Engine Mechanical - 3.5L: Installation: Engine

	2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
	Adjustable Grip Arm, 1735A 014-00001or equivalent
	Powertrain Lift 300-OTC1585AE or equivalent
	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

All vehicles 

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

   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 Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift table.
   Fig 4: Positioning Engine And Transaxle Onto Powertrain Lift Table Using Floor Crane And Spreader Bar

   Courtesy of FORD MOTOR CO.
NOTE: Position a block of wood under the transaxle.
Fig 5: Installing Powertrain Lift And Adjustable Grip Arms
Courtesy of FORD MOTOR CO.
5. Install the Powertrain Lift and Adjustable Grip Arms.
6. Attach the transaxle control wire harness retainer to the transaxle stud bolt.
   Fig 6: Locating Transaxle Control Wire Harness Retainer Of Transaxle Stud Bolt

   Courtesy of FORD MOTOR CO.
7. Connect the transaxle control electrical connector.
   Fig 7: Locating Transaxle Control Electrical Connector

   Courtesy of FORD MOTOR CO.
8. Install the starter, the stud bolt and bolt.
   • Tighten to 27 Nm (20 lb-ft).
     Fig 8: Locating Starter Bolt And Studbolt

     Courtesy of FORD MOTOR CO.
9. Connect the wiring harness retainer to the starter motor stud bolt.
   Fig 9: Locating Wiring Harness Retainer Of Starter Motor Stud Bolt

   Courtesy of FORD MOTOR CO.
10. Attach the starter wire terminals and install the 2 nuts.
    1. Tighten the B+ terminal nut to 12 Nm (106 lb-in).
    2. Tighten the S-terminal nut to 5 Nm (44 lb-in).
       Fig 10: Identifying Starter Wire B+ And S- Terminals Nuts

       Courtesy of FORD MOTOR CO.
11. Install the starter motor solenoid cover.
    Fig 11: Locating Starter Motor Solenoid Cover

    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 12: Locating Engine Mount And Bolts

      Courtesy of FORD MOTOR CO.
14. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
      Fig 13: Locating Engine Mount Nuts

      Courtesy of FORD MOTOR CO.
15. Install the engine mount brace, nut and bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 14: Locating Engine Mount Brace, Nut And Bolt

      Courtesy of FORD MOTOR CO.
16. Install the transaxle support insulator bracket, 3 nuts and the bolt.
    • Tighten the transaxle support insulator bracket nuts to 63 Nm (46 lb-ft).
    • Tighten the transaxle support insulator bolt to 55 Nm (41 lb-ft).
      Fig 15: Locating Nuts, Bolt And Transaxle Support Insulator Bracket

      Courtesy of FORD MOTOR CO.
17. Install the transaxle support insulator through bolt and nut.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 16: Locating Transaxle Mount Through Bolt And Nut

      Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

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

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

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

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

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

    Courtesy of FORD MOTOR CO.
NOTE: A new Power Transfer Unit (PTU) shaft seal must be installed whenever the intermediate shaft is removed or damage to the components can occur.
24. Install a new intermediate shaft seal and deflector. For additional information, refer to TRANSFER CASE - POWER TRANSFER UNIT (PTU) .

    All vehicles 

25. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 23: Locating Oil Pan-To-Transaxle Bolts

      Courtesy of FORD MOTOR CO.
26. Install 3 new torque converter bolts.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 24: Locating Torque Converter Bolt

      Courtesy of FORD MOTOR CO.
27. Install the inspection cover and the 2 fasteners.
    Fig 25: Locating Inspection Cover And Fasteners

    Courtesy of FORD MOTOR CO.
28. Connect the transaxle cooler tubes and install the 2 secondary latches.
    Fig 26: Locating Secondary Latches

    Courtesy of FORD MOTOR CO.
29. 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 27: Locating RH Halfshaft Support Bracket Bolts

      Courtesy of FORD MOTOR CO.
30. Install the 2 halfshaft support bracket studs.
    • Tighten to 10 Nm (89 lb-in).
      Fig 28: Locating Halfshaft Support Bracket Studs

      Courtesy of FORD MOTOR CO.
NOTE: The circlips are unique in size and shape for each shaft. Make sure to use the specified circlip for the application or vehicle damage may occur.
Fig 29: Locating Stub Shaft Circlip
Courtesy of FORD MOTOR CO.
31. Install the correct new circlip on the inboard stub shaft.
NOTE: The sharp edges on the stub shaft splines can slice or puncture the oil seal. Use care when inserting the stub shaft into the transmission or damage to the component may occur.
NOTE: After insertion, pull the halfshaft inner end to make sure the circlip is locked.
32. Push the stub shaft into the transmission so the circlip locks into the differential side gear.
33. Rotate the LH wheel knuckle into position and insert the LH halfshaft into the wheel hub.
34. Install the intermediate and halfshaft assembly and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 30: Locating Intermediate Shaft Bracket Nuts

