Section 1 (Engine - 1.6L ECOBOOST (132KW/180PS) - Sigma): Installation: Engine

For information on Ford Color Coded Illustrations refer to OEM Color Coding .

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-461 Protector, Differential Oil Seal (pair) TKIT-2000AP-FLM/LM TKIT-2002-F/FM
Courtesy of FORD MOTOR COMPANY	300-OTC1585AE Powertrain Lift
Courtesy of FORD MOTOR COMPANY	300-OTC1819E 2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	303-1502 Lifting Device Engine TKIT-2012A-FL TKIT-2012A-ROW
Courtesy of FORD MOTOR COMPANY	303-476 (T94P-9472-A) Socket, Exhaust Gas Oxygen Sensor TKIT-1994-LM/M TKIT-1994-F TKIT-1994-FLM/FM
Cable Ties
Hose Clamp Remover/Installer
Wooden Block

Materials 

1. Lubricate the torque converter pilot hub with multi-purpose grease.

   Material: Motorcraft® High Temperature 4x4 Front Axle and Wheel Bearing Grease / XG-11 (WSS-M1C267-A1)

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2. Align the engine to transmission and install the bolt.

   Torque: 35 lb.ft (48 Nm)

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3. Install the engine to transmission bolts.

   Torque: 35 lb.ft (48 Nm)

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4. Install the engine to transmission bolts.

   Torque: 35 lb.ft (48 Nm)

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5. Install the engine on the table. Install Special Service Tool: 300-OTC1585AE Powertrain Lift. Use the General Equipment: Wooden Block

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6. Remove the engine floor crane. Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.

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7. Remove Special Service Tool: 303-1502 Lifting Device Engine.

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8. Install the coolant hose and attach the retainer.

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9. 1. Install the starter motor and the bolts, position the starter motor solenoid terminal wiring electrical connection and install the nut.

      Torque: 89 lb.in (10 Nm)

   2. Install the solenoid terminal wiring electrical connection nut.

      Torque: 89 lb.in (10 Nm)

   3. Position the ground cable and install the bolt.

      Torque: 35 lb.ft (48 Nm)

   4. Install the coolant hose and the clamps, connect the electrical connector and the wiring harness retainer. Use the General Equipment: Hose Clamp Remover/Installer

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10. Install the bracket and the bolts.

    Torque: 177 lb.in (20 Nm)

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11. Install the new catalytic convertor gasket and loosely install the bolts.

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12. Install the catalytic converter on the loosely installed bolts, install the remaining bolt and then tighten the bolts in the sequence shown.

    Torque: 18 lb.ft (25 Nm)

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13. Install the catalytic converter mounting bracket and the nuts.

    Torque: 18 lb.ft (24 Nm)

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14. Install the heat shield, position the clamp and install the bolts.

    Torque: 89 lb.in (10 Nm)

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15. Using the special tool, install the HO2S. Attach the wiring harness retainer. Use Special Service Tool: 303-476 (T94P-9472-A) Socket, Exhaust Gas Oxygen Sensor.

    Material: Motorcraft® High Temperature Nickel Anti-Seize Lubricant / XL-2

    Torque: 35 lb.ft (48 Nm)

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16. Connect the electrical connectors.

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17. Tighten the engine mounting studs.

    Torque: 89 lb.in (10 Nm)

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18. Using the powertrain lift, raise the powertrain into the vehicle.

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19. 1. Install the engine mount and the nuts.

       Torque: 59 lb.ft (80 Nm)

    2. Install the bolts.

       Torque: 35 lb.ft (48 Nm)

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20. Install the nuts.

    Torque: 92 lb.ft (125 Nm)

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21. Using a new gasket, position the muffler inlet pipe and install the nuts.

    Torque: 35 lb.ft (48 Nm)

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22. Remove the cable ties. Use the General Equipment: Cable Ties

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23. Install the bracket and the bolts.

    Torque: 35 lb.ft (48 Nm)

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24. Clean and inspect the inner LH halfshaft splines and mating surfaces

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25. Replace the LH halfshaft seal. Refer to: Halfshaft Seal LH .
26. NOTE: Make sure a new circlip is installed.

    Install a new LH halfshaft retaining circlip. Remove Special Service Tool: 205-461 Protector, Differential Oil Seal (pair).

