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Installation Procedure

WARNING: This page is about a different car, the 2004 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the parts in the order indicated in the following illustrations and tables.
    Fig 1: Installing Order Of Engine Wiring Harness And Engine-To-Transmission Bolts And Nuts
    G03201385Courtesy of FORD MOTOR CO.
    Fig 2: Installing Order Of Motor Mount And Power Steering Components
    G03201386Courtesy of FORD MOTOR CO.
    Fig 3: Installing Order Of Engine Mount And Transmission Cooler Line Components
    G03201387Courtesy of FORD MOTOR CO.
    Fig 4: Installing Order Of Radiator, Heater, Power Steering Hose And A/C Manifold Bolt
    G03201388Courtesy of FORD MOTOR CO.
    Fig 5: Installing Order Of Crossmember Bolts
    G03201389Courtesy of FORD MOTOR CO.
    Fig 6: Installing Order Of Transmission, Torque Converter And Flexplate Components
    G03201390Courtesy of FORD MOTOR CO.
    Fig 7: Installing Order Of Generator And Starter Motor Components
    G03201391Courtesy of FORD MOTOR CO.
    Fig 8: Installing Order Of Steering Components And Shift Cable
    G03201392Courtesy of FORD MOTOR CO.
    Fig 9: Installing Order Of Suspension And Brake Components (1 Of 2)
    G03201393Courtesy of FORD MOTOR CO.
    Fig 10: Installing Order Of Suspension And Brake Components (2 Of 2)
    G03201394Courtesy of FORD MOTOR CO.
    Fig 11: Installing Order Of A/C Components
    G03201395Courtesy of FORD MOTOR CO.
    Fig 12: Installing Order Of Vacuum Hose, Degas Bottle Hose And Powertrain Components
    G03201396Courtesy of FORD MOTOR CO.
    Fig 13: Installing Order Of Upper Radiator Support And Power Steering Pump Reservoir Components
    G03201397Courtesy of FORD MOTOR CO.
    Fig 14: Installing Order Of Fuel Hose Components
    G03201398Courtesy of FORD MOTOR CO.
  2. Install the driveshaft. For additional information, refer to DRIVELINE SYSTEM .
  3. Install the three-way catalytic converter (TWC). For additional information, refer to EXHAUST SYSTEM .
  4. Install the front wheels and tires.
  5. Install the fresh air filter panel. For additional information, refer to CLIMATE CONTROL SYSTEM .
  6. Install the air cleaner inlet. For additional information, refer to INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L for additional information.
  7. Connect the battery ground cable.
  8. Fill the engine with clean engine oil.
    9. CAUTION: The coolant fill procedure must be followed exactly or damage to the engine can occur.
  9. Fill the engine coolant. For additional information, refer to ENGINE COOLING .
  10. Charge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM .
  11. Charge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM .

Item 1: Engine-to-Transmission Bolts Installation Note  

    NOTE: Align the flexplate to converter marks made during engine removal.
  1. Install the engine to the transmission and install the bolts.

Item 5: Engine and Transmission Assembly Installation Note  

  1. Using a floor crane and the special tool, install the engine onto the subframe.
    2. Fig 15: Supporting Engine With Subframe Using Floor Crane And Special Tool
    G03201399Courtesy of FORD MOTOR CO.

Item 16: Engine and Transmission Assembly Installation Note 

  1. Remove the special tool.
    Fig 16: Removing Special Tool (1 Of 2)
    G03201400Courtesy of FORD MOTOR CO.
  2. Remove the special tool.
    Fig 17: Removing Special Tool (2 Of 2)
    G03201401Courtesy of FORD MOTOR CO.

Item 26: Block Heater Electrical Connector Installation Note 

  1. Connect the engine block heater electrical connector.
    Fig 18: Connecting Engine Block Heater Electrical Connector
    G03201402Courtesy of FORD MOTOR CO.

Item 28: Engine and Transmission Assembly Installation Note 

  1. Using the powertrain lift and the transmission support bracket, carefully raise the entire assembly into the vehicle.
    Fig 19: Raising Engine And Transmission Assembly Using Powertrain Lift And Transmission Support Bracket
    G03201403Courtesy of FORD MOTOR CO.
  2. Install lower air deflector.

Item 33: Engine and Transmission Assembly Installation Note 

  1. Remove the safety stands from the rear of the vehicle.

Item 49: Steering Rack Electrical Connectors Installation Note 

  1. Connect the power steering rack electrical connectors.
    Fig 20: Connecting Power Steering Rack Electrical Connectors
    G03201404Courtesy of FORD MOTOR CO.

Item 50: Shift Cable Installation Note 

  1. Reclip the shift cable to the bracket.
    Fig 21: Reclipping Shift Cable To Bracket
    G03201405Courtesy of FORD MOTOR CO.

Item 51: Shift Cable Installation Note 

  1. Connect the shift cable to the shifter.
    Fig 22: Connecting Shift Cable To Shifter
    G03201406Courtesy of FORD MOTOR CO.

Items 55 and 62: Brake Caliper Installation Note 

  1. Install the brake caliper.

Items 57 and 64: Anti-Lock Brake Sensor Harness Installation Note 

  1. Position the anti-lock brake sensor harness and clip to the brake hose.
    Fig 23: Positioning Anti-Lock Brake Sensor Harness And Clip To Brake Hose
    G03201407Courtesy of FORD MOTOR CO.

Items 58 and 65: Anti-Lock Brake Sensor Electrical Connector Installation Note 

  1. Connect the wheel speed sensor electrical connector.
    Fig 24: Connecting Wheel Speed Sensor Electrical Connector
    G03201408Courtesy of FORD MOTOR CO.
  2. Install the inner splash shield.
    1. Position the inner splash shield back.
    2. Install the pin-type retainers.
    Fig 25: Installing Inner Splash Shield
    G03201409Courtesy of FORD MOTOR CO.

Item 66: Low Pressure Hose Installation Note 

  1. Connect the A/C low pressure hose.
    Fig 26: Connecting A/C Low Pressure Hose
    G03201410Courtesy of FORD MOTOR CO.

Item 83: Coolant Valve Electrical Connector Installation Note 

  1. Clip the harness to the radiator support and connect the coolant valve electrical connector.
    Fig 27: Connecting Coolant Valve Electrical Connector
    G03201411Courtesy of FORD MOTOR CO.

Item 84: Heater Hoses Installation Note 

    NOTE: Install the hoses to the marks made during the removal process.
    Fig 28: Installing Heater Hoses
    G03201412Courtesy of FORD MOTOR CO.
  1. Connect the three quick-disconnect couplings from the coolant control valve hoses to the heater tube assembly. Refer to CLIMATE CONTROL SYSTEM .

Item 90: Vapor Management Valve (VMV) Vapor Tube Installation Note 

  1. Connect the VMV.
    • Vacuum hose.
    • Canister purge valve.
    Fig 29: Connecting VMV
    G03201413Courtesy of FORD MOTOR CO.

Item 91: Power Steering Pump Reservoir Bolts Installation Note 

  1. Position back the power steering pump reservoir and install the bolts.
    Fig 30: Installing Power Steering Pump Reservoir Bolts
    G03201414Courtesy of FORD MOTOR CO.
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