ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Engine - Vehicles Built From: 12-2005 > < Engine - Vehicles Built From: 01-2006

Maverick 2005 (08.2004-)

Engine - 3.0L Duratec-VE (VE6) - Engine—Vehicles Built From: 12/2004 Maverick 2005 (08/2004-)
Installation

Special Tool(s)

Lifting Bracket, Engine

303-050 (T70P-6000)

Powertrain Lift with Tilting Plate

014-00765

Spreader Bar

303-D089 (D93P-6001-A3) or equivalent

Universal Adapter Brackets

014-0001
Materials
Name
Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent
WSS-M2C930-A
Silicone Gasket and Sealant
TA-30
WSE-M4G323-A4

Installation

CAUTION:
CAUTION:If the oil pan was removed during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.
All vehicles
  1. Using the special tools, align the engine with the transaxle.

  1. Install the 7 transaxle bolts.
    • Tighten to 40 Nm (30 lb-ft).

  1. Using the special tools, secure the engine to the powertrain lift.
All wheel drive (AWD) vehicles
  1. Position the power take off, attach the pin-type retainer and install the bolt.
    • Tighten to 14 Nm (10 lb-ft).

  1. Install the halfshaft support bracket and the bolts.
    • Tighten to 48 Nm (35 lb-ft).

  1. Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).

  1. Install a new gasket and the RH exhaust manifold and new nuts.
    • Tighten in the sequence shown to 20 Nm (15 lb-ft).
All vehicles
  1. Connect the turbine speed sensor (TSS) electrical connector.

  1. Attach the transaxle control harness to the brackets.

  1. Connect the transaxle wiring harness electronic control switch electrical connector.

  1. Connect the transmission range (TR) sensor electrical connector.

  1. Attach the pin-type retainers to the transaxle support bracket and connect the heated oxygen sensor (HO2S) and catalyst monitor sensor electrical connectors.

  1. Position the powertrain into the vehicle.

  1. Install the front engine support nuts.
    • Tighten to 55 Nm (41 lb-ft).

  1. Install the rear transaxle support bolt.
    • Tighten to 103 Nm (76 lb-ft).

  1. Position the RH transaxle support insulator and install the bolt and nuts.
    • Tighten to 80 Nm (59 lb-ft).

  1. Install the RH transaxle support insulator bolt.
    • Tighten to 115 Nm (85 lb-ft).

  1. NOTE:
    NOTE:Clean and degrease all sealing surfaces with metal surface cleaner.
    NOTE:
    NOTE:The oil pan must be installed and the bolts tightened within 4 minutes of the sealant application.
    Apply a 10 mm (0.39 in) dot of silicone gasket and sealant to the front cover-to-cylinder block sealing surface.

  1. NOTE:
    NOTE:Install a new oil pan gasket.
    Position the oil pan and gasket and loosely install the bolts and stud bolts.

  1. Install the 2 oil pan-to-transaxle bolts.
    • Tighten to 40 Nm (30 lb-ft).

  1. Tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).

  1. Install the 4 torque converter nuts.
    • Tighten to 40 Nm (30 lb-ft).

  1. Install the torque converter inspection cover.

  1. Install the output shaft speed (OSS) sensor and the bolt and connect the electrical connector.
    • Tighten to 13 Nm (10 lb-ft).

  1. Attach the HO2S wiring retainer to the radiator center support.

  1. If equipped, connect the engine block heater electrical connector.

  1. Attach the wiring harness retainers from the battery tray bracket.

  1. Position the ground strap and the electrical connector and install the bolts.
    • Tighten to 10 Nm (89 lb-in).

  1. Install the cables and the nuts.
    • Tighten to 12 Nm (9 lb-ft).

  1. Install the power distribution box cover.

  1. Attach the ground wire and install the bolt.
    • Tighten to 10 Nm (89 lb-in).

  1. Position the wiring and install the nut. Connect the powertrain control module (PCM) electrical connectors.
    • Tighten to 8 Nm (71 lb-in).

