lemon-mirror:
Home >> Ford >> 2004 >> Thunderbird >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Mechanical >> Engine >> Installation >> Engine

Engine Mechanical: Mechanical: Engine: Installation: Engine

Fig 1: Identifying Special Tool(s)
G03281225Courtesy of FORD MOTOR CO.
MATERIALS

Item Specification
Super Premium SAE 5W-20 XO-5W20-QSP or equivalent WSS-M2C153-H
  1. Install the parts in the order indicated in the following illustrations and tables.
    Fig 2: Installing Components (1 Of 14)
    G03281226Courtesy of FORD MOTOR CO.
    Fig 3: Installing Components (2 Of 14)
    G03281227Courtesy of FORD MOTOR CO.
    Fig 4: Installing Components (3Of 14)
    G03281228Courtesy of FORD MOTOR CO.
    Fig 5: Installing Components (4 Of 14)
    G03281229Courtesy of FORD MOTOR CO.
    Fig 6: Installing Components (5 Of 14)
    G03281230Courtesy of FORD MOTOR CO.
    Fig 7: Installing Components (6 Of 14)
    G03281231Courtesy of FORD MOTOR CO.
    Fig 8: Installing Components (7 Of 14)
    G03281232Courtesy of FORD MOTOR CO.
    Fig 9: Installing Components (8 Of 14)
    G03281233Courtesy of FORD MOTOR CO.
    Fig 10: Installing Components (9 Of 14)
    G03281234Courtesy of FORD MOTOR CO.
    Fig 11: Installing Components (10 Of 14)
    G03281235Courtesy of FORD MOTOR CO.
    Fig 12: Installing Components (11 Of 14)
    G03281236Courtesy of FORD MOTOR CO.
    Fig 13: Installing Components (12 Of 14)
    G03281237Courtesy of FORD MOTOR CO.
    Fig 14: Installing Components (13 Of 14)
    G03281238Courtesy of FORD MOTOR CO.
    Fig 15: Installing Components (14 Of 14)
    G03281239Courtesy of FORD MOTOR CO.
  2. Install the driveshaft. For additional information, refer to DRIVELINE SYSTEM .
  3. Install the three-way catalytic converter (TWC). For additional information, refer to EXHAUST SYSTEM .
  4. Install the front wheels and tires.
  5. Install the fresh air filter panel. For additional information, refer to CLIMATE CONTROL SYSTEM .
  6. Install the air cleaner assembly and outlet pipe. For additional information, refer to INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS .
  7. Connect the battery ground cable.
  8. Fill the engine with clean engine oil.
  9. CAUTION: The coolant fill procedure must be followed exactly or damage to the engine can occur.
  10. Fill the engine coolant. For additional information, refer to ENGINE COOLING .
  11. Fill the power steering system. For additional information, refer to STEERING SYSTEM .
  12. Charge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM .

ITEM 1: ENGINE -TO-TRANSMISSION BOLTS INSTALLATION NOTE 

    NOTE: Align the flexplate to converter marks made during engine removal.
  1. Install the engine to the transmission and install the bolts.

ITEM 5: ENGINE AND TRANSMISSION ASSEMBLY INSTALLATION NOTE 

  1. Using a floor crane and the special tool, install the engine onto the subframe.
    Fig 16: Installing Engine Onto Subframe
    G03281240Courtesy of FORD MOTOR CO.

ITEM 16: ENGINE AND TRANSMISSION ASSEMBLY INSTALLATION NOTE 

  1. Remove the special tool.
    Fig 17: Removing Special Tool (1 Of 2)
    G03281241Courtesy of FORD MOTOR CO.
  2. Remove the special tool.
    Fig 18: Removing Special Tool (2 Of 2)
    G03281242Courtesy of FORD MOTOR CO.

ITEM 26: BLOCK HEATER ELECTRICAL CONNECTOR INSTALLATION NOTE 

  1. Connect the engine block heater electrical connector.
    Fig 19: Connecting Engine Block Heater Electrical Connector
    G03281243Courtesy of FORD MOTOR CO.

