Section 1448 (Engine Mechanical): Installation: Engine: Material

All vehicles 

1. Using the Heavy Duty Floor Crane and Spreader Bar, align the transaxle to the engine.
   Fig 1: Aligning Transaxle To Engine Using Heavy Duty Floor Crane

   Courtesy of FORD MOTOR CO.
2. Install the 5 transaxle-to-engine bolts.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 2: 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 3: Locating Engine-To-Transaxle Bolts

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

   Courtesy of FORD MOTOR CO.
NOTE: Position a block of wood under the transaxle.
Fig 5: Positioning Block Of Wood Under Transaxle
Courtesy of FORD MOTOR CO.
5. Install the Powertrain Lift and Universal Adapter Brackets.
6. Install the starter, the stud bolt and bolt.
   • Tighten to 27 Nm (20 lb-ft).
     Fig 6: Locating Bolt, Stud Bolt And Starter

     Courtesy of FORD MOTOR CO.
7. Connect the wiring harness retainer to the starter motor stud bolt.
   Fig 7: Locating Starter Motor Stud Bolt

   Courtesy of FORD MOTOR CO.
8. 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).
      Fig 8: Identifying Starter Wire Terminals And Nuts

      Courtesy of FORD MOTOR CO.
9. Install the starter motor solenoid cover.
   Fig 9: Locating Starter Motor Solenoid Cover

   Courtesy of FORD MOTOR CO.
10. Raise the engine and transaxle assembly into the vehicle.
11. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 10: Locating Bolts And Engine Mount

      Courtesy of FORD MOTOR CO.
12. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
      Fig 11: Locating Engine Mount Nuts

      Courtesy of FORD MOTOR CO.
13. Install the engine mount brace, nut and bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 12: Locating Nut, Bolt And Engine Mount Brace

      Courtesy of FORD MOTOR CO.
14. Install the transaxle support insulator bracket, 3 nuts and the bolt.
    • Tighten to 80 Nm (59 lb-ft).
      Fig 13: Locating Bolt, Nuts And Transaxle Support Insulator Bracket

      Courtesy of FORD MOTOR CO.
15. Install the transaxle support insulator through bolt and nut.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 14: Locating Transaxle Support Insulator Through Bolt And Nut

      Courtesy of FORD MOTOR CO.

All-Wheel Drive (AWD) vehicles 

16. Position the Power Transfer Unit (PTU) in place and install the 5 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 15: Locating Power Transfer Unit (PTU) And Bolts

      Courtesy of FORD MOTOR CO.
17. Position the PTU  support bracket in place and install the 5 bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 16: Locating PTU Support Bracket And Bolts

      Courtesy of FORD MOTOR CO.
18. Using a new gasket, install the RH catalytic converter and 4 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 17: Locating Nuts And RH Catalytic Converter

      Courtesy of FORD MOTOR CO.
19. Connect the RH catalyst monitor electrical connector.
    Fig 18: Locating RH Catalyst Monitor Electrical Connector

    Courtesy of FORD MOTOR CO.

    All vehicles 

20. Install the RH halfshaft support bracket and the 4 bolts.
    • Tighten the halfshaft support-to-cylinder block bolts to 40 Nm (30 lb-ft).
    • Tighten the catalytic converter-to-halfshaft support bolts to 20 Nm (177 lb-in).
      Fig 19: Locating Bolts And RH Halfshaft Support Bracket

      Courtesy of FORD MOTOR CO.
21. Install the 2 halfshaft support bracket studs.
    • Tighten to 10 Nm (89 lb-in).
      Fig 20: Locating RH Halfshaft Support Bracket Studs

      Courtesy of FORD MOTOR CO.
22. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 21: Locating Oil Pan-To-Transaxle Bolts

      Courtesy of FORD MOTOR CO.
23. Install 3 new torque converter bolts.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 22: Locating Torque Converter Bolts

