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Engine - Manual Transmission

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SPECIAL TOOLS

G08641965
 Heavy Duty Floor Crane
014-00071 or equivalent
G06126494
 Lifting Bracket, Engine
303-F047 (014-00073) or equivalent
G06068086
 Support Bar, Engine
303-F072
G06139341
 Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)		 WSS-M2C945-A
Motorcraft® SAE 5W-50 Full Synthetic Motor Oil
XO-5W50-QGT		 WSS-M2C931-B
Motorcraft® Premium Long-Life Grease
XG-1-C (US); CXG-1-C (Canada)		 ESA-M1C75-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.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.
NOTE: The Boss® 302 requires Motorcraft® SAE 5W-50 Full Synthetic Motor Oil, all other 5.0L (4V) engines require Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil.
  1. Lubricate the end of the transmission shaft with Premium Long-Life Grease.
  2. Using the Heavy Duty Floor Crane and the Engine Lifting Bracket, install the engine into the vehicle.
    Fig 1: Removing/Installing Engine Using Special Tools
    G07474484Courtesy of FORD MOTOR CO.
  3. NOTE: Do not tighten the stud bolt at this time.

    Install the transmission-to-engine stud bolt.

    Fig 2: Locating Transmission-To-Engine Stud Bolt
    G07474483Courtesy of FORD MOTOR CO.
  4. NOTE: Do not position the legs of the Engine Support Bar on the fenders. Instead, the legs should be positioned on the body structure near the suspension strut tower. Failure to follow these instructions may result in body damage.

    Install the Engine Support Bar.

    • Attach the Engine Support Bar to the through bolt on the Engine Lifting Bracket.
    • Once the engine is supported by the Engine Support Bar remove the Heavy Duty Floor Crane.
      Fig 3: Supporting Engine Using Engine Support Bar And Heavy Duty Floor Crane
      G07474482Courtesy of FORD MOTOR CO.
  5. Using the Engine Support Bar, level the engine in the vehicle.
    Fig 4: Identifying Engine Support Bar
    G07474468Courtesy of FORD MOTOR CO.
  6. NOTE: Do not tighten the bolt at this time.

    Install RH transmission-to-engine bolt.

    Fig 5: Locating RH Transmission-To-Engine Bolt
    G07474480Courtesy of FORD MOTOR CO.
  7. Install the 3 LH transmission-to-engine bolts.
    • Tighten the 4 installed transmission-to-engine bolts and the stud bolt to 48 Nm (35 lb-ft).
      Fig 6: Locating LH Transmission-To-Engine Bolts
      G07474479Courtesy of FORD MOTOR CO.
  8. Install the 2 separator plate bolts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 7: Locating Separator Plate Bolts
      G07474478Courtesy of FORD MOTOR CO.
  9. Remove the 3 bolts and lower the underbody shield.
    G07474057
  10. Install the A/C compressor and the 3 stud bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 8: Locating A/C Compressor Stud Bolts
      G07474477Courtesy of FORD MOTOR CO.
  11. NOTE: The engine support insulator bracket must be positioned on the engine support insulator stud. If necessary, adjust the height of the engine using the engine support bar.

    Install the LH engine support insulator bracket, the 3 bolts and the stud bolt.

    • Tighten to 55 Nm (41 lb-ft).
      Fig 9: Locating LH Engine Support Insulator Bracket, Stud Bolt And Bolts
      G07474476Courtesy of FORD MOTOR CO.
  12. Position the steering intermediate shaft and install the bolt.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 10: Locating Steering Intermediate Shaft And Bolt
      G07474475Courtesy of FORD MOTOR CO.
  13. NOTE: The engine support insulator bracket must be positioned on the engine support insulator stud. If necessary, adjust the height of the engine using the engine support bar.

    Install the RH engine support insulator bracket, the 2 bolts and the 2 stud bolts.

    • Tighten to 55 Nm (41 lb-ft).
      Fig 11: Locating RH Engine Support Insulator Bracket, Bolts And Stud Bolts
      G07474220Courtesy of FORD MOTOR CO.
  14. Install the ground strap and the nut to the RH engine support insulator bracket.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 12: Locating RH Engine Support Insulator Bracket Nut And Ground Strap
      G07474219Courtesy of FORD MOTOR CO.
  15. Attach the wiring harness retainers to A/C compressor stud bolts and the RH side of the oil pan.
    Fig 13: Locating A/C Compressor Stud Bolt And Wiring Harness Retainers
    G07474269Courtesy of FORD MOTOR CO.
  16. Attach the wiring harness retainers to the RH side of the oil pan and the RH engine support insulator bracket stud bolt.
    Fig 14: Locating Wiring Harness Retainers
    G07474218Courtesy of FORD MOTOR CO.
  17. Using the Engine Support Bar, lower the engine onto the engine support insulators.
    Fig 15: Identifying Engine Support Bar
    G07474468Courtesy of FORD MOTOR CO.
  18. NOTE: RH shown in illustration, LH similar.

    Install the RH and LH engine support insulator nuts.

    • Tighten to 63 Nm (46 lb-ft).
      Fig 16: Locating Engine Support Insulator Nut
      G06392444Courtesy of FORD MOTOR CO.
  19. Remove the Engine Support Bar and the Engine Lifting Bracket.
  20. Install the top transmission-to-engine bolt and stud bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 17: Locating Top Transmission-To-Engine Bolt And Stud Bolt
      G07474466Courtesy of FORD MOTOR CO.
  21. Install the A/C belt and the accessory drive belt. For additional information, refer to ACCESSORY DRIVE .
  22. Connect the middle PCM electrical connector, the 16 pin electrical connector and attach the wiring harness retainers to the PCM bracket.
    Fig 18: Locating Middle PCM Electrical Connector, 16 Pin Electrical Connector And Wiring Harness Retainers
    G07474464Courtesy of FORD MOTOR CO.
  23. Attach the wiring harness retainers to the LH side of the oil pan and the front oil pan stud bolts and install the 2 nuts.
    • Tighten to 8 Nm (71 lb-in).
      Fig 19: Locating Front Oil Pan Stud Bolts And Wiring Harness Retainer
      G07474463Courtesy of FORD MOTOR CO.
  24. If equipped, connect the 2 coolant hose quick connect couplings to the oil cooler. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
    G07988200
  25. Position the underbody shield and install the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
      G07474057
  26. Install the starter motor. For additional information, refer to STARTING SYSTEM .
  27. NOTE: LH shown in illustration, RH similar.

    Connect the LH and RH Heated Oxygen Sensor (HO2S) sensor electrical connectors.

    Fig 20: Locating LH Heated Oxygen Sensor Electrical Connector
    G07474241Courtesy of FORD MOTOR CO.
  28. Install the RH and LH catalytic converters. For additional information, refer to EXHAUST SYSTEM .
  29. Install the B+ cable, the nut, and the electrical connector to the generator.
    • Tighten to 17 Nm (150 lb-in).
      Fig 21: Locating B+ Cable, Electrical Connector And Nut
      G07474455Courtesy of FORD MOTOR CO.
  30. Install the engine cooling fan assembly, the bolt, and the stud bolt.
    • Tighten to 9 Nm (80 lb-in).
      Fig 22: Locating Engine Cooling Fan Assembly Bolt And Stud Bolt
      G07474454Courtesy of FORD MOTOR CO.
  31. Connect the engine cooling fan electrical connector.
    Fig 23: Locating Engine Cooling Fan Electrical Connector
    G07474453Courtesy of FORD MOTOR CO.
  32. Connect the 2 heater hose quick connect couplings to the heater core. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
    Fig 24: Locating Heater Hose Quick Connect Couplings And Heater Core
    G07474452Courtesy of FORD MOTOR CO.
  33. Connect the lower radiator hose to the engine.
    Fig 25: Locating Lower Radiator Hose Clamp
    G07474451Courtesy of FORD MOTOR CO.
  34. Connect the coolant bypass T assembly to the engine and install the clamp and the spring clip.
    Fig 26: Locating Coolant Bypass T Assembly, Spring Clip And Clamp
    G07474450Courtesy of FORD MOTOR CO.
  35. Install the Air Cleaner (ACL) inlet pipe.
    Fig 27: Locating ACL Inlet Pipe
    G07474449Courtesy of FORD MOTOR CO.
  36. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  37. If equipped, attach the Evaporative Emission (EVAP) tube to the LH valve cover and the LH inner fender.
    Fig 28: Locating Evaporative Emission Tube, LH Valve Cover And LH Inner Fender
    G07474448Courtesy of FORD MOTOR CO.
  38. NOTE: Base 5.0 L (4V) shown in illustration, Boss® 302 similar.

    Attach the fuel supply tube to the LH valve cover.

    Fig 29: Locating LH Valve Cover Fuel Supply Tube And Retainer Clip
    G07474447Courtesy of FORD MOTOR CO.
  39. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  40. Install the degas bottle. For additional information, refer to ENGINE COOLING .
  41. Install the upper radiator sight shield and the 8 pin-type retainers.
    Fig 30: Locating Upper Radiator Sight Shield And Pin-Type Retainers
    G06403276Courtesy of FORD MOTOR CO.
  42. Attach the sound enhancement pipe retainer.
    Fig 31: Locating Sound Enhancement Pipe Retainer
    G07474445Courtesy of FORD MOTOR CO.
  43. Install the ACL outlet pipe and the ACL. For additional information, refer to the INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM -- MUSTANG .
  44. Lift the cowl screen and install the ground strap bolt.
    • Tighten to 10 Nm (89 lb-in).
    • Attach the wiring harness retainer to the cowl.
      G07487024
  45. Install the 2 cowl vent screen plastic rivets.
    G07487023
  46. NOTE: The engine appearance cover rubber grommets may remain on the cover. If so, remove the grommets from the cover and install them on the intake manifold before installing the cover.

    If equipped, install the engine appearance cover.

    Fig 32: Locating Engine Appearance Cover
    G07473994Courtesy of FORD MOTOR CO.
  47. NOTE: Base 5.0 L (4V) shown in illustration, Boss® 302 similar.

    If equipped, install the strut tower cross brace and the 4 nuts.

    • Tighten to 35 Nm (26 lb-ft).
      Fig 33: Locating Strut Tower Cross Brace And Nuts
      G07473993Courtesy of FORD MOTOR CO.
  48. NOTE: Use the hood hinge location index marks made during removal to aid in hood installation.

    Install the hood and the 4 bolts.

    • Tighten to 12 Nm (106 lb-in).
      G07474440
  49. Attach the 2 windshield washer hose retainers and connect the 2 windshield washer hose C-Lock Couplers. For additional information, refer to WIPERS AND WASHERS .
    G07474439
  50. Install the 2 windshield washer hose retainers and the 8 hood insulation pin-type retainers (2 shown in illustration).
    G07474438
  51. Install the 2 steering column dash boot nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 34: Locating Steering Column Dash Boot Nuts
      G06394907Courtesy of FORD MOTOR CO.
  52. Fill the engine with clean engine oil.
  53. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  54. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
  55. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
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