Engine - Body On

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.

   Courtesy of FORD MOTOR COMPANY

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

   Courtesy of FORD MOTOR COMPANY

3. Install the flexplate and the bolts.

   Torque:Stage 1: 43 lb.ft (58 Nm)

   Stage 2: 45 deg.

   Courtesy of FORD MOTOR COMPANY

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

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

   Courtesy of FORD MOTOR COMPANY

5. Using the Heavy Duty Floor Crane, install the engine assembly into the vehicle. Use the General Equipment: Floor Crane

   Courtesy of FORD MOTOR COMPANY

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)

   Courtesy of FORD MOTOR COMPANY

7. Install the bellhousing bolt.

   Torque: 35 lb.ft (48 Nm)

   Courtesy of FORD MOTOR COMPANY

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

   Courtesy of FORD MOTOR COMPANY

9. Using the Heavy Duty Floor Crane, raise the engine assembly to gain clearance to install the LH engine mount. Use the General Equipment: Floor Crane

   Courtesy of FORD MOTOR COMPANY

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

    Torque: 129 lb.ft (175 Nm)

    Courtesy of FORD MOTOR COMPANY

11. Using the Heavy Duty Floor Crane, lower the engine assembly into the installed position.
    1. Remove Heavy Duty Floor Crane. Use the General Equipment: Floor Crane
    2. Remove Special Service Tool: 303-F047 Lifting Bracket, Engine.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

13. Install the upper bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

14. Position the vent hose and attach the retainer.

    Courtesy of FORD MOTOR COMPANY

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)

    Courtesy of FORD MOTOR COMPANY

16. 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.

    Courtesy of FORD MOTOR COMPANY

17. Position the generator and install the bolts.

    Torque: 35 lb.ft (47 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 35 lb.ft (47 Nm)

    Courtesy of FORD MOTOR COMPANY

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

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

    Courtesy of FORD MOTOR COMPANY

20. Attach the transmission wiring harness retainer.

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 53 lb.in (6 Nm)

    Courtesy of FORD MOTOR COMPANY

22. • Connect the center PCM electrical connector and wiring harness retainer.
    • Connect the engine harness electrical connector.

    Courtesy of FORD MOTOR COMPANY

23. 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.

    Courtesy of FORD MOTOR COMPANY

    Vehicles equipped with dual generators 

24. Install new thermostat housing gaskets.

    Courtesy of FORD MOTOR COMPANY

25. Install the thermostat housing and the bolts.

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

    Stage 2: 45 deg.

    Courtesy of FORD MOTOR COMPANY

26. 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.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

28. 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

    Courtesy of FORD MOTOR COMPANY

    Vehicles equipped with single generator 

29. 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 .

    Courtesy of FORD MOTOR COMPANY

    All vehicles 

30. 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.

    Courtesy of FORD MOTOR COMPANY

31. Install the insulators.

    Courtesy of FORD MOTOR COMPANY

32. Install the LH bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

33. Install the RH bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

34. Install the lower bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

35. 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)

    Courtesy of FORD MOTOR COMPANY

36. 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)

    Courtesy of FORD MOTOR COMPANY

37. 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)

    Courtesy of FORD MOTOR COMPANY

38. 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)

    Courtesy of FORD MOTOR COMPANY

39. Install the cylinder block opening cover.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

42. Tighten the nuts.

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

    Courtesy of FORD MOTOR COMPANY

43. Tighten the nuts.

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

    Courtesy of FORD MOTOR COMPANY

44. • 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)

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 177 lb.in (20 Nm)

    Courtesy of FORD MOTOR COMPANY

48. 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)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

50. Position the wiring harness and install the nut.

    Torque: 106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

       Torque: 119 lb.in (13.5 Nm)

    2. Attach the coolant tube retainer.

    Courtesy of FORD MOTOR COMPANY

53. Connect the coolant hose quick release couplings.

    Courtesy of FORD MOTOR COMPANY

54. Install the starter. Refer to: Starter Motor .
55. • Install a new O-ring seal.
    • Connect the A/C tube and install the nut.

      Torque: 133 lb.in (15 Nm)

    Courtesy of FORD MOTOR COMPANY

56. • Install a new O-ring seal.
    • Connect the A/C tube and install the nut.

      Torque: 133 lb.in (15 Nm)

    Courtesy of FORD MOTOR COMPANY

57. NOTE: If equipped.

    Install the skid plate and bolts.

    Torque: 30 lb.ft (40 Nm)

    Courtesy of FORD MOTOR COMPANY

58. NOTE: If equipped.

    Install the underbody shield and the bolts.

    Torque: 71 lb.in (8 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 30 lb.ft (40 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 30 lb.ft (40 Nm)

    Courtesy of FORD MOTOR COMPANY

61. Install the following items:
    1. Front wheels and tires. Refer to: Wheel and Tire .
    2. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

       Refer to: Intake Manifold .

    3. Refer to: Cooling Module .
    4. Refer to: Degas Bottle .
    5. Refer to: Hood .

62. Fill the engine with clean engine oil. Refer to: Engine Oil Draining and Filling .
63. Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
64. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
65. Fill and bleed the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
66. Start engine and check exhaust system for leaks.
67. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
68. Road test the vehicle.