FixVault
Home › Ford › 2003 › ZX2 Standard › Repair and Diagnosis › External Pages › Different car › Section 593 (Engine - 4.0L) › Installation › Engine › Installation

Section 593 (Engine - 4.0L): Installation: Engine: Installation

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles 

CAUTION: If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold.
  1. Position the engine in the vehicle and remove the floor crane and the special tool.
    Fig 1: Removing Floor Crane And Special Tool
    G03180960Courtesy of FORD MOTOR CO.
  2. Install the RH engine support insulator nuts.
    Fig 2: Installing RH Engine Support Insulator Nuts
    G03180961Courtesy of FORD MOTOR CO.
  3. Install the radiator and A/C condenser as an assembly.
    Fig 3: Installing Radiator And A/C Condenser As An Assembly
    G03180962Courtesy of FORD MOTOR CO.
  4. Install the RH radiator support bracket and the two bolts.
    Fig 4: Installing RH Radiator Support Bracket
    G03180963Courtesy of FORD MOTOR CO.
  5. Install the LH radiator support bracket and the two bolts.
    Fig 5: Installing LH Radiator Support Bracket
    G03180964Courtesy of FORD MOTOR CO.
  6. Remove the right front lifting bracket.
    Fig 6: Removing Right Front Lifting Bracket
    G03180965Courtesy of FORD MOTOR CO.
  7. Remove the left side lifting bracket.
    Fig 7: Removing Left Side Lifting Bracket
    G03180966Courtesy of FORD MOTOR CO.
  8. Using the special tool, install a new seal on the power steering pressure (PSP) hose fitting.
    Fig 8: Installing A New Seal On Power Steering Pressure (PSP) Hose Fitting
    G03180967Courtesy of FORD MOTOR CO.
  9. Connect the PSP hose to the power steering pump.
    Fig 9: Connecting PSP Hose To Power Steering Pump
    G03180968Courtesy of FORD MOTOR CO.
  10. Install the PSP hose support bracket and the bolt.
    Fig 10: Installing PSP Hose Support Bracket And Bolt
    G03180969Courtesy of FORD MOTOR CO.
  11. Raise and support the vehicle. For additional information, refer to JACKING & LIFTING .
  12. Install the LH engine support insulator bolt.
    Fig 11: Installing LH Engine Support Insulator Bolt
    G03180970Courtesy of FORD MOTOR CO.
  13. Connect the return hose to the power steering pump.
    Fig 12: Connecting Return Hose
    G03180971Courtesy of FORD MOTOR CO.
  14. Remove the special tool.
    Fig 13: Removing Special Tool
    G03180972Courtesy of FORD MOTOR CO.
    15. NOTE: Make sure the stud and the flexplate marks made during removal line up.
    Fig 14: Positioning Transmission In Vehicle
    G03180973Courtesy of FORD MOTOR CO.
  15. Position the transmission in the vehicle.
  16. Install the eight engine-to-transmission retaining bolts.
    Fig 15: Installing Eight Engine-To-Transmission Retaining Bolts
    G03180974Courtesy of FORD MOTOR CO.
  17. Install the cooler tubes, cooler tube bracket and the nut.
    Fig 16: Installing Cooler Tubes Cooler Tube Bracket
    G03180975Courtesy of FORD MOTOR CO.
  18. Connect the transmission cooler tubes.
    Fig 17: Connecting Transmission Cooler Tubes
    G03180976Courtesy of FORD MOTOR CO.
    19. CAUTION: Use care not to bend or force the transmission cooler tubes. Damage to the tubes or the transmission can occur. Use a wrench to hold the fittings mounted in the transmission.
    Fig 18: Connecting Cooler Tubes To Transmission
    G03180977Courtesy of FORD MOTOR CO.
  19. Connect the cooler tubes to the transmission.
  20. Connect the harness retainers.
    Fig 19: Connecting Harness Retainers
    G03180978Courtesy of FORD MOTOR CO.
    21. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification.
    NOTE: Always install new O-ring seals on the vehicle harness connector.
    NOTE: Clean the area around the connector to prevent contamination of the solenoid body connector.
    NOTE: Use petroleum jelly to lubricate the O-ring seals to aid the installation process.
    Fig 20: Installing Transmission Body Electrical Connector
    G03180979Courtesy of FORD MOTOR CO.
  21. Lubricate and install new O-ring seals on the transmission body electrical connector, connect the electrical connector, and tighten the screw.
  22. Connect the electrical connectors.
    Fig 21: Connecting Electrical Connectors
    G03180980Courtesy of FORD MOTOR CO.
  23. Connect the digital transmission range sensor.
    Fig 22: Connecting Digital Transmission Range Sensor
    G03180981Courtesy of FORD MOTOR CO.
  24. Move the rubber boot back into position.
    Fig 23: Moving Rubber Boot Back Into Position
    G03180982Courtesy of FORD MOTOR CO.
    25. NOTE: Match the identifying mark on the nut, stud and flexplate to allow for correct installation.
    Fig 24: Installing Four Torque Converter Nuts
    G03180983Courtesy of FORD MOTOR CO.
  25. Install the four torque converter nuts.
    • Rotate the crankshaft to access all the nuts.
  26. Connect the LH catalyst monitor connector to the transmission.
    Fig 25: Connecting LH Catalyst Monitor Connector To Transmission
    G03180984Courtesy of FORD MOTOR CO.
  27. Connect the LH heated oxygen sensor (HO2S) electrical connector retainer and the harness clip to the transmission.
    Fig 26: Connecting LH Heated Oxygen Sensor (HO2S) Electrical Connector Retainer
    G03180985Courtesy of FORD MOTOR CO.
  28. If equipped, connect the shift motor electrical connector.
    Fig 27: Connecting Shift Motor Electrical Connector
    G03180986Courtesy of FORD MOTOR CO.
  29. Connect the RH HO2S electrical connector to the transmission.
    Fig 28: Connecting RH HO2S Electrical Connector To Transmission
    G03180987Courtesy of FORD MOTOR CO.
  30. Connect the RH catalyst monitor connector and the fuel tubes to the bracket.
    Fig 29: Connecting RH Catalyst Monitor Connector And Fuel Tubes To Bracket
    G03180988Courtesy of FORD MOTOR CO.
    31. CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with threadlock and sealer.
    CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in the sequence shown.
    NOTE: Align the marks made on the flange and driveshaft during removal.
    NOTE: On 2-wheel drive vehicles, align the marks on the transmission output shaft.
    Fig 30: Positioning Driveshaft And Install Driveshaft-To-Pinion Flange Bolts
    G03180989Courtesy of FORD MOTOR CO.
  31. Position the driveshaft and install the driveshaft-to-pinion flange bolts in the sequence shown.

    32. 4x4 vehicles 

    CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with threadlock and sealer.
    CAUTION: The driveshaft flange fits tightly on the transfer case flange. To make sure that the driveshaft flange seats squarely on the transfer case flange, tighten the bolts evenly in a criss-cross pattern.
    NOTE: Align the marks made on the flange and driveshaft during removal.
    Fig 31: Installing Rear Driveshaft-To-Transfer Case Flange Bolts
    G03180990Courtesy of FORD MOTOR CO.
  32. Install the rear driveshaft-to-transfer case flange bolts.
    33. NOTE: Install new flange bolts and washers.
    Fig 32: Installing Retaining Bolts Finger-Tight
    G03180991Courtesy of FORD MOTOR CO.
  33. Position the front driveshaft flange with the location marks aligned and install the retaining bolts finger-tight.
    34. NOTE: Use new bolts and U-joint straps.
    Fig 33: Installing Front Driveshaft To Front Differential
    G03180992Courtesy of FORD MOTOR CO.
  34. Install the front driveshaft to the front differential.
  35. Tighten the front driveshaft flange bolts in the sequence shown.
    Fig 34: Tightening Front Driveshaft Flange Bolts
    G03180993Courtesy of FORD MOTOR CO.

    36. All vehicles 

  36. Position the manual shift lever into PARK.
    Fig 35: Positioning Manual Shift Lever Into Park
    G03180994Courtesy of FORD MOTOR CO.
  37. Install the bracket and connect the shift cable.
    Fig 36: Installing Bracket And Connect Shift Cable
    G03180995Courtesy of FORD MOTOR CO.

    38. 4x4 vehicles 

  38. Support the transfer case with a suitable jack stand and remove the transmission jack.
    Fig 37: Removing Transmission Jack
    G03180996Courtesy of FORD MOTOR CO.
  39. Disconnect the safety chain and remove the transmission jack.
    Fig 38: Disconnecting Safety Chain And Remove Transmission Jack
    G03180997Courtesy of FORD MOTOR CO.

