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Section 486 (Engine-3.8L): Installation: Engine: Installation

WARNING: This page is about a different car, the 2003 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
  1. All vehicles  Install the separator plate and the flywheel.
    Fig 1: Installing Separator Plate And The Flywheel
    G01623944Courtesy of FORD MOTOR CO.
  2. Using the special tools, position the engine in the vehicle.
    Fig 2: Positioning Engine In Vehicle
    G01623945Courtesy of FORD MOTOR CO.
  3. Remove the special tools.
  4. Raise and support the vehicle.
  5. Install the LH engine mount nut.
    Fig 3: Installing LH Engine Mount Nut
    G01623946Courtesy of FORD MOTOR CO.
  6. Install the RH engine mount nut.
    Fig 4: Installing RH Engine Mount Nut
    G01623947Courtesy of FORD MOTOR CO.
  7. Vehicles equipped with manual transmission  Install the transmission. For additional information, refer to MANUAL TRANSAXLE-T50D .
  8. Install the transmission oil filler tube.
    Fig 5: Installing Transmission Oil Filler Tube
    G01623948Courtesy of FORD MOTOR CO.
  9. Vehicles equipped with automatic transmission  Install the five bellhousing upper bolts.
    Fig 6: Installing Bellhousing Upper Bolts
    G01623949Courtesy of FORD MOTOR CO.
  10. Install the bolts.
    Fig 7: Installing Bolts
    G01623950Courtesy of FORD MOTOR CO.
  11. Install the four torque converter nuts.
    Fig 8: Installing Torque Converter Nuts
    G01623951Courtesy of FORD MOTOR CO.
  12. All vehicles  Install the access cover.
    Fig 9: Installing Access Cover
    G01623952Courtesy of FORD MOTOR CO.
  13. Install the oil pan drain plug.
    Fig 10: Installing Oil Pan Drain Plug
    G01623953Courtesy of FORD MOTOR CO.
  14. Install the bracket.
    Fig 11: Installing Bracket
    G01623954Courtesy of FORD MOTOR CO.
  15. Connect the engine ground strap.
    Fig 12: Connecting Engine Ground Strap
    G01623955Courtesy of FORD MOTOR CO.
  16. Install the bracket.
    Fig 13: Installing Bracket
    G01623956Courtesy of FORD MOTOR CO.
  17. Install the bracket.
    Fig 14: Installing Bracket
    G01623957Courtesy of FORD MOTOR CO.
  18. Install the dual converter Y-pipe. For additional information, refer to EXHAUST SYSTEM .
  19. Install the starter motor. For additional information, refer to STARTERS .
  20. Lower the vehicle.
  21. Connect the evaporative emissions (EVAP) return tube.
    Fig 15: Connecting Evaporative Emissions (EVAP) Return Tube
    G01623958Courtesy of FORD MOTOR CO.
  22. Connect the connector and vacuum tube.
    Fig 16: Connecting Connector And Vacuum Tube
    G01623959Courtesy of FORD MOTOR CO.
  23. Position the wiring harness.
    Fig 17: Installing Wiring Harness
    G01623960Courtesy of FORD MOTOR CO.
  24. Connect the following connectors:
    • 42-pin electrical connector
    • 16-pin electrical connector
    • 8-pin electrical connector
    • A/C pressure switch
      Fig 18: Connecting 42, 16, 8 Pin Electrical Connector And A/C Pressure Switch
      G01623961Courtesy of FORD MOTOR CO.
  25. Connect the heater hoses.
    Fig 19: Connecting Heater Hoses
    G01623962Courtesy of FORD MOTOR CO.
  26. Connect the fuel supply tube spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  27. Connect the A/C compressor electrical connector.
    Fig 20: Connecting A/C Compressor Electrical Connector
    G01623963Courtesy of FORD MOTOR CO.
  28. Connect the A/C manifold and tube. For additional information, refer to AIR CONDITIONING .
  29. Install the air cleaner outlet tube. For additional information, refer to REMOVAL & INSTALLATION .
  30. Install the accelerator cable bracket.
    Fig 21: Installing Accelerator Cable Bracket
    G01623964Courtesy of FORD MOTOR CO.
  31. Connect the accelerator cable.
    Fig 22: Connecting Accelerator Cable
    G01623965Courtesy of FORD MOTOR CO.
  32. Install the radiator coolant recovery reservoir.
    Fig 23: Installing Radiator Coolant Recovery Reservoir
    G01623966Courtesy of FORD MOTOR CO.
  33. Connect the upper radiator hose.
    Fig 24: Connecting Upper Radiator Hose
    G01623967Courtesy of FORD MOTOR CO.
  34. Connect the lower radiator hose.
    Fig 25: Connecting Lower Radiator Hose
    G01623968Courtesy of FORD MOTOR CO.
  35. Connect the power steering pump.
    • Connect the power steering return hose.
    • Position the clamp.
    • Connect the power steering pressure tube.
      Fig 26: Connecting Power Steering Pump
      G01623969Courtesy of FORD MOTOR CO.
  36. Connect the generator electrical connections.
    Fig 27: Connecting Generator Electrical Connections
    G01623970Courtesy of FORD MOTOR CO.
  37. Connect the vacuum hose.
    Fig 28: Connecting Vacuum Hose
    G01623971Courtesy of FORD MOTOR CO.
  38. Install the hood.
    Fig 29: Installing Hood
    G01623972Courtesy of FORD MOTOR CO.
  39. Connect the hood ground strap.
    Fig 30: Connecting Hood Ground Strap
    G01623973Courtesy of FORD MOTOR CO.
  40. Connect the battery negative cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  41. Fill the engine with clean engine oil.
  42. Fill the engine cooling system. For additional information, refer to ENGINE COOLING .
  43. Recharge the A/C refrigerant system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  44. 44. Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
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