Section 69 (Engine - 6.2L V8): Installation: Engine

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING .

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	303-1507 Brackets, Support
Courtesy of FORD MOTOR COMPANY	303-214 (T83T-6312-B) Wrench, Fan Clutch Nut
Courtesy of FORD MOTOR COMPANY	303-478 (T94T-6312-AH) Holding Wrench, Fan Clutch Pulley TKIT-1994-FHFMHFLMHLTH
Courtesy of FORD MOTOR COMPANY	303-F047 Lifting Bracket, Engine
Courtesy of FORD MOTOR COMPANY	307-346 (T97T-7902-A) Retainer, Torque Converter TKIT-1998-LM (NavigatoR) TKIT-1997-F/FLM/LT
Magnetic Socket
Floor Crane
Trolley Jack
Hose Clamp Remover/Installer
1/2 Inch Square Drive Breaker Bar
Wooden Block

Materials 

6-Speed Automatic Transmission - 6R100/6-Speed Automatic Transmission - 6R140 

1. NOTE: Only rotate the crankshaft in a clockwise direction.

   Rotate the flexplate to align the 2 slots at the 6 o'clock position.

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2. Remove the special tool. Use Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

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3. • Lubricate the torque converter pilot hub with multi-purpose grease.

     Material: Motorcraft ® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)

   • Align the paint dot on the torque converter in the 12 o'clock position.

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   5-Speed Manual Transmission - TR4050/6-Speed Automatic Transmission - 6R100/6-Speed Automatic Transmission - 6R140 

4. NOTE: Clean the engine support insulator frame bracket-to-crossmember mating surfaces of any dirt or foreign material prior to engine installation.

   With the help of an assistant and using the floor crane, position the engine assembly into the vehicle and onto the transmission.

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   6-Speed Automatic Transmission - 6R100/6-Speed Automatic Transmission - 6R140 

5. NOTE: The torque converter must be installed in it's original orientation to the flexplate or engine damage may occur.

   Check that the flexplate is positioned so that the 2 slotted holes are shown at the 6 o'clock position and the index marks are aligned.

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6. NOTE: Do not tighten at this time.

   Install the shift cable bracket and the LH transmission-to-engine bolts.

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7. Instal the RH transmission-to-engine bolts.

   Torque: 35 lb.ft (48 Nm)

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8. Tighten the transmission-to-engine bolts.

   Torque: 35 lb.ft (48 Nm)

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   5-Speed Manual Transmission - TR4050/6-Speed Automatic Transmission - 6R100/6-Speed Automatic Transmission - 6R140 

9. Install the RH engine mount.

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10. Install the LH engine mount.

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11. Remove the floor jack and block of wood. Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block

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12. • Using the floor crane and the special tool, lower the engine onto the engine mounts.
    • Remove the floor crane, special tool and the bolts. Use Special Service Tool: 303-1507 Brackets, Support., 303-F047 Lifting Bracket, Engine. Use the General Equipment: Floor Crane

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    6-Speed Automatic Transmission - 6R100/6-Speed Automatic Transmission - 6R140 

13. Install the upper transmission-to-engine bolts.

    Torque: 35 lb.ft (48 Nm)

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    5-Speed Manual Transmission - TR4050/6-Speed Automatic Transmission - 6R100/6-Speed Automatic Transmission - 6R140 

14. NOTE: Do not tighten the fastener at this time.

    Install the new LH engine mount through bolt.

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15. NOTE: Do not tighten the fastener at this time.

    Install the RH engine mount through bolt.

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16. NOTE: Only use hand tools when tightening the engine mount bolts or damage to the engine mount may occur.

    Install the new LH engine support insulator bracket nuts.

    Torque: 148 lb.ft (200 Nm)

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17. NOTE: Only use hand tools when tightening the engine mount bolts or damage to the engine mount may occur.

    Install the new RH engine support insulator bracket nuts.

    Torque: 148 lb.ft (200 Nm)

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18. NOTE: Only use hand tools when tightening the engine support insulator nuts or damage to the engine support insulator may occur.

    Tighten the LH engine mount through bolt.

    Torque: 258 lb.ft (350 Nm)

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19. NOTE: Only use hand tools when tightening the engine support insulator nuts or damage to the engine support insulator may occur.

    Install and tighten the RH engine mount through bolt.

    Torque: 258 lb.ft (350 Nm)

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    6-Speed Automatic Transmission - 6R100/6-Speed Automatic Transmission - 6R140 

20. NOTE: Only rotate the crankshaft in a clockwise direction.

    Install the new the torque converter nuts. Use the General Equipment: Magnetic Socket

    Torque: 26 lb.ft (35 Nm)

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21. Install the torque converter nut access cover.

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22. Install the transmission inspection plate and the bolts.

    Torque: 25 lb.ft (34 Nm)

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    5-Speed Manual Transmission - TR4050/6-Speed Automatic Transmission - 6R100/6-Speed Automatic Transmission - 6R140 

23. Install a new engine oil cooler and the retainer.

    Torque: 43 lb.ft (58 Nm)

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24. Connect the oil cooler coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer

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25. NOTE: Lubricate the oil filter gasket with clean engine oil.

    Install a new engine oil filter.

    Torque:

    Stage 1: 44 lb.in (5 Nm)

    Stage 2: 180 °

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26. If equipped with an engine block heater, position the wiring harness and connect the engine block heater electrical connector.

