Steps 51-102
Engine Front Cover
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.
51. NOTE: LH shown, RH similar.
Install the stabilizer bar links and nuts to the struts.
52. NOTE: LH shown, RH similar.
Install the tie-rod ends and nuts.
- Tighten to 48 Nm (35 lb-ft).
- Install new cotter pins.
53. Install the engine roll restrictor-to-subframe through bolt.
- Tighten to 90 Nm (66 lb-ft).
AWD vehicles
54. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 new bolts (3 shown).
- Tighten to 70 Nm (52 lb-ft).
All vehicles
55. Using new gaskets, install the Y-pipe assembly and the 6 new nuts.
- Tighten to 40 Nm (30 lb-ft).
56. Install a new engine oil filter.
- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
57. Connect the 2 transmission fluid cooler hoses.
58. Connect the power steering cooler tube.
59. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body.
- From under the vehicle, verify that the seal is correctly installed on the steering gear and the retaining clips are fully engaged into the body.
60. If equipped, install the underbody shield and the 6 screws.
61. Install the LH splash shield and the 6 pin-type retainers (4 shown).
62. Position the LH fender splash shield and install the 4 screws.
63. NOTE: Align the index marks made during removal.
Install the steering intermediate shaft onto the steering gear and install a new bolt.
- Tighten to 25 Nm (18 lb-ft).
64. Install the steering joint cover and the 2 nuts.
65. Using a new banjo bolt and 2 new seals, install the PSP tube onto the steering gear.
- Tighten to 37 Nm (27 lb-ft).
66. Install the PSP tube bracket and bolt.
- Tighten to 10 Nm (89 lb-in).
67. Connect the PCM connectors and pin-type retainers.
68. Install the engine mount brace and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
69. Install the ground wire and the bolt.
- Tighten to 10 Nm (89 lb-in).
70. Connect the fuel supply tube to the fuel rail.
71. Attach the power steering reservoir onto the cowl.
72. Connect the hose to the power steering reservoir.
- Attach the pin-type retainer to the engine mount brace.
73. Install the oil level indicator.
74. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
75. Connect the 2 engine wiring harness electrical connectors.
76. Attach the 2 wiring harness retainers.
77. Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
- Tighten to 8 Nm (71 lb-in).
78. Install the A/C tube bracket bolt.
- Tighten to 8 Nm (71 lb-in).
79. Install the 2 A/C tube retaining clamp bolts.
- Tighten to 10 Nm (89 lb-in).
80. Using a new O-ring seal, connect the A/C tube to the condenser and install the nut.
- Tighten to 8 Nm (71 lb-in).
81. Attach the coolant tube retainer clips to the A/C tube.
82. If equipped, attach the engine block heater harness to the radiator support, power steering hose, A/C tube and the engine wiring harness.
83. Install the ground wire and bolt.
- Tighten to 12 Nm (106 lb-in).
84. Position the transaxle control cable bracket in place and install the 3 nuts.
- Tighten to 12 Nm (106 lb-in).
85. Connect the transaxle control cable to the control lever.
86. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
87. Connect the vacuum hose and the Evaporative Emission (EVAP) tube to the upper intake manifold.
88. Install the ground wire and the bolt.
- Tighten to 12 Nm (106 lb-in).
89. Install the 2 battery cables to the positive battery cable and the 2 nuts.
- Tighten to 9 Nm (80 lb-in).
90. Attach the 2 wiring harness retainers to the transmission mount and the battery tray bracket.
91. Connect the 2 engine wiring harness electrical connectors.
92. Install the battery tray. For additional information, refer to Battery, Mounting and Cables Battery Tray.
93. Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering - 3.5L Air Cleaner and Air Cleaner Outlet Pipe.
94. Install the degas bottle. For additional information, refer to Engine Cooling Service and Repair.
95. Install the LH halfshaft and the intermediate shaft.
96. Install the accessory drive belt and the power steering belt. For additional information, refer to Accessory Drive - 3.5L Service and Repair.
97. NOTICE: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
Fill the engine with clean engine oil.
98. Fill and bleed the cooling system. For additional information, refer to Engine Cooling Service and Repair.
99. Fill the power steering system. For additional information, refer to Steering System - Hydraulic Power Assist Steering (HPAS) Power Steering System Filling.
100. Check the transaxle fluid and add fluid if necessary. For additional information, refer to the Transmission Fluid Drain and Refill procedure in Automatic Transaxle/Transmission - Aisin AW21 Transmission Fluid Drain and Refill.
101. Recharge the A/C system. For additional information, refer to Climate Control System - General Information and Diagnostics Air Conditioning (A/C) System Recovery, Evacuation and Charging.
102. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.