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Section 9 (Engine Mechanical - 3.5L): Installation: Engine

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOLS DESCRIPTION

G08977169
 2, 200# Floor Crane, Fold Away
300-OTC1819E
G08977170
 Adjustable Grip Arm, 1735A
014-00001
G08977171
 Powertrain Lift
300-OTC1585AE
G08977172
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
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

All vehicles 

  1. Using the Floor Crane and Spreader Bar, align the engine to the transaxle.
    Fig 1: Locating Floor Crane And Spreader Bar
    G08977173Courtesy 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
      G08977174Courtesy 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
      G08977175Courtesy 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 procedure.

    Fig 4: Locating Fuel Supply Tube Quick Connect Coupling
    G08977176Courtesy 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 procedure.
    • Attach the EVAP tube retainer.
      G08977177

      FWD vehicles 

  6. Install the RH halfshaft bolt and 2 stud bolts.
    • Tighten to 40 Nm (30 lb-ft).
      G08977178

    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 Bolt
      G08977179Courtesy of FORD MOTOR CO.
  8. Install the 2 RH halfshaft-to-PTU bracket bolts.
    • Tighten to 40 Nm (30 lb-ft).
      G08977180

      All vehicles 

  9. Install a ratchet strap from the front subframe to the LH engine lift eye.
    G08977181
  10. Using the Floor Crane and Spreader Bar, position the powertrain and subframe as an assembly onto the Powertrain Lift.
    Fig 6: Locating Floor Crane And Spreader Bar
    G08977182Courtesy of FORD MOTOR CO.
  11. NOTE: RH shown, 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.
        G08977183
  12. Remove the ratchet strap.
    G08977184
  13. Install an Adjustable Grip Arm from the Powertrain Lift to the LH engine-to-transmission bolt hole.
    G08977185
  14. Using a new gasket, install the RH catalytic converter and 4 new nuts (3 shown).
    • Tighten to 40 Nm (30 lb-ft).
      G08977186
  15. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 7: Locating RH Catalyst Monitor Sensor Electrical Connector
    G08977187Courtesy 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).
      G08977188
  17. Install the 2 nuts to valve cover for power steering hose retainers.
    • Tighten to 9 Nm (80 lb-in).
      G08977189
  18. Position the wiring harness and install the ground wire and bolt to the RH cylinder head.
    • Tighten to 10 Nm (89 lb-in).
      G08977190
  19. Connect the transmission control electrical connector.
    • Attach the wiring harness retainer.
      G08977191
  20. Install the starter, the bolt and the stud bolt.
    • Tighten to 27 Nm (20 lb-ft).
      G08977192
  21. Connect the wiring harness retainer to the starter stud bolt.
    G08977193
  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).
      G08977194
  23. Install the starter motor solenoid cover.
    G08977195
  24. Remove the Floor Crane and Spreader Bar.
    Fig 8: Locating Floor Crane And Spreader Bar
    G08977196Courtesy 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
    G08977197Courtesy of FORD MOTOR CO.
  26. Using the Powertrain Lift, raise the powertrain/subframe assembly into the vehicle.
    G08977198
  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
      G08977199Courtesy 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 Insulator Through Bolt And Nut
      G08977200Courtesy of FORD MOTOR CO.
  29. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      G08977201
  30. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
      G08977202
  31. Install the engine mount brace, the nut and the bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 12: Locating Engine Mount Brace Nut And Bolt
      G08977203Courtesy 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
      G08977204Courtesy 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 Insulator Through Bolt And Nut
      G08977205Courtesy of FORD MOTOR CO.
  34. Install the 2 middle subframe nuts.
    • Tighten to 133 Nm (98 lb-ft).
      Fig 15: Locating Middle Subframe Nuts
      G08977206Courtesy 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 Front Subframe Nuts
      G08977207Courtesy of FORD MOTOR CO.
  36. Position the subframe support brackets in place and loosely install the 2 bolts and 2 nuts.
    G08977208
  37. Position the subframe brace and loosely install the 2 bolts.
    G08977209
  38. Tighten the 2 rear subframe bracket nuts to 133 Nm (98 lb-ft).
    G08977210
  39. Tighten the 4 bolts to 90 Nm (66 lb-ft).
    G08977211
  40. Remove the Adjustable Grip Arm and Powertrain Lift.
    G08977212
  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 procedure.

    G08977213
  42. Position the lower bumper on the subframe and install the 3 LH nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 17: Locating LH Subframe-To-Lower Bumper Nuts
      G08977214Courtesy 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
      G08977215Courtesy 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).
      G08977216
  45. Install the roll restrictor heat shield and the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
      G08977217

    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
      G08977218Courtesy of FORD MOTOR CO.

      All vehicles 

  47. Install the 3 new torque converter bolts.
    • Tighten to 55 Nm (41 lb-ft).
      G08977219
  48. Install the inspection cover and the 2 fasteners.
    G08977220
  49. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 20: Locating Oil Pan-To-Transaxle Bolts
      G08977221Courtesy 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.
      G08977222
  52. NOTE: RH shown, LH similar.

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

    • Tighten to 225 Nm (166 lb-ft).
      G08977223
  53. NOTE: RH shown, LH similar.

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

    • Tighten to 7 Nm (62 lb-in).
      G08977224
  54. NOTE: RH shown, 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).
      G08977225
  55. Connect the 2 transmission fluid cooler tubes.
    Fig 21: Locating Transmission Fluid Cooler Tubes
    G08977226Courtesy of FORD MOTOR CO.
  56. Install the 2 secondary latches onto the transmission fluid cooler tubes.
    Fig 22: Locating Transmission Fluid Cooler Tubes Secondary Latches
    G08977227Courtesy 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).
      G08977228
  58. Install the ground wire and bolt to the engine front cover.
    • Tighten to 10 Nm (89 lb-in).
      G08977229
  59. Connect the wiring harness electrical connector.
    • Attach the wiring harness retainer to the RH valve cover stud bolt.
      G08977230
  60. Connect the 2 PCM electrical connectors.
    • Attach the 2 wiring harness retainers to the stud bolts.
      G08977231
  61. Connect the A/C suction tube fitting.
    • Install the safety clip onto the A/C fitting.
      Fig 23: Locating A/C Suction Tube Fitting Safety Clip
      G08977232Courtesy 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 A/C Pressure Tube Fitting Bolt
      G08977233Courtesy of FORD MOTOR CO.
  63. Install the A/C tube bracket bolt.
    • Tighten to 12 Nm (106 lb-in).
      G08977234
  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 Retainers
    G08977235Courtesy of FORD MOTOR CO.
  65. Attach the control cable to the bracket.
    • Connect the transaxle control cable to the control lever.
      Fig 26: Locating Control Cable Bracket
      G08977236Courtesy of FORD MOTOR CO.
  66. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
    G08977237
  67. Connect the vacuum hose to the upper intake manifold.
    G08977238
  68. Attach the 3 wiring harness retainers to the bracket and inner fender.
    G08977239
  69. Connect the wiring harness electrical connector.
    G08977240
  70. Attach the 2 wiring harness retainers to the stud bolt and bracket.
    G08977241
  71. Install the ground wire and bolt.
    • Tighten to 10 Nm (89 lb-in).
    • Connect the wiring harness electrical connector.
      G08977242
  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.
      G08977243
  73. Install the battery tray. For additional information, refer to BATTERY, BATTERY MOUNTING & BATTERY CABLES .
  74. Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM .
  75. Connect the hose to the power steering reservoir.
    Fig 27: Locating ACL Outlet Pipe Clamp
    G08977244Courtesy 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: Locating Power Steering Cooler Bracket Bolt
      G08977245Courtesy of FORD MOTOR CO.
  78. Connect the power steering cooler hose.
    G08977246
  79. Install the accessory drive belt and the power steering belt. Refer to ACCESSORY DRIVE BELT .
  80. Install the LH and RH inner splash shields. Refer to BODY PANEL SYSTEM - FRONT END BODY PANELS .
  81. Install the LH and RH front wheels and tires. Refer to WHEELS & 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 HVAC - 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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