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27. NOTE: When seated correctly, the halfshaft bearing retainer circlip can be felt as it snaps into the differential side gear groove.

    Install the shaft. Pull the halfshaft outward to make sure the circlip is locked.

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28. Clean and inspect the RH inner halfshaft splines and mating surfaces.

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29. Replace the RH halfshaft seal. Refer to: Halfshaft Seal RH .
30. Remove the special tool before completely installing the RH halfshaft. Remove Special Service Tool: 205-461 Protector, Differential Oil Seal (pair).

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31. Install the RH halfshaft.

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32. Install the new halfshaft bearing retaining strap and the nuts.

    Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 18 lb.ft (24 Nm)

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33. Lubricate and install the engine oil filter.

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

    Torque: 128 lb.in (14.5 Nm)

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34. Install the front subframe. Refer to: Front Subframe .
35. 1. Install the TC outlet tube and tighten the clamps.

       Torque: 44 lb.in (5 Nm)

    2. Install the nuts.

       Torque: 97 lb.in (11 Nm)

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36. Install the shield and the retainers.

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37. 1. Install the CAC outlet pipe and the nut.

       Torque: 97 lb.in (11 Nm)

    2. Tighten the clamp and connect the electrical connector.

       Torque: 44 lb.in (5 Nm)

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38. Connect the throttle body hose and tighten the clamp, install the resonator assembly and the hose clamps and connect the hose. Use the General Equipment: Hose Clamp Remover/Installer

    Torque: 44 lb.in (5 Nm)

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39. Install the degas bottle. Refer to: Degas Bottle .
40. NOTE: Install a new the O-ring seal and gasket seal.

    Using a new O-ring, connect the A/C line and install the nut.

    Torque: 133 lb.in (15 Nm)

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41. NOTE: Install a new the O-ring seal and gasket seal.

    Using a new O-ring, connect the A/C line and install the nut.

    Torque: 133 lb.in (15 Nm)

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42. Connect the selector lever cables from the selector levers.

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43. Adjust the gearshift cable. Refer to: Gearshift Cable Adjustment - 6-Speed Manual Transmission - B6 .
44. Connect the clutch cylinder fluid supply tube.

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45. Connect the tube to the retaining clamp.

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46. NOTE: Install the hoses as noted in removal.

    Connect the heater hoses. Use the General Equipment: Hose Clamp Remover/Installer

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47. Connect the coolant tube and attach the retainer. Use the General Equipment: Hose Clamp Remover/Installer

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48. Install the fuel evaporative tube assembly. Connect the quick release couplings and the electrical connector.

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49. Early build vehicles, connect the fuel tube connection. Refer to: Quick Release Coupling .

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50. Late build vehicles, connect the fuel tube connection. Refer to: Spring Lock Couplings .

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51. Install the coolant hose and the clamp. Use the General Equipment: Hose Clamp Remover/Installer

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52. Install the bracket and the nuts.

    Torque: 89 lb.in (10 Nm)

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53. Position the wiring harness and the install the retainers.

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54. Position the wiring harness and the install the retainers.

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55. • Position the wiring harness and attach the retainers.
    • Position the grounding wire and install the bolt.

      Torque: 115 lb.in (13 Nm)

    • Connect the electrical connector.

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56. Install the wire and the nut.

    Torque: 44 lb.in (5 Nm)

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57. Install the battery terminal cover.

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58. Install the battery tray. Refer to: Battery Tray - 1.6L EcoBoost (132kW/180PS) - Sigma .
59. 1. Install the air inlet pipe and the engine appearance cover stud and the nut.

       Torque: 44 lb.in (5 Nm)

    2. Tighten the clamp. Connect the crankcase ventilation tube coupling.

       Torque: 44 lb.in (5 Nm)

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60. Install the air cleaner outlet pipe and tighten the clamp. Connect the quick release coupling.

    Torque: 44 lb.in (5 Nm)

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61. Install the air cleaner. Refer to: Air Cleaner .
62. Connect the vacuum pump inlet tube coupling.

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63. Fill the engine with clean engine oil.

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

64. Install the engine appearance cover.

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65. Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
66. Fill the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation And Charging .
67. Fill the transmission fluid. Refer to: Transmission Draining and Filling .
68. Bleed the clutch hydraulic system. Refer to: Clutch System Bleeding .
69. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.