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Section 1322 (Engine Mechanical - 5.4L (4V)): Installation: Engine

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Special Tools

Illustration Tool Name Tool Number
GF0000536Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0000628Courtesy of FORD MOTOR CO.
 Installer Set, Teflon® Seal 211-D027 (D90P-3517-A) or equivalent
GF0000267Courtesy of FORD MOTOR CO.
 Lifting Bracket, Engine 303-D089 (D93P-6001-A3) or equivalent
Material

Item Specification
Motorcraft SAE 5W-50 Full Synthetic Motor Oil
XO-5W50-QGT or equivalent		 WSS-M2C931-B
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
  1. Using the Heavy Duty Floor Crane and the Engine Lifting Bracket, install the engine into the vehicle.
    2. Fig 1: Identifying Special Tools (014-00071) & (303-D089)
    GF0000575Courtesy of FORD MOTOR CO.
  2. Install the LH engine insulator nut.
    • Tighten to 63 Nm (46 lb-ft).
    3. Fig 2: Locating LH Engine Support Insulator Nut
    GF0000574Courtesy of FORD MOTOR CO.
  3. Install the RH engine insulator nut.
    • Tighten to 63 Nm (46 lb-ft).
    4. Fig 3: Locating RH Engine Support Insulator Nut
    GF0000573Courtesy of FORD MOTOR CO.
  4. Install the ground wire and the bolt to the rear of the LH cylinder head.
    • Tighten to 10 Nm (89 lb-in).
    5. Fig 4: Identifying Ground Wire From Rear Of LH Cylinder Head
    GF0000572Courtesy of FORD MOTOR CO.
  5. Install the clutch disc and pressure plate. For additional information, refer to CLUTCH .
    6. NOTE: Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM .
  6. Install the intermediate steering shaft and the upper bolt.
    • Tighten to 47 Nm (35 lb-ft).
    7. Fig 5: Locating Upper Bolt From Intermediate Steering Shaft
    GF0000445Courtesy of FORD MOTOR CO.
  7. Install a new engine oil filter in the following sequence.
    1. Lubricate the oil filter gasket with clean engine oil and tighten until the seal makes contact.
    2. Using an oil filter strap wrench, tighten the filter an additional 270 degrees.
    8. Fig 6: Identifying Engine Oil Filter
    GF0000447Courtesy of FORD MOTOR CO.
    NOTE: For correct starter installation, the upper bolt must be tightened first.
    NOTE: Clean the starter motor mounting flange and mating surface of the starter motor to make sure there is a correct ground connection.
  8. Install the starter and the 3 bolts finger-tight.
    1. Tighten the upper bolt to 25 Nm (18 lb-ft).
    2. Tighten the 2 lower bolts to 25 Nm (18 lb-ft).
    9. Fig 7: Installing Starter & Bolts
    GF0000629Courtesy of FORD MOTOR CO.
  9. Connect the 2 wires and install the 2 nuts on the starter solenoid.
    • Tighten the B+ terminal to 12 Nm (106 lb-in).
    • Tighten the S-terminal to 5 Nm (44 lb-in).
    10. Fig 8: Disconnecting Wires From Starter Solenoid
    GF0000570Courtesy of FORD MOTOR CO.
  10. Install the starter solenoid terminal cover.
    11. Fig 9: Locating Starter Solenoid Terminal Cover
    GF0000569Courtesy of FORD MOTOR CO.
  11. Attach the 2 wiring harness pin-type retainers to the oil pan.
    12. Fig 10: Locating Wiring Harness Pin-Type Retainers From Oil Pan
    GF0000568Courtesy of FORD MOTOR CO.
  12. Install the ground wire and the nut to the RH engine insulator bracket stud bolt.
    • Tighten to 25 Nm (18 lb-ft).
    13. Fig 11: Locating Ground Wire From RH Engine Support Insulator Bracket Stud Bolt
    GF0000567Courtesy of FORD MOTOR CO.
  13. Install the A/C compressor and the 3 stud bolts.
    • Tighten to 25 Nm (18 lb-ft).
    14. Fig 12: Identifying Stud Bolts & A/C Compressor Aside
    GF0000566Courtesy of FORD MOTOR CO.
  14. Position the Supercharger (SC) drive onto the A/C compressor and attach the 2 wiring harness retainers onto the A/C compressor stud bolts.
