Section 1768 (Engine Mechanical - 3.0L (4V)): Installation: Engine: Installation

All vehicles 

1. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, align the transaxle to the engine.
   Fig 1: Aligning Transaxle To Engine Using Special Tools

   Courtesy of FORD MOTOR CO.
2. Install the 4 transaxle-to-engine bolts.
   • Tighten to 48 Nm (35 lb-ft).
   Fig 2: Locating Transaxle-To-Engine Bolts

   Courtesy of FORD MOTOR CO.
3. Install the transaxle-to-engine bolt.
   • Tighten to 48 Nm (35 lb-ft).
   Fig 3: Locating Transaxle-To-Engine Bolt

   Courtesy of FORD MOTOR CO.
4. Connect the 2 transmission electrical connectors and attach the wiring harness retainer to the stud bolt.
   Fig 4: Locating Transmission Electrical Connectors, Wiring Retainer And Stud Bolt

   Courtesy of FORD MOTOR CO.
5. Attach the wiring harness retainer to the transmission indicator tube.
   Fig 5: Locating Wiring Harness Retainer Of Transmission Indicator Tube

   Courtesy of FORD MOTOR CO.
6. Install the starter and the 2 stud bolts.
   • Tighten to 27 Nm (20 lb-ft).
   Fig 6: Locating Starter Stud Bolts

   Courtesy of FORD MOTOR CO.
7. Install the starter wiring and the 2 nuts.
   • Tighten the small starter motor solenoid wire nut to 5 Nm (44 lb-in).
   • Tighten the large starter motor solenoid battery cable nut to 12 Nm (106 lb-in).
   Fig 7: Locating Starter Wiring Nuts

   Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
8. Use a plastic scraping tool to remove all traces of the oil pan gasket.
   • Clean all sealing surfaces with metal surface prep and install a new oil pan gasket.
9. Install the starter wiring ground wire and nut.
   • Tighten to 18 Nm (159 lb-in).
   Fig 8: Locating Starter Wiring Ground Nut

   Courtesy of FORD MOTOR CO.
10. Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, position the engine and transaxle onto the lift table.
    Fig 9: Positioning Engine And Transaxle Onto Lift Table Using Special Tools

    Courtesy of FORD MOTOR CO.
NOTE: Position a suitable block of wood under the transaxle.
Fig 10: Installing Powertrain Lift And Adjustable Grip Arm Onto Engine
Courtesy of FORD MOTOR CO.
11. Install the Adjustable Grip Arm and the Powertrain Lift to the engine.
12. Raise the engine and transaxle up into the vehicle.
13. Install the engine support insulator bracket, 3 nuts and the bolt.
    • Tighten the nuts to 63 Nm (46 lb-ft).
    • Tighten the bolt to 115 Nm (85 lb-ft).
    Fig 11: Locating Bolt, Nuts And Engine Mount Bracket

    Courtesy of FORD MOTOR CO.
14. Install the damper and bolt.
    • Tighten to 23 Nm (17 lb-ft).
    Fig 12: Locating Bolt And Damper

    Courtesy of FORD MOTOR CO.
15. Install the ground strap and bolt on the engine mount bracket.
    • Tighten to 10 Nm (89 lb-in).
    Fig 13: Locating Bolt And Ground Strap On Engine Mount Bracket

    Courtesy of FORD MOTOR CO.
16. Install the rear transaxle support through bolt.
    • Tighten to 103 Nm (76 lb-ft).
    Fig 14: Locating Rear Transaxle Support Through Bolt

    Courtesy of FORD MOTOR CO.
17. Install the transaxle-to-engine stud and 2 nuts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 15: Locating Nuts And Transaxle-To-Engine Stud

    Courtesy of FORD MOTOR CO.
NOTE: Clean and degrease all sealing surfaces with metal surface prep.
NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of the sealant application.
Fig 16: Locating Sealant On Front Cover-To-Cylinder Block Sealing Surface
Courtesy of FORD MOTOR CO.
18. Apply a 10 mm (0.39 in) dot of silicone gasket and sealant to the front cover-to-cylinder block sealing surface.
NOTE: Install a new oil pan gasket.
Fig 17: Locating Oil Pan Bolts And Stud Bolts
Courtesy of FORD MOTOR CO.
19. Position the oil pan and gasket and loosely install the bolts and stud bolts.
20. Install the 2 oil pan-to-transaxle bolts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 18: Locating Oil Pan-To-Transaxle Bolts

    Courtesy of FORD MOTOR CO.
21. Tighten the oil pan bolts in the sequence shown in the illustration to 25 Nm (18 lb-ft).
    Fig 19: Identifying Oil Pan Bolts Tightening Sequence

    Courtesy of FORD MOTOR CO.
22. Install the 4 torque converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 20: Locating Torque Converter Nuts

    Courtesy of FORD MOTOR CO.
23. Install the access cover.
    Fig 21: Locating Access Cover

    Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

24. Install the Power Transfer Unit (PTU) and the 5 bolts.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 22: Locating Bolts And Power Transfer Unit (PTU)

    Courtesy of FORD MOTOR CO.
25. Install the PTU support bracket and the 5 bolts.
    • Tighten to 55 Nm (41 lb-ft).
    Fig 23: Locating Bolts And PTU Support Bracket

    Courtesy of FORD MOTOR CO.
NOTE: A new PTU seal must be installed whenever the intermediate shaft is removed.
26. Install a new PTU seal. For additional information, refer to TRANSFER CASE - POWER TRANSFER UNIT (PTU) -- FUSION & MILAN article.
27. Using a new gasket, install the RH catalytic converter and 3 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 24: Locating Nuts And RH Catalytic Converter

    Courtesy of FORD MOTOR CO.
28. Install the RH exhaust heat shield bracket (inboard half) and the 2 bolts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 25: Locating Bolts And RH Exhaust Heat Shield Bracket (Inboard Half)

    Courtesy of FORD MOTOR CO.
29. Install the RH exhaust heat shield bracket (outboard half) and the 3 nuts.
    • Tighten to 20 Nm (177 lb-in).
    Fig 26: Locating Nuts And RH Exhaust Heat Shield Bracket (Outboard Half)

    Courtesy of FORD MOTOR CO.
30. Install the RH exhaust heat shield and the 6 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 27: Locating Bolts And RH Exhaust Heat Shield

    Courtesy of FORD MOTOR CO.
31. Using the Exhaust Gas Oxygen Sensor Socket, install the RH Heated Oxygen Sensor (HO2S).
    • Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formulas shown in the illustration below.
      Fig 28: Identifying Torque Wrench Adapter Formulas

      Courtesy of FORD MOTOR CO.
    • To install, tighten to 48 Nm (35 lb-ft).
    Fig 29: Installing RH Heated Oxygen Sensor Using Exhaust Gas Oxygen Sensor Socket

    Courtesy of FORD MOTOR CO.
32. Connect the RH HO2S electrical connector.
    Fig 30: Locating RH Heated Oxygen Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
33. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 31: Locating RH Catalyst Monitor Sensor (CMS) Electrical Connector

    Courtesy of FORD MOTOR CO.

    All vehicles 

34. Position the A/C manifold onto the A/C compressor and install the bolt.
    • Install a new gasket.
    • Tighten to 15 Nm (133 lb-in).
    Fig 32: Locating Bolt And A/C Manifold

    Courtesy of FORD MOTOR CO.
35. Install 6 new LH catalytic converter studs.
    • Tighten to 12 Nm (106 lb-in).
    Fig 33: Locating LH Catalytic Converter Manifold Studs

    Courtesy of FORD MOTOR CO.
36. Install a new gasket, the LH catalytic converter and 6 new nuts.
    • Tighten to 20 Nm (177 lb-in) in the sequence shown in the illustration.
    Fig 34: Locating LH Catalytic Converter And Nuts

    Courtesy of FORD MOTOR CO.
37. Install the heat shield and the 4 bolts (3 shown in the illustration).
    • Tighten to 10 Nm (89 lb-in).
    Fig 35: Locating Bolts And LH Catalytic Converter Heat Shield

    Courtesy of FORD MOTOR CO.
38. Connect the LH CMS electrical connector.
    Fig 36: Locating LH Catalyst Monitor Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
39. Connect the A/C tube and install the nut.
    • Install a new gasket.
    • Tighten to 8 Nm (71 lb-in).
    Fig 37: Locating A/C Tube Nut

    Courtesy of FORD MOTOR CO.
40. Install the A/C tube/windshield washer bottle bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 38: Locating A/C Tube/Windshield Washer Bottle Bracket Bolt

    Courtesy of FORD MOTOR CO.
41. Position the transaxle control cable bracket in place, install the 2 bolts.
    • Tighten to 23 Nm (17 lb-ft).
    Fig 39: Locating Shift Cable Bracket Bolts

    Courtesy of FORD MOTOR CO.
42. Connect the gearshift cable to the transaxle.
    Fig 40: Locating Gearshift Cable

    Courtesy of FORD MOTOR CO.
43. Connect the 2 heater hoses.
    Fig 41: Locating Heater Hoses

    Courtesy of FORD MOTOR CO.
44. Connect the upper and lower radiator hoses.
    Fig 42: Locating Upper And Lower Radiator Hoses

    Courtesy of FORD MOTOR CO.
45. Connect the LH HO2S electrical connector.
    Fig 43: Locating LH Heated Oxygen Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
46. Connect the Evaporative Emission (EVAP) tube-to-EVAP canister purge valve quick connect coupling and the brake booster vacuum tube to the upper intake manifold.
    • Attach the fuel tube and EVAP tube-to-EVAP canister purge valve tube retainer to the upper intake manifold.
    Fig 44: Locating EVAP Tube-To-EVAP Canister Purge Valve Quick Connect Coupling And Brake Booster Vacuum Tube

    Courtesy of FORD MOTOR CO.
47. Connect the fuel supply tube to the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
48. Connect the 3 PCM electrical connectors.
    Fig 45: Locating PCM Electrical Connectors

    Courtesy of FORD MOTOR CO.
49. Position the PCM ground wire and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 46: Locating PCM Ground Bolt

    Courtesy of FORD MOTOR CO.
50. Attach the 2 wiring harness retainers to the battery tray bracket and transaxle mount.
    Fig 47: Locating Wiring Harness Retainers Of Battery Tray Bracket And Transaxle Mount

    Courtesy of FORD MOTOR CO.
51. Install the ground wire-to-inner fender and bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 48: Locating Bolt And Ground Wire

    Courtesy of FORD MOTOR CO.
52. Connect the 2 engine wiring harness electrical connectors.
    Fig 49: Locating Engine Wiring Harness Electrical Connectors

    Courtesy of FORD MOTOR CO.
53. Connect the engine wiring harness electrical connector.
    Fig 50: Locating Engine Wiring Harness Electrical Connector

    Courtesy of FORD MOTOR CO.
54. Connect the power feed wires to the battery terminal and install the 2 nuts.
    • Tighten to 6 Nm (53 lb-in).
    Fig 51: Locating Nuts And Power Feed Wires

    Courtesy of FORD MOTOR CO.
55. Install the battery tray. For additional information, refer to BATTERY, MOUNTING & CABLES -- FUSION, MILAN & MKZ article.
56. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V) -- FUSION & MILAN article.
57. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
    Fig 52: Locating Engine Oil Filter

    Courtesy of FORD MOTOR CO.
58. Position the transmission fluid cooler tubes in place. Install the transmission fluid cooler tubes in the transaxle by inserting the tube into the fitting until a click is heard/felt. Pull back to confirm connection is secure and install the secondary latches.
    Fig 53: Locating Transmission Fluid Cooler Tubes

    Courtesy of FORD MOTOR CO.
59. Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position.
    Fig 54: Positioning Powertrain Lift Under Subframe Assembly

