Engine - (6-Speed Manual Transmission - B6)

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING

Special Tool(s) / General Equipment 

Materials 

1. Apply a thin coating on input shaft.

   Material

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

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2. Inspect the dowels and replace if necessary

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3. NOTE: Make sure that the component is correctly located on the locating dowels.
   NOTE: Make sure that no components catch.

   With the aid of an assistant, install the engine into the vehicle. Use the General Equipment: Floor Crane. Use the General Equipment: Lifting Bracket

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4. Install the transmission-to-engine bolt.

   Torque

   : 35 lb.ft (48 Nm)

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5. Install the transmission-to-engine bolts.

   Torque

   : 35 lb.ft (48 Nm)

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6. Tighten the engine mount studs.

   Torque

   : 89 lb.in (10 Nm)

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7. NOTE: Make sure that the component is installed to the position noted before removal.
   1. Install the RH engine mount and the nuts.

      Torque

      : 59 lb.ft (80 Nm)

   2. NOTE: Only tighten the bolts finger tight at this stage.

      Install the RH engine mount bolts finger-tight.

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8. Remove the wooden block and floor jack from under the transmission. Use the General Equipment: Trolley Jack. Use the General Equipment: Wooden Block

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9. Remove the lift equipment. Remove the General Equipment: Floor Crane. Remove the General Equipment: Lifting Bracket

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10. Tighten the RH engine mount bracket bolts.

    Torque

    : 66 lb.ft (90 Nm)

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11. Install the transmission-to-engine bolts.

    Torque

    : 35 lb.ft (48 Nm)

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12. Install the transmission-to-engine bolt.

    Torque

    : 35 lb.ft (48 Nm)

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13. NOTE: Lubricate the engine oil filter seal with clean engine oil.

    Install a new engine oil filter.

    Material

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

    Torque

    : 133 lb.in (15 Nm)

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14. Install the ground cable bolt.

    Torque

    : 177 lb.in (20 Nm)

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15. Connect the oil pressure switch, the KS and the vacuum solenoid electrical connectors.
    • Attach the wiring harness retainer.

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16. Connect the oil control solenoid electrical connector.
    • Attach the wiring harness retainer.

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17. 1. Install the axle shaft bracket and the bolts.

       Torque

       : 18 lb.ft (25 Nm)

    2. Install a new the axle bearing strap and nuts.

       Torque

       :Stage 1: Lower nut: 44 lb.in (5 Nm) Stage 2: Upper nut: 18 lb.ft (25 Nm) Stage 3: Lower nut: 18 lb.ft (25 Nm)

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18. Connect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

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19. Connect the fuel supply tube. Refer to: Spring Lock Couplings .

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20. NOTE: Install all the bolts finger tight before final tightening.

    Install the bracket and the bolts.

    Torque

    :1: 53 lb.in (6 Nm)2: 106 lb.in (12 Nm)

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21. Connect the high-pressure fuel pump electrical connector and attach the harness retainer.

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22. Connect the degas bottle coolant tube.

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23. 1. Connect the coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer
    2. Attach the wiring harness retainers.

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24. Connect the vacuum solenoid electrical connector.

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25. Connect the CHT electrical connector.

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26. Connect the ECT sensor electrical connector.

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27. Attach the wiring harness retainers.

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28. • Connect the MAP sensor and fuel injection harness electrical connectors.
    • Attach the wiring harness retainers.

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29. Connect the throttle body electrical connector.

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30. Connect the VCT electrical connectors.

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31. Connect the CMP sensors and ignition coils electrical connectors.
    • Attach the wiring harness retainers.

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32. Attach the wiring harness retainers.

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33. 1. Connect the generator electrical connector and attach the wiring harness retainers.
    2. Attach the battery cable, install the nut and cap.

       Torque

       : 159 lb.in (18 Nm)

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34. Connect the CKP sensor electrical connector and attach the wiring harness retainers.

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35. Install the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

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36. Install the coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer

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37. 1. Install the CAC inlet tube and the clamp.
    2. Install the CAC inlet tube mounting nuts and bolt.

       Torque

       :2: 97 lb.in (11 Nm)3: 97 lb.in (11 Nm)

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38. Install the coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer

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39. 1. Install the degas bottle.
    2. Install the degas bottle coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
    3. Connect the degas bottle coolant tubes.

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40. 1. Install the CAC outlet pipe bracket bolt.

       Torque

       : 97 lb.in (11 Nm)

    2. Tighten the CAC outlet pipe clamps.

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41. 1. Install the EVAP tube assembly and attach the retainers.
    2. Connect the quick release couplings. Refer to: Quick Release Coupling .
    3. Connect the EVAP purge valve electrical connector.

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42. 1. Install the TC inlet pipe and clamp.
    2. Install the nuts.

       Torque

       : 97 lb.in (11 Nm)

    3. Connect the quick release couplings. Refer to: Quick Release Coupling .
    4. Connect the vacuum hose. Use the General Equipment: Hose Clamp Remover/Installer

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43. • Connect the turbocharger boost pressure (TCBP) and charger air cooler temperature (CACT) sensor electrical connector.
    • Connect the crankcase pressure sensor electrical connector.
    • Attach the wiring harness retainer.

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44. Install the following items:
    1. Catalytic converter. Refer to: Catalytic Converter .
    2. Starter. Refer to: Starter Motor .

45. Install the cowl panel and the bolts.

    Torque

    : 97 lb.in (11 Nm)

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46. Install the cowl panel grille. Refer to: Cowl Panel Grille .
47. 1. With the aid of an assistant, install the hood and the nuts.

       Torque

       : 97 lb.in (11 Nm)

    2. Connect the windshield washer hose.

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48. Install the hood insulator and the retainers.

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49. Fill the engine with clean engine oil. Refer to: Specifications  .

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50. Fill the cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding .
51. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.