Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Engine - Body Off
For information on Ford Color Coded Illustrations refer to OEM Color Coding .
Special Tool(s) / General Equipment
| Floor Crane |
|---|
| Trolley Jack |
| Hose Clamp Remover/Installer |
| Wooden Block |
Materials
| Name | Specification |
|---|---|
| Motorcraft® Multi-Purpose Grease SprayXL-5-A | ESB-M1C93-B |
| Motorcraft® Threadlock 262TA-26 | WSK-M2G351-A6 |
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- Inspect the engine mount-to-frame nut plate for thread damage.
- If the nut plate is damaged, remove and discard the engine mount-to-frame nut plate.
- Clean the engine mount-to-frame mating surfaces of any dirt or foreign material prior to installation.
- Lubricate the torque converter pilot hub with multi-purpose grease.
Material: Motorcraft® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)
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- Inspect the torque converter stud and flexplate for sticker.
- Align the torque converter stud and flexplate hole near the sticker to the 12 o'clock position.
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NOTE: It may be necessary to install a ratchet strap from the front of engine to the chain to keep the engine level.
With the aid of an assistant, use the floor crane to install the engine assembly in the chassis.
- Attach the generator wiring harness retainer to the lower LH side of the engine block.
- Using the floor crane and chain, position the engine to the transmission. Use the General Equipment: Floor Crane
- Install the transmission-to-engine bolts.
Torque: 35 lb.ft (48 Nm)
- Install the transmission-to-engine bolts.
Torque: 35 lb.ft (48 Nm)
- Using the floor crane and chain, raise the engine for clearance to install the LH engine mount. Use the General Equipment: Floor Crane
- Install the LH engine mount.
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NOTE: Use only hand tools when installing the LH engine mount through bolt or the engine mount may be damaged.
- Install the new LH engine mount through bolt.
- Do not torque at this time.
- Lower the engine to install the engine mount.
- Install the LH engine mount bolts.
Torque: 129 lb.ft (175 Nm)
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- Lower the engine to the installed position and remove the floor crane. Use the General Equipment: Floor Crane
- Remove the ratchet strap.
- Remove the chains.
- 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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NOTE: Use only hand tools when tightening the LH engine mount through bolt or the engine mount may be damaged.
Tighten the LH engine mount through bolt.
Torque: 258 lb.ft (350 Nm)
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- Install the high-pressure fuel pump to port injection fuel rail tube and connect the quick release couplings. Refer to: Quick Release Coupling .
- Connect the fuel supply tube quick release coupling. Refer to: Quick Release Coupling .
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NOTE: When removing or installing the high-pressure fuel pump noise insulator, spreading the openings will reduce the risk of damage.
Install the high-pressure fuel pump noise insulator.
- Install the PCV tube. Refer to: Quick Release Coupling
.
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NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
Inspect the intake manifold for damage or metal debris.
- Install the new upper intake manifold gaskets.
- Install the upper intake manifold and tighten the bolts in sequence shown below.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45°
- Install a new exhaust manifold tube gasket.
- Install the EGR valve to exhaust manifold tube bolts finger tight.
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- Install new EGR tube O-ring seal and gasket.
- Lubricate the O-ring seal with clean engine oil.
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- Install the EGR tube and the bolts finger tight.
- Install the EGR tube to EGR valve bolts finger tight.
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- Tighten the EGR tube bolts.
Torque: 89 lb.in (10 Nm)
- Tighten the EGR tube to EGR valve bolts.
Torque: 89 lb.in (10 Nm)
- Tighten the EGR tube bolts.
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- Install the hoses, EGR transducer and the bolt.
Torque: 80 lb.in (9 Nm)
- Connect the EGR transducer electrical connector.
- Install the hoses, EGR transducer and the bolt.
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- Tighten the EGR valve bracket bolts.
Torque: 89 lb.in (10 Nm)
- Tighten the EGR valve bracket nut.
Torque: 71 lb.in (8 Nm)
- Tighten the EGR valve bracket bolts.
- Tighten the EGR valve to exhaust manifold tube bolts.
Torque: 89 lb.in (10 Nm)
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- Connect the throttle body electrical connector and wire harness retainer.
- Install the upper intake manifold support bracket bolt.
Torque: 89 lb.in (10 Nm)
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- Connect the MAP sensor electrical connector.
- Attach the wiring harness retainers.
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- Install the EVAP canister purge valve and attach to the retainer.
- Connect the EVAP canister purge valve tube quick connect coupling. Refer to: Quick Release Coupling .
- Connect the EVAP canister purge valve wiring harness electrical connector.
- Attach the EVAP canister purge valve tube retainer to the intake manifold.
- Connect the EVAP canister purge valve tube quick connect coupling to the intake manifold. Refer to: Quick Release Coupling .