    Courtesy of FORD MOTOR CO.
NOTE: LH shown in the illustration, RH similar.
Fig 55: Locating Front Subframe Nuts
Courtesy of FORD MOTOR CO.
60. Install the front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
NOTE: LH shown in the illustration, RH similar.
Fig 56: Locating Subframe Brackets And Bolts
Courtesy of FORD MOTOR CO.
61. Position the subframe brackets and install the bolts finger-tight.
NOTE: LH shown in the illustration, RH similar.
Fig 57: Locating Subframe Nuts
Courtesy of FORD MOTOR CO.
62. Install the subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
NOTE: LH shown in the illustration, RH similar.
Fig 58: Locating Subframe Bracket-To-Body Bolts
Courtesy of FORD MOTOR CO.
63. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
64. Attach the 3 wiring harness retainers to the LH front of the subframe.
    Fig 59: Locating Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
65. Connect the 2 Electronic Power Assist Steering (EPAS) electrical connector on the front of the subframe.
    Fig 60: Locating Electronic Power Assist Steering (EPAS) Electrical Connectors

    Courtesy of FORD MOTOR CO.
66. Install the intermediate shaft and the LH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
NOTE: LH shown in the illustration, RH similar.
Fig 61: Locating Stabilizer Bar Links Nut
Courtesy of FORD MOTOR CO.
67. Install the stabilizer bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
NOTE: LH shown in the illustration, RH similar.
Fig 62: Locating Tie-Rod Ends Cotter Pins And Nuts
Courtesy of FORD MOTOR CO.
68. Install the tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install the cotter pin.
69. Install the engine roll restrictor and the 2 bolts.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 63: Locating Bolts And Engine Roll Restrictor

    Courtesy of FORD MOTOR CO.
70. If equipped, install the heat shield and the 2 bolts.
    Fig 64: Locating Bolts And Heat Shield

    Courtesy of FORD MOTOR CO.
71. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips (2 shown in the illustration) into the body.
    • From under the vehicle, verify that the seal is properly installed on the steering gear and the retaining clips are fully engaged into the body.
    Fig 65: Locating Clips And Steering Gear-To-Dash Seal

    Courtesy of FORD MOTOR CO.

    AWD vehicles 

72. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts (3 shown in the illustration).
    • Tighten to 70 Nm (52 lb-ft).
    Fig 66: Locating Driveshaft Bolts

    Courtesy of FORD MOTOR CO.

    All vehicles 

73. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM -- FUSION, MILAN & MKZ article.
74. Install the LH splash shield and the 6 pin-type retainers (4 shown in the illustration).
    Fig 67: Locating Pin-Type Retainers And LH Splash Shield

    Courtesy of FORD MOTOR CO.
75. Position the LH fender splash shield and install the 4 screws.
    Fig 68: Locating Screws And LH Fender Splash Shield

    Courtesy of FORD MOTOR CO.
76. Install the EPAS ground wire and bolt in the RH front wheel well.
    • Tighten to 10 Nm (89 lb-in).
    Fig 69: Locating Electronic Power Assist Steering Wiring Ground Wire Bolt

    Courtesy of FORD MOTOR CO.
77. Install the RH splash shield and the 6 pin-type retainers (4 shown in the illustration).
    Fig 70: Locating Pin-Type Retainers And RH Splash Shield

    Courtesy of FORD MOTOR CO.
78. Position the RH fender splash shield and install the 4 screws.
    Fig 71: Locating RH Fender Splash Shield Screws

    Courtesy of FORD MOTOR CO.
79. Install the steering intermediate shaft onto the steering gear and install the bolt.
    • Tighten to 20 Nm (177 lb-in).
    Fig 72: Locating Steering Column Shaft Bolt

    Courtesy of FORD MOTOR CO.
80. Install the steering joint cover and the 2 nuts.
    Fig 73: Locating Nuts And Steering Joint Cover

    Courtesy of FORD MOTOR CO.
81. Fill the engine with clean engine oil.
82. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING & CABLES -- FUSION, MILAN & MKZ article.
83. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING SYSTEM (EXCEPT HYBRID) article.
84. Check the transaxle fluid and add fluid if necessary. For additional information, refer to the transmission fluid drain and refill procedure in AUTOMATIC TRANSAXLE/TRANSMISSION - AISIN AW21 -- FUSION & MKZ article.
85. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS -- FUSION, MILAN & MKZ (EXCEPT HYBRID) article.
86. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.