Section 37 (ENGINE - 3.5L DURATEC (212kW/278PS)): Installation: Engine

For information on Ford Color Coded Illustrations refer to OEM Color Coding

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	303-1245 Engine Lift Eye TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1529 Lift Eye, Engine TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW
Courtesy of FORD MOTOR COMPANY	307-346 (T97T-7902-A) Retainer, Torque Converter TKIT-1998-LM (NavigatoR) TKIT-1997-F/FLM/LT
Floor Crane
Adjustable Mounting Arm
Hose Clamp Remover/Installer
Powertrain Jack
Wooden Block

Materials 

2WD/4WD 

1. Remove Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

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2. Lubricate the torque converter pilot hub.

   Material: Motorcraft® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)

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3. Inspect the dowel pins and replace if necessary.

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4. Using the floor crane and spreader bar, align the engine to the transaxle. Use the General Equipment: Floor Crane

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5. Install the transaxle-to-engine bolts.

   Torque: 35 lb.ft (48 Nm)

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6. Install the transaxle-to-engine and engine-to-transaxle bolts.

   Torque: 35 lb.ft (48 Nm)

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7. Install the bolts for the RH halfshaft bracket.

   Torque: 35 lb.ft (48 Nm)

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8. NOTE: LH shown, RH similar.

   Install the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

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9. Using the floor crane and the spreader bar, install the powertrain and subframe as an assembly on the powertrain jack. Use the General Equipment: Powertrain Jack. Use the General Equipment: Floor Crane. Use the General Equipment: Wooden Block

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10. NOTE: LH shown, RH similar.

    Remove the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

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11. Install the adjustable mounting arm. Use the General Equipment: Adjustable Mounting Arm

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12. Install a ratchet strap from the front of the subframe under the powertrain jack to the rear of the subframe, to secure the subframe to the powertrain jack.

    4WD 

13. Connect the PTU (power takeoff unit) vent hose.

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14. • Install the PTU bracket and hand start the bolts at the PTU.
    • Install the bolts at the cylinder block.

      Torque: 35 lb.ft (48 Nm)

    • Tighten the bolts at the PTU.

      Torque: 35 lb.ft (48 Nm)

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    2WD/4WD 

15. Position back the wire harness and connect the wire harness retainers.

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16. • Connect the electrical connectors and the wire retainers.
    • Install the generator nut and position back the boot.

      Torque: 150 lb.in (17 Nm)

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17. • Install the new exhaust manifold studs.

      Torque: 106 lb.in (12 Nm)

    • Install the new exhaust manifold gasket.

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18. NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

    Install the RH catalytic converter and new nuts.

    Torque: Stage 1: 18 lb.ft (25 Nm) Stage 2: 18 lb.ft (25 Nm)

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19. Install the heat shield and the bolts.

    Torque: 97 lb.in (11 Nm)

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20. Connect the RH electrical connectors and the wire retainer.

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21. Position back the ground cable and install the stud bolt.

    Torque: 89 lb.in (10 Nm)

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22. Connect the wire retainer and the transmission electrical connector.

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23. Install the starter and the stud bolts.

    Torque: 35 lb.ft (48 Nm)

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24. NOTE: Make sure the starter wiring is on the starter terminals.

    Position back the wire harness and connect the retainers.

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25. 1. Install the starter positive cable nut.

       Torque: 106 lb.in (12 Nm)

    2. Install the starter control nut.

       Torque: 53 lb.in (6 Nm)

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26. Remove the ratchet strap from the RH knuckle to subframe.
27. Remove the floor crane and the spreader bar. Use the General Equipment: Floor Crane

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28. Remove Special Service Tool: 303-1529 Lift Eye, Engine.

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29. Remove Special Service Tool: 303-1245 Engine Lift Eye.

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30. Using the powertrain jack, raise the subframe and powertrain assembly into the vehicle. Use the General Equipment: Powertrain Jack. Use the General Equipment: Wooden Block

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31. Install the transmission mount bolts.

    Torque: 59 lb.ft (80 Nm)

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32. 1. Install the engine mount bolts.

       Torque: 81 lb.ft (110 Nm)

    2. Install the engine mount nut.

       Torque: 66 lb.ft (90 Nm)

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33. Install the engine mount nuts.

    Torque: 59 lb.ft (80 Nm)

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34. NOTE: Align the reference marks made during removal.

    Install the subframe front bolts finger tight.

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35. NOTE: Align the reference marks made during removal.
    • Install the crossmember and the subframe rear bolts finger tight.
    • Install the subframe bolts finger tight.

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36. NOTE: While tightening the subframe bolts, make sure the front subframe does not move.

    Tighten the subframe front bolts.

    Torque: 173 lb.ft (235 Nm)

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37. • Tighten the subframe rear bolts.

      Torque: Stage 1: 76 lb.ft (103 Nm) Stage 2: 270 deg.

    • Tighten the subframe bolts.

      Torque: 44 lb.ft (60 Nm)

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38. Install the RH strut-to-wheel knuckle nuts and bolts.

    Torque: 173 lb.ft (235 Nm)

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39. Install the LH strut-to-wheel knuckle nuts and bolts.

    Torque: 173 lb.ft (235 Nm)

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40. Remove the ratchet strap from the front of the subframe to the rear of the subframe.
41. Remove the adjustable mounting arm and the powertrain jack. Use the General Equipment: Powertrain Jack. Use the General Equipment: Wooden Block. Use the General Equipment: Adjustable Mounting Arm

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    4WD 

42. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the bolts.

    Torque: 52 lb.ft (70 Nm)

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    2WD/4WD 

43. NOTE: Do not lubricate the engine oil filter seal.

    Install the new engine oil filter.

    Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 180 deg.

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44. Install the oil pan-to-transaxle bolts.

    Torque: 35 lb.ft (48 Nm)

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45. Install the new torque converter bolts.

    Torque: 41 lb.ft (55 Nm)

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46. Install the inspection cover and the retainers.

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47. Install the exhaust Y-pipe. Refer to: Exhaust Y-Pipe .
48. Connect the coolant hose retainer.

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49. If equipped, connect the oil cooler hoses. Use the General Equipment: Hose Clamp Remover/Installer

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50. Install the front brake discs. Refer to: Brake Disc .
51. NOTE: Use the internal or external hex-holding feature to prevent the ball and stud from turning while removing or installing the stabilizer bar link nuts. The link boot seal must not be allowed to twist while tightening the link nuts or damage to the boot seal will occur.

    Position back the RH sway bar link and install the nut.

    Torque: 85 lb.ft (115 Nm)

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52. NOTE: Use the internal or external hex-holding feature to prevent the ball and stud from turning while removing or installing the stabilizer bar link nuts. The link boot seal must not be allowed to twist while tightening the link nuts or damage to the boot seal will occur.

    Position back the LH sway bar link and install the nut.

    Torque: 85 lb.ft (115 Nm)

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53. Install the RH anti-lock sensor and bolt.

    Torque: 80 lb.in (9 Nm)

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54. Install the LH anti-lock sensor and bolt.

    Torque: 80 lb.in (9 Nm)

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55. Connect the transmission cooling tubes.

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56. Install the transmission cooler tube secondary latches.

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57. Connect and attach the engine harness electrical connector.

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58. Install the underbody shields and retainers.

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59. Install the underbody shields and retainers.

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60. Install the following items:
    1. Install the accessory drive belt. Refer to: Accessory Drive Belt .
    2. Install the fender splash shields. Refer to: Fender Splash Shield .
    3. Install the front wheels and tires. Refer to: Wheel and Tire .
    4. Install the cooling fan motor and shroud. Refer to: Cooling Fan Motor and Shroud .

61. Install the degas bottle hose.

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62. Position back the ground wire and install the bolt. Connect the wire retainer.

    Torque: 89 lb.in (10 Nm)

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63. Connect the PCM electrical connector and the wire harness retainer.

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64. Connect the electrical connector and the wire harness retainer.

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65. Using a new O-ring, connect the A/C tube fitting and install the nut.

    Torque: 159 lb.in (18 Nm)

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66. • Using a new O-ring, connect the A/C hose and install the nut.

      Torque: 159 lb.in (18 Nm)

    • Connect the A/C pressure switch.

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67. Install the bolt for the A/C tube bracket.

    Torque: 62 lb.in (7 Nm)

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68. • Connect the heater hoses. Use the General Equipment: Hose Clamp Remover/Installer
    • Connect the upper and lower radiator hoses. Use the General Equipment: Hose Clamp Remover/Installer

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69. Position back the transaxle control cable and connect the cable. Install the bolt.

    Torque: 62 lb.in (7 Nm)

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70. Connect the fuel supply tube. Refer to: Spring Lock Couplings .

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71. Connect the vacuum hose and the EVAP hose. Refer to: Quick Release Coupling . Use the General Equipment: Hose Clamp Remover/Installer

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72. Position back the wire harness and connect the wire harness retainer. Install the bolt.

    Torque: 106 lb.in (12 Nm)

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73. Position the electrical wiring harness cables and install the nuts.
    1. Torque: 71 lb.in (8 Nm)
    2. Torque: 106 lb.in (12 Nm)

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74. Close the cover.

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75. • Position the top part of junction box.
    • Latch the tabs.

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76. Connect the junction box electrical connector.

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77. Position back the ground cable and install the stud bolt.

    Torque: 106 lb.in (12 Nm)

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78. Check the selector lever cable adjustment. Refer to: Selector Lever Cable Adjustment - 6-Speed Automatic Transmission - 6F50/6F55 .
79. Install the following items:
    1. Install the battery tray. Refer to: Battery Tray .
    2. Install the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
    3. Install the air cleaner. Refer to: Air Cleaner .
    4. Install the degas bottle. Refer to: Degas Bottle .

80. Install the engine appearance cover.

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81. NOTE: Do not allow the intermediate shaft to rotate while it is connecting 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. Refer to Clockspring or Clockspring - Vehicles With: Adaptive Steering

    Position back the steering shaft and install the new bolt.

    Torque: 18 lb.ft (25 Nm)

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82. Remove the steering wheel holding tool.

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83. Fill the engine with clean engine oil. Refer to: Specifications .

    Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

84. Fill and bleed the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
85. Recharge the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging .
86. Check the transmission fluid level. Refer to: Transmission Fluid Level Check .
87. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.