Section 1848 (Engine Mechanical - 3.5L): Installation: Engine

	2, 200# Floor Crane, Fold Away 300-OTC1819E
	Adjustable Grip Arm, 1735A 014-00001
	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 5 transaxle-to-engine bolts.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 1: Locating 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: Locating Engine-To-Transaxle Bolts

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

   Courtesy of FORD MOTOR CO.
NOTE: Position a block of wood under the transaxle.
Fig 4: Identifying Powertrain Lift And Adjustable Grip Arms
Courtesy of FORD MOTOR CO.
5. Install the Powertrain Lift and Adjustable Grip Arms.
6. Install the starter, the bolt and the stud bolt.
   • Tighten to 27 Nm (20 lb-ft).
     Fig 5: Locating Bolt, Stud Bolt And Starter

     Courtesy of FORD MOTOR CO.
7. Connect the wiring harness retainer to the starter stud bolt.
   Fig 6: Locating Wiring Harness Retainer At Starter Motor Stud Bolt

   Courtesy of FORD MOTOR CO.
8. Attach the starter motor wire terminals and install the 2 nuts.
   1. Tighten the starter B+ terminal nut to 12 Nm (106 lb-in).
   2. Tighten the starter S-terminal nut to 5 Nm (44 lb-in).
      • Position the starter terminal boot over the starter terminal.
        Fig 7: Identifying Starter B+ Terminal Nut And Starter S-Terminal Nut

        Courtesy of FORD MOTOR CO.
9. Connect the transmission control electrical connector.
   • Attach the wiring harness retainer.
     Fig 8: Locating Transmission Control Electrical Connector And Retainer

     Courtesy of FORD MOTOR CO.
NOTE: Do not separate the fuel and vapor tube assembly clip from the transaxle case stud. Failure to follow these instructions can result in damage to the fuel and vapor tube assembly.
Fig 9: Locating Fuel Supply Tube
Courtesy of FORD MOTOR CO.
10. Connect the fuel supply tube. For additional information, refer to the quick connect coupling procedure in FUEL SYSTEM - GENERAL INFORMATION .
11. Connect the EVAP tube quick connect coupling to the purge valve. For additional information, refer to the quick connect coupling procedure in FUEL SYSTEM - GENERAL INFORMATION .
    • Attach the EVAP tube retainer.
      Fig 10: Locating EVAP Tube Retainer

      Courtesy of FORD MOTOR CO.
12. Raise the engine and transaxle assembly into the vehicle.
13. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 11: Locating Engine Mount Bolts

      Courtesy of FORD MOTOR CO.
14. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
      Fig 12: Locating Engine Mount Nuts

      Courtesy of FORD MOTOR CO.
15. Install the engine mount brace, the nut and the bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 13: Locating Nut, Bolt And Engine Mount Brace

      Courtesy of FORD MOTOR CO.
16. Install the transaxle support insulator bracket, the 3 nuts and the bolt.
    1. Tighten the bolt to 80 Nm (59 lb-ft).
    2. Tighten the 3 nuts to 63 Nm (46 lb-ft).
       Fig 14: Identifying Transaxle Support Insulator Bracket Nuts And Bolt

       Courtesy of FORD MOTOR CO.
17. Install the transaxle support insulator through bolt and nut.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 15: Locating Transaxle Support Insulator Through Bolt And Nut

      Courtesy of FORD MOTOR CO.
NOTE: The fuel and vapor tube assembly clip must remain attached to the transaxle case stud during engine removal. Failure to follow these instructions can result in damage to the fuel and vapor tube assembly.
Fig 16: Locating Fuel Supply Tube And Evaporative Emission Tube Quick Connect Couplings
Courtesy of FORD MOTOR CO.
18. Connect the fuel supply tube and Evaporative Emission (EVAP) tube quick connect couplings. For additional information, refer to the quick connect coupling procedure in FUEL SYSTEM - GENERAL INFORMATION .

