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Section 538 (Engine Mechanical - 3.7L): Installation: Engine

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SPECIAL TOOL DESCRIPTION

G09292397
 2, 200# Floor Crane, Fold Away
300-OTC1819E 
G06260116
 Bar, Engine Spreader
303-1454 
G06126494
 Lifting Bracket, Engine
303-F047  (014-00073)
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® Multi-Purpose Grease
XL-5		 ESB-M1C93-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. NOTE: Prior to installation of the engine, the torque converter pilot hub must be lubricated with multipurpose grease or damage to the torque converter or the engine crankshaft can occur

    Lubricate the torque converter pilot hub with multi-purpose grease.

    Fig 1: Locating Torque Converter Pilot Hub
    G06127674Courtesy of FORD MOTOR CO.
  2. Align the torque converter stud and flexplate hole near the paint marks at the 12 o'clock position.
    Fig 2: Locating Torque Converter Stud And Flexplate Hole
    G07959423Courtesy of FORD MOTOR CO.
  3. Using the Heavy Duty Floor Crane and Engine Spreader Bar, position the engine in the engine compartment.
    G07959974
  4. Attach the generator wiring harness retainer to the lower LH side of the engine block.
    G07958827
  5. Using the Heavy Duty Floor Crane and Engine Spreader Bar, position the engine to the transmission.
    G07959974
  6. Align the engine to the transmission and install LH bellhousing-to-engine bolt.
    • Tighten the bolt, it will be torqued at a later step.
      G07959435
  7. Install the engine-to-bellhousing bolt.
    • Tighten the bolt, it will be torqued at a later step.
      G07958998
  8. Install the oil pan-to-bellhousing bolt.
    • Tighten to 48 Nm (35 lb-ft).
      G07958999
  9. Tighten the engine-to-bellhousing bolt.
    • Tighten to 48 Nm (35 lb-ft).
      G07958998
  10. Using the Heavy Duty Floor Crane and Engine Spreader Bar, raise the engine for clearance for the LH engine support insulator.
    G07959974
  11. Install the LH engine support insulator.
    G07958946
  12. NOTE: Use only hand tools when installing the LH engine support insulator through bolt or the engine support insulator may be damaged.
    NOTE: Clean the LH and RH engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to installation.

    Install the new LH engine support insulator and the through bolt.

    • Do not torque at this time.
      Fig 3: Locating LH Engine Support Insulator Mounting Bolt
      G06126794Courtesy of FORD MOTOR CO.
  13. Lower the engine.
  14. Install the 3 LH engine support insulator bolts.
    • Tighten to 175 Nm (129 lb-ft).
      G07958941
  15. Install the 2 LH bellhousing-to-oil pan bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G07959427
  16. Install the LH bellhousing-to-engine bolt.
    • Tighten to 48 Nm (35 lb-ft).
      G07959439
  17. Tighten LH bellhousing-to-engine bolt.
    • Tighten to 48 Nm (35 lb-ft).
      G07959440
  18. Install the 2 new RH engine support insulator studs.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 4: Locating RH Engine Support Insulator Studs
      G07959432Courtesy of FORD MOTOR CO.
  19. NOTE: Use only hand tools when installing the RH engine support insulator nuts or the engine support insulator may be damaged.

    Install the 2 new RH engine support insulator nuts.

    • Tighten to 175 Nm (129 lb-ft).
      G07959433
  20. NOTE: Use only hand tools when tightening the LH engine support insulator through bolt or the engine support insulator may be damaged.

    Tighten the LH engine mount through bolt.

    • Tighten to 350 Nm (258 lb-ft).
      Fig 5: Locating LH Engine Mount Bolt
      G06126794Courtesy of FORD MOTOR CO.
  21. If equipped, install the 2 coolant hoses to the oil cooler.
    G07959962
  22. NOTE: Do not lubricate the engine oil filter gasket.

    Install a new engine oil filter.

