Section 2 (Engine - 2.0L ECOBOOST (184KW/250PS) - Mi4): Installation: Engine

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

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	300-OTC1585AE Powertrain Lift
Courtesy of FORD MOTOR COMPANY	300-OTC1819E2, 200# Floor Crane, Fold Away
Adjustable Mounting Arm
Hose Clamp Remover/Installer

Materials 

1. WARNING: Before beginning any service procedure in this article, refer to Safety Warnings in GENERAL INFORMATION (EXCEPT ELECTRIC) . Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions .

2. NOTE: Wipe off excess grease. The splines should have a thin film of grease only. Excess grease can contaminate the clutch facing and affect clutch function.

   Apply a thin coating.

   Material

   : Motorcraft® Premium Long-Life Grease / XG-1-E1 (ESA-M1C75-B)

   Courtesy of FORD MOTOR COMPANY

3. Install the engine and the transmission-to-engine bolts.

   Torque

   : 35 lb.ft (48 Nm)

   Courtesy of FORD MOTOR COMPANY

4. Install the transmission bolts.

   Torque

   : 35 lb.ft (48 Nm)

   Courtesy of FORD MOTOR COMPANY

5. Install the transmission bolt and attach the wiring harness retainer.

   Torque

   : 35 lb.ft (48 Nm)

   Courtesy of FORD MOTOR COMPANY

6. Install the transmission bolts and the stud.

   Torque

   : 35 lb.ft (48 Nm)

   Courtesy of FORD MOTOR COMPANY

7. Using the special tools, install the engine on the stand. Install Special Service Tool: 300-OTC1585AE Powertrain Lift. Use the General Equipment: Adjustable Mounting Arm

   Courtesy of FORD MOTOR COMPANY

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

   Courtesy of FORD MOTOR COMPANY

9. Connect the EVAP tube coupling.

   Courtesy of FORD MOTOR COMPANY

10. Install the starter motor insulator.

    Courtesy of FORD MOTOR COMPANY

11. Position back the wiring harness, install the starter motor and the nuts.

    Torque

    :Stage 1: 106 lb.in (12 Nm) Stage 2: 44 lb.in (5 Nm)

    Courtesy of FORD MOTOR COMPANY

12. Position the starter motor and install the studs.

    Torque

    : 26 lb.ft (35 Nm)

    Courtesy of FORD MOTOR COMPANY

13. 1. Install the starter motor bracket and the nuts.

       Torque

       : 159 lb.in (18 Nm)

    2. Attach the wire harness retainers.
    3. Connect the coolant hose retainer.

    Courtesy of FORD MOTOR COMPANY

14. Using the special tools, raise the engine.

    Courtesy of FORD MOTOR COMPANY

15. Install the transmission support insulator and the bolt.

    Torque

    : 109 lb.ft (148 Nm)

    Courtesy of FORD MOTOR COMPANY

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

       Torque

       : 59 lb.ft (80 Nm)

    2. Finger tighten the bolts.

    Courtesy of FORD MOTOR COMPANY

17. Remove the stand from the engine. Remove Special Service Tool: 300-OTC1585AE Powertrain Lift. Use the General Equipment: Adjustable Mounting Arm

    Courtesy of FORD MOTOR COMPANY

18. • Install the transmission support insulator bracket and the nuts.

      Torque

      : 35 lb.ft (48 Nm)

    • Attach the wiring harness retainers.

    Courtesy of FORD MOTOR COMPANY

19. Tighten the engine mount bolts.

    Torque

    : 66 lb.ft (90 Nm)

    Courtesy of FORD MOTOR COMPANY

20. Position the roll restrictor and install the bolts.

    Torque

    :1:Stage 1: 16 lb.ft (22 Nm) Stage 2: 270°2: 46 lb.ft (63 Nm)

    Courtesy of FORD MOTOR COMPANY

21. 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-30 Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

    Torque

    :Stage 1: 71 lb.in (8 Nm) Stage 2: 180°

    Courtesy of FORD MOTOR COMPANY

22. Install the new gasket and the catalytic converter clamp.

    Courtesy of FORD MOTOR COMPANY

23. Position the catalytic converter.

    Courtesy of FORD MOTOR COMPANY

24. Finger tight. Tighten the catalytic converter clamp.

    Courtesy of FORD MOTOR COMPANY

25. Install the exhaust isolator bracket bolts.

    Torque

    : 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

26. Install the new muffler inlet gasket.

    Courtesy of FORD MOTOR COMPANY

27. 1. Position the muffler inlet tube.
    2. Install the new nuts.

