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Section 1461 (Engine Mechanical - 2.5L (Hybrid)): Installation: Engine: Material

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

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.

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: Locating Transaxle Damper Bolts
      G06390308Courtesy of FORD MOTOR CO.
    2. 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 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).
      Fig 2: Locating Engine Transaxle Bolts
      G06390309Courtesy of FORD MOTOR CO.
  3. Connect the high-voltage wiring harness electrical connector.
    • Engage the electrical connector locking tab.
      Fig 3: Locating High Voltage Wiring Harness Electrical Connector
      G06390310Courtesy of FORD MOTOR CO.
  4. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift.
    5. NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the Powertrain Lift.
    Fig 4: Identifying Powertrain Lift And Universal Adapter Brackets
    G06390311Courtesy of FORD MOTOR CO.
  5. Using the Universal Adapter Brackets, secure the engine to the Powertrain Lift.
  6. Raise the engine and transaxle into the vehicle.
  7. Install the upper transaxle insulator.
    1. Tighten the nuts to 90 Nm (66 lb-ft).
    2. Tighten the through bolt to 103 Nm (76 lb-ft).
      Fig 5: Locating Upper Insulator Nuts
      G06390312Courtesy of FORD MOTOR CO.
  8. Install the upper transaxle insulator bracket.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 6: Locating Upper Insulator Bracket
      G06390313Courtesy of FORD MOTOR CO.
  9. Install the 3 engine mount bracket nuts.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 7: Locating Engine Mount Bracket
      G06390314Courtesy of FORD MOTOR CO.
  10. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 8: Locating Engine Mount Bracket Bolt
      G06390315Courtesy of FORD MOTOR CO.
  11. Using the Powertrain Lift, raise the subframe into position.
    Fig 9: Raising Subframe Into Position
    G06390316Courtesy of FORD MOTOR CO.
    12. NOTE: RH shown, LH similar.
  12. Install the 2 subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 10: Locating Subframe Nuts
      G06390317Courtesy of FORD MOTOR CO.
    13. 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.
  13. Tighten the 2 subframe bolts.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 11: Locating Front Subframe Bolts
      G06390318Courtesy of FORD MOTOR CO.
  14. Install the rear roll restrictor, bracket and bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 12: Locating Bolts, Roll Restrictor And Bracket
      G06390319Courtesy of FORD MOTOR CO.
  15. Connect the steering column coupling to the steering gear and install the new steering column coupling pinch bolt.
    • Tighten to 63 Nm (46 lb-ft).
      Fig 13: Locating Steering Column Coupling Pinch Bolt
      G06390320Courtesy of FORD MOTOR CO.
  16. Install the rear transaxle insulator through bolt.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 14: Locating Rear Transaxle Insulator Through Bolt
      G06390321Courtesy of FORD MOTOR CO.
  17. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 15: Identifying Transaxle-To-Engine Bolts
      G06390322Courtesy of FORD MOTOR CO.
  18. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 16: Identifying Transaxle-To-Engine Bolts
      G06390323Courtesy of FORD MOTOR CO.
  19. 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 17: Identifying Engine Support Crossmember Nut And Bolts
      G06390324Courtesy of FORD MOTOR CO.
  20. Install the rear roll restrictor-to-crossmember through bolt.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 18: Locating Rear Roll Restrictor-To-Crossmember Bolt
      G06390325Courtesy of FORD MOTOR CO.
  21. Install the lower transaxle insulator through bolt.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 19: Locating Lower Insulator Through Bolt
      G06390326Courtesy of FORD MOTOR CO.
  22. Connect the lower radiator hose to the radiator.
    • Install the retaining clip.
      Fig 20: Locating Lower Radiator Hose
      G06390327Courtesy of FORD MOTOR CO.
  23. Install the auxiliary coolant pump and the 2 bolts.
    • Connect the auxiliary coolant pump electrical connector.
    • Tighten to 10 Nm (89 lb-in).
      Fig 21: Locating Auxiliary Coolant Pump Electrical Connector
      G06390328Courtesy of FORD MOTOR CO.
  24. 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 22: Locating A/C Compressor Nut
      G06390329Courtesy of FORD MOTOR CO.
  25. 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 23: Locating A/C Compressor Nut
      G06390330Courtesy of FORD MOTOR CO.
  26. Install the Motor Electronics Cooling System (MECS) pump and the 2 bolts.
    • Tighten to 20 Nm (177 lb-in).
      Fig 24: Locating MECS Pump Bolts
      G06390331Courtesy of FORD MOTOR CO.
  27. Connect the vacuum pump electrical connector and attach the harness retainer.
