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Section 1345 (Engine Mechanical - 2.5L (Hybrid)): Installation: Engine: Material

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL SPECIFICATIONS TABLE

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, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
  1. Install the transaxle damper.
    • Tighten to 29 Nm (21 lb-ft).
    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.
    Fig 1: Locating Transaxle Damper Bolts
    G06271946Courtesy of FORD MOTOR CO.
  2. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    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.
    Fig 2: Locating Transaxle-To-Engine Bolts
    G06272212Courtesy of FORD MOTOR CO.
  3. Connect the 2 heater hoses to the coolant outlet.
    Fig 3: Locating Heater Hoses To Coolant Outlet
    G06272213Courtesy of FORD MOTOR CO.
  4. Install the 2 engine cover studs onto the valve cover studs.
    Fig 4: Locating Engine Cover Studs From Valve Cover Stud Bolts
    G06271941Courtesy of FORD MOTOR CO.
  5. Position the auxiliary coolant pump and bracket and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 5: Locating Auxiliary Coolant Pump, Bracket & Bolts
    G06272215Courtesy of FORD MOTOR CO.
  6. Using the Heavy Duty Floor Crane and Engine Lifting Bracket, position the engine and transaxle onto the Powertrain Lift.
  7. Using the Universal Adapter Brackets, secure the engine to the Powertrain Lift.
    NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the Powertrain Lift.
    Fig 6: Locating O-Ring Seal
    G06272216Courtesy of FORD MOTOR CO.
  8. Raise the engine and transaxle into the vehicle.
  9. Install the 3 nuts on the upper transaxle insulator.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 7: Locating Upper Transaxle Insulator & Nuts
    G06271939Courtesy of FORD MOTOR CO.
  10. Install the engine mount bracket and 3 nuts.
    • Tighten to 103 Nm (76 lb-ft).
    Fig 8: Locating Engine Mount Bracket & Nuts
    G06271938Courtesy of FORD MOTOR CO.
  11. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
    Fig 9: Locating Engine Mount Bracket Bolt
    G06271937Courtesy of FORD MOTOR CO.
  12. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 10: Bolts With Torque Specifications
    G06271935Courtesy of FORD MOTOR CO.
  13. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 11: Locating Transaxle-To-Engine Bolts
    G06271934Courtesy of FORD MOTOR CO.
  14. Connect the brake booster vacuum hose.
    Fig 12: Locating Brake Booster Vacuum Hose
    G06272222Courtesy of FORD MOTOR CO.
  15. Connect the 2 engine wiring harness connectors and attach the wiring retainer.
    Fig 13: Locating Engine Wiring Harness Connectors & Wiring Retainer
    G06271932Courtesy of FORD MOTOR CO.
  16. Connect the 2 transaxle electrical connectors.
    Fig 14: Locating Transaxle Electrical Connectors
    G06271931Courtesy of FORD MOTOR CO.
  17. Position the master cylinder reservoir and install the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 15: Locating Master Cylinder Reservoir Aside & Bolts
    G06271930Courtesy of FORD MOTOR CO.
  18. Connect the transaxle harness electrical connector, attach the wiring retainer and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 16: Locating Wiring Retainer & Bolt
    G06271929Courtesy of FORD MOTOR CO.
  19. Connect the Motor Electronics Cooling System (MECS) coolant expansion tank hose.
    Fig 17: Locating MECS Coolant Expansion Tank Hose
    G06271928Courtesy of FORD MOTOR CO.
  20. Install the MECS  coolant expansion tank nut and bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 18: Locating MECS Coolant Expansion Tank Nut & Bolt
    G06272228Courtesy of FORD MOTOR CO.
  21. Connect the upper Evaporative Emission (EVAP) tube quick connect coupling to the purge valve. For additional information, refer to QUICK CONNECT COUPLING .
    Fig 19: Locating Upper Evaporative Emission Tube Quick Connect Coupling From Purge Valve
    G06271926Courtesy of FORD MOTOR CO.
  22. Connect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 20: Locating Fuel Supply Tube
    G06271925Courtesy of FORD MOTOR CO.
  23. Connect the engine wiring harness connector and attach it to the bracket.
    Fig 21: Locating Engine Wiring Harness Connector & Bracket
    G06271924Courtesy of FORD MOTOR CO.
  24. Attach the engine wiring harness retainer to the bracket.
    Fig 22: Locating Engine Wiring Harness Retainer From Bracket
    G06271923Courtesy of FORD MOTOR CO.
  25. Connect the 2 heater hoses.
    Fig 23: Locating Heater Hoses
    G06271922Courtesy of FORD MOTOR CO.
