Section 17 (Engine - 5.2L 32V Ti-VCT): Installation: Engine

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	303-F047 Lifting Bracket, Engine
Courtesy of FORD MOTOR COMPANY	303-F072 Support Bar, Engine
Floor Crane
Trolley Jack
Wooden Block

Materials 

Name	Specification
Motorcraft ® Premium Long-Life Grease XG-1-E1	ESA-M1C75-B

• 1.
  
  Clean the input shaft and apply a small amount of grease to the splined surface and the pilot bearing surface.

  Material: Motorcraft ® Premium Long-Life Grease / XG-1-E1 (ESA-M1C75-B)

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• 2.
  
  Using the Floor Crane lower the engine into the vehicle. Use the General Equipment: Floor Crane

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• 3.
  
  

  • 1.
    
    Align the engine to the transmission.

  • 2.
    
    Draw the engine and transmission together using the bolts.

    Torque: 35 lb.ft (48 Nm)

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• 4.
  
  
  NOTE: Do not position the legs of the Engine Support Bar on the fenders. Instead, the legs should be positioned on the body structure. Failure to follow these instructions may result in body damage.

  • 1.
    
    Install the special tools. Use Special Service Tool: 303-F072 Support Bar, Engine.

  • 2.
    
    Once the engine is supported by the Engine Support Bar, remove the Floor Crane. Use the General Equipment: Floor Crane

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• 5.
  
  Remove the jack and wooden block. Use the General Equipment: Wooden Block Use the General Equipment: Trolley Jack

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• 6.
  
  Install the engine rear cover plate stud bolts.

  Torque: 35 lb.ft (48 Nm)

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• 7.
  
  Install LH transmission-to-engine bolt and stud bolt.

  Torque: 35 lb.ft (48 Nm)

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• 8.
  
  Install RH transmission-to-engine stud bolt.

  Torque: 35 lb.ft (48 Nm)

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• 9.
  
  Install the LH engine mount bracket, bolts and stud bolt.

  Torque: 41 lb.ft (55 Nm)

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• 10.
  
  Install the A/C compressor and the stud bolts.

  Torque: 18 lb.ft (25 Nm)

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• 11.
  
  Attach the wiring harness retainers to the A/C compressor stud bolts.

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• 12.
  
  Install the RH engine mount bracket and the fasteners.

  Torque: 41 lb.ft (55 Nm)

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• 13.
  
  If equipped, position the transmission cooler tubes and install the nuts.

  Torque:

  Upper bracket nut: 159 lb.in (18 Nm)

  Lower bracket nut: 80 lb.in (9 Nm)

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• 14.
  
  Position the wiring harness and install the nut.

  Torque: 89 lb.in (10 Nm)

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• 15.
  
  Install the ground strap and nut onto the RH engine mount bracket stud bolt.

  Torque: 35 lb.ft (48 Nm)

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• 16.
  
  Lower the engine onto the engine mounts and remove the special tools Use Special Service Tool: 303-F072 Support Bar, Engine., 303-F047 Lifting Bracket, Engine.

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• 17.
  
  Install the RH engine mount nut.

  Torque: 46 lb.ft (63 Nm)

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• 18.
  
  Install the LH engine mount nut.

  Torque: 46 lb.ft (63 Nm)

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• 19.
  
  Install the top transmission-to-engine bolts.

  Torque: 35 lb.ft (48 Nm)

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• 20.
  
  
  WARNING: DO NOT hammer, pry or force steering column and column shafts during installation or removal. Failure to follow this instruction may cause damage to steering components that could lead to loss of steering control during vehicle operation and could result in serious personal injury or death.
  WARNING: DO NOT attempt to remove or install the steering column lower u-joint at the steering gear without first loosening the steering column dash seal and fasteners. Failure to follow this instruction may cause damage to steering components that could lead to loss of steering control during vehicle operation and could result in serious personal injury or death.

  • 1.
    