- Tighten the upper intake manifold support bracket bolt.
Torque: 89 lb.in (10 Nm)
- Install the crankcase vent tube.
- Attach the generator wiring harness retainer to the oil filter adapter.
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- Install the generator and the bolt finger tight.
- Install the generator stud.
Torque: 71 lb.in (8 Nm)
- Install the generator stud nut.
Torque: 35 lb.ft (47.5 Nm)
- Tighten the generator bolt.
Torque: 35 lb.ft (47.5 Nm)
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- Connect the generator electrical connector.
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NOTE: When installing the B+ terminal nut to the generator, finger-start the nut before tightening or component damage may occur.
Position the B+ wire, install the nut and position the protective cover.
Torque: 155 lb.in (17.5 Nm)
- Attach the transmission wiring harness retainers to the back of the RH cylinder head.
- Attach the transmission wiring harness retainer to the back of the RH valve cover stud bolt.
- Connect the heater hose to the lower intake manifold at the rear of the engine.
- Position the ground strap and install the nut on the RH valve cover stud bolt.
Torque: 71 lb.in (8 Nm)
- Attach the coolant hoses retainers to the intake manifold.
- Connect the PCV tube quick connect coupling to the intake manifold.
- Connect the coolant hoses to the EGR valve.
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- Position the cabin heater coolant pump and coolant hose and install the bolts.
Torque: 62 lb.in (7 Nm)
- Connect the cabin heater coolant pump wiring harness electrical connector.
- Position the cabin heater coolant pump and coolant hose and install the bolts.
- Install a new thermostat housing O-ring seal and lubricate with clean engine coolant.
- Install the thermostat housing, hoses and the bolts.
Torque: Stage 1: 71 lb.in (8 Nm) | Stage 2: 45°
- Connect the coolant hose to the cabin heater coolant pump. Use the General Equipment: Hose Clamp Remover/Installer
- Connect the A/C compressor electrical connector and the wiring harness retainers.
- Connect the generator wiring to the engine front cover.
- Position the wiring harness and transmission cooler tube bracket and install the nut.
Torque: 106 lb.in (12 Nm)
- Install the body. Refer to: Body .
- Install the A/C compressor belt. Refer to: Air Conditioning (A/C) Compressor Belt .
- Install the LH transmission-to-engine bolts.
Torque: 35 lb.ft (48 Nm)
- Install the transmission-to-engine bolt.
Torque: 35 lb.ft (48 Nm)
- Install the engine-to-transmission bolts.
Torque: 35 lb.ft (48 Nm)
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NOTE: Only use hand tools when installing the engine mount studs or damage to the engine mount can occur.
- Apply threadlock to the stud threads prior to installation.
Material: Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)
- Install the engine mount studs.
Torque: 22 lb.ft (30 Nm)
- Apply threadlock to the stud threads prior to installation.
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NOTE: Use only hand tools when installing the RH engine mount nuts or the engine mount may be damaged.
Install the new RH engine mount nuts.
Torque: 111 lb.ft (150 Nm)
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NOTE: Only use hand tools when installing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur.
Tighten the transmission mount-to-crossmember nuts.
Torque: 85 lb.ft (115 Nm)
- Install the new RH catalytic converter-to-exhaust manifold nuts.
Torque: 30 lb.ft (40 Nm)
- Install the new LH catalytic converter-to-exhaust manifold nuts.
Torque: 30 lb.ft (40 Nm)
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- Position the exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe and install the bolts.
- Tighten the inner exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt.
Torque: 46 lb.ft (63 Nm)
- Tighten the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt.
Torque: 46 lb.ft (63 Nm)
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NOTE: Using the crankshaft pulley bolt, turn the engine clockwise.
Install the torque converter nuts.
Torque: 35 lb.ft (48 Nm)
- Install the access cover and pin-type retainers.
- Install the starter motor. Refer to: Starter Motor .
- Install the ground wire and bolt to the oil pan.
Torque: 18 lb.ft (25 Nm)
- Attach the starter motor wiring harness retainer to the oil pan.
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NOTE: Do not lubricate the engine oil filter seal.
Install the new engine oil filter.
Torque: Stage 1: 44 lb.in (5 Nm) | Stage 2: 180°
- If equipped, install the skid plate and the bolts.
Torque: 30 lb.ft (40 Nm)
- If equipped, install the underbody shield and bolts.
Torque: 30 lb.ft (40 Nm)
- If equipped, install the transmission housing cover and the bolts
Torque: 71 lb.in (8 Nm)
- Fill the engine with clean engine oil. Refer to: Specifications .
- Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
- Pressurize the fuel system. Refer to: Fuel System Pressure Release .
- Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
- Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
- Start and check the exhaust system for leaks.
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.