Engine - Installation

Special Service Tools / General Equipment

	300-OTC1819E Floor Crane 2200 lb, Folding
	303-1502 Engine Lifting Device TKIT-2012A-FL TKIT-2012A-RYAD
Adjustable mounting arm
Hose Clamp Removal/Installation Tool

Materials

All vehicles

1. 1
   Lubricate the torque converter hub guide with universal grease.
   Material: Motorcraft® Universal Grease Spray / XL-5-A (ESB-M1C93-B)

   

2. 2
   Inspect the cylinder block dowels. If the dowels are damaged or missing, install new cylinder block dowels.

   

3. 3
   Connect the engine to the transmission and install the bolt.
   Torque: 35 lb-ft (48 N·m)

   

4. 4
   Install the engine to the transmission bolts.
   Torque: 35 lb-ft (48 N·m)

   

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

   

6. 6
   Install the adjustable mounting bracket.
   Use common service equipment: adjustable mounting lever

   

7. 7
   Remove the special service tool: 300-OTC1819E 2200 lb Floor Crane, Folding.

   

8. 8
   Remove the special service tool: 303-1502 Engine Lifting Device.

   

9. 9
   Install the bracket and bolts.
   Torque: 97 lb-in (11 N·m)

   

10. 10
    Install the axle shaft support bracket and bolts.
    Torque: 35 lb-ft (48 N·m)

    

11. 11
    Install the TC intake pipe, tighten the bolt and tighten the clamp.
    Torque:
    1: 71 lb-in (8 N·m)
    2: 44 lb-in (5 N·m)

    

12. 12
    • Install the TC outlet pipe, secure with bolts and tighten the clamps.
      Torque:
      1: 71 lb-in (8 N·m)
      2: 44 lb-in (5 N·m)

    • Connect the TC bypass hose.

    • Install the wiring harness retainers and connect the electrical connectors.

    

13. 13
    • Install the crankcase ventilation hose.
      Use common service equipment: hose clamp removal/installation tool.

    • Secure the wiring harness retainer.

    

14. 14
    Align the marks on the torque converter nuts and tighten the nut.
    Torque: 35 lb-ft (48 N·m)

    

15. 15
    Install the starter insulator.

    

16. 16
    Install the starter, bolts and stud.
    Torque: 35 lb-ft (48 N·m)

    

17. 17
    Position the harness and install the nut.
    Torque: 97 lb-in (11 N·m)

    

18. 18
    • Position the harness and install the nut.
      Torque: 159 lb-in (18 N·m)

    • Slide the generator insulator downward.

    • Install the harness clips and connect the electrical connector.

    

19. 19
    Position the starter cable and install the nuts.
    Torque:
    1: 53 lb-in (6 N·m)
    2: 106 lb-in (12 N·m)

    

Vehicles with automatic stop/start

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

All vehicles

1. 1
   Install the wiring harness retainers and connect the electrical connectors.

   

2. 2
   Install a new catalytic converter gasket and tighten the bolts.

   

3. 3
   Install the catalytic converter, install the bolts and tighten the bolts in the sequence shown.
   Torque: 22 lb-ft (30 N·m)

   

4. 4
   Install the muffler inlet pipe insulator bracket bolts.
   Torque: 18 lb-ft (25 N·m)

   

5. 5
   Tighten the catalytic converter mounting bolts in the sequence shown.
   Torque: 22 lb-ft (30 N·m)

   

6. 6
   Install the retainer and connect the electrical connector.

   

7. 7
   Tighten the engine mount studs.
   Torque: 89 lb-in (10 N·m)

   

8. 8
   Using the powertrain lift, raise the powertrain and subframe assembly.

   

9. 9
   1. Install the engine mount and nuts.
      Torque: 85 lb-ft (115 N·m)

   2. Hand-tighten the engine mount bolts.

   

10. 10
    Install the transaxle mount insulator nut.
    Torque: 98 lb-ft (133 N·m)

    

11. 11
    Hand-tighten the front subframe mounting bolts.

    

12. 12
    1. Install the subframe mount bracket and hand-tighten the bolts.

    2. Hand-tighten the subframe mount bracket bolts.

    

13. 13
    Install the rear subframe mounting bolts.
    Torque: 173 lb-ft (235 N·m)

    

14. 14
    1. Tighten the subframe mount bracket bolts in 2 stages.
       Torque:
       Stage 1: 76 lb-ft (103 N·m)
       Stage 2: 270°

    2. Tighten the subframe mount bracket bolts.
       Torque: 44 lb-ft (60 N·m)

    

15. 15
    Discard.
    Use common shop equipment: adjustable mount link

    

16. 16
    Tighten the engine mount bolts.
    Torque: 66 lb-ft (90 N·m)

    

17. 17
    Install the RH steering knuckle assembly, then install the bolts and nuts.
    Torque: 173 lb-ft (235 N·m)

    

18. 18
    Install the LH steering knuckle assembly, then install the bolts and nuts.
    Torque: 173 lb-ft (235 N·m)

    

19. 19
    Install the brake rotor.
    Refer to Brake Rotor (206-03 Front Disc Brake, Removal and Installation).
20. 20
    Position the RH stabilizer bar link and install the nut.
    Torque: 85 lb-ft (115 N·m)

    

21. 21
    Position the LH stabilizer bar link and install the nut.
    Torque: 85 lb-ft (115 N·m)

    

22. 22
    Position the wheel speed sensor and install the bolt.
    Torque: 80 lb-in (9 N·m)

    

23. 23
    Position the wheel speed sensor and install the bolt.
    Torque: 80 lb-in (9 N·m)

    

24. 24
    Install the catalytic converter bushing and nuts.
    Torque: 18 lb-ft (25 N·m)

    

25. 25
    Install the engine to the transmission bolts.
    Torque: 35 lb-ft (48 N·m)

    

26. 26
    Install the auxiliary water pump and bolts.
    Torque: 17 lb-ft (23 N·m)

    

27. 27
    Install a new muffler inlet pipe gasket.

