Section 133 (Engine - 2.5L DURATEC (125KW/170PS)): Installation: Engine

Special Tool(s) / General Equipment 

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	307-566 Retainer, Torque Converter TKIT-2006C-FFMFLM, TKIT-2006C-LM, TKIT-2006C-ROW
Adjustable Mounting Arm
Hose Clamp Remover/Installer
Wooden Block

Materials 

1. Lubricate the torque converter pilot hub with Multi Purpose Grease.

   Remove Special Service Tool: 307-566 Retainer, Torque Converter.

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2. NOTE: If the transmission is not positioned on the dowel pins, damage to the transmission may occur.

   If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.

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

   Torque: 35 lb.ft (48 Nm)

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4. Install the transmission-to-engine bolts.

   Torque: 35 lb.ft (48 Nm)

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5. Position the engine and transmission onto the Powertrain Lift.

   Use Special Service Tool: 300-OTC1585AE Powertrain Lift.

   Use the General Equipment: Wooden Block

   Use the General Equipment: Adjustable Mounting Arm

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6. • Remove special service tool.
   • General Equipment: Spreader Bar

     Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.

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7. NOTE: Only rotate the engine in a clockwise rotation direction or engine damage may occur.

   Inspect and install the torque converter nuts.

   Torque: 30 lb.ft (40 Nm)

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8. Install the starter motor insulator.

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9. Install the starter motor and the stud bolts.

   Torque: 26 lb.ft (35 Nm)

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10. Position the wire harness and attach the wire harness retainers.

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11. Attach the wire harness retainer.

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12. Attach the wire harness retainers and connect the transmission electrical connector.

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13. Attach the wire harness retainer and connect the TSS sensor electrical connector.

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14. Attach the wire harness retainers.

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15. Install the ground cable and the nut.

    Torque: 159 lb.in (18 Nm)

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16. 1. Position the wiring and install the starter motor cable nut.

       Torque: 106 lb.in (12 Nm)

    2. Install the starter motor control wire nut.

       Torque: 44 lb.in (5 Nm)

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17. Install the coolant hose and attach the hose retainer. Connect the EGR valve coolant hose.

    Use the General Equipment: Hose Clamp Remover/Installer

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18. Install the generator and the bolts.

    Torque: 18 lb.ft (25 Nm)

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19. Connect the generator electrical connectors and install the nut.

    Torque: 106 lb.in (12 Nm)

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20. Position back the generator cable protective cover.

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21. • Rotate the accessory drive belt tensioner counter clockwise.
    • Install the accessory drive belt.
    • Release the accessory drive belt tensioner.

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22. Install the front axle shaft bearing bracket and the bolts.

    Torque: 35 lb.ft (48 Nm)

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23. Install the exhaust manifold bracket and the bolts.

    Torque: 35 lb.ft (48 Nm)

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24. Install the new exhaust manifold studs.

    Torque: 150 lb.in (17 Nm)

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25. Install a new exhaust manifold gasket.

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26. Install the exhaust manifold and the new nuts.

    Torque: 41 lb.ft (55 Nm)

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27. Install the bolts for the exhaust manifold.

    Torque: 18 lb.ft (25 Nm)

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28. Install the exhaust manifold heat shield and the bolts.

    Torque: 89 lb.in (10 Nm)

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29. Attach the wire harness retainers, connect the HO2S and CMS (catalyst monitor sensor) electrical connectors.

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30. Raise the engine and transmission into the vehicle.

    Use Special Service Tool: 300-OTC1585AE Powertrain Lift.

    Use the General Equipment: Wooden Block

    Use the General Equipment: Adjustable Mounting Arm

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31. Install the transmission support insulator nut.

    Torque: 98 lb.ft (133 Nm)

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32. Install the engine mount, the bolts and the nuts.

    Torque:

    Engine mount nuts: 66 lb.ft (90 Nm)

    Engine mount bolts: 66 lb.ft (90 Nm)

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33. Remove the engine from the lift table.

    Use Special Service Tool: 300-OTC1585AE Powertrain Lift.

    Use the General Equipment: Wooden Block

    Use the General Equipment: Adjustable Mounting Arm

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34. Install the new halfshaft seals. Refer to: Halfshaft Seal LH . Refer to: Halfshaft Seal RH - FWD .
35. Inspect the LH halfshaft hub for wear or damage and install a new halfshaft, if necessary.
    1. Inspect the differential seal surface.
    2. Inspect the halfshaft bushing surface. If this surface is damaged, inspect the halfshaft bushing for damage.
    3. Inspect the differential side gear splines.

