Section 1185 (Engine Mechanical - 3.0L (4V)): Installation: Engine: Installation

WARNING: This page is about a different car, the 2010 Mercury Mariner and 2010 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: If the oil pan was removed during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.

All vehicles

Using the Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set and a suitable engine crane, align the engine with the transaxle.

Fig 1: Identifying Spreader Bar, Engine Lifting Brackets, Engine Lifting Bracket Set And Suitable Engine Crane
Courtesy of FORD MOTOR CO.
Install the 5 transaxle-to-engine bolts (3 shown).
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 2: Locating Transaxle-To-Engine Bolts
  Courtesy of FORD MOTOR CO.
Using the Universal Adapter Brackets, secure the engine and transaxle to the Powertrain Lift.

Fig 3: Identifying Universal Adapter Brackets
Courtesy of FORD MOTOR CO.

All-Wheel Drive (AWD) vehicles
Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal.

Fig 4: Identifying Handle And PTO Driven Gear Oil Seal Installer
Courtesy of FORD MOTOR CO.
Install the Power Transfer Unit (PTU) heat shield and the 3 bolts.
- Tighten to 11 Nm (97 lb-in).
  
  Fig 5: Locating Bolts And PTU Heat Shield
  Courtesy of FORD MOTOR CO.
Position the PTU and install the bolt.
- Tighten to 45 Nm (33 lb-ft).
  
  Fig 6: Locating PTU And Bolts
  Courtesy of FORD MOTOR CO.
Install the 3 PTU bolts.
- Tighten to 45 Nm (33 lb-ft).
  
  Fig 7: Locating PTU Bolts
  Courtesy of FORD MOTOR CO.
Install the PTU vent tube, the pin-type retainer and the bolt.
- Tighten to 14 Nm (124 lb-in).
  
  Fig 8: Locating PTU Vent Tube Bolts
  Courtesy of FORD MOTOR CO.
Install the PTU support bracket and bolts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 9: Locating Bolts And Power Transfer Unit (PTU) Support Bracket
  Courtesy of FORD MOTOR CO.
Install a new gasket and the RH catalytic converter and the 3 new nuts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 10: Locating RH Catalytic Converter And Nuts
  Courtesy of FORD MOTOR CO.
Install the 3 bolts and the RH heat shield.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 11: Locating Bolts And RH Heat Shield
  Courtesy of FORD MOTOR CO.
Connect the RH Heated Oxygen Sensor (HO2S) electrical connector.

Fig 12: Locating RH Heated Oxygen Sensor (HO2S) Electrical Connector
Courtesy of FORD MOTOR CO.

All vehicles
Install the 2 stud bolts and the starter.
- Tighten to 27 Nm (20 lb-ft).
  
  Fig 13: Locating Stud Bolts And Starter
  Courtesy of FORD MOTOR CO.
Install the 2 nuts and the starter wiring.
- 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 14: Locating Nuts And Starter Wiring
  Courtesy of FORD MOTOR CO.
Install the nut and the starter wiring ground.
- Tighten to 18 Nm (159 lb-in).
  
  Fig 15: Locating Nut And Starter Wiring Ground
  Courtesy of FORD MOTOR CO.
Position the powertrain into the vehicle.

Fig 16: Locating Powertrain Into Vehicle
Courtesy of FORD MOTOR CO.
Install the engine support bracket, the bolt and the 3 nuts.
- Tighten the nuts to 55 Nm (41 lb-ft).
- Tighten the bolt to 90 Nm (66 lb-ft).
  
  Fig 17: Locating Engine Support Bracket Nuts And Bolt
  Courtesy of FORD MOTOR CO.
Install the rear transaxle support through bolt.
- Tighten to 103 Nm (76 lb-ft).
  
  Fig 18: Locating Rear Transaxle Support Through Bolt
  Courtesy of FORD MOTOR CO.
Position the RH transaxle support insulator and install the bolt and nuts.
- Tighten to 80 Nm (59 lb-ft).
  
