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Section 2056 (Engine Mechanical - 2.5L (Hybrid)): Installation: Engine

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G07782398
 2,200# Floor Crane, Fold Away
300-OTC1819E or equivalent
G07782399
 Lifting Bracket, Engine
303-D089 (D93P-6001-A3) or equivalent
G07782400
 Powertrain Lift
300-OTC1585AE or equivalent
G07782401
 Adjustable Grip Arm, 1735A
014-00001 or equivalent
MATERIAL

Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US);
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)		 WSS-M2C945-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.
    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
    G07782402Courtesy of FORD MOTOR CO.
  1. Install the transaxle damper.
    • Tighten to 29 Nm (21 lb-ft).
    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.
    Fig 2: Locating Engine And Transaxle Mounting Bolts
    G07782403Courtesy of FORD MOTOR CO.
  2. Using the 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).
  3. Connect the 2 heater hoses to the coolant outlet.
    Fig 3: Locating Heater Hoses And Clamps
    G07782404Courtesy of FORD MOTOR CO.
  4. Install the 2 engine cover studs onto the valve cover studs.
    Fig 4: Locating Engine Cover Studs
    G07782405Courtesy 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 And Bracket Mounting Bolts
    G07782406Courtesy of FORD MOTOR CO.
  6. Using the Floor Crane and Engine Lifting Bracket, position the engine and transaxle onto the Powertrain Lift.
    7. NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the Powertrain Lift.
    Fig 6: Mounting Engine To Powertrain Lift Using Powertrain Lift And Adjustable Grip Arm
    G07782407Courtesy of FORD MOTOR CO.
  7. Using the Adjustable Grip Arm, secure the engine to the Powertrain Lift.
  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 Mounting Nuts
    G07782408Courtesy 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 And Nuts
    G07782409Courtesy of FORD MOTOR CO.
  11. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
    Fig 9: Locating Engine Mount Bracket Bolts
    G07782410Courtesy of FORD MOTOR CO.
  12. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 10: Locating Transaxle-To-Engine Bolts
    G07782411Courtesy 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
    G07782412Courtesy of FORD MOTOR CO.
  14. Connect the brake booster vacuum hose.
    Fig 12: Locating Brake Booster Vacuum Hose Clamp
    G07782413Courtesy of FORD MOTOR CO.
  15. Connect the 2 engine wiring harness connectors and attach the wiring retainer.
    Fig 13: Locating Engine Wiring Harness Connectors
    G07782414Courtesy of FORD MOTOR CO.
  16. Connect the 2 transaxle electrical connectors.
    Fig 14: Locating Transaxle Electrical Connectors
    G07782415Courtesy 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 Mounting Bolts
    G07782416Courtesy 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 Transaxle Harness Electrical Connector
    G07782417Courtesy of FORD MOTOR CO.
  19. Connect the Motor Electronics Cooling System (MECS) coolant expansion tank hose.
    Fig 17: Locating MECS Coolant Expansion Tank Clamp
    G07782418Courtesy 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 And Bolt
    G07782419Courtesy of FORD MOTOR CO.
  21. Connect the upper Evaporative Emission (EVAP) tube quick connect coupling to the purge valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
    Fig 19: Locating Upper Evaporative Emission (EVAP) Tube Quick Connect Coupling
    G07782420Courtesy of FORD MOTOR CO.
  22. Connect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
    Fig 20: Locating Fuel Supply Tube
    G07782421Courtesy of FORD MOTOR CO.
  23. Connect the engine wiring harness connector and attach it to the bracket.
    Fig 21: Locating Engine Wiring Harness Connector
    G07782422Courtesy of FORD MOTOR CO.
  24. Attach the engine wiring harness retainer to the bracket.
    Fig 22: Locating Engine Wiring Harness Retainer
    G07782423Courtesy of FORD MOTOR CO.
  25. Connect the 2 heater hoses.
    Fig 23: Locating Heater Hoses
    G07782424Courtesy 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 Valve Cover Stud Bolts
    G07782425Courtesy 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
    G07782426Courtesy 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 Condenser Tube Mounting Nut
    G07782427Courtesy 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 Compressor Mounting Nut
    G07782428Courtesy 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
    G07782429Courtesy 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 Strut Tower A/C Tube Bracket Bolt
    G07782430Courtesy 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 Mounting Nut
    G07782431Courtesy of FORD MOTOR CO.
  33. If equipped, attach the 3 block heater wiring retainers.
    Fig 31: Locating Block Heater Wiring Retainers
    G07782432Courtesy of FORD MOTOR CO.
    34. NOTE: Lower radiator hose shown in illustration, upper similar.
    Fig 32: Connecting Upper And Lower Radiator Hoses
    G07782433Courtesy of FORD MOTOR CO.
  34. Connect the upper and lower radiator hoses and install the retaining clips.
    35. NOTE: Lubricate the oil filter O-ring with clean engine oil before installation.
    Fig 33: Locating Engine Oil Filter
    G07782434Courtesy 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.