ITEM 28: ENGINE AND TRANSMISSION ASSEMBLY INSTALLATION NOTE 

  1. Using the powertrain lift and the transmission support bracket, carefully raise the entire assembly into the vehicle.
    Fig 20: Lifting Entire Assembly Into The Vehicle
    G03281244Courtesy of FORD MOTOR CO.
  2. Install the lower air deflector.

ITEM 32: ENGINE AND TRANSMISSION ASSEMBLY INSTALLATION NOTE 

  1. Remove the safety stands from the rear of the vehicle.

ITEM 49: STEERING RACK ELECTRICAL CONNECTOR INSTALLATION NOTE 

  1. Connect the power steering rack electrical connectors.

    ITEM 50: SHIFT CABLE INSTALLATION NOTE 

  1. Clip the shift cable to the bracket.
    Fig 21: Clipping Shift Cable To Bracket
    G03281245Courtesy of FORD MOTOR CO.

ITEM 51: SHIFT CABLE INSTALLATION NOTE 

  1. Connect the shift cable to the shifter.
    Fig 22: Connecting Shift Cable To Shifter
    G03281246Courtesy of FORD MOTOR CO.

ITEMS 55 AND 62: BRAKE CALIPER INSTALLATION NOTE 

  1. Install the brake caliper.

ITEMS 57 AND 64: ANTI-LOCK BRAKE SENSOR HARNESS INSTALLATION NOTE 

  1. Position the anti-lock brake sensor harness and clip to the brake hose.
    Fig 23: Positioning Anti-Lock Brake Sensor Harness & Clip To Brake Hose
    G03281247Courtesy of FORD MOTOR CO.

ITEMS 58 AND 65: WHEEL SPEED SENSOR HARNESS INSTALLATION NOTE 

  1. Connect the wheel speed sensor electrical connector.
    Fig 24: Connecting Wheel Speed Sensor Electrical Connector
    G03281248Courtesy of FORD MOTOR CO.
  2. Position the inner splash shield aside.
    1. Install the pin-type retainers.
    2. Position the inner splash shield.
      Fig 25: Positioning Inner Splash Shield
      G03281249Courtesy of FORD MOTOR CO.

ITEM 66: LOW PRESSURE HOSE INSTALLATION NOTE 

  1. Connect the A/C low pressure hose.
    Fig 26: Connecting A/C Low Pressure Hose
    G03281250Courtesy of FORD MOTOR CO.

ITEM 83: WATER VALVE ELECTRICAL CONNECTOR INSTALLATION NOTE 

  1. Clip the harness to the radiator support and connect the water valve electrical connector.
    Fig 27: Clipping Harness To Radiator Support & Connecting Water Valve Electrical Connector
    G03281251Courtesy of FORD MOTOR CO.

ITEM 84: HEATER HOSE INSTALLATION NOTE 

    NOTE: Install the hoses to the marks made during the removal process.
    Fig 28: Connecting Three Quick-Disconnect Couplings From Coolant Control Valve Hoses-To-Heater Tube Assembly
    G03281252Courtesy of FORD MOTOR CO.
  1. Connect the three quick-disconnect couplings from the coolant control valve hoses to the heater tube assembly. For additional information, refer to CLIMATE CONTROL SYSTEM .

ITEM 90: VAPOR TUBE INSTALLATION NOTE 

  1. Connect the vapor tube to the vapor management valve (VMV).
    Fig 29: Connecting Vapor Tube-To-Vapor Management Valve (VMV)
    G03281253Courtesy of FORD MOTOR CO.

ITEM 91: POWER STEERING PUMP RESERVOIR BOLTS INSTALLATION NOTE 

  1. Position back the power steering pump reservoir and install the bolts.
    Fig 30: Positioning Back Power Steering Pump Reservoir
    G03281254Courtesy of FORD MOTOR CO.