      Courtesy of FORD MOTOR CO.
24. Install the inspection cover and the 2 fasteners.
    Fig 23: Locating Fasteners And Inspection Cover

    Courtesy of FORD MOTOR CO.
25. Connect the transaxle cooling tubes and install the 2 secondary latches.
    Fig 24: Locating Transaxle Cooling Tubes And Secondary Latches

    Courtesy of FORD MOTOR CO.
26. If equipped, connect the oil cooler coolant hoses.
    Fig 25: Locating Oil Cooler Coolant Hoses

    Courtesy of FORD MOTOR CO.
27. Using the Powertrain Lift, raise the subframe into the installed position.
    Fig 26: Identifying Powertrain Lift

    Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
28. Install the 2 front subframe bolts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 27: Locating Front Subframe Bolts

      Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
Fig 28: Locating Subframe Brackets And Bolts
Courtesy of FORD MOTOR CO.
29. Position the subframe brackets and install the 4 bolts finger-tight.
NOTE: RH shown, LH similar.
30. Install the 2 rear subframe bolts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 29: Locating Rear Subframe Bolt

      Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
Fig 30: Locating Subframe Bracket-To-Body Bolts
Courtesy of FORD MOTOR CO.
31. Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
NOTE: The hex-holding feature can be used to prevent turning of the stud while installing the nuts.
NOTE: RH shown, LH similar.
32. Install new tie-rod end nuts.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 31: Locating Tie-Rod End Nuts

      Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
33. Install new upper stabilizer bar link nuts.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 32: Locating Upper Stabilizer Link Nuts

      Courtesy of FORD MOTOR CO.
34. Install the 2 engine roll restrictor-to-transaxle bolts.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 33: Locating Engine Roll Restrictor-To-Transaxle Bolts

      Courtesy of FORD MOTOR CO.
35. Using a new O-ring seal, install the PSP  tube onto the steering gear, rotate the clamp plate and install the bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 34: Rotating Clamp Plate Clockwise

      Courtesy of FORD MOTOR CO.
36. Install the PSP  tube bracket-to-steering gear bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 35: Locating Power Steering Pressure (PSP) Tube Bracket-To-Steering Gear Bolt

      Courtesy of FORD MOTOR CO.
37. If equipped, attach the oil cooler hose support clip to the subframe.
NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
38. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
      Fig 36: Locating Engine Oil Filter

      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 new 4 bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 37: Locating Bolts And Driveshaft

      Courtesy of FORD MOTOR CO.

All vehicles 

40. Using a new gasket, install the Y-pipe and install the 2 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
    • Attach the exhaust hanger.
      Fig 38: Locating Y-Pipe Flange Nuts

      Courtesy of FORD MOTOR CO.
41. Install the Y-pipe assembly and 4 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 39: Locating Y-Pipe-To-Catalytic Converter Nuts

      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 may 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 .
NOTE: Align the index marks made during removal.
42. Install the steering intermediate shaft onto the steering gear and install a new bolt.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 40: Locating Bolt And Steering Column Shaft

      Courtesy of FORD MOTOR CO.
43. Connect the transaxle control electrical connector.
    Fig 41: Locating Transaxle Control Electrical Connector

    Courtesy of FORD MOTOR CO.
44. Attach the transaxle control wire harness retainer to the cooler tube.
    Fig 42: Locating Transaxle Control Wire Harness Retainer

    Courtesy of FORD MOTOR CO.
45. Connect the hose to the power steering reservoir.
    Fig 43: Locating Power Steering Reservoir Hose

    Courtesy of FORD MOTOR CO.
46. Install the oil level indicator.
    Fig 44: Locating Oil Level Indicator

    Courtesy of FORD MOTOR CO.
47. Install the ground cable and bolt.
    • Tighten to 12 Nm (106 lb-in).
      Fig 45: Locating Bolt And Ground Cable

      Courtesy of FORD MOTOR CO.
48. Attach the wire to the RH valve cover stud bolt.
    Fig 46: Locating Wire Harness Retainer