    Fig 25: Locating Vacuum Pump Assembly Electrical Connector
    G06390332Courtesy of FORD MOTOR CO.
  28. Install the wiring harness fasteners, the ground cable and nut.
    • Tighten to 20 Nm (177 lb-in).
      Fig 26: Locating Harness Fasteners, Nut And Ground Cable
      G06390333Courtesy of FORD MOTOR CO.
  29. 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 27: Identifying Selector Lever Cable Bracket And Nuts
      G06390334Courtesy of FORD MOTOR CO.
  30. Position the control lever between the 2 casting ribs on the transaxle case.
    Fig 28: Identifying Control Lever Position
    G06390335Courtesy of FORD MOTOR CO.
  31. Place the gear selector lever in the D position.
  32. Tighten the transaxle control cable bracket nuts.
    • Tighten to 22 Nm (16 lb-ft).
  33. 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.
  34. Install the transaxle control snow shield and the 2 bolts.
    • Tighten to 22 Nm (16 lb-ft).
      Fig 29: Locating Bolts And Transaxle Control Snow Shield
      G06390336Courtesy of FORD MOTOR CO.
  35. Attach the transaxle selector lever cable fastener to the A/C compressor mounting bracket.
    Fig 30: Locating Transaxle Selector Lever Cable Fastener
    G06390337Courtesy of FORD MOTOR CO.
  36. Attach the transaxle selector lever cable fastener to the engine front cover stud bolt.
    Fig 31: Locating Transaxle Selector Lever Cable Fastener
    G06390338Courtesy of FORD MOTOR CO.
  37. Connect the transaxle coolant hoses.
    Fig 32: Locating Transaxle Coolant Hoses
    G06390339Courtesy of FORD MOTOR CO.
  38. Connect the transaxle coolant temperature sensor electrical connector.
    • Attach the wiring retainer to the transaxle stud bolt.
      Fig 33: Locating Transaxle Coolant Temperature Sensor Electrical Connector
      G06390340Courtesy of FORD MOTOR CO.
  39. Attach the 2 high-voltage electrical system wiring retainers to the valve cover stud bolts.
    Fig 34: Locating High-Voltage Electrical System Wiring Retainers
    G06390341Courtesy of FORD MOTOR CO.
  40. Connect the 2 vehicle high-voltage electrical system electrical connectors.
    • Attach the wiring harness retainer.
      Fig 35: Locating Vehicle High-Voltage Electrical System Electrical Connectors
      G06390342Courtesy of FORD MOTOR CO.
  41. Position the DC-to-DC converter in place and install the 3 nuts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 36: Locating DC-To-DC Converter
      G06390343Courtesy of FORD MOTOR CO.
  42. Connect the DC-to-DC converter electrical connector and 2 wire harness retainers (1 shown).
    • Engage the electrical connector locking tab.
      Fig 37: Locating DC-To-DC Converter Electrical Connector And Wiring Harness Retainers
      G06390344Courtesy of FORD MOTOR CO.
  43. Connect the coolant vent hose.
    Fig 38: Locating Coolant Vent Hose Clamp
    G06390345Courtesy of FORD MOTOR CO.
  44. Connect the 2 low-voltage electrical connectors and the engine harness-to-body harness retainer.
    Fig 39: Locating Low Voltage Electrical Connectors And Engine Harness-To-Body Harness Retainer
    G06390346Courtesy of FORD MOTOR CO.
  45. Connect the transaxle harness electrical connector and install the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 40: Locating Stud Bolt And Transaxle Harness Electrical Connector
      G06390347Courtesy of FORD MOTOR CO.
  46. Connect the upper evaporative emissions Evaporative Emission (EVAP) tube quick connect coupling to the purge valve. For additional information, refer to QUICK CONNECT COUPLING .
    Fig 41: Locating Nuts And Glow Plug Module
    G06390348Courtesy of FORD MOTOR CO.
  47. Connect the engine control harness electrical connector.
    • Attach the engine control harness wiring retainer to the intake manifold.
      Fig 42: Locating Engine Control Harness Electrical Connector
      G06390349Courtesy of FORD MOTOR CO.
  48. If equipped, connect the block heater electrical connector.
    • Attach the harness retainer clips.
      Fig 43: Locating Block Heater Electrical Connector
      G06390350Courtesy of FORD MOTOR CO.
  49. Connect the PCM electrical connector.
    • Position the harness and install the wiring harness retainer.
      Fig 44: Locating PCM Center Electrical Connector
      G06390351Courtesy of FORD MOTOR CO.
  50. Connect the brake booster vacuum hose to the brake booster.
    Fig 45: Locating Nuts And Glow Plug Module
    G06390352Courtesy of FORD MOTOR CO.
  51. Connect the upper radiator hose to the radiator.
    Fig 46: Locating Upper Radiator Coolant Hose
    G06390353Courtesy of FORD MOTOR CO.
  52. Connect the heater hoses to the heater core.
    Fig 47: Locating Heater Hose Clamps
    G06390354Courtesy of FORD MOTOR CO.
  53. Install the spin-on engine oil filter.
    • Tighten the spin-on oil filter three-fourths of a turn after the oil filter gasket makes contact with the oil filter adapter.
      Fig 48: Locating Engine Oil Filter
      G06390355Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