  36. Attach the transaxle shift cable routing retainer to the transaxle.
    Fig 34: Locating Transaxle Shift Cable Routing Retainer
    G07782435Courtesy 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 And Mounting Nuts
    G07782436Courtesy 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 AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS - FUSION HYBRID, MILAN HYBRID & MKZ HYBRID article.
    Fig 36: Locating Transaxle Shift Cable
    G07782437Courtesy 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 And Nut
    G07782438Courtesy 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 Transaxle Coolant Temperature Sensor And Transmission Range (TR) Sensor Electrical Connectors
    G07782439Courtesy 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
    G07782440Courtesy of FORD MOTOR CO.
  42. Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position.
    43. NOTE: LH shown in illustration, RH similar.
    Fig 40: Locating Front Subframe Nuts
    G07782441Courtesy of FORD MOTOR CO.
  43. Install the front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    44. NOTE: LH shown in illustration, RH similar.
    Fig 41: Locating Subframe Brackets And Mounting Bolts
    G07782442Courtesy of FORD MOTOR CO.
  44. Position the subframe brackets and install the bolts finger-tight.
    45. NOTE: LH shown in illustration, RH similar.
    Fig 42: Locating Subframe Nut
    G07782443Courtesy of FORD MOTOR CO.
  45. Install the subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    46. NOTE: LH shown in illustration, RH similar.
    Fig 43: Locating Subframe Bracket-To-Body Bolts
    G07782444Courtesy of FORD MOTOR CO.
  46. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
  47. Connect the MECS electrical connector and attach the pump to the bracket.
    Fig 44: Locating MECS Electrical Connector
    G07782445Courtesy of FORD MOTOR CO.
  48. Attach the 3 wiring harness retainers (2 shown in illustration) to the LH front of the subframe.
    Fig 45: Locating Subframe Wiring Harness Retainers
    G07782446Courtesy of FORD MOTOR CO.
  49. Attach the auxiliary coolant hose retainer to the subframe.
    Fig 46: Locating Auxiliary Coolant Hose Retainer
    G07782447Courtesy 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 Subframe EPAS Electrical Connectors
    G07782448Courtesy of FORD MOTOR CO.
    51. NOTE: RH shown in illustration, LH similar.
    Fig 48: Locating Stabilizer Bar Links And Fastener
    G07782449Courtesy of FORD MOTOR CO.
  51. Install the stabilizer bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
    52. NOTE: RH shown in illustration, LH similar.
    Fig 49: Locating Tie-Rod Ends Cotter Pins And Nuts
    G07782450Courtesy of FORD MOTOR CO.
  52. Install tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install the cotter pin.
  53. Install the engine roll restrictor bolt.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 50: Locating Engine Roll Restrictor Bolt
    G07782451Courtesy of FORD MOTOR CO.
  54. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips (2 shown in illustration) 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 Clips
    G07782452Courtesy of FORD MOTOR CO.
  55. Install the LH splash shield and the 6 pin-type retainers (4 shown in illustration).
    Fig 52: Locating Splash Shield Mounting Retainers
    G07782453Courtesy of FORD MOTOR CO.
  56. Position the LH fender splash shield and install the 4 screws.
    Fig 53: Locating Fender Splash Shield Mounting Screws
    G07782454Courtesy 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 (EPAS) Wiring Mounting Bolt
    G07782455Courtesy of FORD MOTOR CO.
  58. Install the RH splash shield and the 6 pin-type retainers.
    Fig 55: Locating Splash Shield Mounting Retainers
    G07782456Courtesy of FORD MOTOR CO.
  59. Position the RH fender splash shield and install the 4 screws.
    Fig 56: Locating RH Fender Splash Shield Mounting Screws
    G07782457Courtesy of FORD MOTOR CO.
  60. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM -- FUSION, MILAN & MKZ article.
  61. Install the front wheels and tires. For additional information, refer to WHEELS & TIRES article.
  62. Fill the engine with clean engine oil.
  63. If equipped, install the underbody cover and 7 screws.
    Fig 57: Locating Underbody Cover Mounting Screws
    G07782458Courtesy 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 And Mounting Bolts
    G07782459Courtesy of FORD MOTOR CO.
  65. Install the steering joint cover and the 2 nuts.
    Fig 59: Locating Steering Joint Cover And Mounting Nuts
    G07782460Courtesy of FORD MOTOR CO.
  66. Repower the vehicle high-voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY -- FUSION HYBRID, MILAN HYBRID & MKZ HYBRID article.
  67. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING & CABLES -- FUSION, MILAN & MKZ article.
  68. Install the engine Air Cleaner (ACL) outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - (HYBRID) article.
  69. Reset the Passive Anti-Theft System (PATS). For additional information, refer to ANTI-THEFT - PASSIVE ANTI-THEFT SYSTEM (PATS) -- FUSION, MILAN & MKZ article.
  70. Fill and bleed the MECS. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION COOLING -- ECVT - HYBRID article.
  71. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING SYSTEM -- (HYBRID) article.
  72. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS -- FUSION, MILAN & MKZ (HYBRID) article.
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