Removal And Installation: Engine: Installation

WARNING: This page is about a different variant/trim than selected.

Lubricate the torque converter pilot hub with Multi-Purpose Grease.
- Remove the 307-566 and bolt.
Fig 1: Removing Torque Converter Retainer And Bolt
Courtesy of FORD MOTOR CO.
NOTE: Align the torque converter stud marked during removal with the flexplate.

Using the 300-OTC1819E and 303-D089 (D93P-6001-A3), assemble the engine and transaxle.

Fig 2: Installing Engine And Transaxle Using Floor Crane And Spreader Bar
Courtesy of FORD MOTOR CO.
Install the 2 transaxle-to-engine bolts and stud bolt.
- Tighten to 48 Nm (35 lb-ft).
Fig 3: Locating Transaxle-To-Engine Bolts And Stud Bolt
Courtesy of FORD MOTOR CO.
Install the 3 engine-to-transaxle bolts.
- Tighten to 48 Nm (35 lb-ft).
Fig 4: Locating Engine-To-Transaxle Bolts
Courtesy of FORD MOTOR CO.
Install the 3 transaxle-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).
Fig 5: Locating Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
Using the 300-OTC1819E and 303-D089 (D93P-6001-A3) position the engine and transaxle onto the 300-OTC1585AE .

Fig 6: Positioning Of Engine Transaxle Onto Power Train Lift Using Floor Crane And Spreader Bar
Courtesy of FORD MOTOR CO.
NOTE: Position a block of wood under the transaxle.

Install the 014-00001 .

Fig 7: Positioning Power Train Lift And Adjustable Grip Under Transaxle
Courtesy of FORD MOTOR CO.
Connect the PCV tube to the turbocharger inlet pipe.

Fig 8: Connecting PCV Tube To Turbocharger Inlet Pipe
Courtesy of FORD MOTOR CO.
Install the wire terminal and nut on the generator.
- Tighten to 17 Nm (150 lb-in) and install the cap.
  - Disconnect the wire harness electrical connector.
  - Attach the 4 wiring harness retainers to the engine.
Fig 9: Locating Engine Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Attach the wiring harness retainer to the transaxle-to-engine stud bolt.

Fig 10: Locating Wiring Harness Retainer To Transaxle-To-Engine Stud Bolt
Courtesy of FORD MOTOR CO.
NOTE: Only rotate the engine in a clockwise direction or engine damage will occur.

Install the 4 torque converter nuts.
- Tighten to 40 Nm (30 lb-ft).
Fig 11: Locating Torque Converter Nuts
Courtesy of FORD MOTOR CO.
Install the starter insulator.

Fig 12: Locating Starter Insulator
Courtesy of FORD MOTOR CO.
Install the starter and the 2 stud bolts.
- Tighten to 35 Nm (26 lb-ft).
Fig 13: Locating Starter Stud Bolts
Courtesy of FORD MOTOR CO.
Install the 2 starter wire terminals, the ground wire and the 3 nuts.
- Tighten the ground wire nut to 18 Nm (159 lb-in).
- Tighten the large starter wire terminal nut to 12 Nm (106 lb-in).
- Tighten the small starter wire terminal nut to 5 Nm (44 lb-in).
  - Install the starter cable cover.
Fig 14: Locating Starter Cable Cover And Nuts
Courtesy of FORD MOTOR CO.
Raise the engine and transaxle assembly into the vehicle and install the transaxle support insulator bolt.
- Tighten to 150 Nm (111 lb-ft).
Fig 15: Locating Transaxle Support Insulator Bolt
Courtesy of FORD MOTOR CO.
Install the engine support insulator, the 4 nuts and the 3 bolts.
- Tighten bolts to 90 Nm (66 lb-ft).
- Tighten nuts to 125 Nm (92 lb-ft).
Fig 16: Locating Engine Support Insulator Nuts And Bolts
Courtesy of FORD MOTOR CO.
Install the A/C compressor, the 2 bolts and the stud.
- Tighten the bolts to 25 Nm (18 lb-ft) and the stud to 9 Nm (80 lb-in).
- Install the nut and tighten to 25 Nm (18 lb-ft).
Fig 17: Locating A/C Compressor Nut, Stud And Bolts
Courtesy of FORD MOTOR CO.
Install the A/C tube bracket bolt.
- Tighten to 25 Nm (18 lb-ft).
Fig 18: Locating A/C Tube Bracket Bolt
Courtesy of FORD MOTOR CO.
Connect the 2 A/C compressor electrical connectors.
- Attach the wiring harness retainer to the A/C tube stud bolt.
Fig 19: Locating A/C Compressor Electrical Connector And Tube Stud Bolt
Courtesy of FORD MOTOR CO.
Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt onto the A/C compressor.

Fig 20: Rotating Accessory Drive Belt Tensioner Counterclockwise
Courtesy of FORD MOTOR CO.
Connect the transaxle fluid cooler tubes onto the transaxle fluid CBV .

Fig 21: Identifying Transaxle Fluid Cooler Tubes Onto Transaxle Fluid CBV
Courtesy of FORD MOTOR CO.
Install the secondary latches onto the transaxle fluid cooler tubes at the transaxle fluid CBV .

Fig 22: Identifying Secondary Latches Onto Transaxle Fluid Cooler Tubes At Transaxle Fluid CBV
Courtesy of FORD MOTOR CO.
Install the 2 transaxle-to-oil pan bolts.
- Tighten to 48 Nm (35 lb-ft).
NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.

