Section 2154 (Engine - 2.3L - (Hybrid)): Installation: Engine

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	Heavy Duty Floor Crane	014-00071 or equivalent
Courtesy of FORD MOTOR CO.	Spreader Bar	303-D089 (D93P-6001-A3) or equivalent
Courtesy of FORD MOTOR CO.	Powertrain Lift	(014-00765)
Courtesy of FORD MOTOR CO.	Universal Adapter Brackets	014-0001

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.
NOTE: 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. Connect the high voltage wiring harness electrical connector.
Fig 3: High Voltage Wiring Harness Electrical Connector
Courtesy of FORD MOTOR CO.
4. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the lift table.
5. Using the special tools, secure the engine to the lift table.
Fig 4: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
Courtesy of FORD MOTOR CO.
6. Raise the engine and transaxle into the vehicle.
7. Install the rear transaxle mount.
   • Tighten the nuts to 90 Nm (66 lb-ft).
   • Tighten the bolt to 103 Nm (76 lb-ft).
Fig 5: Rear Transaxle Mount & Fasteners
Courtesy of FORD MOTOR CO.
8. Install the rear transaxle mount brace.
   • Tighten to 25 Nm (18 lb-ft).
Fig 6: Rear Transaxle Mount Brace & Bolts
Courtesy of FORD MOTOR CO.
9. Install the engine mount bracket.
   • Tighten to 115 Nm (85 lb-ft).
Fig 7: Engine Mount Bracket Nuts
Courtesy of FORD MOTOR CO.
10. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
Fig 8: Engine Mount Bracket Bolt
Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
11. Using the lift table, raise the sub-frame into position and install the 2 nuts.
    • Tighten to 150 Nm (111 lb-ft).
Fig 9: Identifying Nut
Courtesy of FORD MOTOR CO.
NOTE: When installing the subframe bolts, make sure both of the subframe bolts are fully engaged in their cage nuts before tightening to specification.
NOTE: RH shown, LH similar.
12. Tighten the 2 sub-frame bolts.
    • Tighten to 175 Nm (129 lb-ft).
Fig 10: Identifying Bolt
Courtesy of FORD MOTOR CO.
13. Install the roll restrictor bracket and bolts.
    • Tighten to 115 Nm (85 lb-ft).
Fig 11: Identifying Restrictor Bracket And Bolts
Courtesy of FORD MOTOR CO.
14. Connect the steering column coupling-to-steering gear and install the new pinch bolt.
    • Tighten to 40 Nm (30 lb-ft).
Fig 12: Identifying Pinch Bolt
Courtesy of FORD MOTOR CO.

Early build 

15. Install the RH transaxle mount bracket and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
Fig 13: Insulator Bracket Bolts
Courtesy of FORD MOTOR CO.
16. Install the RH transaxle mount bracket nut.
    • Tighten to 90 Nm (66 lb-ft).
Fig 14: Insulator Nut
Courtesy of FORD MOTOR CO.

Late build 

17. Install the lower support insulator.
Fig 15: Identifying Lower Support Insulator
Courtesy of FORD MOTOR CO.
18. Install the 2 lower support insulator studs.
    • Tighten to 12 Nm (9 lb-ft).
Fig 16: Identifying Studs
Courtesy of FORD MOTOR CO.
19. Install the 2 lower support insulator nuts and 1 lower support insulator bolt.
    • Tighten nuts and bolt to 80 Nm (58 lb-ft).
Fig 17: Identifying Nuts And Bolt
Courtesy of FORD MOTOR CO.
20. Install lower support insulator through bolt.
    • Tighten to 115 Nm (85 lb-ft).
Fig 18: Identifying Through Bolt
Courtesy of FORD MOTOR CO.