       Torque

       : 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

28. Tighten the catalytic converter clamp.

    Torque

    : 177 lb.in (20 Nm)

    Courtesy of FORD MOTOR COMPANY

29. Install the roll restrictor bracket and the nuts.

    Torque

    : 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

30. 1. If equipped. Install the catalytic converter insulator bracket.
    2. Install the catalytic converter support bracket.
    3. Install the grommet.

    Courtesy of FORD MOTOR COMPANY

31. Remove the catalytic converter support bracket nuts.

    Torque

    :Stage 1: 18 lb.ft (25 Nm) Stage 2: 18 lb.ft (24 Nm)

    Courtesy of FORD MOTOR COMPANY

32. Install the following items:
    1. Refer to: Front Halfshaft LH .
    2. Refer to: Front Halfshaft RH .

33. Position the TC outlet tube and install the bolts.

    Torque

    : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

34. Install the TC outlet tube and tighten the clamp.

    Courtesy of FORD MOTOR COMPANY

35. Connect the engine wiring harness electrical connector and attach the wiring harness retainer.

    Courtesy of FORD MOTOR COMPANY

36. Position the A/C line and install the nut.

    Torque

    : 133 lb.in (15 Nm)

    Courtesy of FORD MOTOR COMPANY

37. • Connect the fuel tube and EVAP canister purge valve quick release couplings. Refer to: Quick Release Coupling . Use the General Equipment: Hose Clamp Remover/Installer
    • Connect the coolant hoses and attach the retainers.
    • Connect the brake booster vacuum hose quick release coupling.

    Courtesy of FORD MOTOR COMPANY

38. Position the sound symposer hose.

    Courtesy of FORD MOTOR COMPANY

39. • Connect the slave cylinder hydraulic tube.
    • Bleed the clutch system. Refer to: Clutch System Bleeding - 6-Speed Manual Transmission - MMT6 .

    Courtesy of FORD MOTOR COMPANY

40. • Connect the transmission control lever cable.
    • Adjust the gearshift cable. Refer to: Gearshift Cable Adjustment - 6-Speed Manual Transmission - MMT6 .

    Courtesy of FORD MOTOR COMPANY

41. Position the PCM and attach the wiring harness retainer.

    Courtesy of FORD MOTOR COMPANY

42. Install the PCM. Refer to: Powertrain Control Module (PCM) .
43. • Attach the wiring harness retainers, position the ground cable and install the bolts.

      Torque

      : 17 lb.ft (23 Nm)

    • Connect the electrical connector.

    Courtesy of FORD MOTOR COMPANY

44. Attach the wiring harness retainer.

    Courtesy of FORD MOTOR COMPANY

45. Install the battery tray. Refer to: Battery Tray .
46. • Connect the main wiring harness to the fuse box and the battery feed cable.
    • Attach the wiring harness retainers.

      Torque

      : 106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

47. Install the engine compartment fuse box cover.

    Courtesy of FORD MOTOR COMPANY

48. Install the following items:
    1. Refer to: Cooling Module .
    2. Refer to: Air Cleaner .
    3. Refer to: Air Cleaner Outlet Pipe .
    4. Refer to: Degas Bottle .

49. 1. Install the underbody shield reinforcement and the retainers.
    2. Install the underbody shield and the retainers.

    Courtesy of FORD MOTOR COMPANY

50. Fill the cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding .
51. Recharge the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging - Vehicles With: R134A Refrigerant .
52. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.