Section 1991 (Engine - 2.3L - (Hybrid)): Installation: Engine

Illustration	Tool Name	Tool Number
	Heavy Duty Floor Crane	014-00071 or equivalent
	Spreader Bar	303-D089 (D93P-6001-A3) or equivalent
	Powertrain Lift	(014-00765)
	Universal Adapter Brackets	014-0001
Lifting Bracket Set, Engine		303-D095 (D94L-6001-A) or equivalent

All vehicles 

NOTE: Due to packaging requirements the correct bolt must be used at the damper locations.
NOTE: 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 Nm (21 lb-ft).
Fig 1: Transaxle Damper Bolts
Courtesy of FORD MOTOR CO.
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 Nm (35 lb-ft).
Fig 2: Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
3. Position the high voltage wiring harness and connect the 2 transaxle electrical connectors.
Fig 3: High Voltage Wiring Harness Electrical Connectors
Courtesy of FORD MOTOR CO.
4. Connect the high voltage wiring harness electrical connector.
Fig 4: High Voltage Wiring Harness Electrical Connector
Courtesy of FORD MOTOR CO.
5. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
CAUTION: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the lift table.
6. Using the special tools, secure the engine to the lift table.
Fig 5: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
Courtesy of FORD MOTOR CO.
7. Raise the engine and transaxle into the vehicle.
8. Install the rear transaxle mount.
   • Tighten the nuts to 90 Nm (66 lb-ft).
   • Tighten the bolt to 103 Nm (76 lb-ft).
Fig 6: Rear Transaxle Mount & Fasteners
Courtesy of FORD MOTOR CO.
9. Install the rear transaxle mount brace.
   • Tighten to 25 Nm (18 lb-ft).
Fig 7: Rear Transaxle Mount Brace & Bolts
Courtesy of FORD MOTOR CO.
10. Install the RH transaxle mount bracket.
    • Tighten to 90 Nm (66 lb-ft).
Fig 8: Right Transaxle Mount Bracket Bolts
Courtesy of FORD MOTOR CO.
11. Install the RH transaxle mount bracket nut.
    • Tighten to 90 Nm (66 lb-ft).
Fig 9: Right Transaxle Mount Bracket Nut
Courtesy of FORD MOTOR CO.
12. Install the engine mount bracket.
    • Tighten to 115 Nm (85 lb-ft).
Fig 10: Engine Mount Bracket Nuts
Courtesy of FORD MOTOR CO.
13. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
Fig 11: Engine Mount Bracket Bolt
Courtesy of FORD MOTOR CO.
14. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 12: Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
15. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 13: Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
16. Install the engine support crossmember.
    • Tighten the bolts to 90 Nm (66 lb-ft).
    • Tighten the new nut to 175 Nm (129 lb-ft).
Fig 14: Engine Support Crossmember & Fasteners
Courtesy of FORD MOTOR CO.
17. Install the rear roll restrictor bolt.
    • Tighten to 90 Nm (66 lb-ft).
Fig 15: Rear Insulator Bolt
Courtesy of FORD MOTOR CO.
18. Install the front roll restrictor bolt.
    • Tighten to 115 Nm (85 lb-ft).
Fig 16: Front Roll Restrictor Bolt
Courtesy of FORD MOTOR CO.
19. Install the A/C compressor and connect the A/C compressor electrical connector.
    • Tighten to 25 Nm (18 lb-ft).
Fig 17: A/C Compressor Electrical Connector & Bolts
Courtesy of FORD MOTOR CO.
20. Connect the lower radiator hose to the radiator.
Fig 18: Locating Lower Radiator Hose
Courtesy of FORD MOTOR CO.
21. Position the motor electronics coolant pump and the ground strap. Install the 2 bolts.
    • Tighten to 20 Nm (15 lb-in).
Fig 19: Motor Electronics Coolant Pump & Ground Strap
Courtesy of FORD MOTOR CO.
22. Install the ground cable and nut.
    • Tighten to 20 Nm (15 lb-ft).
Fig 20: Ground Cable & Nut
Courtesy of FORD MOTOR CO.
23. Connect the transaxle coolant hoses.
Fig 21: Transaxle Coolant Hoses
Courtesy of FORD MOTOR CO.
24. Connect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
Fig 22: Motor Electronics Coolant Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
25. Position the transaxle control cable and connect the pin-type retainer.
