Installation
1. Install LH exhaust manifold gasket and LH exhaust manifold. Tighten exhaust manifold bolts to 18-20 Nm (13-15 lb-ft) in sequence.
2. Install EGR valve to exhaust manifold tube to EGR valve and LH exhaust manifold. Tighten retaining nuts to 40-45 Nm (30-33 lb-ft).
3. Connect EGR backpressure transducer hoses to the EGR valve to exhaust manifold tube.
4. Install RH and LH front engine support insulators on cylinder block.
5. Install engine lifting bracketry from Rotunda Engine Lift Bracket Set 014-00340 or equivalent.
Engine Lifting Brackets, RH Side
Engine Lifting Brackets, LH Side
6. Remove engine from stand using spreader bar and chains from Rotunda Engine Lift Bracket Set 014-00340 or equivalent.
7. Install transmission to cylinder block. Tighten transmission mounting bolts to 40-60 Nm (30-44 lb-ft).
8. Position engine and transmission on front sub-frame.
9. Install front engine support insulator through bolts. Tighten to 20-30 Nm (15-22 lb-ft).
10. Raise engine, transmission and front sub-frame into position.
11. Align front sub-frame to body and install sub-frame-to-body bolts. Tighten to 95-130 Nm (73-100 lb-ft).
12. Connect steering coupling at pinch bolt joint.
13. Install rear engine support insulator retaining bolts. Tighten to 20-30 Nm (15-22 lb-ft).
14. Remove Rotunda Powertrain Lift 014-00765 or equivalent and move out of way.
15. Install starter motor. Refer to Starting System. Starting System
16. Connect low oil level sensor to engine control sensor wiring.
17. Install positive battery cable and two retaining nuts to lower engine front cover studs.
18. Install secondary air injection diverter valve. Tighten retaining nuts to 8-12 Nm (6-8 lb-ft).
19. Install RH secondary air injection tube gasket. Tighten fittings to 32-48 Nm (24-35 lb-ft).
20. Install LH secondary air injection tube gasket. Tighten fittings to 32-48 Nm (24-35 lb-ft).
21. Connect LH secondary air injection tube gasket to RH secondary air injection tube gasket. Tighten fitting to 32-48 Nm (24-35 lb-ft).
22. Install the secondary air injection tube bracket retaining bolts. Tighten bolts to 20-30 Nm (15-22 lb-ft).
23. Connect electrical wiring harness clip to secondary air injection manifold tube.
24. Connectsecondary air injection tube gaskets to exhaust manifolds. Tighten fitting to 32-48 Nm (24-35 lb-ft).
25. Connect vacuum supply tube to secondary air injection diverter valve.
26. Install driveshaft to transmission.
27. Lift rear axle assembly into position.
28. Install two nut and bolt assemblies retaining front of the rear axle assembly to the rear sub-frame. Tighten to 98-120 Nm (72-89 lb-ft).
29. Tighten two rear axle differential nuts to 102-127 Nm (75-89 lb-ft).
30. Align driveshaft centering socket yoke to rear axle universal joint flange and install four retaining bolts. Tighten to 95-130 Nm (70-96 lb-ft).
31. Connect lower fluid cooler tube to radiator. Refer to Automatic Transmission - 4R70W. Automatic Transmission/Transaxle
32. Connect engine control sensor wiring.
33. Connect gear selector linkage. Refer to Automatic Transmission - 4R70W. Automatic Transmission/Transaxle
34. Position front suspension lower arms to strut and install retaining bolt. Tighten to 160-220 Nm (118-162 lb-ft).
35. Connect power steering pressure hose. Refer to Steering System. Steering
36. Connect ground strap to RH front fender apron.
37. Install dual converter Y pipe. Refer to Exhaust System.
38. Connect front suspension upper arms to front wheel hub and spindles. Tighten to 68-92 Nm (50-68 lb-ft).
39. Connect ride height sensor wiring connectors.
40. Install disc brake calipers. Refer to Brakes and Traction Control. Brakes and Traction Control
41. Install front wheel and tires. Refer to Wheels and Tires. Wheels and Tires
42. Lower vehicle.
43. Connect A/C lines to A/C compressor. Refer to Heating and Air Conditioning. Heating and Air Conditioning
44. Remove engine lifting brackets from Rotunda Engine Lift Bracket Set 014-00340 or equivalent.
45. Connect upper fluid cooler inlet tube. Refer to Automatic Transmission - 4R70W. Automatic Transmission/Transaxle
46. Install power steering pump. Connect power steering return line hose to power steering pump. Connect power steering pressure hose. Refer to Steering System. Steering
47. Install radiator overflow hose to radiator coolant recovery reservoir.
48. Connect upper radiator hose at water bypass tube.
49. Connect heater inlet and outlet hoses.
50. Connect chassis vacuum supply hose.
51. Connect evaporative emission canister purge vacuum line.
52. Connect accelerator cable and speed control actuator cable.
53. Connect engine control sensor wiring to evaporative emission canister purge valve.
54. Connect generator B+ wiring connector and install power distribution box and harness.
55. Connect 42-pin connector.
56. Install engine appearance cover as outlined.
57. Install 42-pin connector to retaining bracket.
58. Connect fuel tubes. Refer to Fuel Delivery and Air Induction. Fuel Delivery and Air Induction
59. Install cooling fan, fan blade and fan shroud assembly. Refer to Cooling System. Cooling System
60. Connect secondary air injection inlet hose to secondary air injection pump outlet hose.
61. Install secondary air injection inlet hose retainer in fan shroud.
62. Install windshield wiper module assembly. Refer to Wiper and Washer Systems. Wiper and Washer Systems
63. Install air cleaner outlet tube and engine intake air resonator.
64. Connect IAT sensor wiring connector and crankcase ventilation tube.
65. Fill crankcase to proper level with engine oil meeting Ford specification ESE-M2C153-E.
66. Fill power steering pump. Refer to Steering System. Steering
67. Fill radiator with engine coolant. Refer to Cooling System. Cooling System
68. Start engine and check for leaks.
69. Recheck all fluid levels. Fill as required.
70. Evacuate and recharge air conditioning system. Refer to Heating and Air Conditioning. Heating and Air Conditioning
71. Install engine appearance cover.
72. Check front end alignment. Refer to Steering and Suspension. Steering and Suspension