Section 3 (Engine - 2.3L ECOBOOST (257KW/350PS) - Mi4): Installation: Engine

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Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	300-OTC1585AE Powertrain Lift
Floor Crane
Adjustable Mounting Arm
Hose Clamp Remover/Installer

Materials 

1. Apply a thin coating of grease on the input shaft.

   Material

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

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2. NOTE: This step requires the aid of another technician.

   Install the transmission and the upper transmission bolts.

   Torque

   : 35 lb.ft (48 Nm)

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3. Install the lower transmission bolts.

   Torque

   : 35 lb.ft (48 Nm)

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4. • Install the two bottom bolts and tighten the bolts.

     Torque

     : 35 lb.ft (48 Nm)

   • Attach the coolant hose retainers.

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5. Connect the wiring harness electrical connectors and retainers.

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6. Install the engine on the powertrain table and the special tools. Install Special Service Tool: 300-OTC1585AE Powertrain Lift. Use the General Equipment: Adjustable Mounting Arm

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7. Remove the engine lifting equipment. Use the General Equipment: Floor Crane

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8. Install the stater motor isolator.

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9. 1. Connect the battery positive cable housing to the starter motor and install the starter motor battery positive cable retaining nut.

      Torque

      : 159 lb.in (18 Nm)

   2. Install the starter motor control wire nut.

      Torque

      : 106 lb.in (12 Nm)

   3. Position the starter motor and install the stud bolts.

      Torque

      : 26 lb.ft (35 Nm)

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10. • Install the bracket and the nuts.

      Torque

      : 89 lb.in (10 Nm)

    • Attach the wiring harness retainers.

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11. NOTE: Make sure that no components catch.
    NOTE: This step requires the aid of another technician.

    Using the powertrain table, adjustable mounting arm and install the engine and transmission assembly.

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12. Raise the engine and transmission assembly.

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13. Install the transmission support insulator and the bolt.

    Torque

    : 109 lb.ft (148 Nm)

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14. Tighten the engine mount studs.

    Torque

    : 106 lb.in (12 Nm)

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

       Torque

       : 59 lb.ft (80 Nm)

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

       Install the engine mount bolts finger tight.

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16. Remove Special Service Tool: 300-OTC1585AE Powertrain Lift. Use the General Equipment: Adjustable Mounting Arm

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17. • Install the battery tray support bracket and the nuts.

      Torque

      : 35 lb.ft (48 Nm)

    • Attach the wiring harness electrical connector.

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18. Tighten the engine mount bolts.

    Torque

    : 66 lb.ft (90 Nm)

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    Connect the high-pressure fuel pump fuel feed tube quick release coupling and retainer.

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20. Connect the slave cylinder hydraulic tube to the slave cylinder and bracket.

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21. NOTE: Gearshift cables must not be kinked or bent.

    Connect the shift cables to the transmission.

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22. Install the following items:
    1. Install the power transfer unit. Refer to: Power Transfer Unit .
    2. Install the LH halfshaft. Refer to: Front Halfshaft LH .

23. Connect the MAPT sensor electrical connector.

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24. 1. Install the A/C compressor and connect the A/C compressor electrical connector.

       Torque

       : 18 lb.ft (25 Nm)

    2. NOTE: Install new O-ring seals and gasket seals.

       Position the A/C lines and install the nuts.

       Torque

       : 177 lb.in (20 Nm)

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25. Install the CAC pipe and tighten the clamp.

    Torque

    : 44 lb.in (5 Nm)

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26. NOTE: Make sure that a new component is installed.
    NOTE: Component must be lubricated with clean engine oil.

    Install the engine oil filter. Refer to: Specifications  .

    Torque

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

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27. Connect the engine harness electrical connector.

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28. Connect the PCM electrical connectors and retainer.

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    Vehicles with PCM security shield 

29. Install the PCM security shield and tighten the shear bolt until the head is sheared off.

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    Vehicles without PCM security shield 

30. Install the PCM cover and the screws.

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    All vehicles 

31. Install the LH fender splash shield. Refer to: Fender Splash Shield .
32. • Install the degas bottle and connect the coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer
    • Attach the hoses and retainer.

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33. 1. Position the heater hoses and install the clips.
    2. Position the coolant hoses and install the clamps. Use the General Equipment: Hose Clamp Remover/Installer
    3. Attach the wiring and coolant hose retainers.
    4. Connect the fuel pressure sensor electrical connector.
    5. Connect the EVAP canister purge valve quick release coupling. Refer to: Quick Release Coupling .

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34. 1. Install the ground wire and the bolt.

       Torque

       : 106 lb.in (12 Nm)

    2. Install the ground cable and the bolt.

       Torque

       : 159 lb.in (18 Nm)

    3. Attach the wiring and hose retainers.

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35. If equipped, connect the block heater electrical connector.

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36. • Install the power feed cable and the nut.

      Torque

      : 106 lb.in (12 Nm)

    • Connect the main wiring harness to the fuse box and attach the retainers.

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37. Close the junction box cover.

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

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39. Install the following items:
    1. Install the A/C compressor belt. Refer to: Air Conditioning (A/C) Compressor Belt .
    2. Install the cooling fan motor and shield. Refer to: Cooling Fan Motor and Shroud .
    3. Install the catalytic converter. Refer to: Catalytic Converter .

40. Charge the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging - Vehicles With: R134A Refrigerant .
41. Bleed the clutch system. Refer to: Clutch System Bleeding - 6-Speed Manual Transmission - MMT6 .
42. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.