Install a new engine oil filter.
- Tighten to 8 Nm (71 lb-in) plus an additional 180 degrees.
Fig 23: Installing Engine Oil Filter
Courtesy of FORD MOTOR CO.
NOTE: Make sure to install the correct circlip for this application. Failure to use the correct diameter circlip may result in shaft removal concerns or shaft damage during vehicle operation.

Install a new circlip.

Fig 24: Locating Circlip On Shaft
Courtesy of FORD MOTOR CO.
Install 205-461 on the LH halfshaft seal.

Fig 25: Identifying Differential Oil Seal Protector
Courtesy of FORD MOTOR CO.
NOTE: The sharp edges on the halfshaft splines can slice or puncture the oil seal. Use care when inserting the halfshaft into the transmission or damage to the seal may occur.

Push the LH halfshaft into the transmission so the circlip locks into the differential side gear. Pull the halfshaft inner end to make sure the circlip is locked.

Fig 26: Pushing LH Halfshaft Into Transmission
Courtesy of FORD MOTOR CO.
Install the RH halfshaft in the transmission and engage the halfshaft splines with the transmission side gears and install the 2 halfshaft nuts.
- Torque: 25 Nm (18 lb-ft).
Fig 27: Locating Halfshaft Nuts
Courtesy of FORD MOTOR CO.
Install the subframe. REFER to SUBFRAME - FRONT .
Install the catalytic converter. REFER to CATALYTIC CONVERTER - 2.0L GTDI .
Attach the 3 wiring harness retainers to the valve cover stud bolts.

Fig 28: Locating Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Install the ground cable and bolt.
- Tighten to 11 Nm (97 lb-in).
Fig 29: Locating Ground Cable Bolt
Courtesy of FORD MOTOR CO.
Connect the wiring harness electrical connector and the PCM electrical connector.
- Slide the wiring harness down onto the bulkhead until the retainer tabs engage.
- Attach the wiring harness retainer.
Fig 30: Locating PCM Electrical Connector And Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Connect the EVAP tube. REFER to Connect - Type 2. Refer to QUICK CONNECT COUPLING .

Fig 31: Locating EVAP Tube Coupling
Courtesy of FORD MOTOR CO.
Connect the fuel supply tube. REFER to Connect - Type 2. Refer to QUICK CONNECT COUPLING .

Fig 32: Locating Fuel Supply Tube Coupling
Courtesy of FORD MOTOR CO.
Connect the transaxle selector lever cable end to the manual control lever and install the 2 bracket bolts.
- Tighten to 25 Nm (18 lb-ft).
Fig 33: Locating Selector Lever Cable And Bracket Bolts
Courtesy of FORD MOTOR CO.
Connect the vacuum tube quick connect coupling to the brake booster. REFER to Connect - Type 1. Refer to QUICK CONNECT COUPLING .

Fig 34: Locating Vacuum Tube Quick Connect Coupling
Courtesy of FORD MOTOR CO.
Install the lower radiator hose and clamp.

Fig 35: Locating Lower Radiator Hose And Clamp
Courtesy of FORD MOTOR CO.
Install the upper radiator hose, the heater hose and the 2 clamps.
- Connect the heater hose quick connect coupling.
- Attach the hoses to the 2 retaining clips.
Fig 36: Locating Heater Hose Quick Connect Coupling Retaining Clips
Courtesy of FORD MOTOR CO.
Install the degas bottle. REFER to DEGAS BOTTLE .
Connect the oil cooler inlet and outlet hose quick connect couplings.

Fig 37: Locating Oil Cooler Inlet And Outlet Hose Quick Connect Couplings
Courtesy of FORD MOTOR CO.
Install the underbody shield and the 4 retainers.

Fig 38: Locating Underbody Shield Retainers
Courtesy of FORD MOTOR CO.
Connect the CAC outlet tube.

Fig 39: Locating CAC Outlet Tube Clamp
Courtesy of FORD MOTOR CO.
Connect the CAC inlet tube.

Fig 40: Locating CAC Inlet Tube Clamp
Courtesy of FORD MOTOR CO.
Install the TCM bracket, install the 2 nuts and install the bolt.
1. Tighten to 11 Nm (97 lb-in).
2. Tighten to 63 Nm (46 lb-ft).
Fig 41: Identifying TCM Bracket Nuts And Bolts
Courtesy of FORD MOTOR CO.
Install the vacuum tube retainer and the wiring retainer on the TCM bracket.

Fig 42: Locating Vacuum Tube Retainer And Wiring Retainer On TCM Bracket
Courtesy of FORD MOTOR CO.
NOTE: Keep the TCM electrical connector straight when connecting it or damage to the connector terminals can occur.

Connect the TCM electrical connector.
1. Slide the electrical connector straight into the TCM.
2. Push the locking clip down.
Fig 43: Sliding Electrical Connector Straight Into TCM
Courtesy of FORD MOTOR CO.
Connect the power feed wire to the positive battery terminal and install the nut.
- Tighten to 9 Nm (80 lb-in).
  - Connect the power feed electrical connector to the positive battery terminal.
Fig 44: Locating Power Feed Electrical Connector And Nut
Courtesy of FORD MOTOR CO.
Install the ground wire and stud bolt.
- Tighten to 10 Nm (89 lb-in).
  - Connect the engine wiring harness electrical connector.
Fig 45: Locating Engine Wiring Harness Electrical Connector And Stud Bolt
Courtesy of FORD MOTOR CO.
Install the battery tray. REFER to BATTERY AND BATTERY TRAY - EXPLODED VIEW .
Install the engine ACL and ACL outlet pipe. REFER to INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW .
Install the cowl panel. REFER to COWL PANEL .
Fill the engine with clean engine oil.
Fill and bleed the engine cooling system. REFER to COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.0L GTDI .
After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.