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Engine - 3.9L: Installation: Engine: Material

MATERIAL CHART

Item Specification
Super Premium SAE 5W-20
XO-5W20-QSP Or Equivalent		 WSS-M2C153-H
  1. Install the special tool.
    Fig 1: Installing Special Tool
    G03421917Courtesy of FORD MOTOR CO.
  2. Install the special tool.
    Fig 2: Installing Special Tool
    G03421918Courtesy of FORD MOTOR CO.
  3. Using a floor crane and a spreader bar (303-D089) to support the engine, remove the engine from the engine stand.
    4. NOTE: Align the flexplate to converter marks made at removal.
    Fig 3: Installing Transmission-To-Engine Bolts
    G03421919Courtesy of FORD MOTOR CO.
  4. Install the engine to the transmission and install the bolts.
  5. Install the transmission wiring harness.
    Fig 4: Installing Transmission Wiring Harness
    G03421920Courtesy of FORD MOTOR CO.
  6. Using a floor crane and the special tool, install the engine onto the subframe.
    Fig 5: Installing Engine Onto Subframe
    G03421921Courtesy of FORD MOTOR CO.
    7. NOTE: LH shown; RH similar.
    Fig 6: Installing Upper Engine Mounts
    G03421922Courtesy of FORD MOTOR CO.
  7. Install the LH and the RH upper engine mounts.
  8. Remove the engine lifting equipment.
  9. Remove the special tool.
    Fig 7: Removing Special Tool
    G03421923Courtesy of FORD MOTOR CO.
  10. Remove the special tool.
    Fig 8: Removing Special Tool
    G03421924Courtesy of FORD MOTOR CO.
  11. Install a new nylon O-ring seal on the hydraulic fan high pressure line.
    Fig 9: Installing O-Ring Seal On Hydraulic Fan High Pressure Line
    G03421925Courtesy of FORD MOTOR CO.
  12. Install the hydraulic fan pump high pressure line and install the hydraulic fan high pressure line bracket bolt.
    Fig 10: Installing Hydraulic Fan Pump High Pressure Line
    G03421926Courtesy of FORD MOTOR CO.
  13. Install a new nylon O-ring seal on the high pressure power steering line.
    Fig 11: Installing O-Ring Seal On High Pressure Power Steering Line
    G03421927Courtesy of FORD MOTOR CO.
  14. Install the power steering high pressure line and power steering high pressure line bracket bolt.
    Fig 12: Installing Power Steering High Pressure Line
    G03421928Courtesy of FORD MOTOR CO.
  15. Connect the transmission cooler lines.
    Fig 13: Connecting Transmission Cooler Lines
    G03421929Courtesy of FORD MOTOR CO.
  16. Install the transmission cooler line bracket.
    Fig 14: Installing Transmission Cooler Line Bracket
    G03421930Courtesy of FORD MOTOR CO.
  17. Connect heater hose.
    Fig 15: Connecting Heater Hose
    G03421931Courtesy of FORD MOTOR CO.
  18. Connect the KS electrical connector.
    Fig 16: Connecting KS Electrical Connector
    G03421932Courtesy of FORD MOTOR CO.
  19. Connect the radiator hoses.
    Fig 17: Connecting Radiator Hoses
    G03421933Courtesy of FORD MOTOR CO.
  20. Install the lower radiator hose.
    Fig 18: Installing Lower Radiator Hose
    G03421934Courtesy of FORD MOTOR CO.
  21. Install the bracket.
    Fig 19: Installing Bracket
    G03421935Courtesy of FORD MOTOR CO.
  22. Connect the A/C manifold and tube.
    Fig 20: Connecting A/C Manifold & Tube
    G03421936Courtesy of FORD MOTOR CO.
  23. Connect the block heater, if equipped.
    Fig 21: Connecting Block Heater Electrical Connector
    G03421937Courtesy of FORD MOTOR CO.
  24. Using the powertrain lift and the transmission support bracket, carefully raise the entire assembly into the vehicle.
    Fig 22: Identifying Powertrain Lift
    G03421938Courtesy of FORD MOTOR CO.
  25. Install the four front and the four center crossmember bolts.
    Fig 23: Installing Four Center Crossmember Bolts
    G03421939Courtesy of FORD MOTOR CO.
  26. Install the transmission crossmember bolts.
    Fig 24: Installing Transmission Crossmember Bolts
    G03421940Courtesy of FORD MOTOR CO.
  27. Install the engine crossmember.
    Fig 25: Installing Engine Crossmember
    G03421941Courtesy of FORD MOTOR CO.
  28. Remove the safety stands from the rear of the vehicle.
  29. Install the engine block heater plug, if equipped.
    Fig 26: Installing Engine Block Heater Plug
    G03421942Courtesy of FORD MOTOR CO.
