Section 18 (Engine - 2.7L ECOBOOST (238KW/324PS)): Installation: Engine

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	303-1246 Engine Spreader Bar, TKIT-2006UF-FLM, TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1634 Lift Eyes (2), TKIT-2014D-FL_ROW, TKIT-2014D-ROW3
Courtesy of FORD MOTOR COMPANY	307-346 (T97T-7902-A) Retainer, Torque Converter, TKIT-1997-F/FLM/LT, TKIT-1998-LM (NavigatoR)
Floor Crane
Adjustable Mounting Arm
Hose Clamp Remover/Installer
Powertrain Jack
Wooden Block

Materials 

1. Lubricate the torque converter hub with multi-purpose grease. Remove Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

   Material: Motorcraft ® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)

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2. • Inspect the torque converter stud and flexplate for paint marks.
   • Align the torque converter stud and flexplate hole near the paint marks to the 12 o'clock position.

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3. Position the engine onto the transmission and subframe assembly. Use the General Equipment: Floor Crane

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4. • Align the engine to the transmission and install the bolts.
   • Draw the engine and transmission together evenly using the bolts.

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5. Install the transmission bellhousing bolts.

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6. Tighten.

   Torque: 35 lb. ft (48 Nm)

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7. If equipped, install the transmission bellhousing bolt.

   Torque: 35 lb. ft (48 Nm)

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8. Install the transmission bellhousing bolts.

   Torque: 35 lb. ft (48 Nm)

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9. Install. Use the General Equipment: Adjustable Mounting Arm

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10. 1. Remove the floor crane and length of chain with connecting links. Use the General Equipment: Floor Crane
    2. Remove Special Service Tool: 303-1246 Engine Spreader Bar., 303-1634 Lift Eyes (2).

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11. Using the bolts, draw the PTU up to the transmission.

    Torque: 66 lb. ft (90 Nm)

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12. Install the bracket and the bolts.

    Torque:

    Bracket-to-engine block bolts: 35 lb. ft (48 Nm)

    Bracket -to-PTU bolts: 59 lb. ft (80 Nm)

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13. Attach the PTU vent hose retainer.

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14. Install the heat shield and the bolts.

    Torque: 97 lb. in (11 Nm)

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15. Install the heat shield and the bolts.

    Torque: 97 lb. in (11 Nm)

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16. Attach the wiring harness retainers.

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17. Attach the coolant tube retainers to the subframe.

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18. NOTE: Using the crankshaft pulley bolt, turn the engine clockwise.

    Install the new torque converter nuts.

    Torque: 35 lb. ft (48 Nm)

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19. Install the access cover and the retainers.

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20. Install the ground cable and the nut.

    Torque: 18 lb. ft (25 Nm)

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21. Install the starter and the stud bolts.

    Torque: 35 lb. ft (48 Nm)

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22. Install the bracket and the nuts.

    Torque: 17 lb. ft (23 Nm)

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23. NOTE: Make sure that when installing the manual control lever, it is fully seated onto the manual control lever shaft. Damage to the manual control lever shaft will occur and the manual lever will come loose.
    NOTE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.

    Install the manual control lever and the nut.

    Torque: 159 lb. in (18 Nm)

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24. 1. Attach the wiring harness retainers.
    2. Connect the starter electrical connector.
    3. Connect the starter cable and install the nut.

       Torque: 106 lb. in (12 Nm)

    4. Position the starter cable protective cover.

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25. 1. Install the coolant hose assembly and connect the coolant hose quick connectors.
    2. Attach the coolant hose retainer onto the stud bolt.
    3. Slide the coolant hose onto the coolant outlet pipe and tighten the clamp.

       Torque: 44 lb. in (5 Nm)

    4. Slide the coolant hose retainer onto the bracket.

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26. • Connect the transmission electrical connector.
    • Attach the wiring harness retainers.

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27. Attach the wiring harness retainers.

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28. 1. Connect the generator cable and install the nut.

       Torque: 159 lb. in (18 Nm)

    2. Position the generator cable protective cover.
    3. Connect the generator electrical connector.

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29. Install a new RH catalytic converter gasket.

