Engine - Body Off

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

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	303-F047Lifting Bracket, Engine
Magnetic Socket
Floor Crane
Trolley Jack
Hose Clamp Remover/Installer
Wooden Block

Materials 

1. 1. Inspect the engine mount-to-frame nut plate for thread damage.
   2. If the nut plate is damaged, remove and discard the engine mount-to-frame nut plate.
   • Clean the engine mount-to-frame mating surfaces of any dirt or foreign material prior to installation.

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2. Install the engine-to-transmission spacer plate and the crankshaft sensor ring.

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3. Install the flexplate and the bolts.

   Torque:| Stage 1: 43 lb.ft (58 Nm) | Stage 2: 45°

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4. 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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5. • 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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6. With the aid of an assistant, use the floor crane to position the engine assembly in the chassis. Use the General Equipment: Floor Crane

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7. 1. Align the engine to the transmission and install the bolts.
   2. Draw the engine and transmission togethe r evenly using the bolts.

      Torque: 35 lb.ft (48 Nm)

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8. Install the bracket and the bellhousing bolts.

   Torque: 35 lb.ft (48 Nm)

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9. Remove the floor jack and the block of wood. Use the General Equipment: Trolley Jack. Use the General Equipment: Wooden Block

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10. Install the LH engine mount and the new engine mount-to-frame bolts.

    Torque: 129 lb.ft (175 Nm)

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11. Using the Heavy Duty Floor Crane, lower the engine assembly into the installed position.
    • Remove the Heavy Duty Floor Crane. Use the General Equipment: Floor Crane

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12. Remove Special Service Tool: 303-F047 Lifting Bracket, Engine.

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13. Install the upper bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

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14. Position the vent hose and attach the retainer.

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15. NOTE: Only use hand tools when tightening the engine mount through bolts or damage to the engine mount-to-cylinder block bracket can occur.

    Install the new LH engine mount through bolt.

    Torque: 258 lb.ft (350 Nm)

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16. NOTE: Do not lubricate the O-ring seal.

    Install a new oil filter.

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

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17. 1. Position the generator.
    2. Install the B+ wire and the nut.

       Torque: 150 lb.in (17 Nm)

    3. Reposition the wiring protective cover.
    4. Connect the generator electrical connector.

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18. Position the generator and install the bolts.

    Torque: 35 lb.ft (47 Nm)

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19. Install the accessory drive belt tensioner and the bolt.

    Torque: 35 lb.ft (47 Nm)

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20. Rotate the accessory drive belt tensioner counter clockwise and install the accessory drive belt.

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21. Attach the transmission wiring harness retainers.

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22. Install the ground strap and the nut to the LH valve cover stud bolt.

    Torque: 53 lb.in (6 Nm)

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23. Connect the coolant hose quick release couplings.

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24. 1. Install the coolant hose and the clamp. Use the General Equipment: Hose Clamp Remover/Installer
    2. Connect the coolant hose quick release coupling.
    3. Attach the coolant hose retainer to the auxiliary coolant pump bracket.
    4. Attach the coolant hose retainers to the valve cover stud bolts.

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25. 1. Install the coolant hose assembly and the clamps. Use the General Equipment: Hose Clamp Remover/Installer
    2. Install the coolant bypass T assembly and engage the spring clip.
    3. Install the coolant hose and clamp. Use the General Equipment: Hose Clamp Remover/Installer
    4. Install the coolant hose and clamp. Use the General Equipment: Hose Clamp Remover/Installer
    5. Connect the quick release coupling.
    6. Install the coolant hose and clamp. Use the General Equipment: Hose Clamp Remover/Installer
    7. Install the coolant hose and clamp. Use the General Equipment: Hose Clamp Remover/Installer
    8. Install the crankcase vent tube and connect the quick release coupling. Refer to: QUICK RELEASE COUPLING .

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26. Install the insulators.

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27. NOTE: In | Stage 3, if the torque required to tighten any flare nut on the new high-pressure fuel tube reaches or exceeds 55 lb.ft (50 Nm), the n that high pressure fuel tube must be discarded and replaced with anothe r new high-pressure fuel tube.

    Torque:| Stage 1: Tighten the high-pressure fuel tube flare nuts to : 71 lb.in (8 Nm) | Stage 2: Tighten the high-pressure fuel tube flare nuts to : 89 lb.in (10 Nm) | Stage 3: Tighten the high-pressure fuel tube flare nuts an additional : 25°

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28. Install the gaskets.

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29. • Position the intake manifold.
    • Connect the wiring harness electrical connectors.
    • Attach the wiring harness retainers.

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30. Tighten the intake manifold bolts.

    Torque:| Stage 1: 102 lb.in (11.5 Nm) | Stage 2: 35°

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31. Install the fuel rail bolts.

    Torque:| Stage 1: 89 lb.in (10 Nm) | Stage 2: 90°

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32. Connect the LH fuel injector electrical connectors and the fuel sensor electrical connector.

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33. Connect the RH fuel injector electrical connectors.

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34. Connect the throttle body electrical connector.

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35. Install the fuel rail insulators.

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36. 1. Connect the fuel tube spring lock coupling. Refer to: Spring Lock Couplings .
    2. Connect the fuel tube quick release coupling. Refer to: QUICK RELEASE COUPLING .

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37. 1. Slide the EVAP canister purge valve onto the intake manifold.
    2. Connect the EVAP canister purge valve tube. Refer to: QUICK RELEASE COUPLING .
    3. Connect the EVAP canister purge valve tube. Refer to: QUICK RELEASE COUPLING .
    4. Connect the EVAP canister purge valve electrical connector.

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38. 1. Install the vacuum tube assembly and attach the vacuum tube retainer
    2. Connect the vacuum tube quick release couplings. Refer to: QUICK RELEASE COUPLING .

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39. Install the PCV tube and connect the quick release couplings. Refer to: QUICK RELEASE COUPLING .

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40. Install the body. Refer to: Body .
41. Position the bracket and install the lower bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

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42. Install the lower bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

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43. NOTE: Only use hand tools when installing the engine mount studs or damage to the engine mount can occur.
    NOTE: Apply threadlock to the stud threads prior to installation.

    Install the engine mount studs.

    Material: Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)

    Torque: 22 lb.ft (30 Nm)

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44. NOTE: Only use hand tools when installing the engine mount nuts or damage to the engine mount can occur.

    Install the new RH engine mount nuts.

    Torque: 111 lb.ft (150 Nm)

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45. NOTE: Only use hand tools when installing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur.

    Tighten the transmission mount-to-crossmember nuts.

    Torque: 85 lb.ft (115 Nm)

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46. NOTE: Only rotate the crankshaft in a clockwise direction.

    Install the new torque converter-to-flexplate nuts. Use the General Equipment: Magnetic Socket

    Torque: 35 lb.ft (48 Nm)

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47. Install the cylinder block opening cover.

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48. Position the exhaust Y-pipe dual catalytic converter onto the exhaust manifolds and loosely install new RH catalytic converter-to-exhaust manifold nuts.

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49. Loosely install new LH catalytic converter-to-exhaust manifold nuts.

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50. Tighten the nuts.

    Torque: 1: 30 lb.ft (40 Nm) 2: 30 lb.ft (40 Nm)

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51. Tighten the nuts.

    Torque: 1: 30 lb.ft (40 Nm) 2: 30 lb.ft (40 Nm)

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52. Position the exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe and install the bolts.
    • Evenly tighten the bolts.

      Torque: 46 lb.ft (63 Nm)

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53. If equipped, install the front driveshaft. Refer to: Front Driveshaft .
54. 1. Install the nut.

       Torque: 106 lb.in (12 Nm)

    2. Attach the wiring harness retainer.
    3. Position the coolant tube and wiring harness brackets and install the nut.

       Torque: 115 lb.in (13 Nm)

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55. 1. Connect the A/C compressor electrical connectors.
    2. Attach the wiring harness retainers.

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56. 1. Position the transmission fluid cooler.
    2. Connect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

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57. Install the transmission fluid cooler bolts.

    Torque: 22 lb.ft (30 Nm)

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58. Attach the retainer to the oil pan.

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59. Attach the retainer to the oil pan.

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60. Install the starter. Refer to: Starter Motor .
61. Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
62. Fill the engine with clean engine oil. Refer to: Specifications .

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63. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
64. Fill and bleed the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
65. Start engine and check exhaust system for leaks.
66. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.