    All-Wheel Drive (AWD) vehicles 

NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is removed from the vehicle.
Fig 17: Removing Compression Seal Using Small Screwdriver
Courtesy of FORD MOTOR CO.
19. Using a small screwdriver, remove the compression seal and discard.
20. Using a soft-face hammer, install the new compression seal.
    Fig 18: Identifying Compression Seal

    Courtesy of FORD MOTOR CO.
21. Position the PTU in place and install the 5 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 19: Locating PTU Bolts

      Courtesy of FORD MOTOR CO.
22. Position the PTU support bracket in place and install the 5 bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 20: Locating Bolts And Power Transfer Unit Support Bracket

      Courtesy of FORD MOTOR CO.
23. Using a new gasket, install the RH catalytic converter and 4 new nuts (3 shown in illustration).
    • Tighten to 40 Nm (30 lb-ft).
      Fig 21: Locating Nuts And RH Catalytic Converter

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

    Courtesy of FORD MOTOR CO.

    All vehicles 

NOTE: Align the reference marks on the subframe and underbody that were made during the removal of the subframe.
Fig 23: Positioning Powertrain Lift Under Subframe Assembly
Courtesy of FORD MOTOR CO.
25. Using the Powertrain Lift, raise the subframe into the installed position.
26. Install the 2 middle subframe nuts.
    • Tighten to 133 Nm (98 lb-ft).
      Fig 24: Locating Middle Subframe Nuts

      Courtesy of FORD MOTOR CO.
27. Install the 2 front subframe nuts.
    • Tighten to 133 Nm (98 lb-ft).
      Fig 25: Locating Front Subframe Nuts

      Courtesy of FORD MOTOR CO.
28. Position the subframe support brackets in place and loosely install the 2 bolts and 2 nuts.
    Fig 26: Locating Nuts, Bolts And Subframe Support Brackets

    Courtesy of FORD MOTOR CO.
29. Position the subframe brace and loosely install the 2 bolts.
    Fig 27: Locating Bolts And Subframe Brace

    Courtesy of FORD MOTOR CO.
30. Tighten the 2 rear subframe bracket nuts to 133 Nm (98 lb-ft).
    Fig 28: Locating Rear Subframe Bracket Nuts

    Courtesy of FORD MOTOR CO.
31. Tighten the 4 bolts to 90 Nm (66 lb-ft).
    Fig 29: Locating Subframe Brace Bolts

    Courtesy of FORD MOTOR CO.
32. Position the lower bumper on the subframe and install the 3 LH nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 30: Locating LH Subframe-To-Lower Bumper Nuts

      Courtesy of FORD MOTOR CO.
33. Install the 3 RH lower bumper-to-subframe nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 31: Locating RH Subframe-To-Lower Bumper Nuts

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
34. Install the tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install new cotter pins.
      Fig 32: Locating Tie-Rod Ends Nut And Cotter Pin

      Courtesy of FORD MOTOR CO.
NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM .
35. Install the intermediate shaft onto the steering gear and install a new bolt.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 33: Locating Intermediate Shaft And Bolt

      Courtesy of FORD MOTOR CO.
36. Using a new banjo bolt and 2 new seals, install the Power Steering Pressure (PSP) tube.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 34: Locating Power Steering Pressure Tube-To-Steering Gear Banjo Bolt And Seals

      Courtesy of FORD MOTOR CO.
37. Install the engine roll restrictor-to-subframe through bolt.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 35: Locating Engine Roll Restrictor-To-Subframe Through Bolt

      Courtesy of FORD MOTOR CO.
38. Install the roll restrictor heat shield and the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 36: Locating Roll Restrictor Heat Shield And Nuts

      Courtesy of FORD MOTOR CO.

    AWD vehicles 

39. 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).
      Fig 37: Locating Driveshaft Bolts

      Courtesy of FORD MOTOR CO.

    All vehicles 

40. Install the power steering cooler bracket bolt to the RH side of the subframe.
    • Tighten to 9 Nm (80 lb-in).
      Fig 38: Locating Power Steering Cooler Bracket Bolt

      Courtesy of FORD MOTOR CO.
41. Connect the power steering cooler hose.
    Fig 39: Locating Power Steering Cooler Hose

    Courtesy of FORD MOTOR CO.
NOTE: Do not lubricate the oil filter gasket.
42. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
      Fig 40: Locating Engine Oil Filter

      Courtesy of FORD MOTOR CO.
43. Install the 3 new torque converter bolts.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 41: Locating Torque Converter Bolts

      Courtesy of FORD MOTOR CO.
44. Install the inspection cover and the 2 fasteners.
    Fig 42: Locating Fasteners And Inspection Cover