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30. 1. Install the RH catalytic converter.
    2. Install new RH catalytic converter nuts.

       Torque: 30 lb. ft (40 Nm)

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31. 1. Install.

       Torque: 22 lb. ft (30 Nm)

    2. Tighten.

       Torque: 35 lb. ft (48 Nm)

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32. Connect the RH HO2S and RH catalyst monitor sensor electrical connectors.

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33. Using the powertrain jack, raise the powertrain and subframe assembly into the engine compartment. Use the General Equipment: Powertrain Jack

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34. Install the transmission mount bolts.

    Torque: 59 lb. ft (80 Nm)

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35. Install the transmission support insulator bracket, the nuts and the bolt.

    Torque:

    Nuts: 66 lb. ft (90 Nm)

    Bolt: 97 lb. in (11 Nm)

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36. NOTE: Hand tighten fasteners only at this time.
    1. Position the engine mount.
    2. Install the engine mount-to-engine nuts and hand tighten.
    3. Install the engine mount-to-frame bolts and hand tighten.
    4. Install the engine mount-to-frame nut and hand tighten.

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37. Tighten the engine mount-to-engine nuts.

    Torque: 59 lb. ft (80 Nm)

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38. NOTE: Align the reference marks made during removal.
    NOTE: Only tighten the bolts finger tight at this stage.

    Install the new subframe bolts.

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39. NOTE: Align the reference marks made during removal.
    NOTE: Only tighten the bolts finger tight at this stage.
    1. Install the subframe brackets and the new subframe bolts.
    2. Install the subframe bracket bolts.

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40. NOTE: While tightening the subframe bolts, make sure the front subframe does not move.

    Tighten the subframe bolts.

    Torque: 173 lb. ft (235 Nm)

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41. 1. Tighten.

       Torque:

       Stage 1: 76 lb. ft (103 Nm)

       Stage 2: 270 °

    2. Tighten.

       Torque: 35 lb. ft (48 Nm)

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42. Install the bolts and nuts.

    Torque: 173 lb. ft (235 Nm)

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43. Remove. Use the General Equipment: Adjustable Mounting Arm

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44. Install the engine-to-transmission bolt.

    Torque: 35 lb. ft (48 Nm)

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45. Remove. Use the General Equipment: Powertrain Jack Use the General Equipment: Wooden Block

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46. 1. Tighten the engine mount-to-frame bolts.

       Torque: 81 lb. ft (110 Nm)

    2. Tighten the engine mount-to-frame nut.

       Torque: 81 lb. ft (110 Nm)

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47. Install the cooling module support panel and the bolts.

    Torque: 177 lb. in (20 Nm)

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48. Tighten.

    Torque: 66 lb. ft (90 Nm)

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49. Install the following items:
    1. Refer to: Rear Driveshaft .
    2. Refer to: Catalytic Converter LH .
    3. Refer to: Exhaust Flexible Pipe .
    4. NOTE: Do not allow the brake caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur.

       LH brake disc. Refer to : Brake Disc .

    5. RH front halfshaft. Refer to : Front Halfshaft RH .

50. Install the subframe support bracket and the nuts.

    Torque: 33 lb. ft (45 Nm)

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51. 1. Position the tie rod end into the wheel knuckle.
    2. Install the new tie rod end nut.

       Torque: 111 lb. ft (150 Nm)

    3. Tighten the tie rod end jam nut.

       Torque: 52 lb. ft (70 Nm)

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52. NOTE: Use the internal or external hex-holding feature to prevent the ball and stud from turning while removing or installing the stabilizer bar link nuts. The link boot seal must not be allowed to twist while tightening the link nuts or damage to the boot seal will occur.

    Position the RH sway bar link and install the new nut.

    Torque: 85 lb. ft (115 Nm)

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53. NOTE: Use the internal or external hex-holding feature to prevent the ball and stud from turning while removing or installing the stabilizer bar link nuts. The link boot seal must not be allowed to twist while tightening the link nuts or damage to the boot seal will occur.

    Position the LH sway bar link and install the new nut.

    Torque: 85 lb. ft (115 Nm)

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54. Install the LH anti-lock sensor and the bolt.

    Torque: 80 lb. in (9 Nm)

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55. Install the front ride height sensors. Refer to : Front Suspension Height Sensor .
56. 1. Position the A/C line bracket onto the generator stud.
    2. Attach the wiring harness retainer.

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57. Install the generator nut.

    Torque: 35 lb. ft (47 Nm)

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58. Connect the coolant tubes and attach the retainer.

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59. Connect and attach the engine harness electrical connector.

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60. Connect the transmission fluid cooler tube.

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61. Install the transmission fluid cooler tube secondary latch.

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62. Connect the transmission fluid cooler tube.

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63. Install the transmission fluid cooler tube secondary latch.

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64. 1. Position the high-pressure fuel pump noise insulator aside and connect the high-pressure fuel pump fuel feed tube quick release coupling. Refer to : Quick Release Coupling .
    2. Connect the EVAP tube quick release coupling. Refer to: Quick Release Coupling .

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

       Torque: 159 lb. in (18 Nm)

    2. Attach the wiring harness retainers.

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66. Connect the upper radiator hose. Use the General Equipment: Hose Clamp Remover/Installer

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67. 1. Connect the lower radiator hose. Use the General Equipment: Hose Clamp Remover/Installer
    2. Connect the heater hose. Use the General Equipment: Hose Clamp Remover/Installer
    3. Attach the heater hose retainer.
    4. Install the bolt.

       Torque: 80 lb. in (9 Nm)

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68. Connect the coolant hoses to the heater core. Use the General Equipment: Hose Clamp Remover/Installer

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69. Attach the heater hose to the retainers.

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70. 1. Attach the cable to the transmission control lever.
    2. Position the cable and install the bolt.

       Torque: 62 lb. in (7 Nm)

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71. Connect the vacuum tube quick release couplings. Refer to : Quick Release Coupling .

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72. Install the bolt and attach the wiring harness retainers.

    Torque: 106 lb. in (12 Nm)

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73. Position the wiring harness and install the nuts.

    Torque: 89 lb. in (10 Nm)

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74. Close the battery cable terminal cover.

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75. Position and install the fuse box.

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76. Install the ground cable and stud bolt.

    Torque: 106 lb. in (12 Nm)

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77. Install the following items:
    1. Refer to: Battery Tray .
    2. Refer to: Air Conditioning (A/C) Compressor .
    3. Refer to: Accessory Drive Belt .

78. Install the upper CAC outlet pipe and tighten the clamps.

    Torque: 48 lb. in (5. 4 Nm)

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79. Install the following items:
    1. Refer to: Charge Air Cooler (CAC) Intake Pipe .
    2. Refer to: Air Cleaner Outlet Pipe RH .
    3. Refer to: Air Cleaner Outlet Pipe LH .
    4. Refer to: Air Cleaner .
    5. Refer to: Degas Bottle .

80. Attach the wiring harness retainer to the engine mount.

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81. • Connect the engine wiring harness electrical connector and retainer.
    • Connect the PCM electrical connector.

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82. If equipped, install the wiring harness cover and the retainer.

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83. 1. Install the engine appearance cover and the nut.

       Torque: 42 lb. in (4. 8 Nm)

    2. Install the bolt.

       Torque: 93 lb. in (10. 5 Nm)

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84. Install the underbody shields and the retainers.

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85. If equipped, install the front underbody straps and the retainers.

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86. Install the underbody shields and the retainers.

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87. Install the front fender splash shields. Refer to : Fender Splash Shield .
88. Remove the support.

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89. Position steering column shaft and install a new bolt.

    Torque: 18 lb. ft (25 Nm)

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90. Remove the holding device.

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91. Install a new engine oil filter and fill the engine with clean engine oil. Refer to: Engine Oil Draining and Filling .
92. Connect the battery ground cable. Refer to : Battery Disconnect and Connect .
93. Fill and bleed the engine cooling system. Refer to : Cooling System Draining, Vacuum Filling and Bleeding .
94. Charge the A/C system. Refer to : Air Conditioning (A/C) System Recovery, Evacuation and Charging - Vehicles With: R134A Refrigerant .
95. Check the transmission fluid level. Refer to : Transmission Fluid Level Check .
96. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.