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Section 7 (Engine - 3.5L Ti-VCT): Installation: Engine

WARNING: This page is about a different variant/trim than selected.
Special Tool(s)

GFD82137Courtesy of FORD MOTOR COMPANY
 2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
GFD82138Courtesy of FORD MOTOR COMPANY
 Adjustable Grip Arm, 1735A 014-00001 or equivalent
GFD82140Courtesy of FORD MOTOR COMPANY
 Eye, Engine Lift 303-1245
GFD82141Courtesy of FORD MOTOR COMPANY
 Powertrain Lift 300-OTC1585AE or equivalent
GFD82142Courtesy of FORD MOTOR COMPANY
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
Material

Item Specification
Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil (US); Motorcraft ® SAE 5W-20 Super Premium Motor Oil (Canada) XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada) WSS-M2C945-A

All vehicles 

  1. 1.

    Using the Floor Crane and Spreader Bar, align the transaxle to the engine.
GFD82181Courtesy of FORD MOTOR COMPANY

  1. 2.

    Align the transaxle to the engine and install the 5 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
GFD82203Courtesy of FORD MOTOR COMPANY

  1. 3.

    Install the 2 engine-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
GFD82202Courtesy of FORD MOTOR COMPANY

  1. 4.

    Install the RH halfshaft support bracket and the 2 bolts.
    • Tighten to 40 Nm (30 lb-ft).
GFD82201Courtesy of FORD MOTOR COMPANY

  1. 5.

    Install the 2 intermediate shaft bracket studs and nuts.
    • Tighten the studs to 10 Nm (89 lb-in).
    • Tighten the nuts to 25 Nm (18 lb-ft).
GFD82200Courtesy of FORD MOTOR COMPANY

  1. 6.

    NOTE: LH shown, RH similar.

    Install the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

GFD82199Courtesy of FORD MOTOR COMPANY

  1. 7.

    Using the Floor Crane and Spreader Bar, install the powertrain and subframe as an assembly on the powertrain lift table.
GFD82181Courtesy of FORD MOTOR COMPANY

  1. 8.

    NOTE: LH shown, RH similar.

    Remove the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

GFD82199Courtesy of FORD MOTOR COMPANY

  1. 9.

    Install the Adjustable Grip Arm.
GFD82198Courtesy of FORD MOTOR COMPANY

  1. 10.

    Install a ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe, to secure the subframe to the powertrain lift table.

All-Wheel Drive (AWD) vehicles 

  1. 11.

    Position the PTU support bracket in place and install the 5 bolts.
    • Tighten to 48 Nm (35 lb-ft).
GFD82102Courtesy of FORD MOTOR COMPANY

All vehicles 

  1. 12.

    Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).
GFD82347Courtesy of FORD MOTOR COMPANY

  1. 13.

    NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

    Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:

    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
GFD82348Courtesy of FORD MOTOR COMPANY

  1. 14.

    Install the RH catalytic converter heat shield, Catalyst Monitor Sensor (CMS) wiring harness bracket and the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
GFD82195Courtesy of FORD MOTOR COMPANY

  1. 15.

    Connect the RH Heated Oxygen Sensor (HO2S) electrical connector.
GFD82194Courtesy of FORD MOTOR COMPANY

  1. 16.

    Connect the RH CMS electrical connector.
GFD82193Courtesy of FORD MOTOR COMPANY

  1. 17.

    Attach the transaxle control wire harness retainer to the transaxle stud bolt.
GFD82192Courtesy of FORD MOTOR COMPANY

  1. 18.

    Connect the transaxle control electrical connector.
GFD82191Courtesy of FORD MOTOR COMPANY

  1. 19.

    Position the wiring harness and attach the 3 wiring harness retainer to the valve cover stud bolt.
GFD82190Courtesy of FORD MOTOR COMPANY

  1. 20.

    Connect the generator B+ cable and install the nut.
    • Tighten to 17 Nm (150 lb-in).
GFD82189Courtesy of FORD MOTOR COMPANY

  1. 21.

    Position back the generator B+ cable cover and connect the generator electrical connector.
GFD82188Courtesy of FORD MOTOR COMPANY

  1. 22.

    Connect the 2 A/C compressor electrical connectors.
    • Attach the A/C wiring harness retainer.
GFD82187Courtesy of FORD MOTOR COMPANY

  1. 23.

    Install the ground wire to the RH cylinder head and install the bolt.
    • Tighten to 10 nm (89 lb-In).
GFD82186Courtesy of FORD MOTOR COMPANY

  1. 24.

    Install the starter, the stud bolt and bolt.
    • Tighten to 27 Nm (20 lb-ft).
GFD82185Courtesy of FORD MOTOR COMPANY

  1. 25.

    Connect the wiring harness retainer to the starter motor stud bolt.
GFD82184Courtesy of FORD MOTOR COMPANY

  1. 26.

    Attach the starter wire terminals and install the 2 nuts.

    1. 1.

      Tighten the B+ terminal nut to 12 Nm (106 lb-in).

    1. 2.

      Tighten the S-terminal nut to 5 Nm (44 lb-in).
GFD82353Courtesy of FORD MOTOR COMPANY

  1. 27.

    Install the starter motor solenoid cover.
GFD82182Courtesy of FORD MOTOR COMPANY

  1. 28.

    Remove the Heavy Duty Floor Crane and Spreader Bar.
GFD82181Courtesy of FORD MOTOR COMPANY

  1. 29.

    Remove 303-1245 from the LH cylinder head.
GFD82180Courtesy of FORD MOTOR COMPANY

  1. 30.

    Raise the subframe and powertrain assembly into the vehicle.

  1. 31.

    Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
GFD82025Courtesy of FORD MOTOR COMPANY

  1. 32.

    Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
GFD82024Courtesy of FORD MOTOR COMPANY

  1. 33.

    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 80 Nm (59 lb-ft).
GFD82176Courtesy of FORD MOTOR COMPANY

  1. 34.

    Install the transaxle support insulator through bolt and nut.
    • Tighten to 175 Nm (129 lb-ft).
GFD82175Courtesy of FORD MOTOR COMPANY

  1. 35.

    NOTE: RH shown, LH similar.

    Align the subframe and install the new front subframe bolts.

    • Tighten to 200 Nm (148 lb-ft).
GFD82354Courtesy of FORD MOTOR COMPANY

  1. 36.

    NOTE: RH shown, LH similar.

    Install the rear subframe brackets and the new subframe bracket-to-body bolts.

    • Finger tight at this stage.
GFD82355Courtesy of FORD MOTOR COMPANY

  1. 37.

    NOTE: RH shown, LH similar.

    Install the new subframe bracket bolts.

    • Tighten to 150 Nm (111 lb-ft).
GFD82356Courtesy of FORD MOTOR COMPANY

  1. 38.

    NOTE: RH shown, LH similar.

    Tighten the subframe bracket-to-body bolts to 55 Nm (41 lb-ft).

GFD82357Courtesy of FORD MOTOR COMPANY

  1. 39.

    Remove the ratchet strap from the front of the subframe to the rear of the subframe.

  1. 40.

    Remove the Adjustable Grip Arm and the powertrain lift table.
GFD82173Courtesy of FORD MOTOR COMPANY

  1. 41.

    NOTE: LH shown, RH similar.

    Install the strut to the wheel knuckle and install the strut-to-wheel knuckle nuts and bolts.

    • Tighten to 250 Nm (184 lb-ft).
GFD82174Courtesy of FORD MOTOR COMPANY

  1. 42.

    NOTE: LH shown, RH similar.

    Install the brake caliper and the guide pin bolts.

    • 432 mm (17 in) brakes: Tighten to 72 Nm (53 lb-ft).
    • 457 mm (18 in) brakes: Tighten to 75 Nm (55 lb-ft).
GFD82358Courtesy of FORD MOTOR COMPANY

  1. 43.

    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: LH shown, RH similar.
    NOTE: Apply the brake to keep the halfshaft from rotating.

    Using the previously removed wheel hub nut, seat the LH and RH halfshafts.

    • Tighten to 350 Nm (258 lb-ft).
    • Remove and discard the wheel hub nuts.
GFD81670Courtesy of FORD MOTOR COMPANY

  1. 44.

    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: LH shown, RH similar.
    NOTE: Apply the brake to keep the halfshaft from rotating.

    Install a new wheel hub nuts.

    • Tighten to 350 Nm (258 lb-ft).
GFD82170Courtesy of FORD MOTOR COMPANY

  1. 45.

    NOTE: LH shown, RH similar.

    Install the new upper stabilizer link nut.

    • Tighten to 150 Nm (111 lb-ft).
GFD82359Courtesy of FORD MOTOR COMPANY

  1. 46.

    NOTE: LH shown, RH similar.

    Install the wheel speed sensor and the bolt.

    • Tighten to 15 Nm (133 lb-in).
GFD82166Courtesy of FORD MOTOR COMPANY

  1. 47.

    Connect the transaxle cooler tubes and install the 2 secondary latches.
GFD82164Courtesy of FORD MOTOR COMPANY

  1. 48.

    If equipped, install the oil cooler hose retainer to the subframe.
GFD82163Courtesy of FORD MOTOR COMPANY

  1. 49.

    If equipped, connect the 2 oil cooler coolant hoses.
GFD82162Courtesy of FORD MOTOR COMPANY

  1. 50.

    Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
GFD82122Courtesy of FORD MOTOR COMPANY

  1. 51.

    Install 3 new torque converter bolts by rotating the crankshaft clockwise.
    • Tighten to 55 Nm (41 lb-ft).
GFD82360Courtesy of FORD MOTOR COMPANY

  1. 52.

    Install the inspection cover and the 2 fasteners.
GFD82106Courtesy of FORD MOTOR COMPANY

  1. 53.

    NOTE: Do not lubricate the engine oil filter gasket with oil.

    Install a new engine oil filter.

    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
GFD82124Courtesy of FORD MOTOR COMPANY

AWD vehicles 

  1. 54.

    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).
GFD82361Courtesy of FORD MOTOR COMPANY

All vehicles 

  1. 55.

    Install the exhaust Y-pipe. For additional information, refer to Exhaust System .

  1. 56.

    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 .

    Align and connect the steering column shaft to the steering gear and install the bolt.

    • Tighten to 20 Nm (177 lb-in).
GFD82362Courtesy of FORD MOTOR COMPANY

  1. 57.

    If equipped, attach the engine block heater harness to the radiator support.

  1. 58.

    Attach the wiring harness pin-type retainer to the shift cable bracket and connect the transaxle control cable to the shift cable bracket.
GFD82157Courtesy of FORD MOTOR COMPANY

  1. 59.

    Connect the transaxle control cable to the control lever.
GFD82156Courtesy of FORD MOTOR COMPANY

  1. 60.

    Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
GFD82155Courtesy of FORD MOTOR COMPANY

  1. 61.

    Install the ground wire to the RH shock tower and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
GFD82154Courtesy of FORD MOTOR COMPANY

  1. 62.

    Install the engine wiring harness retainer to the bulkhead.

    1. 1.

      Slide the wiring harness in the bulkhead.

    1. 2.

      Make sure the wiring harness retainer tab is below the bulkhead lip.
GFD134071Courtesy of FORD MOTOR COMPANY

  1. 63.

    Connect the PCM electrical connector.
GFD134064Courtesy of FORD MOTOR COMPANY

  1. 64.

    Connect the engine harness electrical connector.
    • Attach the wiring harness retainer.
GFD134063Courtesy of FORD MOTOR COMPANY

  1. 65.

    Connect the Evaporative Emission (EVAP) tube and the fuel supply tube quick connect coupling. For additional information, refer to Fuel System General Information .
GFD82150Courtesy of FORD MOTOR COMPANY

  1. 66.

    Connect the brake booster vacuum hose to the upper intake manifold.
GFD82149Courtesy of FORD MOTOR COMPANY

  1. 67.

    Connect the degas bottle coolant hose to the engine coolant tube.
GFD82148Courtesy of FORD MOTOR COMPANY

  1. 68.

    Install the degas bottle. For additional information, refer to Engine Cooling .

  1. 69.

    Using a new O-ring seal and gasket seal, connect the upper A/C tube to the condenser and install the nut.
    • Tighten to 15 Nm (133 lb-in).
GFD82147Courtesy of FORD MOTOR COMPANY

  1. 70.

    Connect the A/C pressure switch electrical connector.
GFD82146Courtesy of FORD MOTOR COMPANY

  1. 71.

    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).
GFD82018Courtesy of FORD MOTOR COMPANY

  1. 72.

    Install the accessory drive belt. For additional information, refer to Accessory Drive .

  1. 73.

    Position the splash shield and install the 3 pin-type retainers.
GFD82021Courtesy of FORD MOTOR COMPANY

  1. 74.

    Install the front wheels and tires. For additional information, refer to Wheels and Tires .

  1. 75.

    If equipped, install the skid plate and the 10 retainers.
    • Tighten to 70 Nm (52 lb-ft).
GFD82004Courtesy of FORD MOTOR COMPANY

  1. 76.

    If equipped, install the underbody shield and attach the 4 retainers.
GFD82003Courtesy of FORD MOTOR COMPANY

  1. 77.

    Connect the engine wiring harness electrical connector.
GFD82145Courtesy of FORD MOTOR COMPANY

  1. 78.

    Install the ground wire cable and the retainer.
    • Tighten to 10 Nm (89 lb-in).
GFD82144Courtesy of FORD MOTOR COMPANY

  1. 79.

    Connect the 2 battery feed cables to the positive battery terminal and install the nut.
    • Tighten to 5 Nm (44 lb-in).
GFD82143Courtesy of FORD MOTOR COMPANY

  1. 80.

    Install the battery tray. For additional information, refer to Battery, Mounting and Cables .

  1. 81.

    Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering .

  1. 82.

    Install the strut tower brace and the 4 nuts.
    • Tighten to 35 Nm (26 lb-ft).
GFD81762Courtesy of FORD MOTOR COMPANY

  1. 83.

    Install the cowl panel grille. For additional information, refer to Front End Body Panels .

  1. 84.

    Fill the engine with clean engine oil.

  1. 85.

    Fill and bleed the cooling system. For additional information, refer to Engine Cooling .

  1. 86.

    Recharge the A/C system. For additional information, refer to Climate Control System General Information and Diagnostics .

  1. 87.

    Perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
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