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Section 260 (Engine-5.4L): Installation: Engine: Installation

WARNING: This page is about a different car, the 2003 Lincoln Navigator. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using a floor crane, install the engine in the vehicle.
    • Make sure the marks on the flexplate and the torque converter stud made during removal are lined up.
  2. Remove the special tool.
    Fig 1: Removing Special Tool
    G01563325Courtesy of FORD MOTOR CO.
  3. Install the two upper transmission-to-engine bolts. Tighten the bolts to 45 Nm (33 lb-ft).
  4. Remove the floor jack and wood block supporting the transmission.
  5. Raise the vehicle.
  6. Install the RH motor mount nut.
    Fig 2: Installing RH Motor Mount Nut
    G01563326Courtesy of FORD MOTOR CO.
  7. Install the LH motor mount bolt.
    Fig 3: Installing LH Motor Mount Bolt
    G01563327Courtesy of FORD MOTOR CO.
  8. Install the five lower transmission-to-engine bolts.
    Fig 4: Installing Lower Transmission-To-Engine Bolts
    G01563328Courtesy of FORD MOTOR CO.
  9. Install the four torque converter nuts.
    • Rotate the crankshaft, using the crankshaft pulley bolt.
      Fig 5: Installing Four Torque Converter Nuts
      G01563329Courtesy of FORD MOTOR CO.
  10. Install the flexplate-to-torque converter nut access plug.
    Fig 6: Installing Flexplate-To-Torque Converter Nut Access Plug
    G01563330Courtesy of FORD MOTOR CO.
  11. Position the hoses and install the clamps.
    Fig 7: Positioning Hoses And Installing Clamps
    G01563331Courtesy of FORD MOTOR CO.
  12. Install a new oil filter.
    Fig 8: Installing Oil Filter
    G01563332Courtesy of FORD MOTOR CO.
  13. Position the transmission cooler tube and the power steering hose brackets and install the nuts.
    Fig 9: Installing Nuts
    G01563333Courtesy of FORD MOTOR CO.
  14. Connect the crankshaft position (CKP) sensor electrical connector.
    Fig 10: Connecting Crankshaft Position (CKP) Sensor Electrical Connector
    G01563334Courtesy of FORD MOTOR CO.
  15. Position the A/C compressor and install the bolts.
    Fig 11: Positioning A/C Compressor And Installing Bolts
    G01563335Courtesy of FORD MOTOR CO.
  16. Connect the A/C clutch electrical connector.
  17. Install the starter. For additional information, refer to STARTERS .
  18. Position the wire harness bracket and install the nut.
    Fig 12: Positioning Wire Harness Bracket And Installing Nut
    G01563336Courtesy of FORD MOTOR CO.
  19. Position the dual converter Y-pipe and install the four nuts.
    Fig 13: Positioning Dual Converter Y-Pipe And Installing Nuts
    G01563337Courtesy of FORD MOTOR CO.
  20. Connect the heated oxygen sensor (HO2S) electrical connectors.
    Fig 14: Connecting Heated Oxygen Sensor (HO2S) Electrical Connectors
    G01563338Courtesy of FORD MOTOR CO.
    21. NOTE: The bolt is accessed through the RH fender well.
    Fig 15: Positioning Transmission Filler Tube And Installing Bolt
    G01563339Courtesy of FORD MOTOR CO.
  21. Position the transmission filler tube and install the bolt.
  22. Install the skid plate and the bolts, if equipped.
  23. Lower the vehicle.
  24. Connect the auxiliary heater hoses.
    Fig 16: Connecting Auxiliary Heater Hoses
    G01563340Courtesy of FORD MOTOR CO.
  25. Connect the main engine harness electrical connector.
    Fig 17: Connecting Main Engine Harness Electrical Connector
    G01563341Courtesy of FORD MOTOR CO.
  26. Position the vacuum harness and connect the hose.
    Fig 18: Positioning Vacuum Harness And Connecting Hose
    G01563342Courtesy of FORD MOTOR CO.