    15. Fig 13: Identifying SC Drive Belt, A/C Compressor, Wiring Harness Retainers & A/C Compressor Stud Bolts
    GF0000565Courtesy of FORD MOTOR CO.
  15. Attach the wiring harness pin-type retainer to the back of the A/C compressor.
    16. Fig 14: Detaching Wiring Harness Pin-Type Retainer From Back Of A/C Compressor
    GF0000564Courtesy of FORD MOTOR CO.
  16. Connect the A/C compressor electrical connector.
    17. Fig 15: Identifying A/C Compressor Electrical Connector
    GF0000563Courtesy of FORD MOTOR CO.
  17. Attach the wire harness retainer to the A/C compressor stud bolt.
    18. Fig 16: Locating Wire Harness Retainer From A/C Compressor Stud Bolt
    GF0000562Courtesy of FORD MOTOR CO.
  18. Connect the Crankshaft Position (CKP) sensor electrical connector.
    19. Fig 17: Locating Crankshaft Position (CKP) Sensor Electrical Connector
    GF0000561Courtesy of FORD MOTOR CO.
  19. Install the wire harness bracket to the oil pan stud bolt and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    20. Fig 18: Removing Nut & Wire Harness Bracket From Oil Pan Stud Bolt
    GF0000560Courtesy of FORD MOTOR CO.
  20. Attach the wiring harness retainer to the oil pan stud bolt.
    21. Fig 19: Detaching Wiring Harness Retainer From Oil Pan Stud Bolt
    GF0000559Courtesy of FORD MOTOR CO.
  21. Connect the B+ wire to the generator and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    22. Fig 20: Locating B+ Wire From Generator
    GF0046361Courtesy of FORD MOTOR CO.
  22. Connect the power steering return hose.
    23. Fig 21: Locating Power Steering Return Hose
    GF0000557Courtesy of FORD MOTOR CO.
    NOTE: A new Teflon® seal must be installed.
  23. Using the Teflon® Seal Installer Set, install a new Teflon® seal on the Power Steering Pressure (PSP) tube fitting.
    24. Fig 22: Installing Teflon(R) Seal Using Special Tool 211-D027
    G03950191Courtesy of FORD MOTOR CO.
  24. Connect the pressure PSP tube fitting.
    • Tighten to 65 Nm (48 lb-ft).
    25. Fig 23: Locating Power Steering Pressure (PSP) Tube Fitting
    GF0000556Courtesy of FORD MOTOR CO.
  25. Position the lower radiator hose assembly into the vehicle.
    • Connect the lower radiator hose to the radiator.
    26. Fig 24: Disconnecting Lower Radiator Hose From Radiator
    GF0000555Courtesy of FORD MOTOR CO.
  26. Connect the coolant hose to the oil cooler.
    27. Fig 25: Disconnecting Coolant Hose From Oil Cooler
    GF0000554Courtesy of FORD MOTOR CO.
  27. Rotate the SC drive belt tensioner clockwise and install the drive belt onto the SC drive pulley.
    28. Fig 26: Rotating SC Belt Tensioner Clockwise & Remove SC Belt Off SC
    GF0046329Courtesy of FORD MOTOR CO.
  28. Connect the A/C pressure transducer electrical connector.
    29. Fig 27: A/C Pressure Transducer Electrical Connector
    GF0000553Courtesy of FORD MOTOR CO.
  29. Connect the hose to the power steering reservoir.
    30. Fig 28: Power Steering Reservoir Hose
    GF0000552Courtesy of FORD MOTOR CO.
  30. Connect the 16-pin electrical connector and attach the 2 wiring retainers
    31. Fig 29: Locating 16-Pin Electrical Connector
    GF0015116Courtesy of FORD MOTOR CO.
  31. Connect the upper and lower PCM electrical connectors.
    32. Fig 30: Identifying Upper & Lower Powertrain Control Module (PCM) Electrical Connectors
    GF0015115Courtesy of FORD MOTOR CO.
  32. Connect the 68-pin connector to the Power Distribution Box (PDB).
    • Tighten to 6 Nm (53 lb-in).
    • Attach the PDB upper housing to the lower housing.
    33. Fig 31: Locating Power Distribution Box Upper Housing Bolt
    GF0015119Courtesy of FORD MOTOR CO.
  33. Install the PDB cover.
  34. Attach the 2 wiring harness pin-type retainers.
    35. Fig 32: Locating Pin-Type Wiring Harness Retainer
    GF0046360Courtesy of FORD MOTOR CO.