    40. All vehicles 

    NOTE: The assistance of another technician may be required.
    Fig 39: Installing Transmission-Mounted Exhaust Hanger
    G03180998Courtesy of FORD MOTOR CO.
  40. Position the transmission-mounted exhaust hanger, the three-way converter system and RH heat shield.
    • Install the bolt and the converter assembly.
    • If required, install the second bolt and mount.
    41. NOTE: LH shown, RH similar.
    Fig 40: Installing Four Converter-To-Manifold Nuts
    G03180999Courtesy of FORD MOTOR CO.
  41. Install the four converter-to-manifold nuts.
    42. NOTE: Use a new gasket and new flag nuts.
    Fig 41: Connecting Muffler To Converter And Install Bolts
    G03181000Courtesy of FORD MOTOR CO.
  42. Connect the muffler to the converter and install the bolts, springs and flag nuts.
    43. NOTE: RH shown, LH similar.
    Fig 42: Installing Crossmember And Four Lower Bolts
    G03181001Courtesy of FORD MOTOR CO.
  43. Install the crossmember and the four lower bolts.
    44. NOTE: RH shown, LH similar.
    Fig 43: Installing Upper Crossmember Bolts
    G03181002Courtesy of FORD MOTOR CO.
  44. Install the four upper crossmember bolts.

    45. 4x2 vehicles 

  45. Remove the transmission jack from the transmission.
    Fig 44: Removing Transmission Jack From Transmission
    G03181003Courtesy of FORD MOTOR CO.
  46. Install the cable bracket and the bolts to the transmission.
    Fig 45: Installing Cable Bracket And Bolts To Transmission
    G03181004Courtesy of FORD MOTOR CO.

    47. 4x4 vehicles 

  47. Remove the jack stand from under the transfer case.
    Fig 46: Removing Jack Stand From Under Transfer Case
    G03181005Courtesy of FORD MOTOR CO.

