Section 12 (Engine Mechanical - 3.5L): Installation: Engine

	2, 200# Floor Crane, Fold Away 300-OTC1819E
	Adjustable Grip Arm, 1735A 014-00001 or equivalent
	Powertrain Lift 300-OTC1585AE
	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
	Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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).
     Fig 1: Location of Transaxle-To-Engine Stud Bolt And Transaxle-To-Engine Bolts

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

     Courtesy of FORD MOTOR CO.
4. Using the Floor Crane and the Spreader Bar, position the engine and transaxle onto the lift table.
   Fig 3: Aligning Transaxle To Engine Using Floor Crane And Spreader Bar

   Courtesy of FORD MOTOR CO.
NOTE: Position a block of wood under the transaxle.
Fig 4: Installing Powertrain Lift And Adjustable Grip Arms
Courtesy of FORD MOTOR CO.
5. Install the Powertrain Lift and Adjustable Grip Arms.
6. Install the starter and the 2 bolts.
   • Tighten to 26 Nm (19 lb-ft).
     Fig 5: Location of Starter Bolts

     Courtesy of FORD MOTOR CO.
7. Attach the starter wire terminals and install the 2 nuts.
   1. Tighten to 12 Nm (106 lb-in).
   2. Tighten to 5 Nm (44 lb-in).
      • Position the starter terminal boot over the starter terminal.
        Fig 6: Identifying Starter Wire Terminals Nuts

        Courtesy of FORD MOTOR CO.
8. Connect the Transmission Control Module (TCM) electrical connector.
   Fig 7: Location of Transmission Control Module Electrical Connector

   Courtesy of FORD MOTOR CO.
9. Install the ground wire and bolt.
   • Tighten to 12 Nm (106 lb-in).
     Fig 8: Location of Bolt And Ground Wire

     Courtesy of FORD MOTOR CO.
10. Connect the wiring harness fasteners to the transaxle-to-engine stud bolt and the starter.
    Fig 9: Location of Wiring Harness Fasteners And Torque Converter Housing Stud Bolt

    Courtesy 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).
      Fig 10: Location of Engine Mount Nut And Bolts

      Courtesy of FORD MOTOR CO.
13. Install the 2 engine mount spacers and the 4 engine mount nuts.
    • Tighten in the sequence shown in illustration to 70 Nm (52 lb-ft).
      Fig 11: Identifying Engine Mount-To-Engine Nuts Tightening Sequence

      Courtesy of FORD MOTOR CO.
14. Install the 2 transaxle support insulator bracket nuts and the bolt.
    • Tighten to 80 Nm (59 lb-ft).
      Fig 12: Location of Transaxle Support Insulator Bracket Bolt And Nuts

      Courtesy of FORD MOTOR CO.
15. Install the transaxle support insulator through bolt and nut.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 13: Location of Transaxle Support Insulator Through Bolt And Nut

      Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is moved from the vehicle.
Fig 14: Removing Compression Seal Using Screwdriver
Courtesy of FORD MOTOR CO.
16. Using a small screwdriver, remove the compression seal and discard.
17. Using a soft face hammer, install the new compression seal.
    Fig 15: Installing Compression Seal

    Courtesy of FORD MOTOR CO.
18. Position the PTU in place and install the 5 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 16: Location of Bolts And PTU

      Courtesy of FORD MOTOR CO.
19. Position the PTU support bracket in place and install the 5 bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 17: Location of PTU Support Bracket Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Do not tighten the 4 catalytic converter nuts at this time.
Fig 18: Location of RH Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.
20. Using a new gasket, install the RH catalytic converter and 4 new nuts.
21. 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 (177 lb-in).
      Fig 19: Location of Catalytic Converter-To-Bracket Bolts

      Courtesy of FORD MOTOR CO.
22. Connect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 20: Location of RH Catalyst Monitor Sensor (CMS) Electrical Connector

    Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

NOTE: Do not tighten the 2 catalytic converter support bracket bolts at this time.
Fig 21: Location of Catalytic Converter-To-Bracket Bolts
Courtesy of FORD MOTOR CO.
23. Install the RH catalytic converter support bracket and the 2 bolts.
24. 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 (177 lb-in).
      Fig 22: Location of Catalytic Converter Support Bracket Nuts

      Courtesy of FORD MOTOR CO.

