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Engine - Body Off

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Special Tool(s) / General Equipment 

Floor Crane
Trolley Jack
Hose Clamp Remover/Installer
Wooden Block

Materials 

Name Specification
Motorcraft® Multi-Purpose Grease SprayXL-5-A ESB-M1C93-B
Motorcraft® Threadlock 262TA-26 WSK-M2G351-A6
    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.

    GFD552551Courtesy of FORD MOTOR COMPANY
  2. Lubricate the torque converter pilot hub with multi-purpose grease.

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

    GFD552946Courtesy of FORD MOTOR COMPANY
    • If necessary, install a ratchet strap from the front of engine to the chain to keep the engine level.

    • With the aid of an assistant, use the floor crane to install the engine assembly in the chassis.

    GFD553345Courtesy of FORD MOTOR COMPANY
  4. Attach the generator wiring harness retainer to the lower LH side of the engine block.
    GFD553126Courtesy of FORD MOTOR COMPANY
  5. Using the floor crane and chain, position the engine to the transmission. Use the General Equipment: Floor Crane
    GFD553616Courtesy of FORD MOTOR COMPANY
  6. Align the index-mark made during removal.
    GFD553617Courtesy of FORD MOTOR COMPANY
  7. Install the transmission-to-engine bolts.

    Torque: 35 lb.ft (48 Nm)

    GFD553340Courtesy of FORD MOTOR COMPANY
  8. Install the transmission-to-engine bolts.

    Torque: 35 lb.ft (48 Nm)

    GFD553339Courtesy of FORD MOTOR COMPANY
  9. Using the floor crane and chain, raise the engine for clearance to install the LH engine mount. Use the General Equipment: Floor Crane
    GFD553343Courtesy of FORD MOTOR COMPANY
  10. Install the LH engine mount.
    GFD553344Courtesy of FORD MOTOR COMPANY
  11. NOTE: Use only hand tools when installing the LH engine mount through bolt or the engine mount may be damaged.

    • Install the new LH engine mount through bolt.

    • Do not torque at this time.

    GFD553618Courtesy of FORD MOTOR COMPANY
  12. Lower the engine to install the engine mount.
    GFD553619Courtesy of FORD MOTOR COMPANY
  13. Install the LH engine mount bolts.

    Torque: 129 lb.ft (175 Nm)

    GFD553620Courtesy of FORD MOTOR COMPANY
    • Lower the engine to the installed position and remove the floor crane. Use the General Equipment: Floor Crane

    • If installed, remove the ratchet strap.

    GFD553619Courtesy of FORD MOTOR COMPANY
  15. Remove the chains.
    GFD553341Courtesy of FORD MOTOR COMPANY
  16. Remove the floor jack and the block of wood. Use the General Equipment: Trolley JackUse the General Equipment: Wooden Block
    GFD553338Courtesy of FORD MOTOR COMPANY
  17. NOTE: Use only hand tools when tightening the LH engine mount through bolt or the engine mount may be damaged.

    Tighten the LH engine mount through bolt.

    Torque: 258 lb.ft (350 Nm)

    GFD553618Courtesy of FORD MOTOR COMPANY
    • Follow directions to connect the quick release coupling type 2. Install the high-pressure fuel pump to port injection fuel rail tube and connect the quick release couplings. Refer to: Quick Release Coupling .

    • Follow directions to connect the quick release coupling type 10. Connect the fuel supply tube quick release coupling. Refer to: Quick Release Coupling .

    GFD553336Courtesy of FORD MOTOR COMPANY
  19. Follow directions to connect the quick release coupling type 3. Install the PCV tube. Refer to: Quick Release Coupling .
    GFD553335Courtesy of FORD MOTOR COMPANY
  20. Position the ground strap and install the nut on the RH valve cover stud bolt.

    Torque: 71 lb.in (8 Nm)

    GFD553265Courtesy of FORD MOTOR COMPANY
    • Follow directions to release the quick release coupling type 1. Install the EVAP canister purge valve and connect the quick release coupling. Refer to: Quick Release Coupling .

    • Connect the EVAP canister purge valve wiring harness electrical connector.

    GFD553334Courtesy of FORD MOTOR COMPANY
  22. Install the upper intake manifold. Refer to: Upper Intake Manifold .
  23. Tighten the upper intake manifold support bracket bolt.

    Torque: 89 lb.in (10 Nm)

    GFD553621Courtesy of FORD MOTOR COMPANY
  24. Follow directions to connect the quick release coupling type 3. Install the crankcase vent tube. Refer to: Quick Release Coupling .
    GFD553333Courtesy of FORD MOTOR COMPANY
  25. Attach the generator wiring harness retainer to the oil filter adapter.
    GFD553332Courtesy of FORD MOTOR COMPANY
    1. Install the generator and the bolt finger tight.
    2. Install the generator stud.

      Torque: 71 lb.in (8 Nm)

    3. Install the generator stud nut.

      Torque: 35 lb.ft (47.5 Nm)

    4. Tighten the generator bolt.

      Torque: 35 lb.ft (47.5 Nm)

    GFD553622Courtesy of FORD MOTOR COMPANY
    • Connect the generator electrical connector.

    • NOTE: When installing the B+ terminal nut to the generator, finger-start the nut before tightening or component damage may occur.

      Position the B+ wire, install the nut and position the protective cover.

      Torque: 155 lb.in (17.5 Nm)

    GFD553330Courtesy of FORD MOTOR COMPANY
  28. Attach the transmission wiring harness retainer to the back of the RH valve cover stud bolt.
    GFD553329Courtesy of FORD MOTOR COMPANY
  29. Follow directions to connect the quick release coupling type 19. Connect the heater hose to the lower intake manifold at the rear of the engine. Refer to: Quick Release Coupling .
    GFD553328Courtesy of FORD MOTOR COMPANY
  30. Follow directions to connect the quick release coupling type 16. Connect the coolant hoses to the EGR valve. Refer to: Quick Release Coupling .
    GFD553327Courtesy of FORD MOTOR COMPANY
    • Remove the nut and position out the transmission cooler tube bracket and the engine wiring harness aside.

    • Detach the generator wiring harness from the engine front cover.

    GFD553326Courtesy of FORD MOTOR COMPANY
  32. Install a new thermostat housing O-ring seal and lubricate with clean engine coolant.
    GFD553623Courtesy of FORD MOTOR COMPANY
    • Install the coolant hose to the cabin heater coolant pump and release the clamp. Use the General Equipment: Hose Clamp Remover/Installer

    • Follow directions to connect the quick release coupling type 19. Connect the coolant pump coolant hose. Refer to: Quick Release Coupling .

    GFD553324Courtesy of FORD MOTOR COMPANY
  34. Install the thermostat housing, hoses and the bolts.

    Torque:Stage 1: 71 lb.in (8 Nm); Stage 2: 45 deg.

    GFD553322Courtesy of FORD MOTOR COMPANY
    • Install the coolant hoses and release the clamps. Use the General Equipment: Hose Clamp Remover/Installer

    • Follow directions to connect the quick release coupling type 19. Connect the transmission cooler coolant hose. Refer to: Quick Release Coupling .

    GFD553321Courtesy of FORD MOTOR COMPANY
  36. Install the body. Refer to: Body .
  37. Install the LH transmission-to-engine bolts.

    Torque: 35 lb.ft (48 Nm)

    GFD553320Courtesy of FORD MOTOR COMPANY
  38. Install the transmission-to-engine bolt.

    Torque: 35 lb.ft (48 Nm)

    GFD553319Courtesy of FORD MOTOR COMPANY
  39. Install the engine-to-transmission bolts.

    Torque: 35 lb.ft (48 Nm)

    GFD553318Courtesy of FORD MOTOR COMPANY
  40. NOTE: Only use hand tools when installing the engine mount studs or damage to the engine mount can occur.

    • Apply threadlock to the stud threads prior to installation.

      Material

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

    • Install the engine mount studs.

      Torque: 22 lb.ft (30 Nm)

    GFD552558Courtesy of FORD MOTOR COMPANY
  41. NOTE: Use only hand tools when installing the RH engine mount nuts or the engine mount may be damaged.

    Install the new RH engine mount nuts.

    Torque: 111 lb.ft (150 Nm)

    GFD552559Courtesy of FORD MOTOR COMPANY
    • Remove and discard the transmission mount-to-crossmember nuts.

    • Install new transmission mount-to-crossmember nuts.

      Torque: 85 lb.ft (115 Nm)

    GFD553133Courtesy of FORD MOTOR COMPANY
    • Position the coolant tubes and install the nut.

      Torque: 124 lb.in (14 Nm)

    • Attach the coolant tube retainer to the transmission.

    GFD553317Courtesy of FORD MOTOR COMPANY
  44. NOTE: Using the crankshaft pulley bolt, turn the engine clockwise.

    Install the torque converter nuts.

    Torque: 35 lb.ft (48 Nm)

    GFD553624Courtesy of FORD MOTOR COMPANY
  45. Install the access cover and pin-type retainers.
    GFD553315Courtesy of FORD MOTOR COMPANY
  46. Install the new RH catalytic converter-to-exhaust manifold nuts.

    Torque: 30 lb.ft (40 Nm)

    GFD553067Courtesy of FORD MOTOR COMPANY
  47. Install the new LH catalytic converter-to-exhaust manifold nuts.

    Torque: 30 lb.ft (40 Nm)

    GFD553068Courtesy of FORD MOTOR COMPANY
    • Position the exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe and install the bolts.

    • Tighten the inner exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt.

      Torque: 30 lb.ft (40 Nm)

    • Tighten the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt.

      Torque: 30 lb.ft (40 Nm)

    GFD552536Courtesy of FORD MOTOR COMPANY
  49. Connect the A/C compressor wiring harness electrical connectors and the retainer.
    GFD553091Courtesy of FORD MOTOR COMPANY
  50. Attach the starter motor wiring harness retainer to the oil pan.
    GFD553090Courtesy of FORD MOTOR COMPANY
  51. Install the starter motor. Refer to: Starter Motor .
    • Lubricate the oil filter seal with clean engine oil and install and tighten in 2 stages.

    • Stage 1: Install to initial gasket contact.

    • Stage 2: Tighten 3/4 to 1 turn.

    GFD552996Courtesy of FORD MOTOR COMPANY
  53. If equipped, install the skid plate and the bolts.

    Torque: 30 lb.ft (40 Nm)

    GFD552992Courtesy of FORD MOTOR COMPANY
    • If equipped, remove the bolts and the skid plate.

      Torque: 30 lb.ft (40 Nm)

    • If equipped, install the underbody shield and bolts.

      Torque: 30 lb.ft (40 Nm)

    GFD552991Courtesy of FORD MOTOR COMPANY
  55. If equipped, install the transmission housing cover and the bolts

    Torque: 71 lb.in (8 Nm)

    GFD552533Courtesy of FORD MOTOR COMPANY
  56. Fill the engine with clean engine oil. Refer to: Specifications .
    GFD552997Courtesy of FORD MOTOR COMPANY
  57. Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
  58. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
  59. Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
  60. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
  61. Start and check the exhaust system for leaks.
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