Installation - Engine

Special Service Tools / General Equipment

	303-476 (T94P-9472-A) Socket, Exhaust Gas Oxygen Sensor TKIT-1994-LM/M TKIT-1994-F TKIT-1994-FLM/FM
Floor crane
Adjustable mounting arm
Hose Clamp Removal/Installation Tool
Fluid Container
Powertrain jack
Wood block

Materials

1. 1
   Inspect the cylinder block dowels. If the dowels are damaged or missing, install new cylinder block dowels.

   

2. 2
   Install the engine to the transmission.
   Use the common service equipment: floor crane

   

3. 3
   If the dowel pins were pulled out of the cylinder block during removal, install new dowel pins into the cylinder block.
4. 4
   Install the right engine mount to the transmission bolts.
   Torque: 35 lb-ft (48 N·m)

   

5. 5
   Install the left engine mount to the transmission bolts.
   Torque: 35 lb-ft (48 N·m)

   

6. 6
   Install the right adjustable mount link.
   Use the common service equipment: adjustable mount link

   

7. 7
   Install the left adjustable mount link.
   Use the common service equipment: adjustable mount link

   

8. 8
   Install the EGR cooler hose.

   

9. 9
   Install a new PTU onto the transmission compression seal.

   

10. 10
    At this stage, install the PTU and bolts and tighten by hand.

    

11. 11
    Tighten in the sequence shown.
    Torque: 81 lb-ft (110 N·m)

    

12. 12
    Install the vent hose retainer.

    

13. 13
    Install a new exhaust manifold gasket.

    

14. 14
    Install new nuts and the exhaust manifold.
    Torque: 41 lb-ft (55 N·m)

    

15. 15
    Install the exhaust manifold heat shield and bolts.
    Torque: 89 lb-in (10 N·m)

    

16. 16
    Clean and inspect the gasket surface and studs. Replace the studs if necessary.
    Torque: 159 lb-in (18 N·m)

    

17. 17
    Install new exhaust gas recirculation (EGR) cooler inlet pipe gaskets.

    

18. 18
    Install the EGR cooler inlet pipe and tighten the fasteners by hand.

    

19. 19
    Tighten in the sequence shown.
    Torque:
    1: 89 lb-in (10 N·m)
    2: 18 lb-ft (24 N·m)
    1: 18 lb-ft (24 N·m)
    3: 89 lb-in (10 N·m)
    4: 18 lb-ft (24 N·m)
    3: 18 lb-ft (24 N·m)

    

20. 20
    
    

    1. Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formula in Apex. Install the HO2S sensor.
       Use special service tool: 303-476 (T94P-9472-A) Exhaust Gas Oxygen Sensor Socket.
       Material: Motorcraft® High Temperature Nickel Anti-Seize Lubricant / XL-2
       Torque: 35 lb-ft (48 N·m)

    2. Install the wire harness bolts and brackets.

    3. Connect the HO2S sensor electrical connector.

    

21. 21
    Remove the floor crane and the commercially available quick-release link and chain.
    Use the common service equipment: floor crane

    

22. 22
    Install the engine and transmission to the vehicle.
    Use the common service equipment: power jack
    Use the common service equipment: adjustable mount link
    Use the common service equipment: wood block

    

23. 23
    Hand-tighten the transmission mount insulator bolts.

    

24. 24
    Hand-tighten the engine mount fasteners.
    

    1. Tighten the engine mount nuts.
       Torque: 81 lb-ft (110 N·m)

    2. Tighten the engine mount bolts.
       Torque: 129 lb-ft (175 N·m)

    

25. 25
    Tighten the transmission mount insulator bolts.
    Torque: 92 lb-ft (125 N·m)

    

26. 26
    Remove the adjustable mount link.
    Use the common service equipment: power jack
    Use the common service equipment: adjustable mount link
    Use the common service equipment: wood block

    

27. 27
    Remove the adjustable mount link and the powertrain jack.
    Use the common service equipment: power jack
    Use the common service equipment: adjustable mount link
    Use the common service equipment: wood block

    

28. 28
    Install the front subframe.
    Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
29. 29
    
    Install the roll restrictor bracket.
    