  30. Install the inner air deflector.
    Fig 27: Installing Inner Air Deflector
    G03421943Courtesy of FORD MOTOR CO.
  31. Install the eight torque converter nuts.
    Fig 28: Installing Torque Converter Nuts
    G03421944Courtesy of FORD MOTOR CO.
  32. Install the cover.
    Fig 29: Installing Cover
    G03421945Courtesy of FORD MOTOR CO.
  33. Install the six lower transmission to engine bolts.
    Fig 30: Installing Lower Transmission-To-Engine Bolts
    G03421946Courtesy of FORD MOTOR CO.
  34. Install the Three-Way Catalytic (TWC) converter. .
  35. Connect the generator electrical cable.
    Fig 31: Connecting Generator Electrical Cable
    G03421947Courtesy of FORD MOTOR CO.
  36. Connect the starter motor electrical connectors.
    Fig 32: Connecting Starter Motor Electrical Connectors
    G03421948Courtesy of FORD MOTOR CO.
  37. Install the cover.
    Fig 33: Installing Starter Motor Electrical Connector Cover
    G03421949Courtesy of FORD MOTOR CO.
  38. Install the starter motor ground cable.
    Fig 34: Installing Starter Motor Ground Cable
    G03421950Courtesy of FORD MOTOR CO.
  39. Connect the steering coupling.
    Fig 35: Connecting Steering Coupling
    G03421951Courtesy of FORD MOTOR CO.
  40. Install the steering shaft bolt.
    Fig 36: Installing Steering Shaft Bolt
    G03421952Courtesy of FORD MOTOR CO.
  41. Connect the rack and pinion steering unit electrical connectors and install a tie-strap.
    Fig 37: Connecting Rack & Pinion Steering Unit Electrical Connectors
    G03421953Courtesy of FORD MOTOR CO.
  42. Install the retaining bolt for the high pressure power steering line bracket.
    Fig 38: Installing High Pressure Power Steering Line Bracket Retaining Bolt
    G03421954Courtesy of FORD MOTOR CO.
  43. Install the hydraulic cooling fan return line to the RH frame rail.
    Fig 39: Installing Hydraulic Cooling Fan Return Line
    G03421955Courtesy of FORD MOTOR CO.
  44. Install the shift cable bracket.
    Fig 40: Installing Shift Cable Bracket
    G03421956Courtesy of FORD MOTOR CO.
  45. Reclip the shift cable to the bracket.
    Fig 41: Clipping Shift Cable To Bracket
    G03421957Courtesy of FORD MOTOR CO.
  46. Connect the shift cable to the shifter.
    Fig 42: Connecting Shift Cable To Shifter
    G03421958Courtesy of FORD MOTOR CO.
  47. Install the driveshaft. For additional information, refer to DRIVE SHAFTS .
  48. Connect the A/C low pressure line.
    Fig 43: Connecting A/C Low Pressure Line
    G03421959Courtesy of FORD MOTOR CO.
  49. Connect the A/C high pressure line.
    Fig 44: Connecting A/C High Pressure Line
    G03421960Courtesy of FORD MOTOR CO.
  50. Install the center splash shield.
    Fig 45: Installing Center Splash Shield
    G03421961Courtesy of FORD MOTOR CO.
    51. NOTE: LH shown; RH similar.
    Fig 46: Installing Splash Shields
    G03421962Courtesy of FORD MOTOR CO.
  51. Install the LH and the RH splash shields.
    52. NOTE: LH shown; RH similar.
    Fig 47: Installing Lower Strut Mount Bolts
    G03421963Courtesy of FORD MOTOR CO.
  52. Install the LH and the RH lower strut mount bolts.
    53. NOTE: LH shown; RH similar.
    Fig 48: Installing Ball Joints To Spindles
    G03421964Courtesy of FORD MOTOR CO.
  53. Install the LH and the RH ball joints to the spindles and install the nuts.
    54. NOTE: LH shown; RH similar.
    Fig 49: Installing Sway Bar Lower Nuts
    G03421965Courtesy of FORD MOTOR CO.
  54. Install the LH and the RH sway bar lower nuts.
    55. NOTE: LH shown; RH similar.
    Fig 50: Installing Brake Calipers
    G03421966Courtesy of FORD MOTOR CO.
  55. Install the LH and the RH brake calipers.
    56. NOTE: LH shown; RH similar.
    Fig 51: Installing Anti-Lock Brake Sensor Harness
    G03421967Courtesy of FORD MOTOR CO.
  56. Position the LH and the RH anti-lock brake sensor harness and reclip to the brake hoses.
    57. NOTE: LH shown; RH similar.
    Fig 52: Connecting Anti-Lock Brake Sensor Electrical Connectors
    G03421968Courtesy of FORD MOTOR CO.