All vehicles 

21. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 19: Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
22. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 20: Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
23. 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 21: Engine Support Crossmember & Fasteners
Courtesy of FORD MOTOR CO.
24. Install the rear roll restrictor bolt.
    • Tighten to 90 Nm (66 lb-ft).
Fig 22: Rear Insulator Bolt
Courtesy of FORD MOTOR CO.
25. Install the front roll restrictor bolt.
    • Tighten to 115 Nm (85 lb-ft).
Fig 23: Front Roll Restrictor Bolt
Courtesy of FORD MOTOR CO.
26. Install the A/C compressor and connect the A/C compressor electrical connector.
    • Tighten to 25 Nm (18 lb-ft).
Fig 24: A/C Compressor Electrical Connector & Bolts
Courtesy of FORD MOTOR CO.
27. Connect the lower radiator hose to the radiator.
Fig 25: Locating Lower Radiator Hose
Courtesy of FORD MOTOR CO.
28. Position the motor electronics coolant pump and the ground strap. Install the 2 bolts.
    • Tighten to 20 Nm (15 lb-in).
Fig 26: Motor Electronics Coolant Pump & Ground Strap
Courtesy of FORD MOTOR CO.
29. Install the wiring harness fasteners, the ground cable and nut.
    • Tighten to 20 Nm (15 lb-ft).
Fig 27: Ground Cable
Courtesy of FORD MOTOR CO.
30. Connect the transaxle coolant hoses.
Fig 28: Transaxle Coolant Hoses
Courtesy of FORD MOTOR CO.
31. Connect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
Fig 29: Motor Electronics Coolant Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
32. 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 30: Selector Lever Cable Bracket Nuts
Courtesy of FORD MOTOR CO.
33. Position the control lever between the 2 casting ribs on the transaxle case.
Fig 31: Selector Lever Between 2 Ribs On Transaxle Case
Courtesy of FORD MOTOR CO.
34. Place the gear selector lever in the D position.
35. Tighten the transaxle control cable bracket nuts to 22 Nm (16 lb-ft).
36. 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.
37. Install the transaxle control snow shield.
    • Tighten to 22 Nm (16 lb-ft).
Fig 32: Transaxle Control Splash Shield
Courtesy of FORD MOTOR CO.
38. Install the auxiliary coolant pump and connect the electrical connector.
    • Tighten to 10 Nm (89 lb-in).
Fig 33: Auxiliary Coolant Pump Electrical Connector & Bolts
Courtesy of FORD MOTOR CO.
39. If equipped, connect the block heater electrical connector.
    • Attach the harness retainer clips.
Fig 34: Block Heater Electrical Connector
Courtesy of FORD MOTOR CO.
40. Position the DC-to-DC converter in place and install the 3 nuts.
    • Tighten to 12 Nm (9 lb-ft).
Fig 35: DC-To-DC Converter & Nuts
Courtesy of FORD MOTOR CO.
41. Connect the DC-to-DC converter electrical connector and 2 wire harness retainer (1 shown).
Fig 36: DC-To-DC Converter Electrical Connector
Courtesy of FORD MOTOR CO.
42. Connect the 2 low voltage electrical connectors and the engine harness-to-body harness retainer.
Fig 37: Low Voltage Electrical Connectors
Courtesy of FORD MOTOR CO.
43. Connect the transaxle harness electrical connector and install the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 38: Identifying Connector
Courtesy of FORD MOTOR CO.
44. Install the selector lever cable fasteners on the transaxle stud bolts.
Fig 39: Selector Lever Cable Fasteners
Courtesy of FORD MOTOR CO.
45. Connect the upper evaporative emissions (EVAP) tube quick connect coupling to the purge valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
Fig 40: Identifying Upper Evaporative Emissions (EVAP) Tube Quick Connect Coupling
Courtesy of FORD MOTOR CO.
46. Connect the engine control harness electrical connector.
Fig 41: Identifying Connector
Courtesy of FORD MOTOR CO.
47. Connect the PCM electrical connector.
    • Position the harness and install the nut.
      • Tighten to 6 Nm (53 lb-in).
Fig 42: Powertrain Control Module (PCM) Connector & Nut
Courtesy of FORD MOTOR CO.
48. Connect the upper radiator and coolant vent hoses.
Fig 43: Identifying Vent Hoses
Courtesy of FORD MOTOR CO.
49. Attach the heater hose retaining clip to the transaxle mount stud.
Fig 44: Heater Hose Retaining Clip
Courtesy of FORD MOTOR CO.
50. Connect the heater hoses to the heater core.
Fig 45: Locating Heater Hoses
Courtesy of FORD MOTOR CO.

