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Section 215 (Engine Mechanical - 3.5L): Installation: Engine

WARNING: This page is about a different car, the 2014 Ford Edge. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL DESCRIPTION

G09292397
 2, 200# Floor Crane, Fold Away
300-OTC1819E 
G06251559
 Adjustable Grip Arm, 1735A
014-00001 
G09292241
 Powertrain Lift
300-OTC1585AE 
G06251558
 Spreader Bar
303-D089  (D93P-6001-A3) or equivalent
MATERIAL SPECIFICATION

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)		 WSSM2C945-A

All vehicles 

  1. Using the Floor Crane and Spreader Bar, align the engine to the transaxle.
    Fig 1: Removing Engine And Transaxle From Lift Table Using Floor Crane And Spreader Bar
    G08029631Courtesy of FORD MOTOR CO.
  2. Install the 5 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 2: Locating Transaxle-To-Engine Bolts
      G07997920Courtesy of FORD MOTOR CO.
  3. Install the 2 engine-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 3: Locating Engine-To-Transaxle Bolts
      G07997919Courtesy of FORD MOTOR CO.
  4. NOTE: Do not separate the fuel and vapor tube assembly clip from the transaxle case stud. Failure to follow these instructions can result in damage to the fuel and vapor tube assembly.

    Connect the fuel supply tube. For additional information, refer to the QUICK CONNECT COUPLING .

    Fig 4: Locating Fuel And Vapor Tube Assembly Clip
    G09292472Courtesy of FORD MOTOR CO.
  5. Connect the EVAP  tube quick connect coupling to the purge valve. For additional information, refer to the QUICK CONNECT COUPLING .
    • Attach the EVAP  tube retainer.
      G09292308

    FWD vehicles 

  6. Install the RH halfshaft bolt and 2 stud bolts.
    • Tighten to 40 Nm (30 lb-ft).
      G09292470

    All-Wheel Drive (AWD) vehicles 

  7. Position the PTU  support bracket in place and install the 5 bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 5: Locating Power Transfer Unit Support Bracket Bolts
      G06068123Courtesy of FORD MOTOR CO.
  8. Install the 2 RH halfshaft-to-PTU bracket bolts.
    • Tighten to 40 Nm (30 lb-ft).
      G09292468

    All vehicles 

  9. Install a ratchet strap from the front subframe to the LH engine lift eye.
    G08621954
  10. Using the Floor Crane and Spreader Bar, position the powertrain and subframe as an assembly onto the Powertrain Lift.
    Fig 6: Removing Engine And Transaxle From Lift Table Using Floor Crane And Spreader Bar
    G08029631Courtesy of FORD MOTOR CO.
  11. NOTE: RH shown in illustration, LH similar.

    Position the powertrain and subframe with:

    1. the long board directly under the control arms.
    2. the short boards under the engine oil pan and transmission.
      • Remove the ratchet strap securing the RH knuckle to the transaxle.
        G09292442
  12. Remove the ratchet strap.
    G08621954
  13. Install an Adjustable Grip Arm from the Powertrain Lift to the LH engine-to-transmission bolt hole.
    G08621925
  14. Using a new gasket, install the RH catalytic converter and 4 new nuts (3 shown in illustration).
    • Tighten to 40 Nm (30 lb-ft).
      G09292463
  15. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 7: Locating RH Catalyst Monitor Electrical Connector
    G07997901Courtesy of FORD MOTOR CO.
  16. NOTE: Power steering hoses removed from graphic for clarity.

    Install the power steering pump and the 3 bolts.

    • Tighten to 25 Nm (18 lb-ft).
      G09292323
  17. Install the 2 nuts to valve cover for power steering hose retainers.
    • Tighten to 9 Nm (80 lb-in).
      G09292222
  18. Position the wiring harness and install the ground wire and bolt to the RH cylinder head.
    • Tighten to 10 Nm (89 lb-in).
      G08621940
  19. Connect the transmission control electrical connector.
    • Attach the wiring harness retainer.
      G09293059
  20. Install the starter, the bolt and the stud bolt.
    • Tighten to 27 Nm (20 lb-ft).
      G08621939
  21. Connect the wiring harness retainer to the starter stud bolt.
    G08621938
  22. 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).
      G08622486
  23. Install the starter motor solenoid cover.
    G08655799
  24. Remove the Floor Crane and Spreader Bar.
    Fig 8: Removing Engine And Transaxle From Lift Table Using Floor Crane And Spreader Bar
    G08029631Courtesy of FORD MOTOR CO.
  25. Remove the Engine Lift Eye on the LH cylinder head.
    Fig 9: Identifying Engine Lift Eye On LH Cylinder Head
    G07997915Courtesy of FORD MOTOR CO.
  26. Using the Powertrain Lift, raise the powertrain/subframe assembly into the vehicle.
    G09292944
  27. Install the transaxle support insulator bracket, the 3 nuts and the bolt.
    • Do not torque at this time.
      Fig 10: Identifying Transaxle Support Insulator Bracket Nuts And Bolt
      G09292945Courtesy of FORD MOTOR CO.
  28. Install the transaxle support insulator through bolt and nut.
    • Do not torque at this time.
      Fig 11: Locating Transaxle Support Bolt
      G08000575Courtesy of FORD MOTOR CO.
  29. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      G09291976
  30. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
      G09291975
  31. Install the engine mount brace, the nut and the bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 12: Locating Nut, Bolt And Engine Mount Brace
      G09291974Courtesy of FORD MOTOR CO.
  32. Tighten the transaxle support insulator bracket nuts and bolt.
    1. Tighten the bolt to 80 Nm (59 lb-ft).
    2. Tighten the 3 nuts to 63 Nm (46 lb-ft).
      Fig 13: Identifying Transaxle Support Insulator Bracket Nuts And Bolt
      G09292945Courtesy of FORD MOTOR CO.
  33. Tighten the transaxle support insulator through bolt and nut.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 14: Locating Transaxle Support Bolt
      G08000575Courtesy of FORD MOTOR CO.
  34. Install the 2 middle subframe nuts.
    • Tighten to 133 Nm (98 lb-ft).
      Fig 15: Locating Middle Subframe Nut
      G08976423Courtesy of FORD MOTOR CO.
  35. NOTE: Align the reference marks on the subframe and underbody that were made during the removal of the subframe.

    Install the 2 front subframe nuts.

    • Tighten to 133 Nm (98 lb-ft).
      Fig 16: Locating Forward Subframe Nuts
      G08976422Courtesy of FORD MOTOR CO.
  36. Position the subframe support brackets in place and loosely install the 2 bolts and 2 nuts.
    G09292289
  37. Position the subframe brace and loosely install the 2 bolts.
    G09293077
  38. Tighten the 2 rear subframe bracket nuts to 133 Nm (98 lb-ft).
    G09292956
  39. Tighten the 4 bolts to 90 Nm (66 lb-ft).
    G09292957
  40. Remove the Adjustable Grip Arm and Powertrain Lift.
    G08621925
  41. NOTE: The fuel and vapor tube assembly clip must remain attached to the transaxle case stud during engine removal. Failure to follow these instructions can result in damage to the fuel and vapor tube assembly.

    Connect the fuel supply tube and Evaporative Emission (EVAP) tube quick connect couplings. For additional information, refer to the QUICK CONNECT COUPLING .

    G09292280
  42. Position the lower bumper on the subframe and install the 3 LH nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 17: Locating Lower Bumper Subframe And LH Nuts
      G09293082Courtesy of FORD MOTOR CO.
  43. Install the 3 RH lower bumper-to-subframe nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 18: Locating RH Subframe-To-Lower Bumper Nuts
      G08976408Courtesy of FORD MOTOR CO.
  44. 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 SUPPLEMENTAL RESTRAINT SYSTEM .

    Install the intermediate shaft onto the steering gear and install a new bolt.

    • Tighten to 23 Nm (17 lb-ft).
      G09292962
  45. Install the roll restrictor heat shield and the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
      G09293085

    AWD vehicles 

  46. 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 19: Locating Driveshaft Bolts
      G06505095Courtesy of FORD MOTOR CO.

      All vehicles 

  47. Install the 3 new torque converter bolts.
    • Tighten to 55 Nm (41 lb-ft).
      G09292430
  48. Install the inspection cover and the 2 fasteners.
    G09292429
  49. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 20: Locating Oil Pan-To-Transaxle Bolts
      G06062160Courtesy of FORD MOTOR CO.
  50. Install the exhaust Y-pipe. For additional information, refer to EXHAUST SYSTEM .
  51. NOTE: Do not lubricate the oil filter gasket.

    Install a new engine oil filter.

    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
      G09292965
  52. NOTE: RH shown in illustration, LH similar.

    Install the 2 RH and 2 LH front shock absorber lower flag bolts and nuts.

