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Section 217 (Engine Mechanical - 2.0L GTDI): Installation: Engine

WARNING: This page is about a different car, the 2014 Ford Edge. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL DESCRIPTION

G09292397
 2, 200# Floor Crane, Fold Away
300-OTC1819E 
G09292236
 Adjustable Grip Arm, 1735A
014-00001 
G06269562
 Protector, Differential Oil Seal (pair)
205-461 
G06254255
 Powertrain Lift
014-00765  or equivalent
G06097256
 Retainer, Torque Converter
307-566 
G06251558
 Spreader Bar
303-D089  (D93P-6001-A3) or equivalent
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil (Canada)
XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada)		 WSS-M2C946-A
Multi-Purpose Grease
XG-4 and/or XL-5		 ESB-M1C93-B
  1. Lubricate the torque converter pilot hub with Multi-Purpose Grease.
    • Remove the Torque Converter Retainer and bolt.
      G08028803
  2. NOTE: Align the torque converter stud marked during removal with the flexplate.

    Using the Floor Crane and Spreader Bar, assemble the engine and transaxle.

    G08028798
  3. Install the 3 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G08614461
  4. Install the 3 engine-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G08028800
  5. Install the 3 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G08028799
  6. Using the Floor Crane and Spreader Bar, position the engine and transaxle on the Powertrain Lift.
    G08028798
  7. NOTE: Position a block of wood under the transaxle.

    Install the Powertrain Lift and Adjustable Grip Arms.

    G08028788
  8. Connect the Positive Crankcase Ventilation (PCV) tube to the turbocharger inlet pipe.
    G08028810
  9. Connect the heater hose.
    G09294656
  10. Install the wire terminal and nut on the generator.
    • Tighten to 17 Nm (150 lb-in) and install the cap.
    • Connect the wire harness electrical connector.
    • Attach the 2 wiring harness retainers to the engine.
      G09294655
  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).
      G08031076
  12. Install the starter insulator.
    G08031039
  13. Install the starter and the 2 stud bolts.
    • Tighten to 35 Nm (26 lb-ft).
      G08030518
  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.
      G08030517
  15. Raise the engine and transaxle assembly into the vehicle.
    • Install the engine mount, the 4 nuts and the 3 bolts.
      • Tighten to 90 Nm (66 lb-ft).
        G09294482
  16. Install the transaxle support insulator bracket, the 3 nuts and the bolt.
    • Tighten the 3 nuts to 63 Nm (46 lb-ft).
    • Tighten the bolt to 80 Nm (59 lb-ft).
      G09294649
  17. Install the transaxle support insulator through bolt and nut.
    • Tighten to 175 Nm (129 lb-ft).
      G09294648
  18. Connect the return hose and clamp to the power steering pump.
    G09294646
  19. Install the A/C compressor, the 2 bolts and the nut.
    • Tighten to 25 Nm (18 lb-ft).
      G09294645
  20. Connect the 2 A/C compressor electrical connectors.
    • Attach the wiring harness retainer to the A/C tube stud bolt.
      G08028667
  21. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt on the A/C compressor.
    G09294990
  22. 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.

    G08028826
  23. Install Differential Oil Seal Protector on the LH halfshaft seal.
    G08028013
  24. NOTE: The sharp edges on the halfshaft splines can slice or puncture the oil seal. Use care when inserting the halfshaft into the transaxle or damage to the seal may occur.

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

    G08028014
  25. Install the RH halfshaft in the transaxle and engage the halfshaft splines with the transaxle side gears and install the 2 halfshaft nuts.
    • Tighten to 25 Nm (18 lb-ft).
      G08031074
  26. Attach the 2 wiring harness retainers to the RH halfshaft support stud bolts.
    G09294995
  27. 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.
      G08028825
  28. Connect the lower radiator hose and clamp.
    G09294637
  29. Install the 2 transaxle-to-oil pan bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G08028781
  30. Connect the transaxle cooling tubes.
    G08653968
  31. Install the 2 secondary latches onto the transaxle fluid cooler tubes.
    G09295000
  32. Install the front subframe. For additional information, refer to UNI-BODY, SUBFRAME AND MOUNTING SYSTEM .
  33. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM
  34. Connect the fuel tube to the high pressure fuel pump.
    G09295191
  35. Connect the vacuum check valve to the power brake booster.
    G09291554
  36. Connect the Evaporative Emission (EVAP) tube to the EVAP  purge valve. For additional information, refer to the QUICK CONNECT COUPLING .
    G09295003
  37. Install the ground wire and nut to the RH inner fender.
    • Tighten to 11 Nm (97 lb-in).
      G09294630
  38. Attach the wiring harness retainer to the valve cover stud bolt.
    G09294479
  39. Connect the 2 engine wiring harness electrical connectors.
    • Attach the wiring harness retainer to the cowl.
      G09294628
  40. Install the Charge Air Cooler (CAC) inlet tube and the 2 clamps.
    G08653431
  41. Connect the CAC  outlet tube and the clamp.
    G08030997
  42. 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).
      G08031035
  43. Connect the upper radiator hose and the heater hose.
    • Connect the heater hose quick connect coupling.
    • Attach the hoses to the 2 retaining clips.
      G08028768
  44. Connect the wiring harness electrical connector.
    G09294623
  45. Attach the wiring harness retainer to the transaxle mount bracket stud bolt.
    G09294622
  46. Install the ground wire and the nut.
    • Tighten to 9 Nm (80 lb-in).
    • Connect the battery current sensor electrical connector.
      G09294621
  47. Connect the power feed to the battery terminal and install the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
    • Connect the generator current sensor electrical connector.
      G09294620
  48. Install the Transmission Control Module (TCM) bracket and the nut.
    • Tighten to 9 Nm (80 lb-in).
    • Connect the TCM  electrical connector and attach the 3 wiring harness retainers.
      G09291555
  49. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  50. Install the engine Air Cleaner (ACL) and ACL  outlet pipe assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  51. Install the degas bottle. For additional information, refer to ENGINE COOLING .
  52. Fill the engine with clean engine oil.
  53. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
  54. 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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