    Courtesy of FORD MOTOR CO.
45. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 43: Locating Oil Pan-To-Transaxle Bolts

      Courtesy of FORD MOTOR CO.
46. Connect the 2 transmission fluid cooler tubes.
    Fig 44: Locating Transmission Fluid Cooler Tubes

    Courtesy of FORD MOTOR CO.
47. Install the 2 secondary latches onto the transmission fluid cooler tubes.
    Fig 45: Locating Transmission Fluid Cooler Tubes Secondary Latches

    Courtesy of FORD MOTOR CO.
48. Install the LH inner splash shield. For additional information, refer to FRONT END BODY PANELS .
49. Install the exhaust Y-pipe. For additional information, refer to EXHAUST SYSTEM .
50. Install the radio interference capacitor wire and the nut to the engine front cover stud.
    • Tighten to 10 Nm (89 lb-in).
      Fig 46: Locating Nut And Radio Interference Capacitor Wire On Engine Front Cover Stud

      Courtesy of FORD MOTOR CO.
51. Install the ground wire and bolt to the engine front cover.
    • Tighten to 10 Nm (89 lb-in).
      Fig 47: Locating Bolt And Ground Wire On Engine Front Cover

      Courtesy of FORD MOTOR CO.
52. Install the oil level indicator.
    Fig 48: Identifying Oil Level Indicator

    Courtesy of FORD MOTOR CO.
53. Connect the wiring harness electrical connector.
    • Attach the wiring harness retainer to the RH valve cover stud bolt.
      Fig 49: Locating Wiring Harness Electrical Connector And Retainer

      Courtesy of FORD MOTOR CO.
54. Connect the 2 PCM electrical connectors.
    • Attach the 2 wiring harness retainers to the stud bolts.
      Fig 50: Locating PCM Electrical Connectors And Wiring Harness Retainers

      Courtesy of FORD MOTOR CO.
55. Connect the hose to the power steering reservoir.
    Fig 51: Locating Power Steering Reservoir Hose

    Courtesy of FORD MOTOR CO.
56. Connect the A/C suction tube fitting.
    • Install the safety clip onto the A/C fitting.
      Fig 52: Locating Safety Clip And A/C Suction Tube Fitting

      Courtesy of FORD MOTOR CO.
57. Using a new O-ring seal, connect the A/C tube fitting and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 53: Locating Nut And A/C Pressure Tube Fitting

      Courtesy of FORD MOTOR CO.
58. If equipped, attach the engine block heater harness retainers to the radiator support and the A/C suction tube.
    Fig 54: Locating Engine Block Heater Harness, Radiator Support, A/C Suction Tube And Engine Wiring Harness

    Courtesy of FORD MOTOR CO.
59. Attach the control cable to the bracket.
    • Connect the transaxle control cable to the control lever.
      Fig 55: Locating Transaxle Control Cable And Control Lever

      Courtesy of FORD MOTOR CO.
60. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
    Fig 56: Locating Upper Radiator Hose, Lower Radiator Hose And Heater Hoses Of Thermostat Housing

    Courtesy of FORD MOTOR CO.
61. Connect the vacuum hose to the upper intake manifold.
    Fig 57: Locating Vacuum Hose Of Upper Intake Manifold

    Courtesy of FORD MOTOR CO.
62. Attach the 3 wiring harness retainers to the bracket and inner fender.
    Fig 58: Locating Wiring Harness Retainers Of Bracket And Inner Fender

    Courtesy of FORD MOTOR CO.
63. Connect the wiring harness electrical connector.
    Fig 59: Locating Wiring Harness Electrical Connector

    Courtesy of FORD MOTOR CO.
64. Attach the 2 wiring harness retainers to the stud bolt and bracket.
    Fig 60: Locating Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
65. Install the ground wire and bolt.
    • Tighten to 10 Nm (89 lb-in).
    • Connect the wiring harness electrical connector.
      Fig 61: Locating Ground Wire Nut And Wiring Harness Electrical Connector

      Courtesy of FORD MOTOR CO.
66. Connect the power feed to the battery terminal and install the 2 nuts.
    • Tighten to 8 Nm (71 lb-in).
    • Connect the wiring harness electrical connector.
      Fig 62: Locating Power Feed Nuts And Wiring Harness Electrical Connector

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