Section 14 (Engine - 3.7L DURATEC (199KW/270PS)): 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
Floor Crane
Adjustable Mounting Arm
Vehicle/Axle Stands
Hose Clamp Remover/Installer
Wooden Block

Materials 

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

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

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2. • Inspect the torque converter stud and flexplate for paint marks.
   • Align the torque converter stud and flexplate hole near the paint marks to the 12 o'clock position.

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3. • Using the floor crane, lower the engine onto the engine crossmember. Use the General Equipment: Floor Crane
   • Install new engine mount nuts.

     Torque: 85 lb.ft (115 Nm)

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4. Remove the floor crane. Use the General Equipment: Floor Crane

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5. Remove the LH engine lift eye. Use Special Service Tool: 303-1245 Engine Lift Eye.

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6. Using the powertrain lift table raise the engine into the vehicle.

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7. Align the engine to the transmission and make sure the torque convertor stud is through the hole in flexplate.

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8. Draw the engine to the transmission together using the bolts.

   Torque: 35 lb.ft (48 Nm)

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9. Install new engine crossmember bolts.

   Torque: 46 lb.ft (63 Nm)

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10. Install the RH engine crossmember bracket and new bolts.

    Torque: 22 lb.ft (30 Nm)

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11. Install new RH engine crossmember bracket bolts.

    Torque: 46 lb.ft (63 Nm)

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12. Install the LH engine crossmember bracket and new bolts.

    Torque: 22 lb.ft (30 Nm)

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13. Install new LH engine crossmember bracket bolts.

    Torque: 46 lb.ft (63 Nm)

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14. Remove the adjustable mounting arm from the RH side of the engine crossmember. Use the General Equipment: Adjustable Mounting Arm

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15. Remove the adjustable mounting arm from the LH side of the engine crossmember. Use the General Equipment: Adjustable Mounting Arm

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16. Remove the powertrain lift table and wood blocks. Use the General Equipment: Wooden Block

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17. Install the RH side bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

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18. Install the shift cable bracket and the LH side bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

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19. Install the upper bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

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20. Remove the stand. Use the General Equipment: Vehicle/Axle Stands

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21. Install the lower bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

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22. Position the RH catalytic converter and install new flange nuts.

    Torque: 30 lb.ft (40 Nm)

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23. Install the LH catalytic converter flange and new nuts.

    Torque: 30 lb.ft (40 Nm)

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24. Attach the exhaust hanger and install the exhaust flange bolts.

    Torque: 30 lb.ft (40 Nm)

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25. NOTE: Do not lubricate the engine oil filter gasket.

    Install a new engine oil filter.

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

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26. NOTE: Using the crankshaft pulley bolt, turn the engine clockwise.

    Install new torque converter nuts.

    Torque: 35 lb.ft (48 Nm)

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27. Install the access cover and the retainers.

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28. • Push the transmission electrical connector in to connect.
    • Rotate the transmission electrical connector clockwise.
    • Attach the wiring harness retainers.

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29. Install the transmission heat shield, the bolt and the nuts.

    Torque: 18 lb.ft (25 Nm)

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30. Position the wiring harness under the fuel and EVAP tubes, install the bolt and attach the wiring harness retainers.

    Torque: 26 lb.ft (35 Nm)

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31. Connect the RH HO2S and catalyst monitor sensor.

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32. Connect the LH HO2S catalyst monitor sensor and the wiring harness retainers.

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33. NOTE: Lubricate with clean transmission fluid.

    Inspect the transmission cooler tube band seal and backing rings, replace if necessary.

    Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

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34. • Install the transmission cooler tube assembly and bolts.

      Torque: Transmission cooler tube assembly-to-transmission bolt: 18 lb.ft (25 Nm) Transmission cooler tube bracket-to-engine bolt: 106 lb.in (12 Nm)

    • Connect the coolant hoses to the oil cooler. Use the General Equipment: Hose Clamp Remover/Installer

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35. 1. NOTE: Do not tighten the bolts at this time.

       Position the power steering pump assembly and install the bolts by hand.

    2. Install the power steering hose bracket and bolt.

       Torque: 106 lb.in (12 Nm)

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36. Install the power steering pump bracket stud bolt.

    Torque: 27 lb.in (3 Nm)

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37. 1. Tighten the bolt.

       Torque: 26 lb.ft (35 Nm)

    2. Tighten the bolt.

       Torque: 26 lb.ft (35 Nm)

    3. Tighten the stud bolt.

       Torque: 19 lb.ft (26 Nm)

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38. Install the wiring harness conduit and nut.

    Torque: 71 lb.in (8 Nm)

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39. Install the wiring harness conduit bolt.

    Torque: 106 lb.in (12 Nm)

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40. Attach the 2 wiring harness retainers.

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41. • Install the generator B+ terminal nut.

      Torque: 142 lb.in (16 Nm)

    • Position the protective cover.
    • Connect the generator electrical connector and attach wiring harness retainer.

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42. Install the starter motor. Refer to: Starter Motor .
43. • Install a new O-ring seal.
    • Install the A/C tube assembly and nut.

      Torque: 133 lb.in (15 Nm)

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44. • If equipped with rear A/C, install a new O-ring seal.
    • Install the A/C tube and the nut.

      Torque: 133 lb.in (15 Nm)

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45. Install the front wheels and tires. Refer to: Wheel and Tire .
46. Connect the A/C compressor electrical connector and attach the wiring harness retainers.

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47. Install the A/C lines and nuts.

    Torque: 133 lb.in (15 Nm)

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48. Connect the heater hose quick release coupling.

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49. • If equipped, connect the block heater electrical connector and attach the wiring harness retainers.
    • Connect the coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer

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50. Connect the PCM electrical connectors and the main engine harness connector and wiring harness retainer.

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51. Install the LH headlight. Refer to: Headlamp Assembly .
52. Connect the fuel tube and EVAP purge valve quick release coupling and retainer. Refer to: Quick Release Coupling .

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53. 1. Position the vacuum tubes and install the bolt.

       Torque: 97 lb.in (11 Nm)

    2. Attach the vacuum hose retainer to the crankcase vent tube.
    3. Attach the vacuum hose retainer to the throttle body.
    4. Connect the vacuum hose to the upper intake manifold. Use the General Equipment: Hose Clamp Remover/Installer

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54. Install the following items:
    1. Refer to: Cooling Module .
    2. Refer to: Air Conditioning (A/C) Compressor Belt .
    3. Refer to: Air Cleaner Outlet Pipe .

55. Connect the battery ground cable. Refer to: Battery Disconnect and Connect - Vehicles With: Dual Batteries . Refer to: Battery Disconnect and Connect - Vehicles With: Dual Batteries .
56. 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)

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57. Check the transmission fluid. Refer to: Transmission Fluid Level Check .
58. Start and check the exhaust system for leaks.
59. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure using a diagnostic scan tool.