Section 126 (Engine - 2.3L): Installation: Engine

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	Heavy Duty Floor Crane	014-00071 or equivalent
Courtesy of FORD MOTOR CO.	Spreader Bar	303-D089 (D93P-6001-A3) or equivalent

All vehicles 

1. Using the Spreader Bar and the Floor Crane, remove the engine from the stand.
2. Position the engine in the vehicle. Make sure the index marks on the torque converter stud and flexplate made during removal are lined up.
3. Install the 2 side transmission-to-engine bolts.
NOTE: Left side shown in illustration, right side similar.
4. Install the 4 engine support insulator nuts.
   • Tighten to 102 Nm (75 lb-ft).
Fig 1: Locating Engine Support Insulator Nuts
Courtesy of FORD MOTOR CO.
5. Remove the floor jack from the transmission.
6. Remove the floor crane and the spreader bar.

Vehicles with automatic transmission 

7. Install the 4 torque converter nuts.
   • Tighten to 35 Nm (26 lb-ft).
Fig 2: Locating Torque Converter Nut
Courtesy of FORD MOTOR CO.
8. Install the transmission fluid indicator and tube assembly.
Fig 3: Locating Transmission Fluid Indicator & Tube Assembly
Courtesy of FORD MOTOR CO.

All vehicles 

9. Install the remaining 9 transmission-to-engine bolts.
   • Tighten to 48 Nm (35 lb-ft).
Fig 4: Locating Transmission-To-Engine Bolts
Courtesy of FORD MOTOR CO.
10. Position the oil filter adapter and install the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 5: Locating Oil Filter Adapter Bolts
Courtesy of FORD MOTOR CO.
11. Install the starter dust shield.
Fig 6: Locating Starter Dust Shield
Courtesy of FORD MOTOR CO.
12. Install the starter, the bolt and the 2 stud bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 7: Locating Starter, Bolt & 2 Stud Bolts
Courtesy of FORD MOTOR CO.
13. Install a new oil filter.
Fig 8: Locating Oil Filter
Courtesy of FORD MOTOR CO.
14. Connect the engine oil pressure (EOP) sensor electrical connector.
Fig 9: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.

Vehicles with automatic transmission 

15. Attach the wiring harness retainers.
Fig 10: Locating Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
16. Attach the wiring harness retainers and connect the transmission electrical connectors.
Fig 11: Locating Transmission Electrical Connectors
Courtesy of FORD MOTOR CO.
17. Route the wiring harness over the transmission, position the bracket and install the nut. Connect the catalyst monitor sensor electrical connector.
    • Tighten to 10 Nm (89 lb-in).
Fig 12: Locating Catalyst Monitor Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
18. Connect the heated oxygen sensor (HO2S) electrical connector.
Fig 13: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
Courtesy of FORD MOTOR CO.

Vehicles with manual transmission 

19. Attach the wiring harness retainers and connect the transmission electrical connectors.
Fig 14: Locating Wiring Harness Retainers & Connecting Transmission Electrical Connectors
Courtesy of FORD MOTOR CO.
20. Route the wiring harness over the transmission, position the bracket and install the nut. Connect the catalyst monitor sensor electrical connector.
    • Tighten to 10 Nm (89 lb-in).
Fig 15: Locating Catalyst Monitor Sensor Electrical Connector & Nut
Courtesy of FORD MOTOR CO.
21. Connect the HO2S electrical connector.
Fig 16: Locating HO2S Electrical Connector
Courtesy of FORD MOTOR CO.

All vehicles 

22. Connect the electrical connector and attach the wiring harness retainer to the crossmember.
Fig 17: Locating Electrical Connector & Wiring Harness Retainer To Crossmember
Courtesy of FORD MOTOR CO.
23. Position the exhaust front pipe and install the 2 nuts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 18: Locating Exhaust Manifold-To-Front Pipe Nuts
Courtesy of FORD MOTOR CO.
24. Position the transmission dust shield and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 19: Locating Transmission Dust Shield Bolts
Courtesy of FORD MOTOR CO.