  Fig 19: Locating RH Transaxle Support Insulator Bolt And Nuts
  Courtesy of FORD MOTOR CO.

NOTE: Late build AWD equipped with a mass damper shown, other vehicles similar.

Install the RH transaxle support insulator through bolt and mass damper (if equipped).
- Tighten to 115 Nm (85 lb-ft).
  
  Fig 20: Locating Rh Transaxle Support Insulator Bolt And Mass Damper
  Courtesy of FORD MOTOR CO.
Install the 3 bolts and the halfshaft support bracket.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 21: Locating Bolts And Halfshaft Support Bracket
  Courtesy of FORD MOTOR CO.
Install the transaxle-to-engine stud and 2 nuts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 22: Locating Transaxle-To-Engine Stud And Nuts
  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 23: Locating Silicone Gasket And Sealant Area

Courtesy of FORD MOTOR CO.

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 24: Locating Oil Pan Bolts

Courtesy of FORD MOTOR CO.

Position the oil pan and gasket and loosely install the bolts and stud bolts.
Install the 2 oil pan-to-transaxle bolts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 25: Locating Oil Pan-To-Transaxle Bolts
  Courtesy of FORD MOTOR CO.
Tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).

Fig 26: Identifying Oil Pan Bolts In Sequence
Courtesy of FORD MOTOR CO.
Install the 4 torque converter nuts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 27: Locating Torque Converter Nuts
  Courtesy of FORD MOTOR CO.
Install the access cover.

Fig 28: Locating Access Cover
Courtesy of FORD MOTOR CO.
If equipped, connect the engine block heater electrical connector.

Fig 29: Locating Engine Block Heater Electrical Connector
Courtesy of FORD MOTOR CO.
Install the ground wire eyelet and nut to the engine mount stud.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 30: Locating Ground Wire Eyelet And Nut
  Courtesy of FORD MOTOR CO.
Connect the electrical connector to the Power Distribution Box (PDB).

Fig 31: Locating PDB
Courtesy of FORD MOTOR CO.
Install the cable and the nut to the PDB .
- Tighten to 12 Nm (106 lb-in).
  
  Fig 32: Locating Nut And Cable
  Courtesy of FORD MOTOR CO.
Attach the ground wire and install the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 33: Locating Bolt And Ground Wire
  Courtesy of FORD MOTOR CO.
Attach the wiring harness retainer to the battery tray bracket.

Fig 34: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Connect the middle PCM electrical connector and the engine wiring harness electrical connector.
- Attach the 2 wiring harness retainers.
  
  Fig 35: Locating Wiring Harness Retainers
  Courtesy of FORD MOTOR CO.
Connect the Evaporative Emission (EVAP) canister purge valve tube and the brake booster vacuum tube to the intake manifold.

Fig 36: Locating Evaporative Emission (EVAP) Canister Purge Valve Tube And Brake Booster Vacuum Tube
Courtesy of FORD MOTOR CO.
Attach the shift cable retainer to the bracket.

Fig 37: Locating Shift Cable Retainer
Courtesy of FORD MOTOR CO.
Position the shift cable and bracket in place, install the bolts.
- Tighten to 23 Nm (17 lb-ft).
  
  Fig 38: Locating Shift Cable Bracket Bolts
  Courtesy of FORD MOTOR CO.
Connect the gearshift cable to the transaxle.

Fig 39: Locating Gearshift Cable
Courtesy of FORD MOTOR CO.
Connect the fuel supply tube quick connect coupling to the fuel rail. For additional information, refer to QUICK CONNECT COUPLING .

Fig 40: Locating Fuel Supply Tube Quick Connect Coupling
Courtesy of FORD MOTOR CO.
Connect the 2 heater hoses.

Fig 41: Locating Heater Hoses
Courtesy of FORD MOTOR CO.
Connect the upper and lower radiator hoses.