  26. Attach the 2 block heater (if equipped) and the high voltage electrical system wiring retainers to the valve cover stud bolts.
    Fig 24: Locating High Voltage Electrical System Wiring Retainers From Valve Cover Stud Bolts
    G06271921Courtesy of FORD MOTOR CO.
  27. Connect the 2 vehicle high voltage electrical system electrical connectors.
    • Attach the wiring harness retainer.
    Fig 25: Locating Vehicle High Voltage Electrical System Electrical Connectors
    G06271920Courtesy of FORD MOTOR CO.
  28. Install a new gasket and connect the A/C tube to the A/C condenser.
    • Install the nut.
    • Tighten to 15 Nm (133 lb-in).
    Fig 26: Locating A/C Tube To A/C Condenser & Nut
    G06272236Courtesy of FORD MOTOR CO.
  29. Install a new gasket and connect the A/C tube to the A/C compressor.
    • Install the nut.
    • Tighten to 15 Nm (133 lb-in).
    Fig 27: Locating A/C Tube To A/C Compressor & Nut
    G06272237Courtesy of FORD MOTOR CO.
  30. Install the A/C tube bracket bolt.
    • Tighten to 6 Nm (53 lb-in).
    Fig 28: Locating A/C Tube Bracket Bolt
    G06271917Courtesy of FORD MOTOR CO.
  31. Install the A/C tube bracket bolt to the strut tower.
    • Tighten to 6 Nm (53 lb-in).
    Fig 29: Locating A/C Tube Bracket Bolt
    G06271916Courtesy of FORD MOTOR CO.
  32. Install a new gasket and connect the A/C tube.
    • Install the nut.
    • Tighten to 15 Nm (133 lb-in).
    Fig 30: Locating A/C Tube & Nut
    G06271915Courtesy of FORD MOTOR CO.
  33. If equipped, attach the 3 block heater wiring retainers.
    Fig 31: Locating Block Heater Wiring Retainers
    G06272241Courtesy of FORD MOTOR CO.
  34. Connect the upper and lower radiator hoses and install the retaining clips.
    NOTE: Lower radiator hose shown, upper similar.
    Fig 32: Locating Upper & Lower Radiator Hoses With Retaining Clips
    G06272242Courtesy of FORD MOTOR CO.
  35. Tighten the oil filter three-fourths of a turn after the oil filter gasket makes contact with the oil filter adapter.
    NOTE: Lubricate the oil filter O-ring with clean engine oil before installation.
    Fig 33: Identifying Oil Filter
    G06095070Courtesy of FORD MOTOR CO.
  36. Attach the transaxle shift cable routing retainer to the transaxle.
    Fig 34: Locating Transaxle Shift Cable Routing Retainer From Transaxle
    G06271910Courtesy of FORD MOTOR CO.
  37. Position the selector lever cable bracket in place and install the 2 nuts.
    • Tighten to 12 Nm (106 lb-in).
    Fig 35: Locating Transaxle Shift Cable Bracket & Nuts
    G06271909Courtesy of FORD MOTOR CO.
  38. Connect the selector lever cable end to the manual control lever. Check selector lever cable adjustment. For additional information, refer to SELECTOR LEVER CABLE ADJUSTMENT .
    Fig 36: Locating Transaxle Shift Cable From Transaxle
    G06271908Courtesy of FORD MOTOR CO.
  39. Install the transaxle ground wire and nut.
    • Tighten to 10 Nm (89 lb-in).
    Fig 37: Locating Transaxle Ground Wire & Nut
    G06271907Courtesy of FORD MOTOR CO.
  40. Connect the transaxle coolant temperature sensor and the Transmission Range (TR) sensor electrical connectors.
    • Attach the wiring harness retainer.
    Fig 38: Locating Wiring Harness Retainer
    G06271906Courtesy of FORD MOTOR CO.
  41. Connect the vacuum pump assembly electrical connector and attach the wiring retainer.
    Fig 39: Locating Vacuum Pump Assembly Electrical Connector & Wiring Retainer
    G06272249Courtesy of FORD MOTOR CO.
  42. Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position.
  43. Install the front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    NOTE: LH shown, RH similar.
    Fig 40: Locating Front Subframe Nuts
    G06261999Courtesy of FORD MOTOR CO.
  44. Position the subframe brackets and install the bolts finger-tight.
    NOTE: LH shown, RH similar.
    Fig 41: Locating Subframe Brackets & Bolts
    G06262394Courtesy of FORD MOTOR CO.
  45. Install the subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    NOTE: LH shown, RH similar.
    Fig 42: Locating Subframe Nuts
    G06262395Courtesy of FORD MOTOR CO.