All wheel drive (AWD) vehicles 

51. Position the power transfer unit (PTU) in place and install the 4 bolts.
    • Tighten to 45 Nm (33 lb-ft).
Fig 46: Transfer Case-To-Transaxle Bolts
Courtesy of FORD MOTOR CO.
52. Connect the PTU vent hose.
Fig 47: Transfer Case Vent Hose
Courtesy of FORD MOTOR CO.
53. Position the PTU-to-engine support bracket and install the bolts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 48: Transfer Case-To-Engine Bracket Bolts
Courtesy of FORD MOTOR CO.
54. Install the PTU heat shield and the bolts.
    • Tighten to 14 Nm (10 lb-ft).
Fig 49: Transfer Case Heat Shield & Bolts
Courtesy of FORD MOTOR CO.
55. Install the driveshaft. For additional information, refer to DRIVESHAFT article.

All vehicles 

56. Install the intermediate shaft.
Fig 50: Locating Intermediate Shaft
Courtesy of FORD MOTOR CO.
57. Install the intermediate shaft retaining nuts.
    • Tighten to 27 Nm (20 lb-ft).
Fig 51: Locating Intermediate Shaft Retaining Nuts
Courtesy of FORD MOTOR CO.
58. Install the LH halfshafts in the transaxle and the RH halfshaft in the intermediate shaft and install the ball joints in the knuckles.
59. Connect the RH suspension.
    1. Install the lower ball joint-to-knuckle bolt.
       • Tighten to 63 Nm (46 lb-ft).
    2. Position the tie-rod end and install the retaining nut.
       • Tighten to 55 Nm (41 lb-ft).
    3. Connect the stabilizer bar link and install the nut.
       • Tighten to 63 Nm (46 lb-ft).
Fig 52: Identifying Bolt And Nuts
Courtesy of FORD MOTOR CO.
60. Install the RH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (11 lb-ft).
Fig 53: Identifying ABS Sensor Bolt
Courtesy of FORD MOTOR CO.
61. Connect the LH suspension.
    1. Install the lower ball joint-to-knuckle bolt.
       • Tighten to 63 Nm (46 lb-ft).
    2. Position the tie-rod end and install the retaining nut.
       • Tighten to 55 Nm (41 lb-ft).
    3. Connect the stabilizer bar link and install the nut.
       • Tighten to 63 Nm (46 lb-ft).
Fig 54: Identifying Bolt And Nuts
Courtesy of FORD MOTOR CO.
62. Install the LH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (11 lb-ft).
Fig 55: Identifying ABS Sensor Bolt
Courtesy of FORD MOTOR CO.
63. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM article.
64. Install the lateral support crossmember and the bolts.
    • Tighten to 115 Nm (85 lb-ft).
Fig 56: Identifying Lateral Support Crossmember And Bolts
Courtesy of FORD MOTOR CO.
65. Install the oil filter element. For additional information, refer to Engine Lubrication Components - Exploded View  and Oil Filter Element .
66. Install the front wheels and tires. For additional information, refer to WHEELS AND TIRES article.
67. Connect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
Fig 57: Identifying Fuel Supply Tube
Courtesy of FORD MOTOR CO.
68. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - HYBRID article.
69. Install the engine coolant degas bottle. For additional information, refer to ENGINE COOLING - HYBRID article.
70. Install the engine air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID article.
71. Fill the engine with clean engine oil.
72. Enable the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.
73. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
74. Fill and bleed the motor electronics cooling system. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING - HYBRID article.
75. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING - HYBRID article.
76. Fill the transaxle. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - ELECTRONICALLY CONTROLLED CONTINUOUSLY VARIABLE TRANSMISSION (ECVT) article.