    Courtesy of FORD MOTOR CO.
49. Attach the wiring harness retainer to the engine mount bracket stud bolt.
    Fig 47: Locating Engine Mount Bracket Stud Bolt

    Courtesy of FORD MOTOR CO.
50. Connect the 2 engine wiring harness electrical connectors.
    • Attach the electrical connector to the LH valve cover.
      Fig 48: Locating Engine Wiring Harness Electrical Connectors

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

    Courtesy of FORD MOTOR CO.
52. Using a new O-ring seal, install the A/C tube and the bolt.
    • Tighten to 15 Nm (133 lb-in).
      Fig 50: Locating A/C Tube And Bolt

      Courtesy of FORD MOTOR CO.
53. Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
    • Tighten to 15 Nm (133 lb-in).
      Fig 51: Locating A/C Tubes And Nuts

      Courtesy of FORD MOTOR CO.
54. Using a new O-ring seal, connect the upper A/C tube to the condenser and install the nut and connect the A/C pressure switch electrical connector.
    • Tighten to 15 Nm (133 lb-in).
      Fig 52: Locating Nut

      Courtesy of FORD MOTOR CO.
55. If equipped, attach the engine block heater harness to the radiator support and the power steering tube.
56. Connect the transaxle control cable to the shift cable bracket and attach the wiring harness pin-type retainer.
    Fig 53: Locating Transaxle Control Cable

    Courtesy of FORD MOTOR CO.
57. Connect the transaxle control cable to the control lever.
    Fig 54: Locating Transaxle Control Cable

    Courtesy of FORD MOTOR CO.
58. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
    Fig 55: Locating Upper Radiator Hose, Lower Radiator Hose And Heater Hoses

    Courtesy of FORD MOTOR CO.
59. Connect the vacuum hose and the Evaporative Emission (EVAP) tube from the upper intake manifold.
    Fig 56: Locating Vacuum Hose And Evaporative Emission (EVAP) Tube

    Courtesy of FORD MOTOR CO.
60. Attach the EVAP  tube pin-type retainer to the upper intake manifold.
    Fig 57: Locating EVAP Tube Pin-Type Retainer

    Courtesy of FORD MOTOR CO.
61. Connect the ground cable to the negative battery terminal and install the nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 58: Locating Nut And Ground Cable

      Courtesy of FORD MOTOR CO.
62. Connect the power feed wire to the positive battery terminal and install the nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 59: Locating Nut And Power Feed Wire

      Courtesy of FORD MOTOR CO.
63. Connect the engine wiring harness electrical connector.
    Fig 60: Locating Engine Wiring Harness Electrical Connector

    Courtesy of FORD MOTOR CO.
64. Install the battery tray assembly and the nut and bolt.
    • Tighten to 9 Nm (80 lb-in).
      Fig 61: Locating Nut, Bolt And Battery Tray Assembly

      Courtesy of FORD MOTOR CO.
65. Install the 2 lower battery tray bracket bolts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 62: Locating Lower Battery Tray Bracket Bolts

      Courtesy of FORD MOTOR CO.
66. Attach the 2 pin-type wiring harness fasteners to the front of the battery tray.
    Fig 63: Locating Pin-Type Wiring Harness Fasteners

    Courtesy of FORD MOTOR CO.
67. Attach the 4 pin-type wiring harness fasteners to the side of the battery tray.
    Fig 64: Locating Pin-Type Wiring Harness Fasteners

    Courtesy of FORD MOTOR CO.
68. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
69. Install the engine Air Cleaner (ACL) and ACL  outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
70. Install the degas bottle. For additional information, refer to ENGINE COOLING .
71. Connect the power steering cooler tube.
    Fig 65: Locating Power Steering Cooler Tube

    Courtesy of FORD MOTOR CO.
72. Install the LH halfshaft and the RH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
73. Install the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE .
74. Fill the engine with clean engine oil.
75. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
76. Fill the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL INFORMATION .
77. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .