Engine - 4.6L: Installation: Engine: Installation

All Engines 

1. Remove the engine from the engine stand.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
2. Clean and inspect the mating surface.
NOTE: If not secured within four minutes, sealant must be removed and sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Fig 1: Applying Sealant Around Rear Oil Seal Retainer Sealing Surface
Courtesy of FORD MOTOR CO.
3. Apply a bead of sealant around the rear oil seal retainer sealing surface.
4. Install the crankshaft rear oil seal retainer and bolts.
   Fig 2: Identifying Crankshaft Rear Oil Seal Retainer Bolts

   Courtesy of FORD MOTOR CO.
5. Install a new crankshaft rear oil seal.
   Fig 3: Installing Crankshaft Rear Oil Seal

   Courtesy of FORD MOTOR CO.
6. Install the crankshaft oil slinger.
7. Install the flywheel and the bolts. Tighten the bolts in the sequence shown.
   Fig 4: Identifying Flywheel Bolt Tightening Sequence

   Courtesy of FORD MOTOR CO.
8. Support and position the transmission.
9. Install the engine assembly in the vehicle.
   Fig 5: Installing Engine Assembly In Vehicle

   Courtesy of FORD MOTOR CO.
10. Raise the vehicle.
NOTE: When vehicle is raised verify that the torque converter is correctly seated and the index-marks made during removal are lined up.
Fig 6: Tightening Bolts & Stud
Courtesy of FORD MOTOR CO.
11. Install the five bolts and one stud.
12. Install the ground wire and the nut.
    Fig 7: Tightening Ground Wire & Nut

    Courtesy of FORD MOTOR CO.
13. Install the RH bolt.
    Fig 8: Tightening RH Motor Mount Bolt

    Courtesy of FORD MOTOR CO.
14. Install the LH bolts.
    Fig 9: Tightening LH Motor Mount Bolts

    Courtesy of FORD MOTOR CO.
15. Install the four nuts through the torque converter access panel.
    Fig 10: Tightening Flywheel Nuts

    Courtesy of FORD MOTOR CO.
16. Install the inspection cover and the bolts.
    Fig 11: Tightening Inspection Cover Bolts

    Courtesy of FORD MOTOR CO.
17. Install the starter motor (11002) and install the bolts.
    Fig 12: Tightening Starter Motor Bolts

    Courtesy of FORD MOTOR CO.
18. Connect the starter electrical connections and install the nuts.
    Fig 13: Tightening Starter Electrical Connection Nuts

    Courtesy of FORD MOTOR CO.
19. Position the exhaust and install the four nuts.
    Fig 14: Tightening Exhaust Manifold Flange Nuts

    Courtesy of FORD MOTOR CO.
NOTE: Flush the oil cooler with parts cleaner. If metal particles are present in the oil cooler, install a new cooler and hoses.
NOTE: Some vehicles are not equipped with an oil cooler.
Fig 15: Identifying Oil Cooler Hoses
Courtesy of FORD MOTOR CO.
20. Connect the two coolant hoses, position the clamp and install the oil cooler.
21. Position the transmission oil cooler lines and install the bolt.
    Fig 16: Tightening Transmission Oil Cooler Line Bracket Bolt

    Courtesy of FORD MOTOR CO.
22. Lower the vehicle.
23. Install the bolt.
    Fig 17: Tightening Bracket Bolt

    Courtesy of FORD MOTOR CO.
24. Connect the PSP hose.
    Fig 18: Tightening PSP Hose

    Courtesy of FORD MOTOR CO.
25. Connect heated oxygen sensor and position the transmission harness retention clip on the stud.
26. Connect the engine bulkhead connectors.
    Fig 19: Identifying Engine Bulkhead Connectors

    Courtesy of FORD MOTOR CO.
27. Connect the RH heated oxygen sensor electrical connector and snap into the transmission oil level indicator tube.
    Fig 20: Identifying RH Heated Oxygen Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
28. Position the ground strap and install the bolt.
    Fig 21: Tightening Ground Strap Bolt

    Courtesy of FORD MOTOR CO.
29. Connect the heater water hoses.
    Fig 22: Identifying Heater Hoses

    Courtesy of FORD MOTOR CO.
30. Connect the main vacuum supply hose.
    Fig 23: Identifying Main Vacuum Supply Hose

    Courtesy of FORD MOTOR CO.

    Gasoline Engines 

31. Position the EVAP canister purge valve and install the nut.
    Fig 24: Tightening EVAP Canister Purge Valve Nut

    Courtesy of FORD MOTOR CO.
32. Connect the three hoses and the EVAP canister purge valve electrical connection.
    Fig 25: Identifying EVAP Canister Purge Valve Electrical Connection & Hoses

    Courtesy of FORD MOTOR CO.
33. Position the accelerator cable and the speed control actuator cable and install in the clips.
    Fig 26: Identifying Accelerator Cable & Speed Control Actuator Cable Clips

    Courtesy of FORD MOTOR CO.

    All Engines 

34. Connect the accelerator cable and the speed control actuator cable:
    • Install the bolts.
    • Connect the cables.
    Fig 27: Connecting Accelerator Cable & Speed Control Actuator Cable

    Courtesy of FORD MOTOR CO.
35. Connect the air conditioning lines.
    Fig 28: Identifying Air Conditioning Lines

    Courtesy of FORD MOTOR CO.
36. Install the nut and the A/C line bracket.
    Fig 29: Tightening A/C Line Bracket Nut

    Courtesy of FORD MOTOR CO.
37. Connect the A/C cycling switch electrical connector.
    Fig 30: Identifying A/C Cycling Switch Electrical Connector

    Courtesy of FORD MOTOR CO.

    Gasoline Engines 

38. Position the wire and install the nut; connect the electrical connections at the RH inner fender.
    Fig 31: Identifying RH Inner Fender Nut & Electrical Connections

    Courtesy of FORD MOTOR CO.

    Natural Gas Engines 

39. Connect the connectors.
    Fig 32: Identifying Electrical Connections

    Courtesy of FORD MOTOR CO.
40. Install the wires.
    Fig 33: Identifying Power Distribution Box Nut

    Courtesy of FORD MOTOR CO.
41. Install the cover.
    Fig 34: Identifying Power Distribution Box Cover

    Courtesy of FORD MOTOR CO.

    All Engines 

42. Position the ground wires and install the bolt.
    Fig 35: Tightening Ground Wire Nut

    Courtesy of FORD MOTOR CO.
43. Install the radiator assembly.
    Fig 36: Identifying Radiator Assembly

    Courtesy of FORD MOTOR CO.
44. Install the brackets and the bolts.
    Fig 37: Tightening Radiator Mounting Bracket Bolt

    Courtesy of FORD MOTOR CO.
45. Connect the lines to the A/C condenser core and install the nuts.
    Fig 38: Identifying A/C Condenser Core Line Nuts

    Courtesy of FORD MOTOR CO.
46. Connect the fan motor.
    Fig 39: Identifying Cooling Fan Electrical Connector

    Courtesy of FORD MOTOR CO.
47. Connect the upper radiator hose to the water outlet adapter.
    Fig 40: Identifying Upper Radiator Hose

    Courtesy of FORD MOTOR CO.
48. Connect the hoses to the power steering fluid cooler.
    Fig 41: Identifying Power Steering Fluid Cooler Hoses

    Courtesy of FORD MOTOR CO.
49. Connect the hoses to the transmission fluid cooler.
    Fig 42: Identifying Transmission Fluid Cooler Hoses

    Courtesy of FORD MOTOR CO.
50. Install the radiator upper sight shield.
51. Install the battery.
52. Connect the lower radiator hose to the oil filter adapter.
    Fig 43: Identifying Lower Radiator Hose

    Courtesy of FORD MOTOR CO.
53. Install the air cleaner outlet tube.
54. Install the wiper mounting arm and pivot shaft. For additional information, refer to WIPER MOTOR .
55. Fill the crankcase with clean engine oil.
56. Fill and bleed the cooling system.
57. Fill the power steering system.
58. Evacuate and recharge the air conditioning system. For additional information, refer to AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION & CHARGING .
59. Install the hood.