Engine Mechanical: Mechanical: Engine: Installation: Engine

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	303-1246 Engine Spreader Bar
Courtesy of FORD MOTOR COMPANY	303-1654 Lift Eyes
Courtesy of FORD MOTOR COMPANY	307-346 (T97T-7902-A) Retainer, Torque Converter
Floor Crane
Trolley Jack
Hose Clamp Remover/Installer
Wooden Block

Materials 

1. Inspect the TC or engine air intake system components and clean, if necessary.
2. 1. Inspect the LH engine mount-to-frame nut plate for thread damage.
   2. If the nut plate is damaged, remove and discard the engine mount-to-frame nut plate.

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3. NOTE: This step is only necessary when installing a new component.

   Clean the LH engine mount-to-frame mating surfaces of any dirt or foreign material prior to installation.

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4. NOTE: This step is only necessary when installing a new component.

   Install the LH nut plate.

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5. Remove Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

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6. Lubricate the torque converter pilot hub with multi-purpose grease.

   Material: Grease - Multi Purpose (ESB-M1C93-B)

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7. Inspect the engine block dowels. If the dowels are damaged or missing, install new engine block dowels.

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8. 1. Inspect the torque converter stud and flexplate for paint marks.
   2. Align the torque converter stud and flexplate hole near the paint marks to the 12 o'clock position.

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9. NOTE: The use of a ratchet strap may be needed to level the engine.
   NOTE: Use a commercially available quick link on the chain to minimize the spread of the chain.

   Using the floor crane, lift eyes and the engine spreader bar, position the engine in the engine compartment. Use Special Service Tool: 303-1246 Engine Spreader Bar., 303-1654 Lift Eyes. Use the General Equipment: Floor Crane

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10. Position back and attach the generator wiring harness retainer to the lower LH side of the engine block.

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11. Using the floor crane, lift eyes and the engine spreader bar, position the engine to the transmission. Use Special Service Tool: 303-1246 Engine Spreader Bar., 303-1654 Lift Eyes. Use the General Equipment: Floor Crane

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12. Align the engine to the transmission and draw together using the bolts.

    Torque: 48 Nm

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13. Using the floor crane, lift eyes and the engine spreader bar, raise the engine for clearance to install the LH engine mount. Use Special Service Tool: 303-1246 Engine Spreader Bar., 303-1654 Lift Eyes. Use the General Equipment: Floor Crane

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14. Install the LH engine mount.

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15. Rotate the LH engine mount and position to the frame.

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16. NOTE: Use only hand tools when installing the LH engine mount through bolt or the engine mount may be damaged.
    • Install the new LH mount through bolt.
    • Do not torque at this time.

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17. Using the floor crane, lift eyes and the engine spreader bar, lower the engine. Use Special Service Tool: 303-1246 Engine Spreader Bar., 303-1654 Lift Eyes. Use the General Equipment: Floor Crane

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18. Install the new LH engine mount bolts.

    Torque: 175 Nm

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19. Remove the floor jack and the block of wood. Use the General Equipment: Trolley Jack. Use the General Equipment: Wooden Block

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20. Remove the floor crane, lift eyes and the engine spreader bar. Use Special Service Tool: 303-1246 Engine Spreader Bar., 303-1654 Lift Eyes. Use the General Equipment: Floor Crane

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21. Install the right rear ignition coil. Refer to: Ignition Coil-On-Plug .
22. NOTE: Only use hand tools when loosening or tightening the engine mount through bolts or damage to the engine mount-to-cylinder block bracket can occur.

    Tighten the LH engine mount through bolt.

    Torque: 350 Nm

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23. NOTE: Only use hand tools when installing the engine mount studs or damage to the engine mount can occur.
    NOTE: Apply threadlock to the stud threads prior to installation.

    Install the engine mount studs.

    Material: Thread Locking Adhesive (WSK-M2G351-A6)

    Torque: 30 Nm

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24. NOTE: Only use hand tools when installing the engine mount nuts and studs or damage to the engine mount can occur.

    Install the new RH engine mount nuts.

    Torque: 150 Nm

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25. Install the RH side bellhousing bolt.

    Torque: 48 Nm

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26. Install the shift cable bracket and the LH side bellhousing bolts.

    Torque: 48 Nm

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27. Install the upper bellhousing bolts.

    Torque: 48 Nm

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28. Install the lower bellhousing bolt.

    Torque: 48 Nm

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29. Lubricate the oil filter seal with clean oil and install the new oil filter. Refer to: Specifications .