    All vehicles 

NOTE: Align the index marks on the subframe to the index marks on the underbody that were made during removal.
Fig 23: Identifying Powertrain Lift Under Subframe
Courtesy of FORD MOTOR CO.
25. Using the Powertrain Lift, raise the subframe into the installed position.
NOTE: LH shown in illustration, RH similar.
26. Install the 2 front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 24: Location of Front Subframe Nut

      Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
Fig 25: Location of Subframe Bracket And Bolt
Courtesy of FORD MOTOR CO.
27. Position the subframe brackets and install the 4 bolts finger-tight.
NOTE: LH shown in illustration, RH similar.
28. Install the 2 rear subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 26: Location of Rear Subframe Nut And Subframe Bracket

      Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
Fig 27: Location of Front Subframe Nut
Courtesy of FORD MOTOR CO.
29. Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
NOTE: LH shown in illustration, RH similar.
30. Install the stabilizer bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 28: Location of Stabilizer Bar Link Nut

      Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
31. Install the tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install new cotter pins.
      Fig 29: Location of Cotter Pin And Nut On Tie-Rod Ends

      Courtesy of FORD MOTOR CO.
32. Install the engine roll restrictor-to-subframe through bolt.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 30: Location of Engine Roll Restrictor-To-Subframe Through Bolt

      Courtesy of FORD MOTOR CO.

    AWD vehicles 

33. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 new bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 31: Location of Driveshaft Bolts

      Courtesy of FORD MOTOR CO.

    All vehicles 

34. Install 4 new torque converter nuts.
    • Tighten to 36 Nm (27 lb-ft).
      Fig 32: Location of Torque Converter Nut

      Courtesy of FORD MOTOR CO.
35. Install the inspection cover and the 2 fasteners.
    Fig 33: Location of Inspection Cover And Fasteners

    Courtesy of FORD MOTOR CO.
36. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 34: Location of Oil Pan-To-Transaxle Bolts

      Courtesy of FORD MOTOR CO.
37. Using new gaskets, install the Y-pipe assembly and 6 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 35: Location of Nuts And Y-Pipe Assembly

      Courtesy of FORD MOTOR CO.
38. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
39. Connect the 2 transmission fluid cooler hoses.
    Fig 36: Location of Transmission Fluid Cooler Hoses

    Courtesy of FORD MOTOR CO.
40. Connect the power steering cooler tube.
    Fig 37: Location of Power Steering Cooler Tube

    Courtesy of FORD MOTOR CO.
41. 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.
      Fig 38: Location of Clips And Steering Gear-To-Dash Seal

      Courtesy of FORD MOTOR CO.
42. If equipped, install the underbody shield and the 6 screws.
    Fig 39: Location of Underbody Cover Shield Screws

    Courtesy of FORD MOTOR CO.
43. Install the LH splash shield and the 6 pin-type retainers (4 shown in illustration).
    Fig 40: Location of LH Splash Shield And 6 Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
44. Position the LH fender splash shield and install the 4 screws.
    Fig 41: Location of Fender Splash Shield Mounting Screws

    Courtesy of FORD MOTOR CO.
NOTE: Align the index marks made during removal.
45. Install the steering intermediate shaft onto the steering gear and install a new bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 42: Location of Steering Intermediate Shaft Bolt

      Courtesy of FORD MOTOR CO.
46. Install the steering joint cover and the 2 nuts.
    Fig 43: Location of Nuts And Steering Joint Cover

    Courtesy of FORD MOTOR CO.
47. 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).
      Fig 44: Location of PSP Hose Banjo Bolt

      Courtesy of FORD MOTOR CO.
48. Install the PSP tube bracket and bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 45: Location of Power Steering Pressure Hose Bracket Bolt

      Courtesy of FORD MOTOR CO.
49. Connect the PCM electrical connectors and pin-type retainers.
    Fig 46: Location of PCM Electrical Connectors And Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
50. Install the engine mount brace and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 47: Location of Bolts And Engine Mount Brace

      Courtesy of FORD MOTOR CO.
51. Install the ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 48: Location of Bolt And Ground Wire On Engine Mount Brace