  54. Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal.
    Fig 49: Installing Intermediate Shaft Seal
    G06390356Courtesy of FORD MOTOR CO.
  55. Position the Power Transfer Unit (PTU) in place and install the 4 bolts.
    • Tighten to 45 Nm (33 lb-ft).
      Fig 50: Identifying Transfer Case-To-Transaxle Bolts And Transfer Case
      G06390357Courtesy of FORD MOTOR CO.
  56. Connect the PTU  vent hose.
    Fig 51: Locating PTU Vent Hose
    G06390358Courtesy of FORD MOTOR CO.
  57. Install the PTU  heat shield and the bolts.
    • Tighten to 11 Nm (97 lb-in).
      Fig 52: Locating PTU Heat Shield And Bolts
      G06390359Courtesy of FORD MOTOR CO.
    58. NOTE: Catalytic converter manifold is removed for clarity.
  58. Position the PTU  -to-engine support bracket and install the bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 53: Locating Transfer Case-To-Engine Bracket Bolts
      G06390360Courtesy of FORD MOTOR CO.
  59. Install the 2 exhaust bracket bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 54: Locating Exhaust Bracket Bolts
      G06390361Courtesy of FORD MOTOR CO.
  60. Install the driveshaft. For additional information, refer to REMOVAL AND INSTALLATION .

    All vehicles 

  61. Install the intermediate shaft.
    Fig 55: Locating Intermediate Shaft
    G06390362Courtesy of FORD MOTOR CO.
  62. Install the 2 intermediate shaft bearing retainer nuts.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 56: Identifying Intermediate Shaft Retaining Nuts
      G06390363Courtesy of FORD MOTOR CO.
  63. Install the RH and LH halfshafts. For additional information, refer to REMOVAL AND INSTALLATION .
    64. NOTE: RH side shown, LH similar.
  64. Connect the RH and LH suspension.
    1. Position the tie-rod end and install the retaining nut.
      • Tighten to 55 Nm (41 lb-ft).
    2. Connect the stabilizer bar link and install the nut.
      • Tighten to 63 Nm (46 lb-ft).
        Fig 57: Identifying Stabilizer Bar Link And Nut
        G06390364Courtesy of FORD MOTOR CO.
  65. Install the RH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (133 lb-in).
      Fig 58: Locating Brake Hose Retainer And ABS Sensor Retaining Bolt
      G06390365Courtesy of FORD MOTOR CO.
  66. Install the LH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (133 lb-in).
      Fig 59: Locating Brake Hose Retainer And ABS Sensor Retaining Bolt
      G06390366Courtesy of FORD MOTOR CO.
  67. Install the exhaust intermediate pipe. For additional information, refer to EXHAUST INTERMEDIATE PIPE -- 2.5L, HYBRID .
  68. Install the lateral support crossmember and the bolts.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 60: Locating Lateral Support Crossmember Bolts
      G06390367Courtesy of FORD MOTOR CO.
  69. Install the front wheels and tires. For additional information, refer to WHEEL AND TIRE .
  70. Connect the fuel supply tube. For additional information, refer to QUICK CONNECT COUPLING .
    Fig 61: Locating Fuel Supply Tube
    G06390368Courtesy of FORD MOTOR CO.
  71. Install the engine Air Cleaner (ACL). For additional information, refer to AIR CLEANER .
  72. Install the engine coolant degas bottle. For additional information, refer to DEGAS BOTTLE .
  73. Install the battery and the battery tray. For additional information, refer to REMOVAL AND INSTALLATION .
  74. Fill the engine with clean engine oil.
  75. Enable the vehicle high-voltage electrical system. For additional information, refer to HIGH-VOLTAGE TRACTION BATTERY SYSTEMS DEPOWERING .
  76. Reset the Passive Anti-Theft System (PATS). For additional information, refer to PASSIVE ANTI-THEFT SYSTEM (PATS) PARAMETER RESET .
  77. Fill and bleed the MECS  . For additional information, refer to MOTOR ELECTRONICS COOLING SYSTEM DRAINING AND FILLING .
  78. Fill and bleed the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  79. Fill the transaxle with fluid. For additional information, refer to TRANSMISSION FLUID DRAIN AND REFILL .
  80. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS - HYBRID .
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