    Torque: Stage 1: 5 Nm Stage 2: 180 deg.

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30. NOTE: Only use hand tools when loosening or tightening the transmission mount-to-crossmember nuts or damage to the transmission mount can occur.

    Remove and discard the transmission mount-to-crossmember nuts. Install new transmission mount-to-crossmember nuts.

    Torque: 115 Nm

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31. Position the exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe and install the bolts.

    Torque: 63 Nm

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32. Install the new RH catalytic converter-to-turbocharger nuts.

    Torque: 40 Nm

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33. Install the new LH catalytic converter-to-turbocharger nuts.

    Torque: 40 Nm

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34. NOTE: Using the crankshaft pulley bolt, turn the engine clockwise.

    Install new torque converter nuts.

    Torque: 48 Nm

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35. Install the access cover and the retainers.

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36. Install the following items:
    1. Install the starter motor. Refer to: Starter Motor .
    2. If equipped, install the front driveshaft. Refer to: Front Driveshaft .
    3. Install the front stabilizer bar. Refer to: Front Stabilizer Bar . Refer to: Front Stabilizer Bar .

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    1. Install the new PCV tube to the valve cover. Refer to: Quick Release Coupling .

38. Install the ground strap and the nut. Connect the ground strap retainers.

    Torque: 12 Nm

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39. Install the TC bypass valve tube. Use the General Equipment: Hose Clamp Remover/Installer

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40. Connect the lower coolant pump hose. Use the General Equipment: Hose Clamp Remover/Installer

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41. Install and connect the upper radiator hose. Use the General Equipment: Hose Clamp Remover/Installer

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42. • Install and connect the radiator coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
    • Install and connect the thermostat housing coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
    • Install and connect the coolant control valve hose. Use the General Equipment: Hose Clamp Remover/Installer
    • Install and connect the oil cooler cooling hoses. Use the General Equipment: Hose Clamp Remover/Installer

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43. Connect the coolant hose to the degas bottle and connect the degas bottle hose at the thermostat. Use the General Equipment: Hose Clamp Remover/Installer

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44. Connect the PCM electrical connectors and the wire harness retainers.

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45. Follow directions to connect the quick release coupling type 24. Refer to: Quick Release Coupling .

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46. • Connect the electrical connector and the wire harness retainer.
    • Install the generator nut and position back the boot.

      Torque: 17 Nm

    1. Position back the boot.

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47. Connect the generator wiring harness to the engine front cover.

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48. Position back the engine wiring harness.

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49. Position back the transmission cooler tube bracket and install the nut.

    Torque: 12 Nm

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50. If equipped
    1. Connect the wire harness retainer to the coolant hose.
    2. Connect the block heater electrical connector and the wire harness retainer.

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51. If equipped. Install the LH heat shield and bolts.

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52. Install the intake manifold. Refer to: Intake Manifold .
53. Install the A/C compressor. Refer to: Air Conditioning (A/C) Compressor .
54. Install the CAC intake pipe. Refer to: Charge Air Cooler (CAC) Intake Pipe .
55. Install the CAC outlet pipes. Refer to: Air Cleaner Outlet Pipe .
56. Install the cooling module. Refer to: Cooling Module .
57. Remove the pin-type retainer and position the cooler tubes from the oil pan.

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58. Position the wiring harness cover to the oil pan and install the fasteners.

    Torque: 25 Nm

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59. Install the pin-type retainer position the cooler tube back.

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60. Install the cooler tubes, bracket and the nut.

    Torque: 14 Nm

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61. Fill the engine with clean engine oil. Refer to: Specifications .

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62. Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
63. If equipped. Install the skid plate.

    Torque: 20 Nm

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64. If equipped.
    • Install the underbody shield and the bolts.

      Torque: 40 Nm

    • Install the underbody shield and the bolts.

      Torque: 8 Nm

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65. • If equipped. Install the transmission housing cover and attach the retainer.
    • Install the bolts.

      Torque: 8 Nm

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66. If equipped. Install the front skid plate.

    Torque: 40 Nm

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67. If equipped. Install the engine skid plate.

    Torque: 40 Nm

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68. Install the struts.

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69. NOTE: Align the index marks made during hood removal.

    Install the hood and the nuts.

    Torque: 25 Nm

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70. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure using a diagnostic scan tool.
71. Start and check the exhaust system for leaks.
72. Road test the vehicle.