Vehicles with automatic transmission 

25. Install the transmission cooling tubes retaining bracket and the bolt.
    • Tighten to 28 Nm (21 lb-ft).
Fig 20: Locating Transmission Cooling Tubes Retaining Bracket Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

26. Position the engine wiring harness and install the anchor and the pin-type retainer.
Fig 21: Locating Anchor & Pin-Type Retainer
Courtesy of FORD MOTOR CO.
27. If equipped, connect the block heater electrical connector.
Fig 22: Locating Block Heater Electrical Connector
Courtesy of FORD MOTOR CO.
28. Attach the generator wiring pin-type retainer.
Fig 23: Locating Generator Wiring Pin-Type Retainer
Courtesy of FORD MOTOR CO.
29. Connect the generator electrical connections.
    • Tighten to 8 Nm (71 lb-in).
Fig 24: Locating Generator Electrical Connections
Courtesy of FORD MOTOR CO.
30. Position the splash shield and install the pushpins.
Fig 25: Locating Splash Shield Pushpins
Courtesy of FORD MOTOR CO.
31. Position the starter wiring harness and install the support bracket and the bolt.
    • Tighten to 24 Nm (18 lb-ft).
Fig 26: Locating Starter Wiring Harness Clamp Bolt
Courtesy of FORD MOTOR CO.
32. Connect the following starter motor electrical connections.
    • Install the solenoid control wire and nut.
      • Tighten to 6 Nm (53 lb-in).
    • Install the negative battery cable and nut.
      • Tighten to 12 Nm (9 lb-ft).
    • Install the positive battery cable at the starter and the nut.
      • Tighten to 12 Nm (9 lb-ft).
Fig 27: Locating Solenoid Control Wire & Nut
Courtesy of FORD MOTOR CO.
33. Connect the brake booster vacuum hose and the engine ground strap.
    • Tighten to 10 Nm (89 lb-in).
Fig 28: Locating Brake Booster Vacuum Hose & Engine Ground Strap
Courtesy of FORD MOTOR CO.
34. Connect the electrical connectors, the fuel supply tube and the evaporative purge tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
Fig 29: Locating Fuel Supply Tube Spring Lock Coupling
Courtesy of FORD MOTOR CO.
35. Connect the fuel supply tube spring lock coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
NOTE: Install a new nylon O-ring seal.
36. Connect the power steering high-pressure tube and the power steering pressure (PSP) switch electrical connector.
    • Tighten to 20 Nm (15 lb-ft).
Fig 30: Locating Power Steering Pressure (PSP) Switch Electrical Connector
Courtesy of FORD MOTOR CO.
37. Connect the accelerator cable and, if equipped, the speed control cable to the throttle body (TB) and the cable mounting bracket.
Fig 31: Locating Accelerator Cable
Courtesy of FORD MOTOR CO.
38. Remove the plugs and connect the A/C compressor manifold.
    • Tighten to 20 Nm (15 lb-ft).
Fig 32: Locating A/C Compressor Manifold Bolt
Courtesy of FORD MOTOR CO.
39. Connect the mass air flow (MAF) sensor electrical connector.
Fig 33: Locating Mass Airflow Sensor (MAF) Electrical Connector
Courtesy of FORD MOTOR CO.
40. Connect the A/C compressor electrical connector.
Fig 34: Locating A/C Compressor Electrical Connector
Courtesy of FORD MOTOR CO.
41. Connect the coolant reservoir-to-engine supply hose.
Fig 35: Locating Coolant Reservoir-To-Engine Supply Hose
Courtesy of FORD MOTOR CO.
42. Connect the engine-to-coolant reservoir bypass hose.
Fig 36: Locating Engine-To-Coolant Reservoir Bypass Hose
Courtesy of FORD MOTOR CO.
43. Connect the vacuum reservoir tube.
Fig 37: Locating Vacuum Reservoir Tube Connection
Courtesy of FORD MOTOR CO.
44. Install the heater hose assembly.
    1. Connect the heater hoses to the heater core.
    2. Connect the vacuum hose.
    3. Connect the heater hoses to the engine.
Fig 38: Identifying Heater Hose Assembly
Courtesy of FORD MOTOR CO.
45. Install the ground strap and stud bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 39: Locating Ground Strap & Stud Bolt
Courtesy of FORD MOTOR CO.
46. Position the PCM harness, install the harness retaining nut and connect the 3 PCM electrical connectors.
    • Tighten the harness retainer nut to 4 Nm (35 lb-in).
Fig 40: Powertrain Control Module (PCM) Connectors
Courtesy of FORD MOTOR CO.
47. Install the lower radiator hose.
Fig 41: Locating Lower Radiator Hose
Courtesy of FORD MOTOR CO.
48. Install the fan shroud. For additional information, refer to ENGINE COOLING article.
49. Install the upper radiator hose.
Fig 42: Locating Upper Radiator Hose
Courtesy of FORD MOTOR CO.
50. Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING article.
51. Install the hood.
52. Fill the engine with clean engine oil.
53. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING & CABLES article.
54. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING article.
55. Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL INFORMATION article.
56. Evacuate and charge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS article.