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Section 249 (Engine - 3.0L (4V)): Installation: Engine

WARNING: This page is about a different car, the 2005 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
ENGINE INSTALLATION SPECIAL TOOLS

G03897842
 Powertrain Lift With Tilting Plate 014-00765
G03996186
 Transmission Support Bracket 014-00341
G03898369
 Engine Lifting Brackets 303-050
ENGINE INSTALLATION MATERIAL SPECIFICATION

Item Specification
5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP WSS-M2C930-A
  1. Using the special tools and a suitable engine crane, align the engine with the transmission.
    Fig 1: Identifying Suitable Engine Crane
    G03995973Courtesy of FORD MOTOR CO.
  2. Install the 5 transmission-to-engine bolts.
    • Tighten to 45 Nm (33 lb-ft).
    Fig 2: Installing Transmission-To-Engine Bolts
    G03995972Courtesy of FORD MOTOR CO.
  3. Connect the transmission oil cooler tubes and tighten the fittings.
    • Tighten to 20 Nm (15 lb-ft).
    Fig 3: Connecting Transmission Oil Cooler Tubes
    G03995971Courtesy of FORD MOTOR CO.
  4. Position the engine and transmission on the crossmember and cooling system assembly.
    Fig 4: Identifying Engine On Lift
    G03996191Courtesy of FORD MOTOR CO.
  5. Install the RH engine mount nut.
    • Tighten to 63 Nm (46 lb-ft).
    Fig 5: Installing RH Engine Mount Nut
    G03995969Courtesy of FORD MOTOR CO.
  6. Remove the LH engine mount nut.
    • Tighten to 63 Nm (46 lb-ft).
    Fig 6: Removing LH Engine Mount Nut
    G03995968Courtesy of FORD MOTOR CO.
  7. Attach the transmission cooler tube bracket to the oil pan and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    Fig 7: Attaching Transmission Cooler Tube Bracket To Oil Pan And Nut
    G03995965Courtesy of FORD MOTOR CO.
  8. If equipped, connect the oil cooler hoses.
    Fig 8: Locating Oil Cooler Hoses
    G03995964Courtesy of FORD MOTOR CO.
  9. Connect the heater hose and the lower radiator hose to the coolant pump.
    Fig 9: Connecting Heater Hose And Lower Radiator Hose To Coolant Pump
    G03995963Courtesy of FORD MOTOR CO.
  10. Connect the coolant inlet hose.
    Fig 10: Connecting Coolant Inlet Hose
    G03995962Courtesy of FORD MOTOR CO.
  11. Position the power steering pump and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    • Secure the power steering fluid reservoir to the engine.
    Fig 11: Installing Power Steering Pump Bolts
    G03995961Courtesy of FORD MOTOR CO.
  12. Connect the power steering pressure (PSP) switch electrical connector.
    Fig 12: Connecting Power Steering Pressure Switch Electrical Connector
    G03995960Courtesy of FORD MOTOR CO.
  13. Position the A/C compressor and manifold assembly. Install the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 13: Installing A/C Compressor And Manifold Assembly
    G03995959Courtesy of FORD MOTOR CO.
  14. Connect the A/C compressor electrical connector.
    Fig 14: Connecting A/C Compressor Electrical Connector
    G03995958Courtesy of FORD MOTOR CO.
  15. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
    Fig 15: Rotating Accessory Drive Belt Tensioner Counterclockwise
    G03995957Courtesy of FORD MOTOR CO.
  16. Position the starter motor and install the 2 bolts and the stud bolt.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 16: Installing Starter Motor And Stud Bolt
    G03995956Courtesy of FORD MOTOR CO.
  17. Position the wiring harness and attach the 2 retainers.
    Fig 17: Identifying Wiring Harness And Attaching Retainers
    G03995955Courtesy of FORD MOTOR CO.
  18. Using the special tools, carefully position the entire assembly into the vehicle.
    Fig 18: Positioning Entire Assembly Into Vehicle
    G03995951Courtesy of FORD MOTOR CO.
    19. NOTE: LH shown, RH similar
    Fig 19: Installing Front Crossmember And Center Crossmember Bolts
    G03995953Courtesy of FORD MOTOR CO.
  19. Install the 8 front and center crossmember bolts.
    • Tighten to 103 Nm (76 lb-ft).
    20. NOTE: RH shown, LH similar.
  20. Install the 4 center crossmember I brace bolts.
    • Tighten to 103 Nm (76 lb-ft).
  21. Install the 4 transmission crossmember bolts.
    • Tighten to 55 Nm (41 lb-ft).
    Fig 20: Installing Transmission Crossmember Support Bolts
    G03995952Courtesy of FORD MOTOR CO.
  22. Install the 4 lower engine-to-transmission bolts.
    • Tighten to 45 Nm (33 lb-ft).
    Fig 21: Installing Lower Engine-To-Transmission Bolts
    G03995950Courtesy of FORD MOTOR CO.
  23. Install the engine-to-transmission bolt.
    • Tighten to 45 Nm (33 lb-ft).
    Fig 22: Installing Engine-To-Transmission Bolt
    G03995949Courtesy of FORD MOTOR CO.
  24. Install the engine-to-transmission bolt.
    • Tighten to 45 Nm (33 lb-ft).
    Fig 23: Installing Engine-To-Transmission Bolt
    G03995948Courtesy of FORD MOTOR CO.
  25. Install the 4 torque converter nuts.
    • Tighten to 38 Nm (28 lb-ft).
    Fig 24: Installing Torque Converter Nuts
    G03996211Courtesy of FORD MOTOR CO.
  26. Install the torque converter access cover.
    Fig 25: Installing Torque Converter Bolt Access Cover
    G03995946Courtesy of FORD MOTOR CO.
  27. Connect the B+ terminal to the generator and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    Fig 26: Connecting B+ Terminal To Generator And Install Nut
    G03996213Courtesy of FORD MOTOR CO.
  28. Position the starter motor cables and install the nuts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 27: Installing Starter Motor Nuts
    G03996214Courtesy of FORD MOTOR CO.
  29. Install the starter motor terminal cover.
    Fig 28: Identifying Starter Motor Terminal Cover
    G03995943Courtesy of FORD MOTOR CO.
  30. Position the ground strap and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    Fig 29: Installing Ground Strap And Nut
    G03996216Courtesy of FORD MOTOR CO.
  31. If equipped, connect the block heater electrical connector.
    Fig 30: Locating Block Heater Electrical Connector
    G03995941Courtesy of FORD MOTOR CO.
  32. Position the PSP tube bracket and install the bolt.
    Fig 31: Installing PSP Tube Bracket Bolt
    G03995940Courtesy of FORD MOTOR CO.
  33. Attach the PSP tube bracket to the oil pan stud bolt and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    Fig 32: Attaching PSP Tube Bracket To Oil Pan Stud Bolt And Nut
    G03995939Courtesy of FORD MOTOR CO.
    34. CAUTION: Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the wheel has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM .
    Fig 33: Attaching Steering Column Intermediate Shaft To Steering Gear And Bolt
    G03995938Courtesy of FORD MOTOR CO.
  34. Attach the steering column intermediate shaft to the steering gear and install the bolt.
    • Tighten to 35 Nm (26 lb-ft).
  35. Install the steering intermediate shaft bolt.
    • Tighten to 30 Nm (22 lb-ft).
    Fig 34: Installing Steering Intermediate Shaft Bolt
    G03996221Courtesy of FORD MOTOR CO.
  36. Attach the power steering return tube to the PSP tube clip.
    Fig 35: Attaching Power Steering Return Tube To PSP Tube Clip
    G03995936Courtesy of FORD MOTOR CO.
  37. Connect the variable assist power steering (VAPS) actuator electrical connector.
    Fig 36: Locating Variable Assist Power Steering Actuator Electrical Connector
    G03995935Courtesy of FORD MOTOR CO.
  38. Attach the shift cable pin-type retainer to the exhaust heat shield.
    Fig 37: Attaching Shift Cable Pin-Type Retainer To Exhaust Heat Shield
    G04007506Courtesy of FORD MOTOR CO.
  39. Position shift cable bracket and install the bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 38: Locating Shift Cable Bracket-To-Body Bolts
    G03995933Courtesy of FORD MOTOR CO.
  40. Connect the shift cable from the shifter.
    Fig 39: Identifying Shift Cable Connection Point At Shifter
    G03995932Courtesy of FORD MOTOR CO.
  41. Install the 2 strut-to-control arm bolts and nuts.
    • Tighten to 175 Nm (129 lb-ft).
    Fig 40: Identifying Lower Strut-To-Control Arm Bolt And Nut
    G03995931Courtesy of FORD MOTOR CO.
    42. NOTE: To install the nut, first loosen the nut, then use the hex-holding feature to prevent the upper ball joint stud from turning while tightening the nut.
    Fig 41: Identifying Upper Ball Joint Nut At Wheel Knuckle
    G03995930Courtesy of FORD MOTOR CO.
  42. Connect the upper ball joints to the wheel knuckles and install the 2 nuts.
    • Tighten to 90 Nm (66 lb-ft).
    43. NOTE: To install the nut, first loosen the nut, then use the hex-holding feature to prevent the stabilizer bar link ball joint from turning while tightening the nut.
    Fig 42: Identifying Stabilizer Bar Link Connection Point At Lower Control Arm
    G03995929Courtesy of FORD MOTOR CO.
  43. Connect the stabilizer bar links to the lower control arms and install the 2 nuts.
    44. CAUTION: Do not allow the brake caliper to hang from the brake hose or damage to the brake hose can occur.
    Fig 43: Identifying Brake Caliper Mounting Bolts
    G03995928Courtesy of FORD MOTOR CO.
  44. Position the front brake calipers and install the 4 bolts.
    • Tighten to 103 Nm (76 lb-ft).
  45. Attach the RH and LH anti-lock brake sensor harnesses to the brake hose clips.
    Fig 44: Identifying Anti-Lock Brake Sensor Harnesses-To-Hose Clips
    G03995927Courtesy of FORD MOTOR CO.
  46. Connect the 2 anti-lock brake sensor electrical connectors.
    Fig 45: Locating Anti-Lock Brake Sensor Electrical Connector
    G03995926Courtesy of FORD MOTOR CO.
  47. Position the RH and LH inner fender splash shields aside.
    1. Position the inner splash shields.
    2. Install the 3 pin-type retainers.
    Fig 46: Installing Inner Splash Shields
    G03996233Courtesy of FORD MOTOR CO.
  48. Connect the A/C low pressure hose and install the safety clip.
    Fig 47: Identifying Low Pressure A/C Hose
    G03996234Courtesy of FORD MOTOR CO.
  49. Connect the A/C high-pressure tube at the right frame rail and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    Fig 48: Connecting A/C High-Pressure Tube At Right Frame Rail
    G03995923Courtesy of FORD MOTOR CO.
    50. NOTE: Install the hoses to the marks made during the removal procedure.
    NOTE: Hose assemblies shown with components removed for clarity.
    Fig 49: Identifying Heater Hose Quick Release Couplings
    G03995921Courtesy of FORD MOTOR CO.
  50. Connect the 3 quick-disconnect couplings to the coolant control valve hoses. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    51. CAUTION: Install the bolts, washers and nuts in their original positions or driveshaft NVH can occur. Install the driveshaft flex coupling bolts with the head of the bolt seated against the flange and the nuts seated against the flex coupling.
    NOTE: The bolt heads are serrated. Hold the bolt and tighten the nut.
    Fig 50: Identifying Flange Nuts & Locating Index Mark
    G03995919Courtesy of FORD MOTOR CO.
  51. Install the bolts, washers and nuts.
    • Coat the nut and bolt threads with sealer.
    • Tighten to 81 Nm (60 lb-ft).
  52. Install the catalytic converters. For additional information, refer to EXHAUST SYSTEM .
  53. Install the inner air deflector.
    Fig 51: Installing Inner Air Deflector
    G03995918Courtesy of FORD MOTOR CO.
  54. Install the center splash shield.
    Fig 52: Locating Air Deflector/Splash Shield Mounting Points
    G03995633Courtesy of FORD MOTOR CO.
    55. NOTE: LH shown, RH similar.
    Fig 53: Locating Splash Shields
    G03995916Courtesy of FORD MOTOR CO.
  55. Install the LH and the RH splash shields.
  56. Connect the coolant valve electrical connector and attach the wiring retainer.
    Fig 54: Connecting Coolant Valve Electrical Connector
    G03995915Courtesy of FORD MOTOR CO.
  57. Attach the wiring harness retainer to the bracket.
    Fig 55: Identifying Wiring Harness Retainer Bracket
    G03995914Courtesy of FORD MOTOR CO.
  58. Connect the 2 engine wiring harness connectors.
    Fig 56: Identifying Engine Wiring Harness Connectors
    G03995913Courtesy of FORD MOTOR CO.
  59. Position the main transmission wiring harness connector and tighten the bolt.
    • Tighten to 6 Nm (53 lb-in).
    Fig 57: Installing Main Transmission Wiring Harness Connector And Bolt
    G03995912Courtesy of FORD MOTOR CO.
  60. Position the main engine wiring harness connector and tighten the bolt.
    • Tighten to 6 Nm (53 lb-in).
    Fig 58: Installing Main Engine Wiring Harness Connector And Bolt
    G03995911Courtesy of FORD MOTOR CO.
  61. Position the ground strap and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 59: Installing Ground Strap And Bolt
    G03995842Courtesy of FORD MOTOR CO.
  62. Position the A/C manifold tube and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    Fig 60: Installing A/C Manifold Tube And Nut
    G03995909Courtesy of FORD MOTOR CO.
  63. Connect the evaporative emissions (EVAP) hose to the EVAP canister purge valve.
    Fig 61: Connecting Evaporative Emissions (EVAP) Hose To EVAP Canister Purge Valve
    G03995908Courtesy of FORD MOTOR CO.
  64. Position the brake booster vacuum hose and attach the retainers.
    Fig 62: Installing Brake Booster Vacuum Hose And Attaching Retainers
    G03995907Courtesy of FORD MOTOR CO.
  65. Connect the brake booster vacuum hose to the upper intake manifold.
    Fig 63: Connecting Brake Booster Vacuum Hose To Upper Intake Manifold
    G03995906Courtesy of FORD MOTOR CO.
  66. Connect the coolant hose from the upper intake manifold.
    Fig 64: Connecting Coolant Hose From Upper Intake Manifold
    G03995905Courtesy of FORD MOTOR CO.
  67. Position the positive crankcase ventilation (PCV) tube and degas bottle coolant hose. Attach the retainer to the upper intake manifold.
    Fig 65: Positioning Positive Crankcase Ventilation (PCV) Tube And Degas Bottle Coolant Hose
    G03995904Courtesy of FORD MOTOR CO.
  68. Connect the degas bottle coolant hose and the PCV tube to the upper intake manifold.
    Fig 66: Connecting Degas Bottle Coolant Hose And PCV Tube To Upper Intake Manifold
    G03995903Courtesy of FORD MOTOR CO.
  69. Position power steering fluid reservoir and install the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 67: Installing Power Steering Fluid Reservoir Bolts
    G03995902Courtesy of FORD MOTOR CO.
  70. Connect the A/C pressure switch electrical connector.
    Fig 68: Locating A/C Pressure Switch Electrical Connector
    G03995901Courtesy of FORD MOTOR CO.
    71. NOTE: RH shown, LH similar.
    Fig 69: Identifying Upper Radiator Support Bracket & Bolts
    G03995900Courtesy of FORD MOTOR CO.
  71. Install the 2 upper radiator support brackets and the 6 bolts.
  72. Install the upper radiator sight shield.
    Fig 70: Locating Upper Radiator Sight Shield
    G04007969Courtesy of FORD MOTOR CO.
  73. Fill the engine with clean oil
  74. Connect the fuel tube. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  75. Install the clean air inlet duct. For additional information, refer to AIR DISTRIBUTION & FILTERING .
  76. Install the air cleaner assembly. For additional information, refer to FUEL CHARGING & CONTROLS - 3.0L (4V) .
  77. Install the air cleaner outlet pipe and the air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  78. Charge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  79. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  80. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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