    • Tighten to 225 Nm (166 lb-ft).
      G09292270
  53. NOTE: RH shown in illustration, LH similar.

    Position the RH and LH front wheel speed sensors and install the 2 bolts.

    • Tighten to 7 Nm (62 lb-in).
      G09292269
  54. NOTE: RH shown in illustration, LH similar.
    NOTE: The guide pin bolts are different sizes. The longer/bigger bolt is the upper guide pin bolt.

    Install the RH and LH brake caliper and install the guide pin bolts.

    • Tighten to 88 Nm (63 lb-ft).
      G09292968
  55. Connect the 2 transmission fluid cooler tubes.
    Fig 21: Locating Transmission Fluid Cooler Tubes
    G06068154Courtesy of FORD MOTOR CO.
  56. Install the 2 secondary latches onto the transmission fluid cooler tubes.
    Fig 22: Locating Secondary Latches
    G06062156Courtesy of FORD MOTOR CO.
  57. Install the radio interference capacitor wire and the nut to the engine front cover stud.
    • Tighten to 10 Nm (89 lb-in).
      G09293096
  58. Install the ground wire and bolt to the engine front cover.
    • Tighten to 10 Nm (89 lb-in).
      G09291965
  59. Connect the wiring harness electrical connector.
    • Attach the wiring harness retainer to the RH valve cover stud bolt.
      G09292263
  60. Connect the 2 PCM electrical connectors.
    • Attach the 2 wiring harness retainers to the stud bolts.
      G09292262
  61. Connect the A/C suction tube fitting.
    • Install the safety clip onto the A/C fitting.
      Fig 23: Locating Safety Clip And A/C Suction Tube Fitting
      G06501037Courtesy of FORD MOTOR CO.
  62. Using a new O-ring seal, connect the A/C tube fitting and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 24: Locating Nut And A/C Pressure Tube Fitting
      G06501214Courtesy of FORD MOTOR CO.
  63. Install the A/C tube bracket bolt.
    • Tighten to 12 Nm (106 lb-in).
      G09292259
  64. If equipped, attach the engine block heater harness retainers to the radiator support and the A/C suction tube.
    Fig 25: Locating Engine Block Heater Harness, Radiator Support, A/C Suction Tube And Engine Wiring Harness
    G06501036Courtesy of FORD MOTOR CO.
  65. Attach the control cable to the bracket.
    • Connect the transaxle control cable to the control lever.
      Fig 26: Locating Transaxle Control Cable And Control Lever
      G06501211Courtesy of FORD MOTOR CO.
  66. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
    G09292256
  67. Connect the vacuum hose to the upper intake manifold.
    G09292255
  68. Attach the 3 wiring harness retainers to the bracket and inner fender.
    G09293107
  69. Connect the wiring harness electrical connector.
    G09292253
  70. Attach the 2 wiring harness retainers to the stud bolt and bracket.
    G09292252
  71. Install the ground wire and bolt.
    • Tighten to 10 Nm (89 lb-in).
    • Connect the wiring harness electrical connector.
      G09292251
  72. Connect the power feed to the battery terminal and install the 2 nuts.
    • Tighten to 8 Nm (71 lb-in).
    • Connect the wiring harness electrical connector.
      G09292250
  73. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  74. Install the engine Air Cleaner (ACL) and the ACL  outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  75. Connect the hose to the power steering reservoir.
    Fig 27: Locating Power Steering Reservoir Hose Clamp
    G07997655Courtesy of FORD MOTOR CO.
  76. Install the degas bottle. Refer to ENGINE COOLING .
  77. Install the power steering cooler bracket bolt to the RH side of the subframe.
    • Tighten to 9 Nm (80 lb-in).
      Fig 28: Measuring Resistance Between Driver Safety Belt Buckle C3065-4, Circuit RR137 (BU/GY), Harness Side And Ground
      G09293113Courtesy of FORD MOTOR CO.
      G09292247
  78. Connect the power steering cooler hose.
  79. Install the accessory drive belt and the power steering belt. Refer to ACCESSORY DRIVE .
  80. Install the LH and RH inner splash shields. Refer to FRONT END BODY PANELS .
  81. Install the LH and RH front wheels and tires. Refer to WHEELS AND TIRES .
  82. Fill the engine with clean engine oil.
  83. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  84. Fill the power steering system. For additional information, refer to STEERING SYSTEM .
  85. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
  86. Install the engine appearance cover. For additional information, refer to ENGINE APPEARANCE COVER - EXPLODED VIEW  .
  87. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.
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