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Section 4 (Engine - 2.3L - (Hybrid)): Installation: Engine

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL(S) DESCRIPTION

G03898823
 Heavy Duty Floor Crane 014-00071 or equivalent
G03898617
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
G03897842
 Powertrain Lift (014-00765)
G03899013
 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: 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: Installing Transaxle Damper Tightening Bolts
      G03898863Courtesy 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 Nm (35 lb-ft).
      Fig 2: Installing Transaxle-To-Engine Bolts
      G03899015Courtesy of FORD MOTOR CO.
  3. Position the high voltage wiring harness and connect the 2 transaxle electrical connectors.
    Fig 3: Connecting Transaxle Electrical Connectors
    G03898862Courtesy of FORD MOTOR CO.
  4. Connect the high voltage wiring harness electrical connector.
    Fig 4: Connecting High Voltage Wiring Harness Electrical Connector
    G03898861Courtesy 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: Identifying Engine Lift Table
    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 115 Nm (85 lb-ft).
    • Tighten the bolt to 90 Nm (66 lb-ft).
      Fig 6: Installing Rear Transaxle Mounting Nut
      G03898860Courtesy of FORD MOTOR CO.
  9. Install the rear transaxle mount brace.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 7: Installing Rear Transaxle Mount Brace
      G03898859Courtesy of FORD MOTOR CO.
  10. Install the RH transaxle mount bracket.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 8: Installing RH Transaxle Mount Bracket
      G03898858Courtesy of FORD MOTOR CO.
  11. Install the RH transaxle mount bracket nut.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 9: Installing RH Transaxle Mount Bracket Nut
      G03898857Courtesy of FORD MOTOR CO.
  12. Install the engine mount bracket.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 10: Installing Engine Mount Bracket
      G03898856Courtesy of FORD MOTOR CO.
  13. Install the engine mount bracket bolt.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 11: Installing Engine Mount Bracket Bolt
      G03898855Courtesy of FORD MOTOR CO.
  14. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 12: Installing Transaxle-To-Engine Bolts
      G03898853Courtesy of FORD MOTOR CO.
  15. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 13: Installing Transaxle-To-Engine Bolts
      G03898852Courtesy of FORD MOTOR CO.
  16. Install the engine support crossmember.
    • Tighten to the bolts to 90 Nm (66 lb-ft).
    • Tighten to the nut to 175 Nm (129 lb-ft).
      Fig 14: Installing Engine Support Crossmember Tightening Bolts
      G03898851Courtesy of FORD MOTOR CO.
  17. Install the rear roll restrictor bolt.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 15: Installing Rear Roll Restrictor Bolt
      G03898850Courtesy of FORD MOTOR CO.
  18. Install the front roll restrictor bolt.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 16: Installing Front Roll Restrictor Bolt
      G03898849Courtesy 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: Connecting A/C Compressor Electrical Connector
      G03898848Courtesy of FORD MOTOR CO.
  20. Connect the lower radiator hose to the radiator.
    Fig 18: Locating Lower Radiator Hose At Radiator
    G03897882Courtesy of FORD MOTOR CO.
  21. Install the motor electronics coolant pump.
    • Tighten to 7 Nm (62 lb-in).
      Fig 19: Installing Motor Electronics Coolant Pump And Bolts
      G03898846Courtesy of FORD MOTOR CO.
  22. Install the ground cable and nut.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 20: Installing Ground Cable And Nut
      G03898845Courtesy of FORD MOTOR CO.
  23. Connect the transaxle coolant hoses.
    Fig 21: Connecting Transaxle Coolant Hoses
    G03898844Courtesy of FORD MOTOR CO.
  24. Connect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
    Fig 22: Connecting Transaxle Coolant Temperature Sensor Electrical Connector
    G03898843Courtesy of FORD MOTOR CO.
  25. Position the transaxle control cable and connect the pin-type retainer.
    Fig 23: Connecting Pin-Type Retainer
    G03898842Courtesy of FORD MOTOR CO.
  26. Connect the pin-type retainer.
    Fig 24: Connecting Pin-Type Retainer
    G03898841Courtesy 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: Connecting Transaxle Control Cable And Nuts
      G03898840Courtesy of FORD MOTOR CO.
  28. Position the control lever between the 2 casting ribs on the transaxle case.
    Fig 26: Identifying Control Lever Position
    G03899039Courtesy 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: Locating Bolts And Transaxle Control Snow Shield
      G03898839Courtesy of FORD MOTOR CO.
  33. Install the auxiliary coolant pump and connect the electrical connector.
    • Tighten to 10 Nm (89 lb-in).
      Fig 28: Connecting Electrical Connector
      G03898838Courtesy 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: Installing Harness Retainer Clips
      G03898837Courtesy of FORD MOTOR CO.
  35. Install the fuel supply tube and evaporative emissions (EVAP) tube.
    Fig 30: Connecting Fuel Supply Tube And Evaporative Emissions (EVAP) Tube
    G03898836Courtesy of FORD MOTOR CO.
  36. Connect the DC-to-DC converter electrical connector and pin-type retainer.
    Fig 31: Connecting DC-To-DC Converter Electrical Connector
    G03898835Courtesy of FORD MOTOR CO.
  37. Connect the transaxle harness electrical connector and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 32: Connecting Transaxle Harness Electrical Connector
      G03898834Courtesy of FORD MOTOR CO.
  38. Connect the 2 engine control harness electrical connectors and the 2 pin-type retainers.
    Fig 33: Connecting Engine Control Harness Electrical Connectors
    G03898833Courtesy of FORD MOTOR CO.
  39. 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 34: Connecting Engine Control Harness
      G03898832Courtesy of FORD MOTOR CO.
  40. Connect the following electrical connectors:
    • Transaxle mount control solenoid
    • Purge valve
      Fig 35: Connecting Electrical Connectors
      G03898831Courtesy of FORD MOTOR CO.
  41. Connect the upper radiator and coolant vent hoses.
    Fig 36: Connecting Upper Radiator And Coolant Vent Hoses
    G03898830Courtesy of FORD MOTOR CO.
  42. Attach the heater hose retaining clip to the transaxle mount stud.
    Fig 37: Connecting Heater Hose
    G03898829Courtesy of FORD MOTOR CO.
  43. Connect the heater hoses to the heater core.
    Fig 38: Locating Heater Hoses At Heater Core
    G03897868Courtesy of FORD MOTOR CO.

    44. 4x2 vehicles 

  44. Install the lateral support crossmember.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 39: Identifying Lateral Support Crossmember And Bolts
      G03897847Courtesy of FORD MOTOR CO.
  45. Install the front drive intermediate halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .

    46. 4x4 vehicles 

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

    47. All vehicles 

  47. Install the LH front drive halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  48. Install the oil filter element. For additional information, refer to ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW .
  49. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - HYBRID .
  50. Install the engine coolant degas bottle. For additional information, refer to ENGINE COOLING - HYBRID .
  51. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
  52. Install the engine air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID .
  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 .
  55. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  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 .
  58. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING - HYBRID .
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