Fig 23: Pin-Type Retainer
Courtesy of FORD MOTOR CO.
26. Connect the pin-type retainer.
Fig 24: Pin-Type Retainer
Courtesy 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: Selector Lever Cable Bracket Nuts
Courtesy of FORD MOTOR CO.
28. Position the control lever between the 2 casting ribs on the transaxle case.
Fig 26: Selector Lever Between 2 Ribs On Transaxle Case
Courtesy of FORD MOTOR CO.
29. Place the gear selector lever in the D position.
30. Tighten the transaxle control cable bracket nuts to 22 Nm (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 Nm (16 lb-ft).
Fig 27: Transaxle Control Splash Shield
Courtesy of FORD MOTOR CO.
33. Install the auxiliary coolant pump and connect the electrical connector.
    • Tighten to 10 Nm (89 lb-in).
Fig 28: Auxiliary Coolant Pump Electrical Connector & Bolts
Courtesy of FORD MOTOR CO.
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: Block Heater Wiring Harness
Courtesy of FORD MOTOR CO.
35. Install the fuel supply tube and evaporative emissions (EVAP) tube.
Fig 30: Fuel Supply Tube And Evaporative Emissions (EVAP) Tube
Courtesy of FORD MOTOR CO.
36. Position the DC-to-DC converter in place and install the 3 nuts.
    • Tighten to 12 Nm (9 lb-ft).
Fig 31: DC-To-DC Converter & Nuts
Courtesy of FORD MOTOR CO.
37. Connect the DC-to-DC converter electrical connector and pin-type retainer.
Fig 32: DC-To-DC Converter Electrical Connector
Courtesy of FORD MOTOR CO.
38. Connect the transaxle harness electrical connector and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 33: Transaxle Harness Electrical Connector & Bolt
Courtesy of FORD MOTOR CO.
39. Connect the 2 engine control harness electrical connectors and the 2 pin-type retainers.
Fig 34: Engine Control Harness Electrical Connectors
Courtesy 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 Nm (53 lb-in).
Fig 35: Powertrain Control Module (PCM) Connector & Nut
Courtesy of FORD MOTOR CO.
41. Connect the following electrical connectors:
    • Transaxle mount control solenoid
    • Purge valve
Fig 36: Transaxle Mount Control Solenoid & Purge Valve Electrical Connectors
Courtesy of FORD MOTOR CO.
42. Connect the upper radiator and coolant vent hoses.
Fig 37: Upper Radiator & Coolant Vent Hoses
Courtesy of FORD MOTOR CO.
43. Attach the heater hose retaining clip to the transaxle mount stud.
Fig 38: Heater Hose Retaining Clip
Courtesy of FORD MOTOR CO.
44. Connect the heater hoses to the heater core.
Fig 39: Locating Heater Hoses
Courtesy of FORD MOTOR CO.

Front wheel drive (FWD) vehicles 

45. Install the lateral support crossmember.
    • Tighten to 115 Nm (85 lb-ft).
Fig 40: Identifying Lateral Support Crossmember And Bolts
Courtesy of FORD MOTOR CO.
46. Install the front drive intermediate halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.

All wheel drive (AWD) vehicles 

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

All vehicles 

48. Install the LH front drive halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
49. Install the oil filter element. For additional information, refer to Engine Lubrication Components - Exploded View  and Oil Filter Element  in this section.
50. Install the engine coolant degas bottle. For additional information, refer to ENGINE COOLING - HYBRID article.
51. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM article.
52. Install the engine air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID article.
53. Install the intake manifold. For additional information, refer to Intake Manifold .
54. Enable the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.
55. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
56. Fill the engine with clean engine oil.
57. Fill and bleed the motor electronics cooling system. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING - HYBRID article.
58. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING - HYBRID article.