  1. Connect the manifold absolute pressure (MAP) sensor electrical connector and vacuum tube.

  1. Connect the brake booster vacuum tube and the vacuum reservoir tube.

  1. Connect the evaporative emissions purge valve vacuum tube to the intake manifold.
    • Attach the vacuum tube retainer to the transmission fill tube.

  1. Position the exhaust gas recirculation (EGR) tube and loosely install the fittings.
    • Tighten the EGR tube-to-EGR valve fitting to 40 Nm (30 lb-ft).

  1. Connect the differential pressure feedback EGR sensor electrical connector and attach the pin-type retainer.

  1. Position the gearshift cable bracket and install the bolts.
    • Tighten to 19 Nm (14 lb-ft).

  1. Attach the wiring harness pin-type retainer to the gearshift cable bracket.
  1. Connect the fuel supply tube quick connect coupling at the fuel rail. For additional information, refer to Section 310-00 Fuel System - General Information.

  1. Connect the heater hoses and the throttle body coolant hose.

  1. Connect the hoses.

  1. Position the accelerator and speed control cables and bracket. Install the nut.
    • Tighten to 10 Nm (89 lb-in).

  1. Position the bracket and install the bolts.
    • Tighten to 10 Nm (89 lb-in).
    • Connect the accelerator cable and the speed control actuator cable.

  1. Position the accelerator cable snow shield and install the bolts.
    • Tighten to 10 Nm (89 lb-in).

  1. Tighten the EGR tube-to-RH catalytic converter fitting to 40 Nm (30 lb-ft).

  1. Connect the 2 transmission cooler tubes.

  1. Install the crossbrace and the new nut.
    • Tighten to 175 Nm (129 lb-ft).

  1. Install the bolt for the transaxle mount and install the 2 bolts for the crossbrace.
    • Tighten the transaxle mount bolt to 115 Nm (85 lb-ft).
    • Tighten the crossbrace bolts to 90 Nm (66 lb-ft).

  1. Install the lateral support crossmember and the 4 bolts.
    • Tighten to 115 Nm (85 lb-ft).

  1. Position the power steering pump and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).

  1. Install the power steering pump pulley and the nut.
    • Tighten to 49 Nm (36 lb-ft).

  1. Install the A/C compressor and the bolts.
    • Tighten to 25 Nm (18 lb-ft).

  1. Connect the A/C clutch field coil electrical connector.
AWD vehicles
  1. CAUTION:
    CAUTION:Do not reuse the bolts and straps for the center U-joint. Install new bolts and straps or damage to the vehicle may occur.
    NOTE:
    NOTE:There is a difference in the length of the head of the replacement yoke strap bolts from the production bolts. The longer head pinion bolts can be used in either location.
    Install the driveshaft.
    1. Align the driveshaft with the index marks.
    1. Install the new straps and bolts.
    • Tighten to 23 Nm (17 lb-ft).

  1. CAUTION:
    CAUTION:Do not reuse the CV joint bolts and washers. Install new bolts and washers or damage to the vehicle may occur.
    Install the 6 front driveshaft-to-power take off bolts and washers.
    • Tighten to 37 Nm (27 lb-ft).
All vehicles
  1. Install the LH halfshaft. For additional information, refer to Section 205-04 Front Drive Halfshafts.
  1. Position the accessory drive belt on all pulleys except the generator pulley.
  1. Install the generator. For additional information, refer to Section 414-02 Generator and Regulator.
  1. Install the exhaust system flexpipe. For additional information, refer to Section 309-00 Exhaust System.

  1. Install the lower radiator air deflectors.

  1. Position the power steering hose bracket and install the nut.
    • Tighten to 25 Nm (18 lb-ft).
    • Connect the power steering pressure (PSP) switch electrical connector.
  1. Install the air cleaner outlet pipe and air cleaner. For additional information, refer to Section 303-12A Intake Air Distribution and FilteringSection 303-12B Intake Air Distribution and Filtering.
  1. Install the battery tray. For additional information, refer to Section 414-01 Battery, Mounting and Cables.
  1. Fill and bleed the cooling system. For additional information refer to Section 303-03 Engine Cooling.
  1. Fill the engine with clean engine oil.

Engine - Vehicles Built From: 12-2005 > < Engine - Vehicles Built From: 01-2006