    • Install the stud and bolts.
      Torque: 81 lb-ft (110 N·m)

    • Install the fork bolt.
      Torque: 129 lb-ft (175 N·m)

    

30. 30
    Install the PTU support bracket and bolts.
    Torque: 35 lb-ft (48 N·m)

    

31. 31
    Connect the PTU temperature sensor, engine connectors and retainers.

    

32. 32
    Install the driveshaft into position and make sure the alignment marks are aligned.

    

33. 33
    Install new PTU flange bolts.
    Torque: 26 lb-ft (35 N·m)

    

34. 34
    Install the intermediate shaft.
    Refer to: Intermediate Shaft (205-04 Front Drive Axle Shafts, Removal and Installation).
35. 35
    Install the left front axle shaft.
    Refer to: Front Axle Shaft, Left (205-04 Front Axle Shafts, Removal and Installation).
36. 36
    Install the coolant hoses.
    Use common service equipment: hose clamp removal and installation tool.

    

37. 37
    Install the engine oil filter.
    Torque: 133 lb-in (15 N·m)

    

38. 38
    Install new O-rings and gaskets, the A/C line and nuts.
    Torque: 159 lb-in (18 N·m)

    

39. 39
    Install the transmission coolant line and bolt.
    Use the common service equipment: fluid container
    Torque: 18 lb-ft (25 N·m)

    

40. 40
    Connect the upper radiator hose.
    Use the common service equipment: hose clamp removal/installation tool.

    

41. 41
    Connect the coolant hose.

    

42. 42
    Connect the electrical connectors and install the wiring harness retainers.

    

43. 43
    Install the PCM cover and bolts.

    

44. 44
    Connect the transmission electrical connector and install the wiring harness retainers.

    

45. 45
    
    

    • Install the wiring harness bracket and bolts.

    • Connect the high-voltage cable to the ISC and tighten the retainer.
      Torque: 97 lb-in (11 N·m)

    

46. 46
    1. Connect C199A (40-way connector) and lock the lever.

    2. Connect C199B (22-way connector).

    3. Install the wiring harness retainer.

    

47. 47
    Connect the A/C electrical connectors and install the wiring harness retainers.

    

48. 48
    Connect the coolant pump electrical connector and install the wiring harness retainers.

    

49. 49
    Install the coolant hoses and clamps.
    Use the common service equipment: hose clamp removal/installation tool.

    

50. 50
    If equipped.
    Connect the oil cooler hose.
    Use the common service equipment: hose clamp removal/installation tool.

    

51. 51
    Connect the coolant hose.
    Use common service equipment: hose clamp removal and installation tool.

    

52. 52
    Connect the coolant hose.
    Use common service equipment: hose clamp removal and installation tool.

    

53. 53
    If equipped with a block heater.
    Connect the cylinder block heater electrical connector.

    

54. 54
    If equipped with a block heater.
    Install the block heater electrical connector cover.

    

55. 55
    Install the oil pan bolts.
    Torque: 35 lb-ft (48 N·m)

    

56. 56
    Install the left subframe support bracket and new bolts.
    Torque: 22 lb-ft (30 N·m)

    

57. 57
    Install the right subframe support bracket and new bolts.
    Torque: 22 lb-ft (30 N·m)

    

58. 58
    Install the exhaust manifold bracket and bolts.
    Torque: 18 lb-ft (25 N·m)

    

59. 59
    Install a new exhaust clamp.
    Torque: 17 lb-ft (23 N·m)

    

60. 60
    Install the bracket and nuts.
    Torque: 35 lb-ft (48 N·m)

    

61. 61

    NOTICE: Do not bend or twist the exhaust pipe. Failure to follow these instructions may damage the flexible pipe.

    Remove the flex exhaust pipe support.

    

62. 62
    Install the coolant hoses and pin retainers.
    Use the common service equipment: hose clamp removal/installation tool.

    

63. 63
    If equipped.
    Reposition the block heater wiring harness and attach the clips.

    

64. 64
    Remove the commercially available lifting eye.

    

65. 65
    Install the ground wire.
    Torque: 133 lb-in (15 N·m)

    

66. 66
    Connect the coolant hoses.
    Use the common service equipment: hose clamp removal/installation tool.

    

67. 67
    Connect the fuel vapor and fuel supply tubes.
    Refer to: Quick Release Coupling (310-00C Fuel System - General Information, General Procedures).
    Refer to: Spring Lock Couplings (310-00C Fuel System - General Information, General Procedures).

    

68. 68
    
    

    1. Install the air cleaner.

    2. Connect the air cleaner inlet tube.

    3. Tighten the clamp.

    4. Connect the breather tube.

    5. Install the bolt.

    

69. 69
    Position the steering column shaft and install a new bolt.
    Torque: 46 lb-ft (63 N·m)

    

70. 70
    Using a holding device, hold the steering wheel in the straight-ahead position.

    

71. 71
    Install the following components:

    1. Install the degas bottle.
       Refer to: Degas Bottle (303-03C Engine Cooling, Removal and Installation).
    2. Install the front bumper cover.
       Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
    3. Install the front fender splash shields.
       Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
72. 72
    Fill the engine with clean engine oil.
    Refer to: Specifications (303-03C Engine Cooling, Specifications).

    

73. 73
    Connect the battery cables.
    Refer to: Battery Cables - Duratec 2.5 L - Hybrid (121 kW/164 L hp) (BG) (414-01 Battery, Mounting and Cables, Removal and Installation).
74. 74
    Service the vehicle high-voltage system.
    Refer to: High-Voltage System Disabling (414-03A High-Voltage Battery, Mounting and Cables, General Procedures).
75. 75
    Relieve the fuel system pressure.
    Refer to: Fuel System Pressure Release (310-00C Fuel System - General Information, General Procedures).
76. 76
    Fill and bleed the cooling system.
    Refer to: Engine Cooling System Draining, Vacuum Filling and Air Bleeding (303-03C Engine Cooling - General Procedures).
77. 77
    Fill and bleed the electric drive cooling system.
    Refer to: Cooling System Filling and Air Bleeding (303-03D Electric Transmission Cooling - Hybrid Electric Vehicle (HEV), General Procedures).
78. 78
    Charge the air conditioning system.
    Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging - 2.5 L Duratec - Hybrid (121 kW/164 L hp) (BG) (412-00 Climate Control System - General Information, General Procedures).
    Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging - Hybrid Electric Vehicle (HEV), vehicles with: R134a Refrigerant (412-00 Climate Control System - General Information - 2.5 L Duratec - Hybrid (121 kW/164 L hp) (BG)).
79. 79
    Check and, if necessary, add transmission fluid.
    Refer to: Transmission Fluid Level Check (307-01B Automatic Transmission - Automatic Transmission - HF45, General Procedures).
80. 80
    Check the PTU (power transfer unit) fluid level.
    Refer to: Front Axle Shaft, Left (205-04 Front Axle Shafts, Removal and Installation).
81. 81
    Install the lower shield and brackets.

    

82. 82
    
    

    1. If the engine appearance cover stud is loosened or removed, install/tighten it in the valve cover.
       Torque: 62 lb-in (7 N·m)

    2. Position the engine appearance cover on the engine so that the bushings are aligned with the studs.

    3. Press down on the engine appearance cover at each bushing location to attach the bushings to the studs.

    4. Install the engine appearance cover nut.
       Torque: 44 lb-in (5 N·m)

    

83. 83
    Start the vehicle and check the exhaust system for leaks.
84. 84
    If the engine was disassembled, perform the misfire monitor neutral profile correction procedure.