      Courtesy of FORD MOTOR CO.
35. Rotate the RH wheel knuckle into position and insert the RH halfshaft into the wheel hub.
NOTE: Align the index marks on the subframe to the index marks on the underbody that were made during removal.
Fig 31: Raising Subframe Using Powertrain Lift
Courtesy of FORD MOTOR CO.
36. Using the Powertrain Lift, raise the subframe into the installed position.
NOTE: RH shown in illustration, LH similar.
37. Install the 2 front subframe bolts.
    • Tighten to 200 Nm (148 lb-ft).
      Fig 32: Locating Front Subframe Bolt

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
Fig 33: Locating Subframe Bracket And Bolts
Courtesy of FORD MOTOR CO.
38. Position the subframe brackets and install the 4 bolts finger-tight.
NOTE: RH shown in illustration, LH similar.
39. Install the 2 rear subframe bolts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 34: Locating Rear Subframe Bolt

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
Fig 35: Locating Subframe Bracket-To-Body Bolts
Courtesy of FORD MOTOR CO.
40. Tighten the 4 subframe bracket-to-body bolts to 55 Nm (41 lb-ft).
NOTE: RH shown in illustration, LH similar.
41. Position the ball joints into the wheel knuckles. Install the new ball joint nuts.
    • Tighten to 200 Nm (148 lb-ft).
      Fig 36: Locating Lower Ball Joint-To-Wheel Knuckle Nut

      Courtesy of FORD MOTOR CO.
NOTE: The hex-holding feature can be used to prevent turning of the stud while installing the nuts.
NOTE: RH shown in illustration, LH similar.
42. Install new tie-rod end nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 37: Locating Tie-Rod End And Nut

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
43. Install new upper stabilizer bar link nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 38: Locating Upper Stabilizer Bar Link Nut

      Courtesy of FORD MOTOR CO.
NOTE: The engine roll restrictor is equipped with a heat shield. If the engine roll restrictor was removed, it must be installed with the heat shield facing the exhaust.
44. Position the engine roll restrictor and install the engine roll restrictor-to-subframe through bolt.
    • Tighten the 2 engine roll restrictor through bolts to 103 Nm (76 lb-ft).
      Fig 39: Locating Engine Roll Restrictor Through Bolts

      Courtesy of FORD MOTOR CO.
45. Using a new O-ring seal, install the Power Steering Pressure (PSP) tube onto the steering gear, rotate the clamp plate and install the bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 40: Locating Clamp Plate, Bolt And PSP Tube

      Courtesy of FORD MOTOR CO.
46. Install the PSP tube bracket-to-steering gear bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 41: Locating Power Steering Pressure (PSP) Tube Bracket-To-Steering Gear Bolt

      Courtesy of FORD MOTOR CO.
47. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
      Fig 42: Locating Engine Oil Filter

      Courtesy of FORD MOTOR CO.

    AWD vehicles 

48. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 new bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 43: Locating Driveshaft Bolts

      Courtesy of FORD MOTOR CO.

    All vehicles 

49. 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 44: Locating Exhaust Hanger And Y-Pipe Nuts

      Courtesy of FORD MOTOR CO.
50. Install the Y-pipe assembly and 4 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 45: 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.
51. Install the steering intermediate shaft onto the steering gear and install a new bolt.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 46: Locating Index Mark And Steering Column Shaft Mounting Bolt

      Courtesy of FORD MOTOR CO.
52. Position the RH brake hose bracket and install the bolt.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 47: Locating RH Brake Hose Bracket Bolt

      Courtesy of FORD MOTOR CO.
53. Position the rubber shield and install the 2 lower scrivets.
    Fig 48: Locating Lower Scrivets Of Rubber Shield

    Courtesy of FORD MOTOR CO.
NOTE: Do not tighten the wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.
NOTE: Apply the brake to keep the halfshaft from rotating.
NOTE: RH shown in illustration, LH similar.
54. Using the previously removed RH and LH wheel hub nuts, seat the halfshaft.
    • Tighten to 350 Nm (258 lb-ft).
    • Remove and discard the wheel hub nuts.
      Fig 49: Locating Halfshaft Nuts

      Courtesy of FORD MOTOR CO.
NOTE: The wheel hub nut contains a one-time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur.
NOTE: Apply the brake to keep the halfshaft from rotating.
NOTE: RH shown in illustration, LH similar.
55. Install a new RH and LH wheel hub nut.
    • Tighten to 350 Nm (258 lb-ft).
      Fig 50: Locating Halfshaft Nuts

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

    Courtesy of FORD MOTOR CO.
57. Install the ground cable and bolt.
    • Tighten to 12 Nm (106 lb-in).
      Fig 52: Locating Bolt And Ground Cable

      Courtesy of FORD MOTOR CO.
58. Attach the wire to the RH valve cover stud bolt.
    Fig 53: Locating RH Valve Cover Stud Bolt Wire Harness Retainer

    Courtesy of FORD MOTOR CO.
59. Attach the engine wiring harness retainer.
    Fig 54: Locating Engine Wiring Harness Retainer

    Courtesy of FORD MOTOR CO.
60. Connect the fuel supply tube to the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 55: Locating Fuel Supply Tube

    Courtesy of FORD MOTOR CO.
61. Using a new O-ring seal, connect the upper A/C tube to the condenser, install the nut and connect the A/C pressure switch electrical connector.
    • Tighten to 15 Nm (133 lb-in).
      Fig 56: Locating A/C Pressure Switch Electrical Connector And Nut

      Courtesy of FORD MOTOR CO.
62. If equipped, attach the engine block heater harness to the radiator support.
63. Attach the wiring harness pin-type retainer and connect the transaxle control cable to the shift cable bracket.
    Fig 57: Locating Shift Cable Bracket And Wiring Harness Pin-Type Retainer

    Courtesy of FORD MOTOR CO.
64. Connect the transaxle control cable to the control lever.
    Fig 58: Locating Control Lever Transaxle Control Cable

    Courtesy of FORD MOTOR CO.
65. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
    Fig 59: Locating Upper Radiator Hose, Lower Radiator Hose And Heater Hoses

    Courtesy of FORD MOTOR CO.
66. Install the engine wiring harness retainer to the bulkhead.
    1. Slide the wiring harness in the bulkhead.
    2. Make sure the wiring harness retainer tab is below the bulkhead lip.
       Fig 60: Identifying Engine Wiring Harness Retainer Tab And Bulkhead

       Courtesy of FORD MOTOR CO.
67. Connect the 2 PCM electrical connectors.
    Fig 61: Locating PCM Electrical Connectors

    Courtesy of FORD MOTOR CO.
68. Connect the PCM and engine harness electrical connectors.
    • Attach the wiring harness retainer.
      Fig 62: Locating PCM And Engine Harness Electrical Connectors With Wiring Harness Retainer

      Courtesy of FORD MOTOR CO.
69. Install the Evaporative Emission (EVAP) canister purge valve. For additional information, refer to EVAPORATIVE EMISSIONS .
70. Attach the EVAP tube pin-type retainer to the upper intake manifold.
    Fig 63: Locating EVAP Tube Pin-Type Retainer Of Upper Intake Manifold

    Courtesy of FORD MOTOR CO.
71. Connect the vacuum hose and the EVAP tube from the upper intake manifold.
    Fig 64: Locating Vacuum Hose And Evaporative Emission (EVAP) Tube Clamp

    Courtesy of FORD MOTOR CO.
72. Install the degas bottle. For additional information, refer to ENGINE COOLING .
73. Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
    • Tighten to 15 Nm (133 lb-in).
      Fig 65: Locating A/C Tube And Nut

      Courtesy of FORD MOTOR CO.
74. Using a new O-ring seal and gasket seal, connect the A/C tube and install the nut.
    • Tighten to 15 Nm (133 lb-in).
      Fig 66: Locating A/C Tube Nut

      Courtesy of FORD MOTOR CO.
75. Connect the power steering cooler tube.
    Fig 67: Locating Power Steering Cooler Tube Clamp

    Courtesy of FORD MOTOR CO.
76. Install the front valance, 3 pushpins and 7 screws.
    Fig 68: Locating Pushpins, Screws And Front Valance

    Courtesy of FORD MOTOR CO.
77. Install the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE .
78. Install the LF wheel and tire. For additional information, refer to WHEELS AND TIRES .
79. Connect the ground cable to the negative battery terminal and install the nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 69: Locating Negative Battery Terminal Ground Cable And Nut

      Courtesy of FORD MOTOR CO.
80. Connect the 2 power feed wires to the positive battery terminal and install the nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 70: Locating Battery Positive Terminal Nut

      Courtesy of FORD MOTOR CO.
81. Connect the engine wiring harness electrical connector.
    Fig 71: Locating Engine Wiring Harness Electrical Connector

    Courtesy of FORD MOTOR CO.
82. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
83. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
84. Install the strut tower brace and the 4 nuts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 72: Locating Strut Tower Brace And Nuts

      Courtesy of FORD MOTOR CO.
85. Attach the brake booster vacuum hose retainers to the strut tower brace.
    Fig 73: Locating Brake Booster Vacuum Hose Retainer Of Strut Tower Brace

    Courtesy of FORD MOTOR CO.
86. Install the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
87. Fill the engine with clean engine oil.
88. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
89. Fill the power steering system. For additional information, refer to STEERING SYSTEM - HYDRAULIC POWER ASSIST STEERING (HPAS) .
90. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .