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Home >> Ford >> 2012 >> Explorer Limited, 3.5 8, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 221 (Engine Mechanical -2.0L GTDI) >> Removal And Installation >> Engine >> Installation

Removal And Installation: Engine: Installation

WARNING: This page is about a different car, the 2013 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles 

  1. Lubricate the torque converter pilot hub with Multi-Purpose Grease.
    • Remove the 307-566 and bolt.
      G09085172
  2. NOTE: Align the torque converter stud marked during removal with the mark on the flexplate.

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

    G09085173
  3. Install the 2 transaxle-to-engine bolts and stud bolt.
    • Tighten to 48 Nm (35 lb-ft).
      G09085174
  4. Install the 3 engine-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G09085175
  5. Install the 3 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G09085176
  6. Using the 300-OTC1819E and 303-D089 D93P-6001-A3 position the engine and transaxle onto the 300-OTC1585AE.
    G09085177
  7. NOTE: Position a block of wood under the transaxle.

    Install the 014-00001.

    G09085178
  8. Connect the PCV  tube to the turbocharger inlet pipe.
    G09085179
  9. 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.
      G09085180
  10. Attach the wiring harness retainer to the transaxle-to-engine stud bolt.
    G09085181
  11. 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).
      G09085182
  12. Install the starter insulator.
    G09085183
  13. Install the starter and the 2 stud bolts.
    • Tighten to 35 Nm (26 lb-ft).
      G09085184
  14. 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.
      G09085185
  15. Raise the engine and transaxle assembly into the vehicle and install the transaxle support insulator bolt.
    • Tighten to 150 Nm (111 lb-ft).
      G09085186
  16. 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).
      G09085187
  17. 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).
      G09085188
  18. Install the A/C tube bracket bolt.
    • Tighten to 25 Nm (18 lb-ft).
      G09085189
  19. Connect the 2 A/C compressor electrical connectors.
    • Attach the wiring harness retainer to the A/C tube stud bolt.
      G09085190

    Early build vehicles 

  20. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt onto the A/C compressor.
    G09085191
  21. Connect the oil cooler inlet and outlet hose quick connect couplings.
    G09085192

    Late build vehicles 

  22. Install the A/C drive belt. REFER to ACCESSORY DRIVE BELT -- 2.0L GTDI .

    All vehicles 

  23. Connect the transaxle fluid cooler tubes onto the transaxle fluid CBV.
    G09085193
  24. Install the secondary latches onto the transaxle fluid cooler tubes at the transaxle fluid CBV.
    G09085194
  25. Install the 2 transaxle-to-oil pan bolts.
    • Tighten to 48 Nm (35 lb-ft).
  26. 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.
      G09085195
  27. 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.

    G09085196
  28. Install 205-461 on the LH halfshaft seal.
    G09085197
  29. 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.

    G09085198
  30. 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).
      G09085199
  31. Install the subframe. REFER to SUBFRAME - FRONT .
  32. Install the catalytic converter. REFER to CATALYTIC CONVERTER - 2.0L GTDI .
  33. Attach the 3 wiring harness retainers to the valve cover stud bolts.
    G09085200
  34. Install the ground cable and bolt.
    • Tighten to 11 Nm (97 lb-in).
      G09085201
  35. 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.
      G09085202
  36. Connect the EVAP  tube. REFER to QUICK CONNECT COUPLING, CONNECT -- TYPE II .
    G09085203
  37. Connect the fuel supply tube. REFER to QUICK CONNECT COUPLING, CONNECT -- TYPE II .
    G09085204
  38. 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).
      G09085205
  39. Connect the vacuum tube quick connect coupling to the brake booster. REFER to QUICK CONNECT COUPLING , Connect - Type 1.
    G09085206
  40. Install the lower radiator hose and clamp.
    G09085207
  41. 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.
      G09085208
  42. Install the degas bottle. REFER to DEGAS BOTTLE .
  43. Install the underbody shield and the 4 retainers.
    G09085209
  44. Connect the CAC  outlet tube.
    G09085210
  45. Connect the CAC  inlet tube.
    G09085211
  46. 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).
      G09085212
  47. Install the vacuum tube retainer and the wiring retainer on the TCM  bracket.
    G09085213
  48. 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.
      G09085214
  49. 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.
      G09085215
  50. Install the ground wire and stud bolt.
    • Tighten to 10 Nm (89 lb-in).
    • Connect the engine wiring harness electrical connector.
      G09085216
  51. Install the battery tray. REFER to BATTERY AND BATTERY TRAY - EXPLODED VIEW .
  52. Install the engine ACL and ACL outlet pipe. REFER to INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW .
  53. Install the cowl panel. REFER to COWL PANEL .
  54. Fill the engine with clean engine oil.
  55. Fill and bleed the engine cooling system. REFER to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  56. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
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