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Section 1618 (Engine Mechanical): Installation: Engine: Installation

WARNING: This page is about a different car, the 2009 Mercury Grand Marquis and 2009 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
    WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in FIRE SUPPRESSION SYSTEM article. Failure to follow the instructions may result in serious personal injury.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.
  2. Using the Engine Lifting Bracket Set, install the engine assembly in the vehicle.
    3. Fig 1: Special Tools
    GF0013681Courtesy of FORD MOTOR CO.
    NOTE: When vehicle is raised, verify that the torque converter is correctly seated.
  3. Install the 4 transmission bellhousing bolts and 1 stud.
    • Tighten to 48 Nm (35 lb-ft).
    4. Fig 2: Transmission Bolts
    GF0013680Courtesy of FORD MOTOR CO.
  4. Attach the wiring harness to the retainers on the transmission.
  5. Connect the Output Shaft Speed (OSS) sensor, Transmission Range (TR) sensor and the Turbine Shaft Speed (TSS) sensor electrical connectors.
    6. Fig 3: Output Shaft Speed Sensor, Transmission Range Sensor & Turbine Shaft Speed Sensor Electrical Connectors
    GF0013677Courtesy of FORD MOTOR CO.
  6. Connect the Heated Oxygen Sensor (HO2S) and the solenoid body sensor electrical sensors.
    7. Fig 4: HO2S Sensor & Solenoid Body Sensor Electrical Connectors
    GF0013676Courtesy of FORD MOTOR CO.
  7. Raise the transmission and install the transmission insulator.
  8. Install the 2 insulator bolts.
    • Tighten to 90 Nm (66 lb-ft).
    9. Fig 5: Rear Transmission Insulator Bolts
    GF0013675Courtesy of FORD MOTOR CO.
  9. Lower the transmission and install the 2 transmission insulator nuts.
    • Tighten to 30 Nm (22 lb-ft).
    10. Fig 6: Rear Transmission Insulator Nuts
    GF0013674Courtesy of FORD MOTOR CO.
    NOTE: LH shown in illustration, RH similar.
  10. Install the 2 engine mount nuts.
    • Tighten to 90 Nm (66 lb-ft).
    11. Fig 7: Engine Mount Nut
    GF0013607Courtesy of FORD MOTOR CO.
    NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S.
  11. Using the Exhaust Gas Oxygen Sensor Socket, install the HO2S.
    • Tighten to 40 Nm (30 lb-ft).
    12. Fig 8: Heated Oxygen Sensor (HO2S) Special Tool
    GF0013672Courtesy of FORD MOTOR CO.
  12. Connect the LH HO2S electrical connector.
    13. Fig 9: LH HO2S Electrical Connector
    GF0013671Courtesy of FORD MOTOR CO.
  13. Connect the RH HO2S electrical connector.
    14. Fig 10: Right Side Heated Oxygen Sensor (HO2S) Electrical Connector
    GF0013801Courtesy of FORD MOTOR CO.
  14. Install the 4 torque converter nuts.
    • Rotate the crankshaft to access the nuts.
    • Tighten to 36 Nm (27 lb-ft).
    15. Fig 11: Torque Converter Nut
    GF0013726Courtesy of FORD MOTOR CO.
  15. Install the rubber access plug.
    16. Fig 12: Locating Rubber Access Plug
    GF0003547Courtesy of FORD MOTOR CO.
  16. Install the inspection cover and the 3 bolts.
    • Tighten to 19 Nm (168 lb-in).
    17. Fig 13: Inspection Cover & Bolts
    GF0013678Courtesy of FORD MOTOR CO.
  17. Install the starter motor. For additional information, refer to STARTING SYSTEM article.
  18. Position the exhaust, install the 4 new nuts and remove the support.
    • Tighten to 48 Nm (35 lb-ft).
    19. Fig 14: Exhaust Nuts
    GF0013673Courtesy of FORD MOTOR CO.
  19. Install the power steering pump and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    20. Fig 15: A/C Compressor Bolts
    GF0046704Courtesy of FORD MOTOR CO.
  20. Install the A/C compressor and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    21. Fig 16: A/C Compressor Bolts
    GF0013668Courtesy of FORD MOTOR CO.
  21. Connect the A/C compressor electrical connector.
    22. Fig 17: A/C Compressor Electrical Connector
    GF0013667Courtesy of FORD MOTOR CO.
  22. Connect the engine wiring harness retainers to the A/C compressor.
    23. Fig 18: Engine Wiring Harness Retainers
    GF0013666Courtesy of FORD MOTOR CO.
  23. Connect the Crankshaft Position (CKP) sensor electrical connector.
    24. Fig 19: Crankshaft Position (CKP) Sensor Electrical Connector
    GF0013729Courtesy of FORD MOTOR CO.
  24. Position the transmission oil cooler tube bracket and install the bolt.
    • Tighten to 15 Nm (133 lb-in).
    25. Fig 20: Transmission Cooler Tube Support Bracket Bolt
    GF0013664Courtesy of FORD MOTOR CO.
  25. Install the transmission cooler tube support bracket.
    • Tighten to 9 Nm (80 lb-in).
    26. Fig 21: Transmission Cooler Tube Support Bracket Nut
    GF0013663Courtesy of FORD MOTOR CO.
  26. Install the power steering tube bracket.
    • Tighten to 10 Nm (89 lb-in).
    27. Fig 22: Power Steering Tube Bracket
    GF0013665Courtesy of FORD MOTOR CO.
    NOTE: The oil cooler must be replaced or severe damage to the engine can occur.
  27. If equipped, install a new oil cooler and oil cooler hoses. For additional information, refer to Oil Cooler .
  28. Connect the Power Steering Pressure (PSP) switch electrical connector.
    29. Fig 23: Power Steering Pressure (PSP) Switch Electrical Connector
    GF0013662Courtesy of FORD MOTOR CO.
  29. Connect the power steering electrical connector.
    30. Fig 24: Block Heater Electrical Connector
    GF0013660Courtesy of FORD MOTOR CO.
  30. If equipped, connect the block heater electrical connector.
  31. Connect the EOP switch electrical connector.
    32. Fig 25: Oil Pressure Sender Electrical Connector
    GF0013661Courtesy of FORD MOTOR CO.
  32. Install the 2 top transmission bellhousing bolts.
    • Tighten to 48 Nm (35 lb-ft).
    33. Fig 26: Top Transmission Bolts
    GF0013682Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the oil filter seal with clean engine oil.
  33. Install the oil filter.
  34. Install the cooling fan. For additional information, refer to ENGINE COOLING article.
    35. NOTE: Do not reuse hose clamps. Use appropriately sized worm-style clamps in place of the constant tension clamps.
  35. Connect the lower radiator hose.
    36. Fig 27: Lower Radiator Hose
    GF0013659Courtesy of FORD MOTOR CO.
  36. Connect the upper radiator hose to the hose connection.
    37. Fig 28: Upper Radiator Hose
    GF0013658Courtesy of FORD MOTOR CO.
  37. Connect the PCM electrical connectors.
    38. Fig 29: PCM Electrical Connectors
    GF0013652Courtesy of FORD MOTOR CO.
  38. Position the ground strap and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
    39. Fig 30: Ground Strap
    GF0013657Courtesy of FORD MOTOR CO.
    NOTE: Do not reuse hose clamps. Use appropriately sized worm-style clamps in place of the constant tension clamps.
  39. Connect the heater hoses.
    40. Fig 31: Heater Hoses
    GF0013656Courtesy of FORD MOTOR CO.
  40. Connect the A/C low charge protection switch electrical connector.
    41. Fig 32: A/C Low Charge Protection Switch Electrical Connector
    GF0013655Courtesy of FORD MOTOR CO.
  41. Connect the A/C electrical connector.
    42. Fig 33: A/C Electrical Connector
    GF0013654Courtesy of FORD MOTOR CO.
  42. Install the ground strap and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    43. Fig 34: Ground Wire Bolt
    GF0013653Courtesy of FORD MOTOR CO.
  43. Attach the pin-type retainer and install the generator battery cable and nut.
    • Tighten to 9 Nm (80 lb-in).
    44. Fig 35: Generator Battery Cable & Retainer
    GF0013651Courtesy of FORD MOTOR CO.
  44. Attach the generator battery cable retainer to the RH valve cover stud bolt.
    45. Fig 36: Generator Battery Cable Retainer
    GF0013650Courtesy of FORD MOTOR CO.
  45. Connect the fuel tube spring lock coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  46. Connect the 2 hoses and the Evaporative Emission (EVAP) canister purge valve electrical connection.
    47. Fig 37: Evaporative Emission (EVAP) Canister Purge Valve
    GF0013649Courtesy of FORD MOTOR CO.
  47. Connect the vacuum hose.
    48. Fig 38: Vacuum Hose
    GF0013648Courtesy of FORD MOTOR CO.
  48. Install the air cleaner and outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING article.
  49. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE article.
  50. Install the support bracket and the 2 nuts.
    • Tighten to 10 Nm (89 lb-in).
    51. Fig 39: Support Bracket & Nuts
    GF0013647Courtesy of FORD MOTOR CO.
  51. Install the wiper mounting arm and pivot shaft. For additional information, refer to WIPERS & WASHERS article.
  52. Fill the crankcase with clean engine oil.
  53. Connect both battery cables. For additional information, refer to CHARGING SYSTEM - GENERAL INFORMATION article.
  54. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING article.
  55. Install the hood.
    56. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM article. Failure to follow these instructions may result in serious personal injury.
  56. If equipped with fire suppression system, repower the system.
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