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Section 973 (Engine): Installation: Engine

WARNING: This page is about a different car, the 2007 Lincoln MKZ. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000536
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0017081
 Powertrain Lift 014-00765
GF0000267
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0024108
 Universal Adapter Brackets 014-0001
Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent
Material

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent		 WSS-M2C930-A

All vehicles 

  1. Align the transaxle to the engine.
  2. Install the 4 transaxle-to-engine bolts and the transaxle-to-engine stud bolt.
    • Tighten to 48 Nm (35 lb-ft).
    3. Fig 1: Locating Transaxle-To-Engine Stud Bolt & Transaxle-To-Engine Bolts
    GF0029164Courtesy of FORD MOTOR CO.
  3. Install the 2 engine-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
    4. Fig 2: Locating Engine-To-Transaxle Bolts
    GF0029163Courtesy of FORD MOTOR CO.
  4. Using the special tools, position the engine and transaxle onto the lift table.
    5. Fig 3: Removing Engine & Transaxle From Lift Table Using Special Tools (303-D089, 014-00071) & Suitable Engine Crane
    GF0029162Courtesy of FORD MOTOR CO.
    NOTE: Position a block of wood under the transaxle.
  5. Install the special tools.
    6. Fig 4: Positioning Block Of Wood Under Transaxle Using Special Tools (014-0001) & (014-00765)
    GF0029154Courtesy of FORD MOTOR CO.
  6. Install the starter and the 2 bolts.
    • Tighten to 26 Nm (19 lb-ft).
    7. Fig 5: Locating Starter Motor Bolts
    GF0029000Courtesy of FORD MOTOR CO.
  7. Attach the starter wire terminals and install the 2 nuts.
    1. Tighten to 12 Nm (9 lb-ft).
    2. Tighten to 5 Nm (44 lb-in).
      • Position the starter terminal boot over the starter terminal.
    8. Fig 6: Identifying Starter Motor Wire Terminals & Nuts
    GF0029337Courtesy of FORD MOTOR CO.
  8. Connect the transmission control module (TCM) electrical connector.
    9. Fig 7: Locating Transmission Control Module (TCM) Electrical Connector
    GF0028998Courtesy of FORD MOTOR CO.
  9. Install the ground wire and bolt.
    • Tighten to 12 Nm (9 lb-ft).
    10. Fig 8: Identifying Ground Wire & Bolt
    GF0029160Courtesy of FORD MOTOR CO.
  10. Connect the wiring harness fasteners to the transaxle-to-engine stud bolt and the starter.
    11. Fig 9: Identifying Wiring Harness Fasteners & Torque Converter Housing Stud Bolt
    GF0029159Courtesy of FORD MOTOR CO.
  11. Raise the engine and transaxle assembly into the vehicle.
  12. Install the engine mount, the nut and the 2 bolts.
    • Tighten the bolts to 55 Nm (41 lb-ft).
    • Tighten the nut to 63 Nm (46 lb-ft).
    13. Fig 10: Identifying Nut, Bolts & Engine Mount
    GF0029158Courtesy of FORD MOTOR CO.
  13. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
    14. Fig 11: Identifying Engine Mount Nuts
    GF0029157Courtesy of FORD MOTOR CO.
  14. Install the 2 transaxle mount bracket nuts and the bolt.
    • Tighten to 80 Nm (59 lb-ft).
    15. Fig 12: Identifying Transaxle Mount Bracket Bolt
    GF0029156Courtesy of FORD MOTOR CO.
  15. Install the transaxle mount through bolt and nut.
    • Tighten to 90 Nm (66 lb-ft).
    16. Fig 13: Identifying Transaxle Support Insulator Through Bolt
    GF0029155Courtesy of FORD MOTOR CO.

    All wheel drive (AWD) vehicles 

  16. Position the power transfer unit (PTU) in place and install the 5 bolts.
    • Tighten to 90 Nm (66 lb-ft).
    17. Fig 14: Locating PTU Bolts
    GF0028974Courtesy of FORD MOTOR CO.
  17. Position the PTU support bracket in place and install the 5 bolts.
    • Tighten to 70 Nm (52 lb-ft).
    18. Fig 15: Locating Power Transfer Unit (PTU) Support Bracket & Bolts
    GF0029153Courtesy of FORD MOTOR CO.
  18. Install the 4 new RH catalytic converter-to-exhaust manifold studs.
    • Tighten to 25 Nm (18 lb-ft).
    19. Fig 16: Locating RH Catalytic Converter-To-Exhaust Manifold Stud
    GF0029152Courtesy of FORD MOTOR CO.
    NOTE: Do not tighten the 4 catalytic converter nuts at this time.
  19. Using a new gasket, install the RH catalytic converter and 4 new nuts.
    20. Fig 17: Locating RH Catalytic Converter Nuts
    GF0029151Courtesy of FORD MOTOR CO.
  20. Install the 2 catalytic converter-to-bracket bolts.
    • Tighten the 4 catalytic converter nuts to 40 Nm (30 lb-ft).
    • Tighten the 2 catalytic converter-to-bracket bolts to 20 Nm (15 lb-ft).
    21. Fig 18: Identifying RH Catalytic Converter Support Bracket Bolts
    GF0029147Courtesy of FORD MOTOR CO.
  21. Connect the RH catalyst monitor electrical connector.
    22. Fig 19: Locating RH Catalyst Monitor Electrical Connector
    GF0029150Courtesy of FORD MOTOR CO.
    NOTE: A new PTU seal must be installed whenever the intermediate shaft is removed.
  22. Install a new PTU seal. For additional information, refer to TRANSFER CASE - POWER TRANSFER UNIT (PTU) .
    23. NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.
  23. Position the RH halfshaft in the transaxle and install the 2 bolts.
    • Tighten to 23 Nm (17 lb-ft).
    24. Fig 20: Locating RH Halfshaft Bearing Support Bracket Bolts
    GF0028972Courtesy of FORD MOTOR CO.

    Front wheel drive (FWD) vehicles 

    NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new if necessary.
  24. Position the RH halfshaft in the transaxle and install the bolt and the 2 stud bolts.
    • Tighten to 55 Nm (41 lb-ft).
    25. Fig 21: Identifying RH Halfshaft Bolts
    GF0029149Courtesy of FORD MOTOR CO.
    NOTE: Do not tighten the 2 catalytic converter support bracket bolts at this time.
  25. Install the RH catalytic converter support bracket and the 2 bolts.
    26. Fig 22: Identifying RH Catalytic Converter Support Bracket Bolts
    GF0029147Courtesy of FORD MOTOR CO.
  26. Install the 2 catalytic converter support bracket nuts.
    • Tighten to 40 Nm (30 lb-ft).
    • Tighten the 2 catalytic converter support bracket bolts to 20 Nm (15 lb-ft).
    27. Fig 23: Identifying Catalytic Converter Support Bracket & Nuts
    GF0029148Courtesy of FORD MOTOR CO.

    All vehicles 

    NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.
  27. Install the LH halfshaft into the transaxle.
    28. Fig 24: Identifying LH Halfshaft
    GF0029079Courtesy of FORD MOTOR CO.
  28. Using the special tool, raise the subframe into the installed position.
    29. Fig 25: Positioning Special Tool (014-00765) Under Subframe Assembly
    GF0028656Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  29. Install the 2 front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    30. Fig 26: Locating Front Subframe Nuts
    GF0028659Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  30. Position the subframe brackets and install the 4 bolts finger-tight.
    31. Fig 27: Locating Subframe Brackets And Bolts Finger-Tight
    GF0028860Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  31. Install the 2 rear subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    32. Fig 28: Locating Rear Subframe Nut
    GF0028657Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  32. Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
    33. Fig 29: Locating Subframe Bracket-To-Body Bolts
    GF0028658Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  33. Install the through bolts into the lower control arms.
    • Tighten to 103 Nm (76 lb-ft).
    34. Fig 30: Locating Lower Control Arms Through Bolt
    GF0028655Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  34. Install the 4 lower ball joint nuts.
    • Tighten to 200 Nm (148 lb-ft).
    35. Fig 31: Locating Lower Ball Joint Nuts
    GF0028653Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  35. Install the stabilizer bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
    36. Fig 32: Locating Sway Bar Links And Nuts
    GF0028754Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  36. Install the tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install new cotter pins.
    37. Fig 33: Locating Tie-Rod Ends Nuts And Cotter Pin
    GF0028751Courtesy of FORD MOTOR CO.
  37. Install the engine roll restrictor-to-subframe through bolt.
    • Tighten to 90 Nm (66 lb-ft).
    38. Fig 34: Locating Roll Restrictor Bolt
    GF0029146Courtesy of FORD MOTOR CO.

    AWD vehicles 

  38. 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.
    • Tighten to 70 Nm (52 lb-ft).
    39. Fig 35: Identifying Drive Shaft Bolts
    GF0028933Courtesy of FORD MOTOR CO.

    All vehicles 

  39. Install 4 new torque converter nuts.
    • Tighten to 36 Nm (27 lb-ft).
    40. Fig 36: Identifying Torque Converter Nuts
    GF0029145Courtesy of FORD MOTOR CO.
  40. Install the inspection cover and the 2 fasteners.
    41. Fig 37: Identifying Inspection Cover & Fasteners
    GF0029144Courtesy of FORD MOTOR CO.
  41. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
    42. Fig 38: Locating Oil Pan-To-Transaxle Bolts
    GF0029143Courtesy of FORD MOTOR CO.
  42. Using new gaskets, install the Y-pipe assembly and 6 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
    43. Fig 39: Locating Y-Pipe Nuts & Y-Pipe Assembly
    GF0029142Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
  43. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
    44. Fig 40: Identifying Engine Oil Filter
    GF0029141Courtesy of FORD MOTOR CO.
  44. Connect the 2 transmission fluid cooler hoses.
    45. Fig 41: Locating Transaxle Cooler Hoses Clamps
    GF0028938Courtesy of FORD MOTOR CO.
  45. Connect the power steering cooler tube.
    46. Fig 42: Locating Power Steering Cooler Tube
    GF0028753Courtesy of FORD MOTOR CO.
  46. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips 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.
    47. Fig 43: Locating Steering Gear-To-Dash Seal Clips
    GF0028750Courtesy of FORD MOTOR CO.
  47. If equipped, install the underbody shield and the 6 screws.
    48. Fig 44: Locating Underbody Shield Screws
    GF0028645Courtesy of FORD MOTOR CO.
  48. Install the LH splash shield and the 6 pin-type retainers (4 shown).
    49. Fig 45: Locating LH Splash Shield Pin-Type Retainers
    GF0028648Courtesy of FORD MOTOR CO.
  49. Position the LH fender splash shield and install the 4 screws.
    50. Fig 46: Locating LH Fender Splash Shield Screws
    GF0028647Courtesy of FORD MOTOR CO.
    NOTE: Align the index marks made during removal.
  50. Install the steering intermediate shaft onto the steering gear and install a new bolt.
    • Tighten to 23 Nm (17 lb-ft).
    51. Fig 47: Locating Steering Intermediate Shaft Bolt
    GF0028863Courtesy of FORD MOTOR CO.
  51. Install the steering joint cover and the 2 nuts.
    52. Fig 48: Locating Steering Joint Cover And Nuts
    GF0028747Courtesy of FORD MOTOR CO.
  52. Using a new banjo bolt and 2 new seals, install the power steering pressure (PSP) tube onto the steering gear.
    • Tighten to 37 Nm (27 lb-ft).
    53. Fig 49: Locating PSP Hose Banjo Bolt
    GF0028935Courtesy of FORD MOTOR CO.
  53. Install the PSP tube bracket and bolt.
    • Tighten to 10 Nm (89 lb-in).
    54. Fig 50: Locating Power Steering Pressure (PSP) Hose Bracket Bolt
    GF0028934Courtesy of FORD MOTOR CO.
  54. Connect the PCM electrical connectors and pin-type retainers.
    55. Fig 51: Locating PCM Electrical Connectors & Pin-Type Retainers
    GF0029139Courtesy of FORD MOTOR CO.
  55. Install the engine mount brace and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    56. Fig 52: Locating Engine Mount Brace Bolts
    GF0029138Courtesy of FORD MOTOR CO.
  56. Install the ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    57. Fig 53: Identifying Ground Wire Bolt From Engine Mount Brace
    GF0029137Courtesy of FORD MOTOR CO.
  57. Connect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    58. Fig 54: Identifying Fuel Supply Tube From Fuel Rail
    GF0029136Courtesy of FORD MOTOR CO.
  58. Attach the power steering reservoir onto the cowl.
    59. Fig 55: Attaching Power Steering Reservoir Onto Cowl
    GF0029338Courtesy of FORD MOTOR CO.
  59. Connect the hose to the power steering reservoir.
    • Attach the pin-type retainer to the engine mount brace.
    60. Fig 56: Identifying Pin-Type Retainer From Engine Mount Brace
    GF0029135Courtesy of FORD MOTOR CO.
  60. Install the oil level indicator.
    61. Fig 57: Identifying Oil Level Indicator
    GF0029134Courtesy of FORD MOTOR CO.
  61. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
    62. Fig 58: Identifying Wiring Harness Retainers From LH Valve Cover Stud Bolts
    GF0029133Courtesy of FORD MOTOR CO.
  62. Connect the 2 engine wiring harness electrical connectors.
    63. Fig 59: Identifying Engine Wiring Harness Electrical Connectors
    GF0029090Courtesy of FORD MOTOR CO.
  63. Attach the 2 wiring harness retainers.
    64. Fig 60: Identifying Wiring Harness Retainers
    GF0029089Courtesy of FORD MOTOR CO.
  64. Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
    • Tighten to 8 Nm (71 lb-in).
    65. Fig 61: Locating A/C Tubes And Nuts
    GF0028957Courtesy of FORD MOTOR CO.
  65. Install the A/C tube bracket bolt.
    • Tighten to 8 Nm (71 lb-in).
    66. Fig 62: Locating A/C Tube Bracket Bolt
    GF0029132Courtesy of FORD MOTOR CO.
  66. Install the 2 A/C tube bracket bolts.
    • Tighten to 10 Nm (89 lb-in).
    67. Fig 63: Locating A/C Tube Bracket Bolts
    GF0028769Courtesy of FORD MOTOR CO.
  67. Using a new O-ring seal, connect the A/C tube to the condenser and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    68. Fig 64: Locating A/C Tube From Condenser
    GF0029131Courtesy of FORD MOTOR CO.
  68. Attach the coolant tube retainer clips to the A/C tube.
    69. Fig 65: Identifying Coolant Tube Retainer Clips
    GF0029130Courtesy of FORD MOTOR CO.
  69. If equipped, attach the engine block heater harness to the radiator support, power steering hose, A/C tube and the engine wiring harness.
  70. Install the ground wire and bolt.
    • Tighten to 12 Nm (9 lb-ft).
    71. Fig 66: Locating Ground Wire And Bolt
    GF0028949Courtesy of FORD MOTOR CO.
  71. Position the transaxle control cable bracket in place and install the 3 nuts.
    • Tighten to 12 Nm (9 lb-ft).
    72. Fig 67: Identifying Selector Lever Cable Bracket Bolts & Nuts
    GF0029129Courtesy of FORD MOTOR CO.
  72. Connect the transaxle control cable to the control lever.
    73. Fig 68: Locating Transaxle Control Cable To Transaxle Selector Lever
    GF0028947Courtesy of FORD MOTOR CO.
  73. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
    74. Fig 69: Locating Upper Radiator Hose, Lower Radiator Hose & Heater Hoses From Thermostat Housing
    GF0029128Courtesy of FORD MOTOR CO.
  74. Connect the vacuum hose and the evaporative emissions (EVAP) tube to the upper intake manifold.
    75. Fig 70: Locating Vacuum Hose & Evaporative Emissions (EVAP) Tube From Upper Intake Manifold
    GF0029127Courtesy of FORD MOTOR CO.
  75. Install the ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    76. Fig 71: Locating Ground Wire And Bolt
    GF0028757Courtesy of FORD MOTOR CO.
  76. Connect the power feed to the battery terminal and install the nut.
    • Tighten to 6 Nm (53 lb-in).
    77. Fig 72: Locating Power Feed To Battery Terminal And Nut
    GF0028941Courtesy of FORD MOTOR CO.
  77. Attach the 2 wiring harness retainers to the transmission mount and the battery tray bracket.
    78. Fig 73: Locating Wiring Harness Retainers From Transmission Mount & Battery Tray Bracket
    GF0029126Courtesy of FORD MOTOR CO.
  78. Connect the 2 engine wiring harness electrical connectors.
    79. Fig 74: Locating Engine Wiring Harness Electrical Connectors
    GF0028756Courtesy of FORD MOTOR CO.
  79. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  80. Install the engine air cleaner and the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 3.5L .
  81. Install the degas bottle. For additional information, refer to ENGINE COOLING .
  82. Install the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE - 3.5L .
  83. Fill the engine with clean engine oil.
  84. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  85. Fill the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL INFORMATION .
  86. 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 - 6 SPEED .
  87. Recharge the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
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