Section 8 (Engine Mechanical - 3.0L (4V)): Installation: Engine: Installation

All vehicles 

1. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, align the engine with the transaxle.
   Fig 1: Remove/Install Engine And Transaxle Using Special Tools

   Courtesy of FORD MOTOR CO.
2. Install the 5 transaxle-to-engine bolts (3 shown in illustration).
   • Tighten to 48 Nm (35 lb-ft).
     Fig 2: Locating Transaxle-To-Engine Bolts

     Courtesy of FORD MOTOR CO.
3. Using the Adjustable Grip Arm, secure the engine and transaxle to the Powertrain Lift.
   Fig 3: Securing Engine And Transaxle

   Courtesy of FORD MOTOR CO.

   All-Wheel Drive (AWD) vehicles 

4. Using the Handle and PTO  Driven Gear Oil Seal Installer, install the intermediate shaft seal.
   Fig 4: Installing Intermediate Shaft Seal Using Special Tools

   Courtesy of FORD MOTOR CO.
5. Install the Power Transfer Unit (PTU) heat shield and the 3 bolts.
   • Tighten to 11 Nm (97 lb-in).
     Fig 5: Locating PTU Heat Shield And Bolts

     Courtesy of FORD MOTOR CO.
6. Position the PTU  and install the bolt.
   • Tighten to 45 Nm (33 lb-ft).
     Fig 6: Locating PTU And Bolts

     Courtesy of FORD MOTOR CO.
7. Install the 3 PTU  bolts.
   • Tighten to 45 Nm (33 lb-ft).
     Fig 7: Locating PTU Bolts

     Courtesy of FORD MOTOR CO.
8. Install the PTU  vent tube, the pin-type retainer and the bolt.
   • Tighten to 14 Nm (124 lb-in).
     Fig 8: Locating PTU Vent Tube And Bolt

     Courtesy of FORD MOTOR CO.
9. Install the PTU  support bracket and bolts.
   • Tighten to 55 Nm (41 lb-ft).
     Fig 9: Locating PTU Support Bracket And Bolts

     Courtesy of FORD MOTOR CO.
10. Install a new gasket and the RH catalytic converter and the 3 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 10: Locating RH Catalytic Converter Nuts

      Courtesy of FORD MOTOR CO.
11. Install the 3 bolts and the RH heat shield.
    • Tighten to 10 Nm (89 lb-in).
      Fig 11: Locating RH Heat Shield Bolts

      Courtesy of FORD MOTOR CO.
12. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 12: Locating RH Heated Oxygen Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.

    All vehicles 

13. Install the 2 stud bolts and the starter.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 13: Locating Starter Stud Bolts

      Courtesy of FORD MOTOR CO.
14. Install the 2 nuts and the starter wiring.
    • Tighten the small starter motor solenoid wire nut to 5 Nm (44 lb-in).
    • Tighten the large starter motor solenoid battery cable nut to 12 Nm (106 lb-in).
      Fig 14: Locating Starter Wiring Nut

      Courtesy of FORD MOTOR CO.
15. Install the nut and the starter wiring ground.
    • Tighten to 18 Nm (159 lb-in).
      Fig 15: Locating Starter Wiring Ground Nut

      Courtesy of FORD MOTOR CO.
16. Position the powertrain into the vehicle.
    Fig 16: Positioning Powertrain Into Vehicle

    Courtesy of FORD MOTOR CO.
17. Install the engine support bracket, the bolt and the 3 nuts.
    • Tighten the nuts to 55 Nm (41 lb-ft).
    • Tighten the bolt to 90 Nm (66 lb-ft).
      Fig 17: Locating Engine Support Bracket Nuts

      Courtesy of FORD MOTOR CO.
18. Install the rear transaxle support through bolt.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 18: Locating Rear Transaxle Support Through Bolt

      Courtesy of FORD MOTOR CO.
19. Position the RH transaxle support insulator and install the bolt and nuts.
    • Tighten to 80 Nm (59 lb-ft).
      Fig 19: Locating RH Transaxle Support Insulator Bolt And Nuts

      Courtesy of FORD MOTOR CO.
NOTE: Late build AWD  equipped with a mass damper shown in illustration, other vehicles similar.
20. Install the RH transaxle support insulator through bolt and mass damper (if equipped).
    • Tighten to 115 Nm (85 lb-ft).
      Fig 20: Locating RH Transaxle Support Insulator Bolt And Mass Damper

      Courtesy of FORD MOTOR CO.
21. Install the 3 bolts and the halfshaft support bracket.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 21: Locating Halfshaft Support Bracket Bolts

      Courtesy of FORD MOTOR CO.
22. Install the transaxle-to-engine stud and 2 nuts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 22: Locating Transaxle-To-Engine Stud Nuts

      Courtesy of FORD MOTOR CO.
NOTE: Clean and degrease all sealing surfaces with metal surface prep.
NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of the sealant application.
Fig 23: Locating Silicone Gasket And Sealant Applying Area Of Front Cover-To-Cylinder Block Sealing Surface
Courtesy of FORD MOTOR CO.
23. Apply a 10 mm (0.39 in) dot of silicone gasket and sealant to the front cover-to-cylinder block sealing surface.
NOTE: Install a new oil pan gasket.
Fig 24: Locating Oil Pan Bolt
Courtesy of FORD MOTOR CO.
24. Position the oil pan and gasket and loosely install the bolts and stud bolts.
25. Install the 2 oil pan-to-transaxle bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 25: Locating Oil Pan-To-Transaxle Bolts

      Courtesy of FORD MOTOR CO.
26. Tighten the oil pan bolts in the sequence shown in illustration to 25 Nm (18 lb-ft).
    Fig 26: Identifying Oil Pan Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
27. Install the 4 torque converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 27: Locating Torque Converter Nut

      Courtesy of FORD MOTOR CO.
28. Install the access cover.
    Fig 28: Locating Access Cover

    Courtesy of FORD MOTOR CO.
29. If equipped, connect the engine block heater electrical connector.
    Fig 29: Locating Engine Block Heater Electrical Connector

    Courtesy of FORD MOTOR CO.
30. Install the ground wire eyelet and nut to the engine mount stud.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 30: Locating Engine Mount Stud Nut

      Courtesy of FORD MOTOR CO.
31. Connect the electrical connector to the Power Distribution Box (PDB).
    Fig 31: Locating PDB Electrical Connector

    Courtesy of FORD MOTOR CO.
32. Install the cable and the nut to the PDB.
    • Tighten to 12 Nm (106 lb-in).
      Fig 32: Locating Power Distribution Box Cable Nut

      Courtesy of FORD MOTOR CO.
33. Attach the ground wire and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 33: Locating Ground Wire Bolt

      Courtesy of FORD MOTOR CO.
34. Attach the wiring harness retainer to the battery tray bracket.
    Fig 34: Locating Wiring Harness Retainer Of Battery Tray Bracket

    Courtesy of FORD MOTOR CO.
35. Connect the middle PCM electrical connector and the engine wiring harness electrical connector.
    • Attach the 2 wiring harness retainers.
      Fig 35: Locating PCM Electrical Connector And Wiring Harness Retainers

      Courtesy of FORD MOTOR CO.
36. Connect the Evaporative Emission (EVAP) canister purge valve tube and the brake booster vacuum tube to the intake manifold.
    Fig 36: Locating Evaporative Emission Canister Purge Valve Tube And Brake Booster Vacuum Tube

    Courtesy of FORD MOTOR CO.
37. Attach the shift cable retainer to the bracket.
    Fig 37: Locating Shift Cable Retainer

    Courtesy of FORD MOTOR CO.
38. Position the shift cable and bracket in place, install the bolts.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 38: Locating Shift Cable Bracket Bolts

      Courtesy of FORD MOTOR CO.
39. Connect the gearshift cable to the transaxle.
    Fig 39: Locating Gearshift Cable

    Courtesy of FORD MOTOR CO.
40. Connect the fuel supply tube quick connect coupling to the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
    Fig 40: Locating Fuel Supply Tube Quick Connect Coupling

    Courtesy of FORD MOTOR CO.
41. Connect the 2 heater hoses.
    Fig 41: Locating Heater Hoses

    Courtesy of FORD MOTOR CO.
42. Connect the upper and lower radiator hoses.
    Fig 42: Locating Upper And Lower Radiator Hoses

    Courtesy of FORD MOTOR CO.
43. Connect the 2 transmission electrical connectors and attach the wiring retainer to the stud bolt.
    Fig 43: Locating Transmission Electrical Connector And Wiring Retainer

    Courtesy of FORD MOTOR CO.
44. Connect the 2 transaxle fluid cooler tubes.
    Fig 44: Locating Transaxle Fluid Cooler Tubes

    Courtesy of FORD MOTOR CO.
45. Install the 2 secondary latches to the transaxle fluid cooler tubes.
    Fig 45: Locating Secondary Latches Of Transaxle Fluid Cooler Tubes

    Courtesy of FORD MOTOR CO.
46. Install the cross brace and the new nut finger-tight.
    Fig 46: Locating Engine Support Crossmember And Rear Nut

    Courtesy of FORD MOTOR CO.
47. Install the 2 bolts for the cross brace and the bolt for the front roll restrictor.
    • Tighten the 2 cross brace bolts to 90 Nm (66 lb-ft).
    • Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
      Fig 47: Locating Front Roll Restrictor And Engine Support Cross Brace

      Courtesy of FORD MOTOR CO.
48. Tighten the cross brace nut to 175 Nm (129 lb-ft).
    Fig 48: Locating Cross Brace Nut

    Courtesy of FORD MOTOR CO.
49. Connect the generator electrical connector.
    Fig 49: Locating Generator Electrical Connector

    Courtesy of FORD MOTOR CO.
50. Position the A/C compressor and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 50: Locating A/C Compressor Bolts

      Courtesy of FORD MOTOR CO.
51. Connect the A/C compressor electrical connector.
    Fig 51: Locating A/C Compressor Electrical Connector

    Courtesy of FORD MOTOR CO.
52. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
    Fig 52: Remove/Install Accessory Drive Belt

    Courtesy of FORD MOTOR CO.

    AWD  vehicles

NOTE: Do not reuse the driveshaft flange bolts and washers. Install new bolts and washers or damage to the vehicle may occur.
53. Align the index-marks made during removal and install 6 new front driveshaft-to-PTU  bolts and washers.
    • Tighten to 37 Nm (27 lb-ft).
      Fig 53: Identifying Front Driveshaft-To-PTU Bolts

      Courtesy of FORD MOTOR CO.

    All vehicles 

54. Install the intermediate shaft.
    Fig 54: Locating Intermediate Shaft

    Courtesy of FORD MOTOR CO.
55. Install the 2 intermediate shaft bearing retainer nuts.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 55: Locating Intermediate Shaft Bearing Retainer Nuts

      Courtesy of FORD MOTOR CO.
56. Install the RH and LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
57. Install the exhaust-Y-pipe. For additional information, refer to EXHAUST SYSTEM article.
58. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 56: Locating RH CMS Electrical Connector

    Courtesy of FORD MOTOR CO.
59. Connect the LH CMS  electrical connector.
    Fig 57: Locating LH Catalyst Monitor Sensor (CMS) Electrical Connector

    Courtesy of FORD MOTOR CO.
60. Install the lateral support crossmember and the 4 bolts.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 58: Locating Lateral Support Crossmember Bolts

      Courtesy of FORD MOTOR CO.
61. Install the lower splash shields and bolts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 59: Locating Lower Splash Shields

      Courtesy of FORD MOTOR CO.
62. Install the front wheels and tires. For additional information, refer to TIRES & WHEELS article.
63. Install the Air Cleaner (ACL) outlet pipe and ACL  . For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V) article.
64. Install the battery tray. For additional information, refer to BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES article.
65. Fill the engine with clean engine oil.
66. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING article.
67. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.