    Connect the steering column shaft to the steering gear universal joint.

  • 2.
    
    Install the new steering column shaft bolt.

    Torque: 22 lb.ft (30 Nm)

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• 21.
  
  Inspect the steering column lower shaft. Refer to: Steering Column Collapsed Check .

• 22.
  
  Attach the wiring harness retainer.

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• 23.
  
  Install the wiring harness retainer and the nut.

  Torque: 124 lb.in (14 Nm)

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• 24.
  
  Attach the wiring harness retainers to the oil pan.

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• 25.
  
  Connect the oil cooler hoses and install the bolts.

  Torque: 22 lb.ft (30 Nm)

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• 26.
  
  Install a new oil filter. Refer to: Engine Oil Draining and Filling .

• 27.
  
  Install the following items:
  1. Refer to: Starter Motor .
  2. Refer to: Catalytic Converter RH .
  3. Refer to: Catalytic Converter LH .

• 28.
  
  
  • Attach the wiring harness retainer.
  • Connect the wiring harness electrical connector.
  • Connect the B+ cable and install the nut.

    Torque: 159 lb.in (18 Nm)

  • Position the cover.

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• 29.
  
  Attach the EVAP tube to the LH valve cover and the LH inner fender.

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• 30.
  
  Install the intake manifold. Refer to: Intake Manifold .

• 31.
  
  Connect the heater hose quick connect couplings.

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• 32.
  
  Connect the lower radiator hose to the thermostat housing assembly.

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• 33.
  
  

  • 1.
    
    Install the coolant bypass T assembly and clamp onto the engine.

  • 2.
    
    Slide the spring clip until it hits the stop on the hose fitting.

  • 3.
    
    Install the degas bottle hose and clamp.

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• 34.
  
  Connect the top PCM electrical connector, the 16 pin electrical connector and attach the wiring harness retainers to the PCM bracket.

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• 35.
  
  Install the battery heat shield and fasteners.

  Torque: 80 lb.in (9 Nm)

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• 36.
  
  Install the cowl extension and fasteners.

  Torque: 26 lb.ft (35 Nm)

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• 37.
  
  
  NOTE: It is not necessary to separate the air cleaner outlet pipe and the air cleaner, the 2 components can be removed as an assembly.

  Install the following items:

  1. Refer to: Cowl Panel Grille .
  2. Refer to: Battery Tray .
  3. Refer to: Air Conditioning (A/C) Compressor Belt .
  4. Refer to: Cooling Fan Motor and Shroud .
  5. Refer to: Degas Bottle .
  6. Refer to: Air Cleaner .
  7. Refer to: Air Cleaner Outlet Pipe .

• 38.
  
  Install the engine ground wire and nut.

  Torque: 80 lb.in (9 Nm)

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• 39.
  
  

  • 1.
    
    Install the strut tower cross brace and nuts.

    Torque: 41 lb.ft (55 Nm)

  • 2.
    
    Attach the wiring harness retainer.

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• 40.
  
  
  NOTE: Use the index-mark for location to aid in hood installation.

  Install the hood and the nuts.

  Torque: 62 lb.in (7 Nm)

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• 41.
  
  

  • 1.
    
    Connect the windshield washer hose C-Lock Couplers.

  • 2.
    
    Attach the windshield washer hose retainers.

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• 42.
  
  Install the hood insulation and the pin-type retainers.

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• 43.
  
  Remove the holding device.

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• 44.
  
  

  • 1.
    
    Position the steering column dash seal.

  • 2.
    
    Tighten the steering column dash seal nuts.

    Torque: 80 lb.in (9 Nm)

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• 45.
  
  Fill the engine with clean engine oil. Refer to: Specifications .

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• 46.
  
  Connect the battery ground and positive cables. Refer to: Battery Disconnect and Connect .

• 47.
  
  Fill and bleed the engine cooling system. Refer to: Cooling System Draining, Vacuum Filling And Bleeding .

• 48.
  
  Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.