    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
      G07959766
  23. NOTE: LH shown, RH similar.

    Install the new 2 LH and RH catalytic converter-to-exhaust manifold nuts.

    • Tighten to 45 Nm (35 lb-ft).
      G07958937
  24. Position the exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe and install the 2 new bolts.
    • Tighten the inner exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt to 63 Nm (46 lb-ft).
    • Tighten the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt to 63 Nm (46 lb-ft).
      G07959726
  25. NOTE: LH shown, RH similar.

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

    G07959957
  26. Install the 4 torque converter nuts.
    • Tighten to 44 Nm (32 lb-ft).
      G08336958
  27. Install the access cover and the 2 pin-type retainers.
    G07476065
  28. Attach the starter motor wiring harness retainer to the oil pan.
    G09539167
  29. Install the starter motor. For additional information, refer to STARTING SYSTEM .
  30. If equipped, install the front driveshaft. For additional information, refer to DRIVESHAFT .
  31. Install the 4 upper bellhousing-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 6: Locating Upper Bellhousing-To-Engine Mounting Bolts
      G07958789Courtesy of FORD MOTOR CO.
  32. Install the cowl panel and attach the 2 clips and install the 6 screws.
    G07958930
  33. Install the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
  34. Install the ground strap and bolt to the cowl.
    • Tighten to 10 Nm (89 lb-in).
      Fig 7: Locating Ground Strap And Bolt
      G06126817Courtesy of FORD MOTOR CO.
  35. Attach the wiring harness retainers to the rear of the RH valve cover stud bolt and the rear of the RH cylinder head.
    Fig 8: Locating Wiring Harness Retainers From Rear Of RH Valve Cover Stud Bolt
    G07958983Courtesy of FORD MOTOR CO.
  36. Connect the 2 coolant hoses to the degas bottle.
    G07958982
  37. Connect the 2 heater hose couplings at the rear of the engine.
    G07958981
  38. Install the crankcase vent tube quick connect coupling to LH valve cover. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    G07959948
  39. Install the PCV tube quick connect coupling to RH valve cover. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    G07959947
  40. Connect the fuel supply tube quick connect coupling to the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    G07959946
  41. Install the upper intake manifold. For additional information, refer to UPPER INTAKE MANIFOLD .
  42. Attach and connect the engine harness electrical connector.
    G07960894
  43. Connect the middle PCM electrical connector.
    • Attach the wiring harness retainer to the fender splash shield.
      G07959944
  44. Install the Air Conditioning (A/C) compressor belt. For additional information, refer to ACCESSORY DRIVE .
  45. Install the generator. For additional information, refer to CHARGING SYSTEM .
  46. Connect the A/C compressor electrical connector.
    • Attach the A/C compressor wiring harness to the A/C compressor.
      G07958979
  47. Attach the generator wiring harness to the engine front cover.
    G09540124
  48. Install the transmission cooler line bracket and nut to the engine front cover stud bolt.
    • Tighten to 12 Nm (106 lb-in).
      G08336941
  49. Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
    • Tighten to 15 Nm (133 lb-in).
      G07958976
  50. Connect the Battery Junction Box (BJB) wiring harness and the A/C pressure transducer electrical connectors.
    G07958975
  51. Fill the engine with clean engine oil.
  52. Install the Air Cleaner (ACL) upper tray. For additional information, refer to Intake Air System Components - Exploded View, 3.7L in INTAKE AIR DISTRIBUTION AND FILTERING .
  53. Install the cooling module. For additional information, refer ENGINE COOLING .
  54. If equipped, connect the block heater electrical connector at the thermostat housing.
    • Attach the block heater wiring harness retainer to the LH valve cover stud bolt.
      G07958974
  55. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  56. NOTE: Align the index marks made during hood removal.
    NOTE: RH shown, LH similar.

    Position the hood and install the 4 bolts.

    • Tighten to 12 Nm (106 lb-in).
      G07958929
  57. 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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