Fig 42: Locating Upper And Lower Radiator Hoses
Courtesy of FORD MOTOR CO.
Connect the 2 transmission electrical connectors and attach the wiring retainer to the stud bolt.

Fig 43: Locating Transmission Electrical Connectors And Wiring Retainer
Courtesy of FORD MOTOR CO.
Connect the 2 transaxle fluid cooler tubes.

Fig 44: Locating Transaxle Fluid Cooler Tubes
Courtesy of FORD MOTOR CO.
Install the 2 secondary latches to the transaxle fluid cooler tubes.

Fig 45: Locating Secondary Latches And Transaxle Fluid Cooler Tubes
Courtesy of FORD MOTOR CO.
Install the cross brace and the new nut finger-tight.

Fig 46: Locating Nut And Engine Support Crossmember
Courtesy of FORD MOTOR CO.
Install the 2 bolts for the cross brace and the bolt for the front roll restrictor.
- Tighten the 2 cross brace bolts to 90 Nm (66 lb-ft).
- Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
  
  Fig 47: Locating Front Roll Restrictor Bolts
  Courtesy of FORD MOTOR CO.
Tighten the cross brace nut to 175 Nm (129 lb-ft).

Fig 48: Locating Cross Brace Nut
Courtesy of FORD MOTOR CO.
Connect the generator electrical connector.

Fig 49: Locating Generator Electrical Connector
Courtesy of FORD MOTOR CO.
Position the A/C compressor and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 50: Locating Bolts And A/C Compressor
  Courtesy of FORD MOTOR CO.
Connect the A/C compressor electrical connector.

Fig 51: Locating A/C Compressor Electrical Connector
Courtesy of FORD MOTOR CO.
Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.

Fig 52: Rotating Accessory Drive Belt Tensioner Counterclockwise
Courtesy of FORD MOTOR CO.

AWD vehicles

NOTE: Do not reuse the driveshaft flange bolts and washers. Install new bolts and washers or damage to the vehicle may occur.

Align the index-marks made during removal and install 6 new front driveshaft-to- PTU bolts and washers.
- Tighten to 37 Nm (27 lb-ft).
  
  Fig 53: Locating Front Driveshaft-To-PTU Bolts
  Courtesy of FORD MOTOR CO.
All vehicles
Install the intermediate shaft.

Fig 54: Locating Intermediate Shaft
Courtesy of FORD MOTOR CO.
Install the 2 intermediate shaft bearing retainer nuts.
- Tighten to 27 Nm (20 lb-ft).
  
  Fig 55: Locating Intermediate Shaft Bearing Retainer Nuts
  Courtesy of FORD MOTOR CO.
Install the RH and LH halfshaft and the intermediate shaft. For additional information, refer to HALFSHAFT .
Install the exhaust-Y-pipe. For additional information, refer to EXHAUST Y-PIPE -- 3.0L .
Connect the RH Catalyst Monitor Sensor (CMS) electrical connector.

Fig 56: Locating RH CMS Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the LH CMS electrical connector.

Fig 57: Locating LH Catalyst Monitor Sensor (CMS) Electrical Connector
Courtesy of FORD MOTOR CO.
Install the lateral support crossmember and the 4 bolts.
- Tighten to 115 Nm (85 lb-ft).
  
  Fig 58: Locating Bolts And Lateral Support Crossmember
  Courtesy of FORD MOTOR CO.
Install the lower splash shields and bolts.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 59: Locating Lower Splash Shields
  Courtesy of FORD MOTOR CO.
Install the front wheels and tires. For additional information, refer to WHEEL AND TIRE .
Install the Air Cleaner (ACL) outlet pipe and ACL . For additional information, refer to AIR CLEANER OUTLET PIPE .
Install the battery tray. For additional information, refer to BATTERY TRAY -- NON-HYBRID .
Fill the engine with clean engine oil.
Fill and bleed the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.