    48. All vehicles 

  48. Install the plastic shield and the two nuts on the right side of the crossmember.
    Fig 47: Installing Plastic Shield And Two Nuts On Right Side Of Crossmember
    G03181006Courtesy of FORD MOTOR CO.
  49. Install the crossmember-to-transmission support insulator nuts.
    Fig 48: Installing Crossmember-To-Transmission Support Insulator Nuts
    G03181007Courtesy of FORD MOTOR CO.
  50. Install the LH heat shield bolt.
    Fig 49: Installing LH Heat Shield Bolt
    G03181008Courtesy of FORD MOTOR CO.
  51. Install the RH heat shield bolts.
    Fig 50: Installing RH Heat Shield Bolts
    G03181009Courtesy of FORD MOTOR CO.
    52. NOTE: RH shown, LH similar.
    Fig 51: Connecting Two Catalyst Monitor Sensor Electrical Connectors
    G03181010Courtesy of FORD MOTOR CO.
  52. Connect the two catalyst monitor sensor electrical connectors.
    53. NOTE: LH shown, RH similar.
    Fig 52: Connecting Two Heated Oxygen Sensor Electrical Connectors
    G03181011Courtesy of FORD MOTOR CO.
  53. Connect the two heated oxygen sensor electrical connectors.
  54. Install the two bolts and the RH heat shield.
    Fig 53: Installing Two Bolts And RH Heat Shield
    G03181012Courtesy of FORD MOTOR CO.
  55. Attach the battery cable retainer bracket and install the nut.
    Fig 54: Attaching Battery Cable Retainer Bracket And Install Nut
    G03181013Courtesy of FORD MOTOR CO.
  56. Position the lower air shroud panel and install the pushpins.
    Fig 55: Positioning Lower Air Shroud Panel And Install Pushpins
    G03181014Courtesy of FORD MOTOR CO.
  57. Install the starter. For additional information, refer to INTAKE AIR, FUEL CHARGING, STARTING AND ENGINE ELECTRONICS - 4.0L SOHC .
  58. Install the exhaust gas recirculation (EGR) tube.
    Fig 56: Installing Exhaust Gas Recirculation (EGR) Tube
    G03181015Courtesy of FORD MOTOR CO.
  59. Connect the A/C tube to the condenser.
    • Install a new O-ring seal.
    Fig 57: Connecting A/C Tube To Condenser
    G03181016Courtesy of FORD MOTOR CO.
  60. Connect the A/C tube to the retainer.
    Fig 58: Connecting A/C Tube To Retainer
    G03181017Courtesy of FORD MOTOR CO.
  61. Connect the A/C high-pressure cut-off switch electrical connector.
    Fig 59: Connecting A/C High-Pressure Cut-Off Switch Electrical Connector
    G03181018Courtesy of FORD MOTOR CO.
  62. Connect the vacuum hoses.
    Fig 60: Connecting Vacuum Hoses
    G03181019Courtesy of FORD MOTOR CO.
  63. Connect the A/C tube to the condenser and install the nut.
    • Install a new O-ring seal.
    Fig 61: Installing A New O-Ring Seal
    G03181020Courtesy of FORD MOTOR CO.
  64. Connect the A/C tube to the accumulator.
    • Install a new O-ring seal.
    Fig 62: Connecting A/C Tube To Accumulator
    G03181021Courtesy of FORD MOTOR CO.
  65. Connect the coolant hoses to the degas bottle.
    Fig 63: Connecting Coolant Hoses To Degas Bottle
    G03181022Courtesy of FORD MOTOR CO.
  66. Connect the lower radiator hose at the coolant pump.
    Fig 64: Connecting Lower Radiator Hose At Coolant Pump
    G03181023Courtesy of FORD MOTOR CO.
  67. Connect the upper radiator hose and heater hose.
    Fig 65: Connecting Upper Radiator Hose And Heater Hose
    G03181024Courtesy of FORD MOTOR CO.
  68. Install the heater hose bracket and retaining bolts.
    Fig 66: Installing Heater Hose Bracket And Retaining Bolts
    G03181025Courtesy of FORD MOTOR CO.
  69. Connect the vacuum hose and the heater hose.
    Fig 67: Connecting Vacuum Hose And Heater Hose
    G03181026Courtesy of FORD MOTOR CO.
  70. Install the ground wire and the bolt to the engine.
    Fig 68: Installing Ground Wire And Bolt To Engine
    G03181027Courtesy of FORD MOTOR CO.
  71. Connect the vacuum hose.
    Fig 69: Connecting Vacuum Hose
    G03181028Courtesy of FORD MOTOR CO.
  72. Connect the evaporative emissions (EVAP) return tube.
    Fig 70: Connecting Evaporative Emissions (EVAP) Return Tube
    G03181029Courtesy of FORD MOTOR CO.
  73. Connect the fuel tube spring lock coupling. For additional information, refer to FUEL SYSTEM .
  74. Connect the transmission control wiring harness pin -type retainers to the fuel charging wiring harness.
    Fig 71: Connecting The Transmission Control Wiring Harness Pin -Type Retainers To The Fuel Charging Wiring Harness
    G03181030Courtesy of FORD MOTOR CO.
  75. Install the fuel charging wiring harness in the clips on the bulkhead.
    Fig 72: Installing Fuel Charging Wiring Harness In Clips On Bulkhead
    G03181031Courtesy of FORD MOTOR CO.
  76. Connect the powertrain control module (PCM) electrical connectors.
    Fig 73: Connecting Powertrain Control Module (PCM) Electrical Connectors
    G03181032Courtesy of FORD MOTOR CO.
  77. Install the air cleaner.
    Fig 74: Installing Air Cleaner
    G03181033Courtesy of FORD MOTOR CO.
  78. Connect the mass airflow (MAF) electrical connector.
    Fig 75: Connecting Mass Airflow (MAF) Electrical Connector
    G03181034Courtesy of FORD MOTOR CO.
  79. Install the power steering pump pulley. For additional information, refer to STEERING SYSTEM .
    80. NOTE: Align the marks made during removal.
    Fig 76: Installing Hood Four Bolts And Hood Supports
    G03181035Courtesy of FORD MOTOR CO.
  80. Install the hood, the four bolts and the hood supports.
  81. Connect the windshield washer hose.
    Fig 77: Connecting Windshield Washer Hose
    G03181036Courtesy of FORD MOTOR CO.
  82. Connect the battery cable to the power distribution box.
    Fig 78: Connecting Battery Cable To Power Distribution Box
    G03181037Courtesy of FORD MOTOR CO.
  83. Connect the electrical connector and attach the wiring harness retainer.
    Fig 79: Connecting Electrical Connector And Attach Wiring Harness Retainer
    G03181038Courtesy of FORD MOTOR CO.
  84. Install the ground wire and nut.
    Fig 80: Installing Ground Wire And Nut
    G03181039Courtesy of FORD MOTOR CO.
  85. Install the cooling fan and shroud. For additional information, refer to ENGINE COOLING .
  86. Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR, FUEL CHARGING, STARTING AND ENGINE ELECTRONICS - 4.0L SOHC .
  87. Fill the engine with clean engine oil.
  88. Connect both battery cables. For additional information, refer to BATTERY DISCONNECT .
  89. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  90. Fill the power steering system. For additional information, refer to STEERING SYSTEM .
  91. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM .
  92. Start the engine and check for leaks. Stop the engine and check all fluid levels.
  93. Carry out the fluid level check for the transmission. For additional information, refer to AUTOMATIC TRANSMISSION - 5R55S .
About FixVault