Section 416 (Engine - 2.0L DURATEC-He (125KW/170PS) - Mi4 (Except Electric Vehicle)): Installation: Engine

WARNING: This page is about a different car, the 2015 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

Special Tool(s) / General Equipment

Courtesy of FORD MOTOR COMPANY	300-OTC 1585AE Powertrain Lift
Courtesy of FORD MOTOR COMPANY	300-OTC1819E 2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	303-D089 (D93P-6001-A3) Spreader Bar
Magnetic Socket
Adjustable Mounting Arm
Hose Clamp Remover/Installer
Wooden Block

Materials

Name	Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP	WSS-M2C945-A

1.

NOTE: If using the existing clutch assembly, align the index marks on the flexplate and the clutch stud made during removal.

If using a new clutch assembly, make sure the flexplate-to-clutch alignment marks are aligned.

GFD61464

Courtesy of FORD MOTOR COMPANY

2.

NOTE: Use caution not to damage the transmission wiring harness or sensors.

NOTE: If using the existing automatic transmission clutch assembly, align the index marks on the flexplate and the clutch stud made during removal.

NOTE: Automatic transmission shown in illustration, manual transmission similar.

Align the transmission to the engine.

GFD61465

Courtesy of FORD MOTOR COMPANY

3.
- If equipped with automatic transmission. Install the 4 bellhousing-to-engine fasteners.
  Torque
  
  : 33 lb.ft (45 Nm)
- If equipped with manual transmission, Install the 5 bellhousing-to-engine fasteners.
  Torque
  
  : 33 lb.ft (45 Nm)

GFD61340

Courtesy of FORD MOTOR COMPANY

4.

Install the ground wire and the nut.
Torque

: 177 lb.in (20 Nm)

GFD61264

Courtesy of FORD MOTOR COMPANY

5.

NOTE: Automatic transmission shown in illustration, manual transmission similar.

Install the engine-to-transmission bolt.

Torque

: 33 lb.ft (45 Nm)

GFD61272

Courtesy of FORD MOTOR COMPANY

6.

Raise the engine and transmission assembly onto the lift table.
Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away, 303-D089 (D93P-6001-A3) Spreader Bar.

GFD61339

Courtesy of FORD MOTOR COMPANY

7.

NOTE: Position a block of wood under the transmission.

Attach the powertrain to the powertrain lift.

Use Special Service Tool: 300-OTC1585AE Powertrain Lift.

Use the General Equipment: Adjustable Mounting Arm

Use the General Equipment: Wooden Block

GFD61333

Courtesy of FORD MOTOR COMPANY

8.

NOTE: Make sure that new flexplate-to-clutch nuts are installed.

NOTE: Rotate the engine in a clockwise direction only or engine damage may occur.

NOTE: Using a magnetic socket will help ease the installation of new flexplate-to-clutch nuts. If the flexplate-to-clutch nuts fall into the clutch housing, the transmission will have to be removed to retrieve them.

Install the new flexplate-to-clutch nuts in the location shown in illustration.

Use the General Equipment: Magnetic Socket

Torque

: 106 lb.in (12 Nm)

multimedia:A supplement to the article is available.

GFD61466

Courtesy of FORD MOTOR COMPANY

9.

NOTE: Make sure that new flexplate-to-clutch nuts are installed.

NOTE: Rotate the engine in a clockwise direction only or engine damage may occur.

NOTE: Using a magnetic socket will help ease the installation of new flexplate-to-clutch nuts. If the flexplate-to-clutch nuts fall into the clutch housing, the transmission will have to be removed to retrieve them.

Install the new flexplate-to-clutch nuts. Tighten the flexplate-to-clutch nuts in sequence shown in illustration.

Use the General Equipment: Magnetic Socket

Torque

: 18 lb.ft (25 Nm)

Fig 1: Flexplate-To-Clutch Nuts Tightening Sequence

GFD61467

Courtesy of FORD MOTOR COMPANY

10.

NOTE: Failure to torque the flexplate-to-clutch nuts in the sequence described may result in a first order engine vibration. Misalignment can be resolved by removing and discarding all 6 flexplate-to-clutch nuts and repeating the previous 2 steps.

multimedia:A supplement to the article is available.

11.

Install the stater motor isolator.

GFD61337

Courtesy of FORD MOTOR COMPANY

12.

