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Section 1507 (Engine - 2.3L - (Hybrid)): Installation: Engine

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G04619214Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04619215Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04619216Courtesy of FORD MOTOR CO.
 Powertrain Lift
(014-00765)
G04619217Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets 014-0001
Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent
MATERIALS

Item 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
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

    All vehicles 

    NOTE:
    1. Due to packaging requirements the correct bolt must be used at the damper locations.
    2. The damper contains a clutch which is designed to slip briefly during vehicle operation. It is essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use grease on transmission input shaft. Should the damper become contaminated, it must be replaced.
  1. Install the transaxle damper.
    • Tighten to 29 N.m (21 lb-ft).
      Fig 1: Locating Transaxle Damper Bolts
      G04619218Courtesy of FORD MOTOR CO.
    2. CAUTION: When positioning the engine to the transaxle, care must be taken to maintain alignment of the damper spline with the transaxle input shaft.
    NOTE: Transaxle removed from view for clarity.
  2. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts.
    • Tighten to 48 N.m (35 lb-ft).
      Fig 2: Locating Transaxle-To-Engine Bolts
      G04619219Courtesy of FORD MOTOR CO.
  3. Position the high voltage wiring harness and connect the 2 transaxle electrical connectors.
    Fig 3: Locating High Voltage Wiring Harness
    G04619220Courtesy of FORD MOTOR CO.
  4. Connect the high voltage wiring harness electrical connector.
    Fig 4: Locating High Voltage Wiring Harness Electrical Connector
    G04619221Courtesy of FORD MOTOR CO.
  5. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
    6. CAUTION: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the lift table.
    Fig 5: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
    G03897890Courtesy of FORD MOTOR CO.
  6. Using the special tools, secure the engine to the lift table.
  7. Raise the engine and transaxle into the vehicle.
  8. Install the rear transaxle mount.
    • Tighten the nuts to 90 N.m (66 lb-ft).
    • Tighten the bolt to 103 N.m (76 lb-ft).
      Fig 6: Locating Rear Transaxle Mount
      G04619223Courtesy of FORD MOTOR CO.
  9. Install the rear transaxle mount brace.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 7: Locating Rear Transaxle Mount Brace
      G04619224Courtesy of FORD MOTOR CO.
  10. Install the RH transaxle mount bracket.
    • Tighten to 90 N.m (66 lb-ft).
      Fig 8: Locating RH Transaxle Mount Bracket
      G04619225Courtesy of FORD MOTOR CO.
  11. Install the RH transaxle mount bracket nut.
    • Tighten to 90 N.m (66 lb-ft).
      Fig 9: Locating RH Transaxle Mount Bracket Nut
      G04619226Courtesy of FORD MOTOR CO.
  12. Install the engine mount bracket.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 10: Locating Engine Mount Bracket
      G04619227Courtesy of FORD MOTOR CO.
  13. Install the engine mount bracket bolt.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 11: Locating Engine Mount Bracket Bolt
      G04619228Courtesy of FORD MOTOR CO.
  14. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 N.m (35 lb-ft).
      Fig 12: Locating Transaxle-To-Engine Bolts (1 Of 2)
      G04619229Courtesy of FORD MOTOR CO.
  15. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 N.m (35 lb-ft).
      Fig 13: Locating Transaxle-To-Engine Bolts (2 Of 2)
      G04619230Courtesy of FORD MOTOR CO.
  16. Install the engine support crossmember.
    • Tighten the bolts to 90 N.m (66 lb-ft).
    • Tighten the new nut to 175 N.m (129 lb-ft).
      Fig 14: Locating Engine Support Crossmember
      G04619231Courtesy of FORD MOTOR CO.
  17. Install the rear roll restrictor bolt.
    • Tighten to 90 N.m (66 lb-ft).
      Fig 15: Locating Rear Roll Restrictor Bolt
      G04619232Courtesy of FORD MOTOR CO.
  18. Install the front roll restrictor bolt.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 16: Locating Front Roll Restrictor Bolt
      G04619233Courtesy of FORD MOTOR CO.
  19. Install the A/C compressor and connect the A/C compressor electrical connector.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 17: Locating A/C Compressor Electrical Connector
      G04619234Courtesy of FORD MOTOR CO.
  20. Connect the lower radiator hose to the radiator.
    Fig 18: Locating Lower Radiator Hose
    G03897882Courtesy of FORD MOTOR CO.
  21. Install the motor electronics coolant pump.
    • Tighten to 20 N.m (15 lb-ft).
      Fig 19: Locating Motor Electronics Coolant Pump
      G04619236Courtesy of FORD MOTOR CO.
  22. Install the ground cable and nut.
    • Tighten to 20 N.m (15 lb-ft).
      Fig 20: Locating Ground Cable & Nut
      G04619237Courtesy of FORD MOTOR CO.
  23. Connect the transaxle coolant hoses.
    Fig 21: Locating Transaxle Coolant Hoses
    G04619238Courtesy of FORD MOTOR CO.
  24. Connect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
    Fig 22: Locating Transaxle Coolant Temperature Sensor Electrical Connector
    G04619239Courtesy of FORD MOTOR CO.