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27. Attach the starter motor wiring harness pin-type retainer to the oil pan.

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    6-Speed Automatic Transmission - 6R100/6-Speed Automatic Transmission - 6R140 

28. NOTE: The transmission support insulator-to-crossmember nuts must be discarded and new nuts installed, or damage to the vehicle or transmission support insulator may occur.

    Remove and discard the transmission support insulator nuts.

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29. • NOTE: The transmission support insulator studs may come out of the insulator while removing the nuts.

      If required, tighten transmission support insulator studs.

      Torque: 66 lb.ft (90 Nm)

    • If the transmission support insulator studs can not be tightened, the transmission support insulator must be replaced. Refer to: Transmission Support Insulator 6-Speed Automatic Transmission - 6R100 . Refer to: Transmission Support Insulator 6-Speed Automatic Transmission - 6R140 .
    • Install new transmission support insulator nuts.

      Torque: 85 lb.ft (115 Nm)

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30. Install the new LH catalytic converter pipe-to-manifold nuts.

    Torque: 30 lb.ft (40 Nm)

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31. Install the new RH catalytic converter pipe-to-manifold nuts.

    Torque: 30 lb.ft (40 Nm)

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32. Install the starter motor. Refer to: Starter Motor .
33. Install the RH HO2S. Refer to: Heated Oxygen Sensor (HO2S) .
34. Connect the LH HO2S wiring harness electrical connector.

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35. Install and lubricate the transmission fluid level indicator tube O-ring seal.

    Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON ® LV) (WSS-M2C938-A)

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36. 1. Install the transmission fluid level indicator tube and the bolts.

       Torque: 89 lb.in (10 Nm)

    2. Install the transmission fluid indicator.

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    5-Speed Manual Transmission - TR4050/6-Speed Automatic Transmission - 6R100/6-Speed Automatic Transmission - 6R140 

37. Position the engine wiring harness and connect the wiring harness electrical connector and the retainers.

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38. Connect the wiring harness electrical connector and the retainers.

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39. Connect the wiring harness electrical connectors and the retainer.

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40. Connect the wiring harness electrical connectors and the retainer.

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41. Connect the wiring harness electrical connectors and the retainers.

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42. Position the engine ground straps and install the nuts.

    Torque: 89 lb.in (10 Nm)

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43. Connect the oil pressure switch wiring harness electrical connector and the retainers.

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44. Connect the lower radiator hose to the block. Use the General Equipment: Hose Clamp Remover/Installer

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45. Position the power steering pump and install the bolts.

    Torque: 18 lb.ft (25 Nm)

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46. Install the power steering pump pressure line and the bolt.

    Torque: 18 lb.ft (25 Nm)

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47. Position the A/C compressor and install the bolts.

    Torque: 18 lb.ft (25 Nm)

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48. • Install the starter motor wiring harness bracket.
    • If equipped with automatic transmission, install the transmission cooler lines bracket.
    • Install the nut.

      Torque: 18 lb.ft (25 Nm)

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49. Connect the A/C compressor electrical connector and attach the wiring harness retainers.

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50. Connect the A/C pressure switch wiring harness electrical connector.

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51. NOTE: Primary battery vehicles shown, secondary battery vehicles similar.

    Attach the generator wiring harness pin-type retainers.

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52. Install and lubricate the coolant tube O-ring seal.

    Material: Motorcraft ® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

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53. Install and lubricate the coolant tube O-ring seal.

    Material: Motorcraft ® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

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54. Position the coolant tubes and install the bolts.

    Torque: 89 lb.in (10 Nm)

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55. Using the special tools, install the cooling fan. Use Special Service Tool: 303-478 (T94T-6312-AH) Holding Wrench, Fan Clutch Pulley., 303-214 (T83T-6312-B) Wrench, Fan Clutch Nut. Use the General Equipment: 1/2 Inch Square Drive Breaker Bar

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56. • Install the cooling fan wiring harness support bracket nut.

      Torque: 177 lb.in (20 Nm)

    • Connect the cooling fan wiring harness electrical connector.

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    5-Speed Manual Transmission - TR4050 

57. 5-Speed Manual Transmission - TR4050/6-Speed Automatic Transmission - 6R100/6-Speed Automatic Transmission - 6R140 

58. Install the PCV tube and attach the retainer. Refer to: Quick Release Coupling .

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59. Install the crankcase vent tube. Refer to: Quick Release Coupling .

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60. Install the following items:
    1. Install the air cleaner. Refer to: Air Cleaner .
    2. Install the cooling module. Refer to: Cooling Module .
    3. Install the intake manifold. Refer to: Intake Manifold .
    4. Install the accessory drive belt. Refer to: Accessory Drive Belt .
    5. Install the cowl panel. Refer to: Cowl Panel .

61. Fill the engine with clean engine oil. Refer to: Specifications .

    Material: Motorcraft ® SAE 5W-30 Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

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62. Fill and bleed the cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding .
63. If equipped with an automatic transmission, check the transmission fluid.
    • 6R100 Refer to: Transmission Fluid Level Check .
    • 6R140 Refer to: Transmission Fluid Level Check .

64. Fill the power steering system. Refer to: Power Steering System Filling .
65. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.