Installation

1. Install Lifting Bracket Set D91P-6001-A or equivalent.
2. Connect Rotunda Floor Crane 014-00071 to lifting brackets and remove engine from work stand.
3. Carefully lower engine into engine compartment.

NOTE: Make sure studs on torque converter (7902) align with holes in flywheel (6375).

4. Start torque converter pilot into flywheel and align paint marks on flywheel and torque converter.
5. Fully engage engine to transmission and lower onto front engine support insulators.
6. Remove engine-lifting equipment.
7. Install bolt retaining RH front engine support insulator to front sub-frame.
8. Raise vehicle.
9. Install six bolts retaining engine to transmission and tighten to 40-60 Nm (30-44 ft. lbs.).

NOTE: Two through bolts are required on LH front engine support insulator and one through bolt on RH front engine support insulator.

10. Install front engine support insulator through bolts. Tighten to 20-30 Nm (15-22 ft. lbs.).

NOTE: Rotate crankshaft until each nut (four required) is accessible.

11. Install four torque converter retaining nuts. Tighten to 30-35 Nm (23-25 ft. lbs.).
12. Install transmission housing cover to cylinder block. Position power steering pump on cylinder block and install four retaining nuts. Tighten to 20-30 Nm (15-22 ft. lbs.).
14. Install starter motor. Refer to Starting and Charging.
15. Install three bolts and stud bolt retaining transmission case to cylinder block front bracket to engine. Tighten bolts and stud bolt to 25-43 Nm (19-31 ft. lbs.).
16. Position transmission line bracket to transmission case to cylinder block bracket stud and install retaining nut. Tighten to 20-30 Nm (15-22 ft. lbs.).

NOTE: Make sure three way catalytic converter clears No.3 crossmember. Adjust as necessary.

17. Remove wire and position exhaust system to both exhaust manifolds. Install four nuts and tighten to 27-41 Nm (20-30 ft. lbs.).
18. Connect fuel charging wiring to the power steering control valve actuator (3783).
19. Lower vehicle.
20. Connect inlet and outlet hoses to A/C compressor. Tighten retaining nut on engine front cover stud to 8-12 Nm (71-106 inch lbs.).
21. Connect generator harness from front fender apron and power distribution box.
22. Connect heater supply and return hoses.





23. Connect vacuum supply hose to throttle body adapter vacuum port.
25. Connect fuel charging wiring and evaporative emission return tube to evaporative emission canister purge valve (EVAP canister purge valve)(9C915).
26. Connect evaporative emission return tube to evaporative emissions canister purge line.





27. Connect accelerator cable and speed control actuator cables.
28. Connect 42-pin engine harness connector and eight-pin transmission harness connector at power brake booster (2005).
29. Install transmission harness on retention bracket on rear of LH cylinder head.
30. Install windshield wiper governor and support bracket.
31. Connect fuel lines. Refer to Powertrain Management.
32. Install radiator, fan blade and fan shroud.
33. Install air cleaner outlet tube.
34. Fill and bleed engine cooling system.
35. Evacuate and recharge air conditioning system. Refer to Heating and Air Conditioning.
36. Install hood.
37. Connect battery ground cable.
38. Fill engine crankcase with clean oil meeting Ford specification WSS-M2C910-A1 to the specified level.
39. Start engine and check for coolant, oil and fuel leaks.