  57. Connect the LH and the RH anti-lock brake sensor electrical connectors.
    58. NOTE: LH shown; RH similar.
    Fig 53: Installing Inner Splash Shields
    G03421969Courtesy of FORD MOTOR CO.
  58. Install the LH and the RH inner splash shields.
  59. Install the front wheels and tires.
  60. Clip the harness to the radiator support and connect the water valve electrical connector.
    Fig 54: Connecting Water Valve Electrical Connector
    G03421970Courtesy of FORD MOTOR CO.
    61. NOTE: Install the two hoses to the marks made during removal.
    Fig 55: Connecting Hoses To Water Control Valve
    G03421971Courtesy of FORD MOTOR CO.
  61. Connect the hoses to the water control valve.
  62. Connect the cooling fan hoses and install the hydraulic cooling fan reservoir.
    Fig 56: Installing Hydraulic Cooling Fan Reservoir
    G03421972Courtesy of FORD MOTOR CO.
  63. Connect the connectors.
    Fig 57: Connecting Connectors
    G03421973Courtesy of FORD MOTOR CO.
  64. Install the fresh air filter panel.
    1. Position the panel.
    2. Install the nuts.
    3. Install the pin-type retainer.
    Fig 58: Installing Fresh Air Filter Panel
    G03421974Courtesy of FORD MOTOR CO.
    65. NOTE: The connectors are located on the backside of the RH strut tower.
    Fig 59: Connecting Powertrain Bulkhead Electrical Connectors
    G03421975Courtesy of FORD MOTOR CO.
  65. Connect the powertrain bulkhead electrical connectors.
  66. Install the fresh air filter housing.
    Fig 60: Installing Fresh Air Filter Housing
    G03421976Courtesy of FORD MOTOR CO.
  67. Install the fresh air filter.
    Fig 61: Installing Fresh Air Filter
    G03421977Courtesy of FORD MOTOR CO.
  68. Connect the ground strap.
    Fig 62: Connecting Ground Strap
    G03421978Courtesy of FORD MOTOR CO.
  69. Connect the accelerator cable and the speed control cable.
    Fig 63: Connecting Accelerator Cable
    G03421979Courtesy of FORD MOTOR CO.
  70. Connect the degas bottle hose.
    Fig 64: Connecting Degas Bottle Hose
    G03421980Courtesy of FORD MOTOR CO.
  71. Install the bracket.
    1. Install the bracket.
    2. Install the seven bolts and one nut.
    3. Install the windshield washer hose.
    Fig 65: Installing Bracket
    G03421981Courtesy of FORD MOTOR CO.
  72. Reclip the hose.
    Fig 66: Recliping Hose
    G03421982Courtesy of FORD MOTOR CO.
  73. Install the cowl vent screen. For additional information, refer to FRONT END BODY PANELS .
  74. Connect the main vacuum supply hose.
    Fig 67: Connecting Main Vacuum Supply Hose
    G03421983Courtesy of FORD MOTOR CO.
  75. Connect the VMV.
    • Vacuum hose.
    • Canister purge valve.
    Fig 68: Connecting VMV
    G03421984Courtesy of FORD MOTOR CO.
  76. Install the VMV cover.
    Fig 69: Installing VMV Cover
    G03421985Courtesy of FORD MOTOR CO.
  77. Connect the fuel line. For additional information, refer to FUEL SYSTEM .
  78. Connect the power steering pump reservoir hoses and install the power steering pump reservoir.
    Fig 70: Connecting Power Steering Pump Reservoir Hoses
    G03421986Courtesy of FORD MOTOR CO.
  79. Attach the power steering return line to the brake lines.
    Fig 71: Attaching Power Steering Return Line To Brake Lines
    G03421987Courtesy of FORD MOTOR CO.
  80. Connect the A/C pressure switch electrical connector.
    Fig 72: Connecting A/C Pressure Switch Electrical Connector
    G03421988Courtesy of FORD MOTOR CO.
  81. Install the two upper radiator support brackets.
    Fig 73: Installing Upper Radiator Support Brackets
    G03421989Courtesy of FORD MOTOR CO.
  82. Install the upper radiator sight shield.
    Fig 74: Installing Upper Radiator Sight Shield
    G03421990Courtesy of FORD MOTOR CO.
  83. Fill the engine with clean engine oil.
  84. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  85. Install the air cleaner assembly and outlet pipe.
    86. CAUTION: The cooling system filling and bleeding procedure must be followed exactly or damage to the engine may occur.
  86. Fill the engine cooling system. For additional information, refer to ENGINE COOLING .
  87. Fill the power steering reservoir to the correct level. For additional information, refer to POWER STEERING .
  88. Fill and bleed the hydraulic cooling fan. For additional information, refer to ENGINE COOLING .
  89. Charge the A/C system. For additional information, refer to GENERAL SERVICING PROCEDURES .
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