and install the 3 LH nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 26: Locating LH Subframe-To-Lower Bumper Nuts

      Courtesy of FORD MOTOR CO.
29. Install the 3 RH lower bumper-to-subframe nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 27: Locating RH Subframe-To-Lower Bumper Nuts

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
30. Install the tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install new cotter pins.
      Fig 28: Locating Tie-Rod Ends And Nuts

      Courtesy of FORD MOTOR CO.
NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to CLOCKSPRING .
31. Install the intermediate shaft onto the steering gear and install a new bolt.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 29: Locating Steering Intermediate Shaft Bolt

      Courtesy of FORD MOTOR CO.
32. Using a new banjo bolt and 2 new seals, install the Power Steering Pressure (PSP) tube.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 30: Locating Power Steering Pressure Tube-To-Pump Banjo Bolt

      Courtesy of FORD MOTOR CO.
33. Install the engine roll restrictor-to-subframe through bolt.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 31: Locating Engine Roll Restrictor-To-Subframe Through Bolt

      Courtesy of FORD MOTOR CO.
34. Install the roll restrictor heat shield and the 2 nuts.
    • Tighten to 11 Nm (97 lb-in).
      Fig 32: Locating Roll Restrictor Heat Shield Nuts

      Courtesy of FORD MOTOR CO.

    AWD vehicles 

35. Line up the index marks on the rear driveshaft to the index marks on the PTU  flange made during removal and install the 4 bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 33: Locating Driveshaft Bolts

      Courtesy of FORD MOTOR CO.

    All vehicles 

36. Install the power steering cooler bracket bolt to the RH side of the subframe.
    • Tighten to 9 Nm (80 lb-in).
      Fig 34: Locating Power Steering Cooler Bracket Bolt

      Courtesy of FORD MOTOR CO.
37. Connect the power steering cooler hose.
    Fig 35: Locating Power Steering Cooler Hose

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
38. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
      Fig 36: Locating Engine Oil Filter

      Courtesy of FORD MOTOR CO.
39. Install the 3 new torque converter bolts.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 37: Locating Torque Converter Bolts

      Courtesy of FORD MOTOR CO.
40. Install the inspection cover and the 2 fasteners.
    Fig 38: Locating Inspection Cover Fasteners

    Courtesy of FORD MOTOR CO.
41. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 39: Locating Oil Pan-To-Transaxle Bolts

      Courtesy of FORD MOTOR CO.
42. Connect the 2 transmission fluid cooler tubes.
    Fig 40: Locating Transmission Fluid Cooler Tubes

    Courtesy of FORD MOTOR CO.
43. Install the 2 secondary latches onto the transmission fluid cooler tubes.
    Fig 41: Locating Secondary Latches

    Courtesy of FORD MOTOR CO.
44. Install the LH inner splash shield. For additional information, refer to FRONT END BODY PANELS .
45. Install the radiator splash shield, the 3 pin-type retainers and the 7 screws.
    Fig 42: Locating Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
46. Using a new gasket, install the Y-pipe and exhaust flexible pipe assembly and 4 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 43: Locating Exhaust Flexible Pipe Nuts

      Courtesy of FORD MOTOR CO.
47. Install the 2 exhaust hangers and tighten the exhaust clamp.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 44: Locating Exhaust Flexible Pipe Clamp

      Courtesy of FORD MOTOR CO.
48. Install the ground wire, the radio interference capacitor wire and the nut to the engine front cover stud.
    • Tighten to 10 Nm (89 lb-in).
      Fig 45: Locating Ground Wire Nut

      Courtesy of FORD MOTOR CO.
49. Install the ground wire and bolt to the engine front cover.
    • Tighten to 10 Nm (89 lb-in).
      Fig 46: Locating Ground Wire Bolt

      Courtesy of FORD MOTOR CO.
50. Attach the wiring harness retainer to the RH valve cover stud bolt.
    Fig 47: Locating Wiring Harness Retainer

    Courtesy of FORD MOTOR CO.
51. Install the oil level indicator.
    Fig 48: Locating Oil Level Indicator

    Courtesy of FORD MOTOR CO.
52. Connect the 2 engine wiring harness electrical connectors.
    • Attach the electrical connector to the LH valve cover.
      Fig 49: Locating Engine Wiring Harness Electrical Connectors

      Courtesy of FORD MOTOR CO.
53. Connect the fuel hose routing clip to the transaxle stud.
    Fig 50: Locating Fuel Hose Routing Clip

    Courtesy of FORD MOTOR CO.
54. Connect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 51: Locating Fuel Supply Tube

    Courtesy of FORD MOTOR CO.
55. Connect the hose to the power steering reservoir.
    Fig 52: Locating Hose

    Courtesy of FORD MOTOR CO.
56. Connect the A/C suction tube fitting.
    • Install the safety clip onto the A/C fitting.
      Fig 53: Locating A/C Suction Tube Safety Clip

      Courtesy of FORD MOTOR CO.
57. Using a new O-ring seal, connect the A/C tube fitting and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 54: Locating A/C Pressure Tube Fitting And Nut

      Courtesy of FORD MOTOR CO.
58. If equipped, attach the engine block heater harness retainers to the radiator support and the A/C suction tube.
    Fig 55: Locating Engine Block Heater Harness And A/C Suction Tube

    Courtesy of FORD MOTOR CO.
59. Connect the transaxle control electrical connector.
    Fig 56: Locating Transaxle Control Electrical Connector

    Courtesy of FORD MOTOR CO.
60. Attach the control cable to the bracket.
    • Connect the transaxle control cable to the control lever.
      Fig 57: Locating Transaxle Control Cable

      Courtesy of FORD MOTOR CO.
61. Attach the wiring harness retainer to the transaxle control cable bracket.
    Fig 58: Locating Wiring Harness Retainer

    Courtesy of FORD MOTOR CO.
62. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
    Fig 59: Locating Upper And Lower Radiator Hose

    Courtesy of FORD MOTOR CO.
63. Connect the upper Evaporative Emission (EVAP) tube quick connect coupling to the purge valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 60: Locating Upper Evaporative Emission Tube

    Courtesy of FORD MOTOR CO.
64. Connect the vacuum hose to the upper intake manifold.
    Fig 61: Locating Vacuum Hose

    Courtesy of FORD MOTOR CO.
65. Install the ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    • Attach the 2 wiring harness retainers to the cowl.
      Fig 62: Locating Wiring Harness Retainers

      Courtesy of FORD MOTOR CO.
66. Connect the power feed to the battery terminal and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 63: Locating Battery Terminal Nut

      Courtesy of FORD MOTOR CO.
67. Connect the battery harness electrical connector.
    Fig 64: Locating Battery Harness Electrical Connector

    Courtesy of FORD MOTOR CO.
68. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
69. Install the engine Air Cleaner (ACL) and the ACL  outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
70. Install the degas bottle. For additional information, refer to ENGINE COOLING .
71. Install the LH halfshaft and intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
72. Install the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE .
73. Fill the engine with clean engine oil.
74. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
75. Fill the power steering system. For additional information, refer to STEERING SYSTEM .
76. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .