Engine - Body Off

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING INFORMATION

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 

All vehicles 

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 deg.

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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. 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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6. 1. Align the engine to the transmission and install the bolts.
   2. Draw the engine and transmission together evenly using the bolts.

      Torque: 35 lb.ft (48 Nm)

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7. Install the bellhousing bolt.

   Torque: 35 lb.ft (48 Nm)

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

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

   Torque: 129 lb.ft (175 Nm)

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

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12. Install the upper bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

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13. Position the vent hose and attach the retainer.

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14. 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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15. 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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16. Position the generator and install the bolts.

    Torque: 35 lb.ft (47 Nm)

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

    Torque: 35 lb.ft (47 Nm)

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18. NOTE: Single generator engine shown, dual generator engine similar.

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

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19. Attach the transmission wiring harness retainer.

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20. Install the ground strap and the nut to the RH valve cover stud bolt.

    Torque: 53 lb.in (6 Nm)

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21. 1. Position the coolant pump and install the fasteners.

       Torque: 62 lb.in (7 Nm)

    2. Attach the wiring harness retainer.
    3. Connect the coolant pump electrical connector.
    4. Attach the coolant hose retainers.
    5. Connect the heater hose.

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    Vehicles equipped with dual generators 

22. Install new thermostat housing gaskets.

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23. Install the thermostat housing and the bolts.

    Torque:Stage 1: 89 lb.in (10 Nm)

    Stage 2: 45 deg.

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24. 1. Install the generator and the fasteners.

       Torque: 35 lb.ft (47 Nm)

    2. Position the wiring harness and install the bolt.

       Torque: 177 lb.in (20 Nm)

    3. Connect the generator electrical connector.
    4. Install the B+ wire and the nut.

       Torque: 150 lb.in (17 Nm)

    5. Position the wiring protective cover.

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25. Rotate the belt tensioner counterclockwise and install the secondary generator drive belt.

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26. 1. Install the coolant hose and clamps. Use the General Equipment: Hose Clamp Remover/Installer
    2. Install the coolant hose and clamp. Use the General Equipment: Hose Clamp Remover/Installer
    3. Attach the coolant hose retainer.
    4. Position the coolant hose and connect the quick release coupling.
    5. Install the coolant hose and connect the quick release coupling.
    6. Install the coolant hose and clamp. Use the General Equipment: Hose Clamp Remover/Installer

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    Vehicles equipped with single generator 

27. 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. Follow directions to release the quick release coupling type 3. Install the crankcase vent tube. Refer to: Quick Release Coupling .

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    All vehicles 

28. 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), then that high pressure fuel tube must be discarded and replaced with another 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 deg.

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29. Install the insulators.

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30. Install the gaskets.

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31. • Install the intake manifold.
    • Attach the wiring harness retainers.
    • Connect the MAP sensor electrical connector.

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32. Tighten the intake manifold bolts.

    Torque:Stage 1: 102 lb.in (11.5 Nm)

    Stage 2: 35 deg.

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33. Install the fuel rail bolts.

    Torque:Stage 1: 89 lb.in (10 Nm)

    Stage 2: 90 deg.

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34. Connect the RH fuel injector harness electrical connector.

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35. Connect the LH fuel injector harness and fuel pressure sensor electrical connectors.

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36. Connect the throttle body electrical connector.

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37. Install the fuel rail insulators.

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38. 1. Follow directions to connect the quick release coupling type 1. Connect the fuel supply tube. Refer to: Quick Release Coupling .
    2. Follow directions to connect the quick release coupling type 2. Connect the fuel jumper tube. Refer to: Quick Release Coupling .

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39. Follow directions to connect the quick release coupling type 3. Install the crankcase vent tube. Refer to: Quick Release Coupling .

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40. 1. Slide the EVAP canister purge valve onto the intake manifold.
    2. Follow directions to connect the quick release coupling type 2. Connect the EVAP canister purge valve tube. Refer to: Quick Release Coupling .
    3. Follow directions to connect the quick release coupling type 2. 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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41. Install the body. Refer to: Body .
42. Install the LH bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

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43. Install the RH bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

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44. Install the lower bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

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45. 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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46. 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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47. 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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48. NOTE: Only rotate the crankshaft in a clockwise direction.

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

    Torque: 30 lb.ft (40 Nm)

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49. Install the cylinder block opening cover.

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

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52. Tighten the nuts.

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

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53. Tighten the nuts.

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

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54. • 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)

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55. If equipped, install the front driveshaft. Refer to: Front Driveshaft .
56. Install a new the engine oil filter. Refer to: Engine Oil Draining and Filling .
57. Install the LH heat shield and the bolts.

    Torque: 177 lb.in (20 Nm)

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58. 1. Position the wiring harness and attach the wiring harness retainer.
    2. Position the coolant tubes and install the nut.

       Torque: 106 lb.in (12 Nm)

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59. 1. Connect the oil level sensor electrical connector.
    2. Attach the wiring harness retainers.

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60. Position the wiring harness and install the nut.

    Torque: 106 lb.in (12 Nm)

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61. 1. Connect the A/C compressor electrical connectors.
    2. Attach the wiring harness retainer.
    3. Install the pin-type retainer.

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62. 1. Position the coolant tubes and bracket and install the nut.

       Torque: 119 lb.in (13.5 Nm)

    2. Attach the coolant tube retainer.

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63. Connect the coolant hose quick release couplings.

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64. Install the starter. Refer to: Starter Motor .
65. NOTE: If equipped.

    Install the skid plate and bolts.

    Torque: 30 lb.ft (40 Nm)

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66. NOTE: If equipped.

    Install the underbody shield and the bolts.

    Torque: 71 lb.in (8 Nm)

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67. If equipped, install the underbody shield and fasteners.

    Torque: 30 lb.ft (40 Nm)

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68. If equipped, install the skid plate and bolts.

    Torque: 30 lb.ft (40 Nm)

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69. Fill the engine with clean engine oil. Refer to: Engine Oil Draining and Filling .
70. Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
71. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
72. Fill and bleed the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
73. Start engine and check exhaust system for leaks.
74. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.