  46. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
    NOTE: LH shown, RH similar.
    Fig 43: Locating Subframe Bracket-To-Body Bolts
    G06262396Courtesy of FORD MOTOR CO.
  47. Connect the MECS  electrical connector and attach the pump to the bracket.
    Fig 44: Locating MECS Electrical Connector & Pump To Bracket
    G06272254Courtesy of FORD MOTOR CO.
  48. Attach the 3 wiring harness retainers (2 shown) to the LH front of the subframe.
    Fig 45: Locating Wiring Harness Retainers From LH Front Of Subframe
    G06271899Courtesy of FORD MOTOR CO.
  49. Attach the auxiliary coolant hose retainer to the subframe.
    Fig 46: Locating Auxiliary Coolant Hose Retainer From Subframe
    G06271898Courtesy of FORD MOTOR CO.
  50. Connect the 2 Electronic Power Assist Steering (EPAS) electrical connectors near the front of the subframe.
    • Attach the connector retainer from the subframe.
    Fig 47: Locating EPAS Electrical Connectors Near Front Of Subframe
    G06271897Courtesy of FORD MOTOR CO.
  51. Install the stabilizer bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
    NOTE: RH shown, LH similar.
    Fig 48: Locating Stabilizer Bar Links & Nuts
    G06261995Courtesy of FORD MOTOR CO.
  52. Install tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install the cotter pin.
    NOTE: RH shown, LH similar.
    Fig 49: Locating Cotter Pins & Nuts From Tie-Rod Ends
    G06261993Courtesy of FORD MOTOR CO.
  53. Install the engine roll restrictor bolt.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 50: Locating Engine Roll Restrictor Bolt
    G06272260Courtesy of FORD MOTOR CO.
  54. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips (2 shown) into the body.
    • From under the vehicle, verify that the seal is correctly installed on the steering gear and the 4 retaining clips are fully engaged into the dash.
    Fig 51: Locating Steering Gear-To-Dash Seal Off Of Steering Gear & Clips
    G06261983Courtesy of FORD MOTOR CO.
  55. Install the LH splash shield and the 6 pin-type retainers (4 shown).
    Fig 52: Locating LH Splash Shield & Pin-Type Retainers
    G06262403Courtesy of FORD MOTOR CO.
  56. Position the LH fender splash shield and install the 4 screws.
    Fig 53: Locating LH Fender Splash Shield & Screws
    G06261987Courtesy of FORD MOTOR CO.
  57. Install the EPAS  wiring ground wire and bolt in the RH front wheel well.
    • Tighten to 10 Nm (89 lb-in).
    Fig 54: Locating Electronic Power Assist Steering Wiring Ground & Bolt
    G06263475Courtesy of FORD MOTOR CO.
  58. Install the RH splash shield and the 6 pin-type retainers (4 shown).
    Fig 55: Locating RH Splash Shield & Pin-Type Retainers
    G06272546Courtesy of FORD MOTOR CO.
  59. Position the RH fender splash shield and install the 4 screws.
    Fig 56: Locating RH Fender Splash Shield & Screws
    G06257214Courtesy of FORD MOTOR CO.
  60. Install the exhaust flexible pipe. For additional information, refer to INSTALLATION .
  61. Install the front wheels and tires. For additional information, refer to INSTALLATION .
  62. Fill the engine with clean engine oil.
  63. If equipped, install the underbody cover and 7 screws.
    Fig 57: Locating Underbody Cover & Screws
    G06257240Courtesy of FORD MOTOR CO.
  64. Connect the steering column shaft to the steering gear and install the bolt.
    • Tighten to 20 Nm (177 lb-in).
    Fig 58: Locating Steering Column Shaft To Steering Gear & Bolt
    G06261981Courtesy of FORD MOTOR CO.
  65. Install the steering joint cover and the 2 nuts.
    Fig 59: Locating Steering Joint Cover & Nuts
    G06261980Courtesy of FORD MOTOR CO.
  66. Repower the vehicle high-voltage electrical system. For additional information, refer to HIGH-VOLTAGE TRACTION BATTERY SYSTEMS DEPOWERING .
  67. Connect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION .
  68. Install the engine Air Cleaner (ACL) outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION .
  69. Reset the Passive Anti-Theft System (PATS). For additional information, refer to PASSIVE ANTI-THEFT SYSTEM (PATS) PARAMETER RESET .
  70. Fill and bleed the MECS  . For additional information, refer to FILLING AND BLEEDING .
  71. Fill and bleed the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  72. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS - HYBRID .
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