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36. Install the new inner halfshaft retaining circlip.

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37. Install the seal protector.

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38. Using the seal protector, insert the splines of the halfshaft through the halfshaft seal and remove the seal protector.

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

    Insert the halfshaft until the halfshaft retaining clip is fully seated.

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40. Inspect the RH halfshaft hub for wear or damage and install a new halfshaft, if necessary.
    1. Inspect the RH halfshaft seal surface.
    2. Inspect the dust shield.
    3. Inspect the differential side gear splines.

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41. Install the seal protector.

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42. Push the RH halfshaft into the transmission so the splines go through the special tool and remove the seal protector.

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43. Install the RH halfshaft assembly.

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44. Install the bearing strap and the new halfshaft retaining nuts. Tighten the nuts in 3 stages.

    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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45. Install the engine bolt.

    Torque: 35 lb.ft (48 Nm)

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46. Install the transmission bolts.

    Torque: 35 lb.ft (48 Nm)

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47. Position the A/C compressor and install the bolts.

    Torque: 18 lb.ft (25 Nm)

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48. Install the A/C compressor stud and the nut.

    Torque:

    1: 80 lb.in (9 Nm)

    2: 18 lb.ft (25 Nm)

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49. Position the bracket and install the nut.

    Torque: 133 lb.in (15 Nm)

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50. Attach the wire harness retainer and connect the A/C compressor electrical connector.

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51. Attach the wire harness retainer and connect the A/C compressor electrical connector.

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52. Connect the engine harness electrical connector

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53. Attach the coolant hose retainer. Position the degas bottle and install the bolt.

    Torque: 44 lb.in (5 Nm)

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54. Attach the wire harness retainer.

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55. • Connect the PCM electrical connector.
    • Attach the wire harness retainer and connect the engine harness electrical connector.

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56. Connect the coolant hose.

    Use the General Equipment: Hose Clamp Remover/Installer

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57. Connect the coolant hoses.

    Use the General Equipment: Hose Clamp Remover/Installer

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58. Connect the engine vent hose and attach the hose retainer.

    Use the General Equipment: Hose Clamp Remover/Installer

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59. If equipped.
    • Connect the block heater electrical connector.

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60. Connect the coolant hoses.

    Use the General Equipment: Hose Clamp Remover/Installer

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61. Position the coolant hose clip.

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62. Connect the fuel vapor tube. Refer to: Quick Release Coupling .

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

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64. Connect the brake booster tube onto the intake manifold.

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65. • Position the transmission control cable and connect the cable.
    • Install the bolt.

      Torque: 106 lb.in (12 Nm)

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66. Connect the transmission fluid cooler tubes to the transmission fluid cooler.

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67. Install the transmission fluid cooler tube secondary latches.

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68. • Position the wire harness and attach the wire harness retainers.
    • Install the ground bolts.

      Torque: 106 lb.in (12 Nm)

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69. Position the cables and install the nuts.

    Torque:

    1: 71 lb.in (8 Nm)

    2: 106 lb.in (12 Nm)

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70. Close the cover.

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71. 1. Position the top part of the junction box.
    2. Latch the tabs.

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72. Position the ground cable and install the stud bolt.

    Torque: 106 lb.in (12 Nm)

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73. Remove the bolts and the cooling module support panel.

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74. Install the front subframe. Refer to: Front Subframe .
75. Install a new gasket.

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76. 1. Position the exhaust system.
    2. Install the new nuts.

       Torque: 35 lb.ft (48 Nm)

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77. NOTE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.

    Remove the exhaust flexible pipe support.

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78. Install the A/C compressor belt. Refer to: Air Conditioning (A/C) Compressor Belt .
79. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.

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

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80. Install the battery tray. Refer to: Battery Tray .
81. Check the selector lever cable adjustment. Refer to: Selector Lever Cable Adjustment - 6-Speed Automatic Transmission - 6F35 .
82. Install the air cleaner. Refer to: Air Cleaner .
83. Fill the engine with clean engine oil.

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

84. Fill and bleed the cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding .
85. Check and fill the transmission fluid as necessary. Refer to: Transmission Fluid Drain and Refill .
86. After completing the repairs, preform the Misfire Monitor Neutral Profile Correction procedure.