    

28. 28
    Position the muffler inlet pipe and install the nuts.
    Torque: 35 lb-ft (48 N·m)

    

29. 29
    Install the transverse brace and bolts.
    Torque: 33 lb-ft (45 N·m)

    

30. 30
    Install the engine oil filter.
    Material: Engine oil — SAE 5W-20 — synthetic engine oil / XO-5W20-Q1SP (WSS-M2C945-B1)
    Torque: 128 lb-in (14.5 N·m)

    

31. 31
    Position the A/C lines and install the nuts.
    Torque:
    1: 133 lb-in (15 N·m)
    2: 89 lb-in (10 N·m)

    

32. 32
    Connect the electrical connectors and secure the retainers.

    

33. 33
    Connect the coolant hose.
    Use common service equipment: hose clamp removal and installation tool.

    

34. 34
    Connect the coolant hoses.
    Use the common service equipment: hose clamp removal/installation tool.

    

35. 35
    Install the lower radiator support, retainers and bolts.
    Torque: 177 lb-in (20 N·m)

    

36. 36
    Connect the electrical connector.

    

37. 37
    Install the deflector shields and retainers.

    

38. 38
    Install the stone shield and retainers.

    

39. 39
    Install the RH and LH front wheels and tires.
    Refer to: Wheels and Tires (204-04A Wheels and Tires, Removal and Installation).
40. 40
    Install the accessory drive belt.
    Refer to: Accessory Drive Belt (303-05A Accessory Drive — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
41. 41
    Remove the cooling module support.

    

42. 42
    • Install the degas bottle and retainer.
      Torque: 80 lb-in (9 N·m)

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

    

43. 43
    Install the harness clip and connect the electrical connector.

    

44. 44
    Connect the PCM electrical connector.

    

45. 45
    Connect the coolant hose.
    Use common service equipment: hose clamp removal and installation tool.

    

46. 46
    Connect the coolant hoses to the transmission fluid warmer coolant control valve and install the clamps.
    Use common service equipment: hose clamp removal/installation tool.

    

47. 47
    Connect the coolant hoses to the heater core.
    Use common service equipment: hose clamp removal/installation tool.

    

48. 48
    Connect the shift cable end to the selector lever assembly and install the bolts.
    Torque: 18 lb-ft (25 N·m)

    

49. 49
    Install the retainers and connect the coolant tube.

    

50. 50
    Install the retainer and connect the coolant hose.
    Use common service equipment: hose clamp removal/installation tool.

    

51. 51
    Connect the transmission fluid cooler lines.

    

52. 52
    Install the secondary latches of the transmission fluid cooler lines.

    

53. 53
    Connect the coolant hose.
    Use common service equipment: hose clamp removal and installation tool.

    

54. 54
    Position the wiring harness, install the bolts and secure the retainers.
    Torque: 97 lb-in (11 N·m)

    

55. 55
    Position the wiring harness and install the nuts.
    Torque: 89 lb-in (10 N·m)

    

56. 56
    Close the battery cable terminal cover.

    

57. 57
    Position and install the fuse block.

    

58. 58
    Position the wiring harness and install the stud.
    Torque: 106 lb-in (12 N·m)

    

59. 59
    Install the EVAP canister purge valve.
    Refer to: Fuel Vapor Management Valve (303-13A Evaporative Emission Control — 1.5 L EcoBoost (118 kW/160 L hp) — I4, Removal and Installation).
60. 60
    Connect the electrical connector of the oil pan pressure sensor wiring harness and the wiring harness clip.

    

61. 61
    Secure the retainer and connect the vacuum tube coupling.

    

62. 62
    Secure the retainers and connect the fuel tube fittings.

    

63. 63
    Install the following components:

    1. Install the battery tray.
       Refer to: Battery Compartment (414-01 Battery, Mounting and Cables, Removal and Installation).
    2. Install the upper air cleaner outlet pipe.
       Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation).
    3. Install the air cleaner.
       REFER TO: Air Cleaner Element (303-12A Intake Air Distribution and Filtering - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation).
64. 64
    Connect the steering column shaft to the steering gear input shaft and install the bolt.
    Torque: 18 lb-ft (25 N·m)

    

65. 65
    Remove the special service tool.

    

66. 66
    Fill the engine with clean engine oil.
    Material: Engine Oil - SAE 5W-20 - Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)
67. 67
    Fill the cooling system.
    Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine Cooling, 1.5 L EcoBoost (118 kW/160 L hp) — I4, General Procedures).
68. 68
    Adjust the shift cable.
    Refer to: Selector Lever Cable Adjustment — 1.5 L EcoBoost (118 kW/160 L hp) — I4 (307-05A Automatic Transmission External Controls — 6-Speed Automatic Transmission — 6F35, General Procedures).
69. 69
    Charge the A/C system.
    Refer to: Refrigerant Recovery, Evacuation and Charging (A/C) - Vehicles With: R1234YF Refrigerant (412-00 Climate Control System - General Information, General Procedures).
70. 70
    Install the engine outer cover.

    

71. 71
    Start the engine and check the exhaust system for leaks.
72. 72
    Use the Powertrain Control Module (PCM) misfire monitor profile correction procedure with the diagnostic scan tool.
73. 73
    Check and, if necessary, adjust the front toe.
    Refer to: Front Toe Adjustment (204-00 Suspension System — General Information, General Procedures).