  25. Position the transaxle control cable and connect the pin-type retainer.
    Fig 23: Locating Transaxle Control Cable
    G04619240Courtesy of FORD MOTOR CO.
  26. Connect the pin-type retainer.
    Fig 24: Locating Pin-Type Retainer
    G04619241Courtesy of FORD MOTOR CO.
  27. Connect the transaxle control cable.
    • Install the transaxle control cable bracket and the 2 nuts finger tight.
    • Attach the transaxle control cable to the control lever.
      Fig 25: Locating Transaxle Control Cable Bracket
      G04619242Courtesy of FORD MOTOR CO.
  28. Position the control lever between the 2 casting ribs on the transaxle case.
    Fig 26: Positioning Control Lever
    G04619243Courtesy of FORD MOTOR CO.
  29. Place the gear selector lever in the D position.
  30. Tighten the transaxle control cable bracket nuts to 22 N.m (16 lb-ft).
  31. To verify the correct cable adjustment, observe the control lever on the transaxle while an assistant shifts the gear selector lever to each range position ending in the D position.
  32. Install the transaxle control snow shield.
    • Tighten to 22 N.m (16 lb-ft).
      Fig 27: Locating Transaxle Control Snow Shield
      G04619244Courtesy of FORD MOTOR CO.
  33. Install the auxiliary coolant pump and connect the electrical connector.
    • Tighten to 10 N.m (89 lb-in).
      Fig 28: Locating Auxiliary Coolant Pump Electrical Connector
      G04619245Courtesy of FORD MOTOR CO.
    34. NOTE: Parts removed from view for clarity.
  34. If equipped, install the block heater wiring harness.
    • Route the harness through the radiator support.
    • Attach the 3 harness retainer clips.
      Fig 29: Locating Harness Retainer Clips
      G04619246Courtesy of FORD MOTOR CO.
  35. Install the fuel supply tube and evaporative emissions (EVAP) tube.
    Fig 30: Locating Fuel Supply Tube & Evaporative Emissions (EVAP) Tube
    G04619247Courtesy of FORD MOTOR CO.
  36. Position the DC-to-DC converter in place and install the 3 nuts.
    • Tighten to 12 N.m (9 lb-ft).
      Fig 31: Locating DC-To-DC Converter
      G04619248Courtesy of FORD MOTOR CO.
  37. Connect the DC-to-DC converter electrical connector and pin-type retainer.
    Fig 32: Locating DC-To-DC Converter Electrical Connector
    G04619249Courtesy of FORD MOTOR CO.
  38. Connect the transaxle harness electrical connector and install the bolt.
    • Tighten to 10 N.m (89 lb-in).
      Fig 33: Locating Transaxle Harness Electrical Connector
      G04619250Courtesy of FORD MOTOR CO.
  39. Connect the 2 engine control harness electrical connectors and the 2 pin-type retainers.
    Fig 34: Locating Engine Control Harness Electrical Connectors
    G04619251Courtesy of FORD MOTOR CO.
  40. Connect the engine control harness.
    • Engage the powertrain control module (PCM) connector.
    • Install the harness retaining nut.
    • Tighten to 6 N.m (53 lb-in).
      Fig 35: Locating Harness Retaining Nut
      G04619252Courtesy of FORD MOTOR CO.
  41. Install the ground strap on the PCM stud and install the nut.
    • Tighten to 6 N.m (53 lb-in).
      Fig 36: Locating Ground Strap & Nut
      G04619253Courtesy of FORD MOTOR CO.
  42. Connect the following electrical connectors:
    • Transaxle mount control solenoid
    • Purge valve
      Fig 37: Locating Transaxle Mount Control Solenoid & Purge Valve
      G04619254Courtesy of FORD MOTOR CO.
  43. Connect the upper radiator and coolant vent hoses.
    Fig 38: Locating Upper Radiator & Coolant Vent Hoses
    G04619255Courtesy of FORD MOTOR CO.
  44. Attach the heater hose retaining clip to the transaxle mount stud.
    Fig 39: Locating Heater Hose Retaining Clip
    G04619256Courtesy of FORD MOTOR CO.
  45. Connect the heater hoses to the heater core.
    Fig 40: Locating Heater Hoses
    G03897868Courtesy of FORD MOTOR CO.

    46. 4x2 vehicles 

  46. Install the lateral support crossmember.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 41: Identifying Lateral Support Crossmember And Bolts
      G03897847Courtesy of FORD MOTOR CO.
  47. Install the front drive intermediate halfshaft. For additional information, refer to REMOVAL AND INSTALLATION .

    48. 4x4 vehicles 

  48. Install the transfer case. For additional information, refer to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .

    49. All vehicles 

  49. Install the LH front drive halfshaft. For additional information, refer to INSTALLATION .
  50. Install the oil filter element. For additional information, refer to ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW  and OIL FILTER ELEMENT .
  51. Install the engine coolant degas bottle. For additional information, refer to REMOVAL AND INSTALLATION .
  52. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
  53. Install the engine air cleaner. For additional information, refer to REMOVAL AND INSTALLATION .
  54. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  55. Enable the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY .
  56. Connect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION .
  57. Fill the engine with clean engine oil.
  58. Fill and bleed the motor electronics cooling system. For additional information, refer to MOTOR ELECTRONICS COOLING SYSTEM DRAINING AND FILLING .
  59. Fill and bleed the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
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