  27. Position the ground cable and install the bolt.
    Fig 19: Positioning Ground Cable And Installing Bolt
    G01563343Courtesy of FORD MOTOR CO.
    28. NOTE: Install a new O-ring. Lubricate the O-ring with clean engine coolant. Use the same coolant type that was drained from the engine.
    Fig 20: Positioning Tube
    G01563344Courtesy of FORD MOTOR CO.
  28. Position the tube.
  29. Install the bolt.
    Fig 21: Installing Bolt
    G01563345Courtesy of FORD MOTOR CO.
  30. Position the hoses and install the clamps.
    Fig 22: Positioning Hoses And Installing Clamps
    G01563346Courtesy of FORD MOTOR CO.
  31. Install the engine noise shield.
    Fig 23: Installing Engine Noise Shield
    G01563347Courtesy of FORD MOTOR CO.
  32. Position the power steering pump and install the three bolts.
    Fig 24: Positioning Power Steering Pump And Installing Bolts
    G01563348Courtesy of FORD MOTOR CO.
  33. Using the special tool, install a new O-ring seal on the power steering pressure hose fitting.
    Fig 25: Installing O-Ring Seal On Power Steering Pressure Hose Fitting Using Special Tool
    G01563349Courtesy of FORD MOTOR CO.
  34. Connect the power steering pressure hose.
    Fig 26: Connecting Power Steering Pressure Hose
    G01563350Courtesy of FORD MOTOR CO.
  35. Using the special tool, install the power steering pump pulley.
    Fig 27: Installing Power Steering Pump Pulley Using Special Tool
    G01563351Courtesy of FORD MOTOR CO.
  36. Position the generator and install the bolts.
    Fig 28: Positioning Generator And Installing Bolts
    G01563352Courtesy of FORD MOTOR CO.
    37. NOTE: Position the rubber boot on the B+ connector after tightening the nut.
    Fig 29: Connecting Generator Electrical Connectors
    G01563353Courtesy of FORD MOTOR CO.
  37. Connect the generator electrical connectors.
    38. NOTE: For correct drive belt routing, refer to SPECIFICATIONS & DRIVE BELT ROUTING .
    Fig 30: Installing Drive Belt
    G01563354Courtesy of FORD MOTOR CO.
  38. Rotate the belt tensioner counterclockwise and install the drive belt.
  39. Connect the spring lock couplers and install the safety clips. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 31: Connecting Spring Lock Couplers And Install Safety Clips
    G01563355Courtesy of FORD MOTOR CO.
  40. Connect the A/C hoses at the junction block.
    Fig 32: Connecting A/C Hoses At Junction Block
    G01563356Courtesy of FORD MOTOR CO.
  41. Connect the heater hoses to the heater core.
    Fig 33: Connecting Heater Hoses To Heater Core
    G01563357Courtesy of FORD MOTOR CO.
  42. Connect the auxiliary heater hoses at the right side valve cover.
    Fig 34: Connecting Auxiliary Heater Hoses At Right Side Valve Cover
    G01563358Courtesy of FORD MOTOR CO.
  43. Install the power train control module (PCM) mounting bracket.
    Fig 35: Installing Power Train Control Module (PCM) Mounting Bracket
    G01563359Courtesy of FORD MOTOR CO.
  44. Install the PCM and the bolts.
    Fig 36: Installing PCM And Bolts
    G01563360Courtesy of FORD MOTOR CO.
  45. Connect the PCM electrical connectors.
    Fig 37: Connecting PCM Electrical Connectors
    G01563361Courtesy of FORD MOTOR CO.
  46. Install the lower intake manifold. For additional information, refer to LOWER INTAKE MANIFOLD .
  47. Fill the engine with clean engine oil.
  48. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  49. Install the radiator. For additional information, refer to ENGINE COOLING .
  50. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  51. Fill and bleed the power steering system. For additional information, refer to POWER STEERING .
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