      Courtesy of FORD MOTOR CO.
52. Connect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 49: Location of Fuel Supply Tube

    Courtesy of FORD MOTOR CO.
53. Attach the power steering reservoir onto the cowl.
    Fig 50: Location of Power Steering Reservoir

    Courtesy of FORD MOTOR CO.
54. Connect the hose to the power steering reservoir.
    • Attach the pin-type retainer to the engine mount brace.
      Fig 51: Location of Pin-Type Retainer At Engine Mount Brace

      Courtesy of FORD MOTOR CO.
55. Install the oil level indicator.
    Fig 52: Location of Oil Level Indicator

    Courtesy of FORD MOTOR CO.
56. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
    Fig 53: Location of Wiring Harness Retainers At LH Valve Cover Stud Bolts

    Courtesy of FORD MOTOR CO.
57. Connect the 2 engine wiring harness electrical connectors.
    Fig 54: Location of Engine Control Wiring Harness Electrical Connectors

    Courtesy of FORD MOTOR CO.
58. Attach the 2 wiring harness retainers.
    Fig 55: Location of Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
59. Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
    • Tighten to 8 Nm (71 lb-in).
      Fig 56: Location of A/C Tubes Nuts

      Courtesy of FORD MOTOR CO.
60. Install the A/C tube bracket bolt.
    • Tighten to 8 Nm (71 lb-in).
      Fig 57: Location of A/C Tube Bracket Bolt

      Courtesy of FORD MOTOR CO.
61. Install the 2 A/C tube bracket bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 58: Location of A/C Tube Bracket Bolts

      Courtesy of FORD MOTOR CO.
62. 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).
      Fig 59: Location of A/C Tube Nut

      Courtesy of FORD MOTOR CO.
63. Attach the coolant tube retainer clips to the A/C tube.
    Fig 60: Location of Coolant Tube Retainer Clips On A/C Tube

    Courtesy of FORD MOTOR CO.
64. If equipped, attach the engine block heater harness to the radiator support, power steering hose, A/C tube and the engine wiring harness.
65. Install the ground wire and bolt.
    • Tighten to 12 Nm (106 lb-in).
      Fig 61: Location of Ground Wire And Bolt

      Courtesy of FORD MOTOR CO.
66. Position the transaxle control cable bracket in place and install the 3 nuts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 62: Location of Selector Lever Cable Bracket Bolts And Nut

      Courtesy of FORD MOTOR CO.
67. Connect the transaxle control cable to the control lever.
    Fig 63: Location of Selector Lever Cable End

    Courtesy of FORD MOTOR CO.
68. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
    Fig 64: Location of Upper Radiator Hose, Lower Radiator Hose And Heater Hoses At Thermostat Housing

    Courtesy of FORD MOTOR CO.
69. Connect the vacuum hose and the Evaporative Emission (EVAP) tube to the upper intake manifold.
    Fig 65: Location of Vacuum Hose And Evaporative Emission (EVAP) Tube

    Courtesy of FORD MOTOR CO.
70. Install the ground wire and the bolt.
    • Tighten to 12 Nm (106 lb-in).
      Fig 66: Location of Battery Bolt

      Courtesy of FORD MOTOR CO.
71. Install the 2 battery cables to the positive battery cable and the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 67: Location of Battery Cables Of Positive Battery Cable With Nuts

      Courtesy of FORD MOTOR CO.
72. Attach the 2 wiring harness retainers to the transmission mount and the battery tray bracket.
    Fig 68: Location of Wiring Harness Retainers At Transmission Mount And Battery Tray Bracket

    Courtesy of FORD MOTOR CO.
73. Connect the 2 engine wiring harness electrical connectors.
    Fig 69: Location of Engine Wiring Harness Electrical Connectors

    Courtesy of FORD MOTOR CO.
74. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
75. Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 3.5L .
76. Install the degas bottle. For additional information, refer to ENGINE COOLING .
77. Install the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
78. Install the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE - 3.5L .
79. Fill the engine with clean engine oil.
80. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
81. Fill the power steering system. For additional information, refer to STEERING SYSTEM - HYDRAULIC POWER ASSIST STEERING (HPAS) .
82. 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 .
83. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
84. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.