Install the starter motor. REFER to: Starter Motor .

13.

Attach the wire harness retainer.

GFD61336

Courtesy of FORD MOTOR COMPANY

14.

If equipped with automatic transmission. Connect the wiring harness electrical connector.

GFD61335

Courtesy of FORD MOTOR COMPANY

15.

Position the powertrain into the vehicle.

16.

Install the transmission mount bolt.
Torque

: 111 lb.ft (150 Nm)

GFD61334

Courtesy of FORD MOTOR COMPANY

17.
- Install the engine mount and the bolts.
  Torque
  
  : 66 lb.ft (90 Nm)
- Install the nuts.
  Torque
  
  : 59 lb.ft (80 Nm)

GFD61303

Courtesy of FORD MOTOR COMPANY

18.

Attach the A/C line to the routing clamp.

GFD61206

Courtesy of FORD MOTOR COMPANY

19.

Install the engine mounting Restrictor and the bolts.
Torque

: 63 lb.ft (86 Nm)

GFD61271

Courtesy of FORD MOTOR COMPANY

20.

NOTE: Automatic transmission shown in illustration, manual transmission similar.

Install the oil pan bolts.

Torque

: 35 lb.ft (48 Nm)

GFD61270

Courtesy of FORD MOTOR COMPANY

21.

NOTE: Automatic transmission shown in illustration, manual transmission similar.

Install the oil pan-to-transmission bolt.

Torque

: 35 lb.ft (48 Nm)

GFD61269

Courtesy of FORD MOTOR COMPANY

22.

Install the cooling fan motor and shroud. REFER to: Cooling Fan Motor and Shroud .

23.

NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.

Install a new engine oil filter.

Material

: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

Torque:

Stage 1: 71 lb.in (8 Nm)

Stage 2: 180°

GFD61259

Courtesy of FORD MOTOR COMPANY

24.

Install the lower radiator hose and clamp.
Use the General Equipment: Hose Clamp Remover/Installer

GFD61332

Courtesy of FORD MOTOR COMPANY

25.

NOTE: Install 2 new O-ring seals.
- Position back the A/C lines and tighten the nuts.
  Torque
  
  : 177 lb.in (20 Nm)
- Tighten the bolt.
  Torque
  
  : 18 lb.ft (25 Nm)

GFD61331

Courtesy of FORD MOTOR COMPANY

26.

Install the A/C pipe bracket bolt.
Torque

: 159 lb.in (18 Nm)

GFD61330

Courtesy of FORD MOTOR COMPANY

27.

Refer to: Front Halfshaft RH . REFER to: Front Halfshaft LH .

28.

If equipped with a manual transmission. Connect the shift cable and tighten the bracket nuts.
Torque

: 35 lb.ft (48 Nm)

GFD61329

Courtesy of FORD MOTOR COMPANY

29.

NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

If equipped with a manual transmission. Connect the clutch hydraulic tube.

GFD61328

Courtesy of FORD MOTOR COMPANY

30.

If equipped with an automatic transmission. Position back the shift cable and install the bolts.
Torque

: 89 lb.in (10 Nm)

GFD61262

Courtesy of FORD MOTOR COMPANY

31.

If equipped with an automatic transmission. Attach the selector lever cable retainer.

GFD61327

Courtesy of FORD MOTOR COMPANY

32.

If equipped with an automatic transmission. Attach the selector lever cable retainer.

GFD61326

Courtesy of FORD MOTOR COMPANY

33.

If equipped with an automatic transmission. Connect the selector lever cable end to the manual control lever.

GFD61261

Courtesy of FORD MOTOR COMPANY

34.

Connect the vacuum tube quick release coupling at the rear of the intake manifold.

GFD61156

Courtesy of FORD MOTOR COMPANY

35.

Connect the electrical connector and the fuel tube quick release coupling. REFER to: Quick Release Coupling .

GFD61325

Courtesy of FORD MOTOR COMPANY

36.

Connect the fuel tube quick release coupling. REFER to: Quick Release Coupling .

GFD61324

Courtesy of FORD MOTOR COMPANY

37.

NOTE: Install 5 new catalytic converter-to-cylinder head studs.

Install the new manifold studbolts.

Torque

: 150 lb.in (17 Nm)

GFD61256

Courtesy of FORD MOTOR COMPANY

38.

NOTE: Failure to tighten the catalytic converter manifold nuts to specification a second time may cause the converter to develop an exhaust leak.

NOTE: Always install new fasteners and gaskets as indicated. Clean flange faces prior to new gasket installation to make sure of proper sealing.

Using a new gasket, position the catalytic converter and install the new catalytic converter manifold-to-cylinder head nuts and tighten in 2 stages in sequence shown in illustration.

Torque:

Stage 1: Tighten: 41 lb.ft (55 Nm)

Stage 2: Retighten: 41 lb.ft (55 Nm)

Fig 2: Catalytic Converter Manifold-To-Cylinder Head Nuts Tightening Sequence

GFD61257

Courtesy of FORD MOTOR COMPANY

39.

Install the tailpipe mount bracket bolts.
Torque

: 18 lb.ft (25 Nm)

GFD61244

Courtesy of FORD MOTOR COMPANY

40.
- Install the catalytic converter manifold-to-muffler and tailpipe nuts, tighten the first nut.
  Torque
  
  : 35 lb.ft (48 Nm)
- Tighten the second nut.
  Torque
  
  : 35 lb.ft (48 Nm)
- Tighten the first nut to specification a second time.
  Torque
  
  : 35 lb.ft (48 Nm)

GFD61243

Courtesy of FORD MOTOR COMPANY

41.

Install the bolts to the exhaust manifold.
Torque

: 18 lb.ft (25 Nm)

GFD61242

Courtesy of FORD MOTOR COMPANY

42.

Install the exhaust manifold heat shield, position back the catalyst monitor sensor wiring harness and install the bolts.
Torque

: 89 lb.in (10 Nm)

GFD61323

Courtesy of FORD MOTOR COMPANY

43.

Connect the catalyst monitor sensor electrical connector and wire retainer.

GFD61239

Courtesy of FORD MOTOR COMPANY

44.

Install the HO2S. REFER to: Heated Oxygen Sensor (HO2S) .

45.

If equipped. Connect the engine block heater electrical connector.

GFD61322

Courtesy of FORD MOTOR COMPANY

46.

Connect the coolant hoses to the heater core and attach the hose retainers.

GFD61321

Courtesy of FORD MOTOR COMPANY

47.

Connect the coolant hoses and install the hose clips.
Use the General Equipment: Hose Clamp Remover/Installer

GFD61320

Courtesy of FORD MOTOR COMPANY

48.

Position back the wiring harness.

GFD61319

Courtesy of FORD MOTOR COMPANY

49.

Attach the wiring harness retainers.

GFD61318

Courtesy of FORD MOTOR COMPANY

50.

Install the bolts on the ground strap and attach the ground cable retainer.
Torque

: 177 lb.in (20 Nm)

GFD61317

Courtesy of FORD MOTOR COMPANY

51.

NOTE: The electrical connector is located behind the PCM case.

Connect the engine wiring harness electrical connector.

GFD61316

Courtesy of FORD MOTOR COMPANY

52.

Install the PCM. REFER to: Powertrain Control Module (PCM) .

53.

Attach the ground cable retainer.

GFD61315

Courtesy of FORD MOTOR COMPANY

54.

Install the engine ground strap and nut.

GFD61314

Courtesy of FORD MOTOR COMPANY

55.

If equipped with automatic transmission. Attach the wiring harness retainers.

GFD61313

Courtesy of FORD MOTOR COMPANY

56.

Install the following items:
- Install the air cleaner and the air cleaner outlet pipe. REFER to: Air Cleaner . REFER to: Air Cleaner Outlet Pipe .
- Install the battery tray. REFER to: Battery Tray .
- Install the degas bottle. REFER to: Degas Bottle .

57.

If equipped with manual transmission, fill and bleed the clutch system. REFER to: Clutch System Bleeding - 6-Speed Manual Transmission - MMT6 .

58.

Fill the cooling system. REFER to: Cooling System Draining, Vacuum Filling and Bleeding . REFER to: Cooling System Draining, Filling and Bleeding .

59.

Install the underbody shield and the bolts.

GFD60400

Courtesy of FORD MOTOR COMPANY

60.

Charge the A/C system. REFER to: Air Conditioning (A/C) System Recovery, Evacuation and Charging .

61.

Fill the engine with clean engine oil.
Material

: Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

62.

After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.