  35. Attach the pin-type wire harness retainer to the cowl.
    36. Fig 33: Detaching Pin-Type Wire Harness Retainer From Cowl
    GF0000549Courtesy of FORD MOTOR CO.
  36. Connect the 2 heater hoses to the coolant tube assembly at the rear of the engine.
    37. Fig 34: Disconnecting Heater Hoses From Coolant Tube Assembly At Rear Of Engine
    GF0000548Courtesy of FORD MOTOR CO.
  37. Install the Evaporative Emission (EVAP) canister purge valve.
    • Connect the lower EVAP tube and electrical connector to the EVAP canister purge valve.
    38. Fig 35: Disconnecting Lower EVAP Tube & Electrical Connector From EVAP Canister Purge Valve
    GF0000547Courtesy of FORD MOTOR CO.
  38. Connect the EVAP tube and brake booster vacuum supply tube to the Throttle Body (TB) spacer.
    39. Fig 36: Disconnecting Evaporative Emissions (EVAP) Tube & Brake Booster Vacuum Supply Tube From Throttle Body (TB) Spacer
    GF0000546Courtesy of FORD MOTOR CO.
  39. Connect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    40. Fig 37: Locating Fuel Supply Tube
    GF0000545Courtesy of FORD MOTOR CO.
  40. Connect the coolant hose to the coolant pump.
    41. Fig 38: Disconnecting Coolant Hose From Coolant Pump
    GF0000544Courtesy of FORD MOTOR CO.
  41. Connect the coolant hose to the thermostat housing.
    42. Fig 39: Disconnecting Coolant Hose From Thermostat Housing
    GF0000543Courtesy of FORD MOTOR CO.
  42. Connect the coolant hose to the coolant tube assembly (above the generator).
    43. Fig 40: Disconnecting Coolant Hose From Coolant Tube Assembly
    GF0000542Courtesy of FORD MOTOR CO.
  43. Connect the coolant hose from the Charge Air Cooler (CAC).
    44. Fig 41: Disconnecting Coolant Hose From Charge Air Cooler (CAC)
    GF0000541Courtesy of FORD MOTOR CO.
    NOTE: RH bolt shown, LH similar.
  44. Install the cooling fan assembly and the 2 bolts.
    • Tighten to 9 Nm (80 lb-in).
    45. Fig 42: Locating Cooling Fan Assembly Bolts
    GF0000540Courtesy of FORD MOTOR CO.
  45. Connect the cooling fan electrical connector.
    46. Fig 43: Disconnecting Cooling Fan Electrical Connector
    GF0000539Courtesy of FORD MOTOR CO.
  46. Connect the upper radiator hose from the thermostat housing.
    47. Fig 44: Disconnecting Upper Radiator Hose From Thermostat Housing
    GF0000538Courtesy of FORD MOTOR CO.
  47. Install the SC coolant degas bottle. For additional information, refer to SUPERCHARGER COOLING .
  48. Install the engine coolant degas bottle. For additional information, refer to ENGINE COOLING .
  49. Install the 2 steering column dash boot nuts.
    • Tighten to 9 Nm (80 lb-in).
    50. Fig 45: Locating Steering Column Dash Boot Nuts
    GF0000537Courtesy of FORD MOTOR CO.
  50. Install the battery tray and battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  51. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
    52. NOTE: Use the hood hinge location index marks made during removal to aid in hood installation.
  52. Install the hood and 4 bolts.
    • Tighten to 12 Nm (106 lb-in).
  53. Connect the windshield washer hose and position the hood insulation.
    54. Fig 46: Locating Windshield Washer Hose
    GF0015096Courtesy of FORD MOTOR CO.
  54. Install the hood insulation pin-type retainer and attach the 2 windshield washer hose retainers.
    55. Fig 47: Locating Windshield Washer Hose Retainers
    GF0015095Courtesy of FORD MOTOR CO.
  55. Install the strut tower cross brace and the 4 nuts.
    • Tighten to 35 Nm (26 lb-ft).
    56. Fig 48: Locating Strut Tower Cross Brace & Nuts
    GF0000372Courtesy of FORD MOTOR CO.
  56. Fill the engine with clean engine oil.
  57. Install the battery and tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  58. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
  59. Fill and bleed the SC cooling system. For additional information, refer to SUPERCHARGER COOLING .
  60. Fill the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL INFORMATION .
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