Section 27 (Engine - 1.5L ECOBOOST (118KW/160PS) - I4): Installation: Engine

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	300-OTC1819E2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	303-1502 Lifting Device Engine TKIT-2012A-FL, TKIT-2012A-ROW
Adjustable Mounting Arm
Hose Clamp Remover/Installer

Materials 

All vehicles 

1. Draw the engine to the transmission together and install the bolt.

   Torque: 35 lb.ft (48 Nm)

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2. Install the engine to transmission bolts.

   Torque: 35 lb.ft (48 Nm)

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3. Install the engine to transmission bolts.

   Torque: 35 lb.ft (48 Nm)

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4. Install the Adjustable Mounting Arm.

   Use the General Equipment: Adjustable Mounting Arm

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

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6. Remove Special Service Tool: 303-1502 Lifting Device Engine.

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7. Install the bracket and the bolts.

   Torque: 97 lb.in (11 Nm)

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8. Position the halfshaft support bracket and install the bolts.

   Torque: 35 lb.ft (48 Nm)

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9. Install the TC inlet pipe, bolt and tighten the clamp.

   Torque:

   1: 71 lb.in (8 Nm)

   2: 44 lb.in (5 Nm)

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10. • Install the TC outlet pipe, bolt and tighten the clamps.

      Torque:

      1: 71 lb.in (8 Nm)

      2: 44 lb.in (5 Nm)

    • Connect the TC bypass hose.
    • Attach the wiring harness retainers and connect the electrical connectors.

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11. • Install the crankcase vent hose. Use the General Equipment: Hose Clamp Remover/Installer
    • Connect the wiring harness electrical connector and wire harness the retainer.

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12. NOTE: Only rotate the crankshaft in a clockwise direction.

    Match the index-mark the torque converter nuts and tighten the nut.

    Torque: 35 lb.ft (48 Nm)

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13. Install the starter motor insulator.

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14. Install the starter motor, bolts and the stud bolt.

    Torque: 35 lb.ft (48 Nm)

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15. Position the wiring harness and install the nut.

    Torque: 97 lb.in (11 Nm)

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16. • Position the wiring harness and install the nut.

      Torque: 159 lb.in (18 Nm)

    • Slide the generator insulator down.
    • Attach the wiring harness retainers and connect the electrical connector.

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17. Position the starter motor cable and install the nuts.

    Torque:

    1: 53 lb.in (6 Nm)

    2: 106 lb.in (12 Nm)

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    Vehicles with automatic start-stop 

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

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    All vehicles 

19. Attach the wiring harness retainers and connect the electrical connectors.

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20. Install the new catalytic converter gasket and loosely install the bolts.

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21. Install the catalytic converter, bolt and tighten the bolts in sequence shown below.

    Torque: 22 lb.ft (30 Nm)

    Fig 1: Catalytic Converter Tightening Sequence

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22. Install the muffler inlet pipe isolator bracket bolts.

    Torque: 18 lb.ft (25 Nm)

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23. Tighten the catalytic converter mounting bolts in sequence shown below.

    Torque: 22 lb.ft (30 Nm)

    Fig 2: Catalytic Converter Tightening Sequence

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24. NOTE: Make sure the sensor wiring is routed away from hot surfaces and sharp edges or damage to the wiring may occur.

    Attach the retainer and connect the electrical connector.

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25. Tighten the engine mount studs.

    Torque: 89 lb.in (10 Nm)

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26. Using the powertrain lift, raise the powertrain and subframe as an assembly.

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

       Torque: 85 lb.ft (115 Nm)

    2. Install the engine mount bolts finger-tight.

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28. Install the transmission support insulator nut.

    Torque: 98 lb.ft (133 Nm)

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29. NOTE: Align the reference marks made during removal.

    Install the subframe front mounting bolts finger-tight.

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30. NOTE: Align the reference marks made during removal.
    1. Install the subframe support bracket and the bolts finger-tight.
    2. Install the subframe support bracket bolts finger-tight.

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

    Install the subframe rear mounting bolts.

    Torque: 173 lb.ft (235 Nm)

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32. 1. Tighten the subframe support bracket bolts in 2 stages.

       Torque:

       Stage 1: 76 lb.ft (103 Nm)

       Stage 2: 270 °

    2. Tighten the subframe support bracket bolts.

       Torque: 44 lb.ft (60 Nm)

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

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34. Tighten the engine mount bolts.

    Torque: 66 lb.ft (90 Nm)

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35. Position the RH wheel knuckle assembly, install the bolts and the nuts.

    Torque: 173 lb.ft (235 Nm)

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36. Position the LH wheel knuckle assembly, install the bolts and the nuts.

    Torque: 173 lb.ft (235 Nm)

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37. Install the brake disc. Refer to: Brake Disc .
38. Position the RH stabilizer bar link and install the nut.

    Torque: 85 lb.ft (115 Nm)

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39. Position the LH stabilizer bar link and install the nut.

    Torque: 85 lb.ft (115 Nm)

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40. Position the wheel speed sensor and install the bolt.

    Torque: 80 lb.in (9 Nm)

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41. Position the wheel speed sensor and install the bolt.

    Torque: 80 lb.in (9 Nm)

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42. Install the catalytic converter grommet and the nuts.

    Torque: 18 lb.ft (25 Nm)

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43. Install the engine to transmission bolts.

    Torque: 35 lb.ft (48 Nm)

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44. Position the auxiliary water pump and install the bolts.

    Torque: 17 lb.ft (23 Nm)

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45. Install the new muffler inlet pipe gasket.

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46. Position the muffler inlet pipe and install the nuts.

    Torque: 35 lb.ft (48 Nm)

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47. Install the cross support and the bolts.

    Torque: 33 lb.ft (45 Nm)

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48. Install the engine oil filter.

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

    Torque: 128 lb.in (14.5 Nm)

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49. NOTE: Use new O-ring seals and gasket seals.

    Position the A/C lines and install the nuts.

    Torque:

    1: 133 lb.in (15 Nm)

    2: 89 lb.in (10 Nm)

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50. Connect the electrical connectors and attach the retainers.

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

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52. Connect the coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer

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53. Install the lower radiator support, retainers and the bolts.

    Torque: 177 lb.in (20 Nm)

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54. NOTE: LF inner fender well removed for clarity.

    Connect the electrical connector.

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55. Install the deflector shields and the retainers.

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56. Install the stone guard and the retainers.

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57. Install the RH and LH front wheels and tires. Refer to: Wheel and Tire .
58. Install the accessory drive belt. Refer to: Accessory Drive Belt .
59. Remove the cooling module support.

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60. • Install the degas bottle and the retainer.

      Torque: 80 lb.in (9 Nm)

    • Connect the coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer

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61. Attach the wiring harness retainer and connect the electrical connector.

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62. Connect the PCM electrical connector.

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

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

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65. Connect the gearshift cable end to selector lever assembly and install the bolts.

    Torque: 18 lb.ft (25 Nm)

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66. NOTE: If equipped with block heater.

    Attach the retainers and connect the coolant tube.

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67. Attach the retainer and connect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

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68. Connect the transmission fluid cooler tubes.

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69. Install the transmission fluid cooler tubes secondary latches.

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

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71. Position the wiring harness, install the bolts and attach the retainers.

    Torque: 97 lb.in (11 Nm)

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72. Position the wiring harness and install the nuts.

    Torque: 89 lb.in (10 Nm)

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73. Close the battery cable terminal cover.

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74. Position and install the fuse box.

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75. Position the wiring harness and install the stud bolt.

    Torque: 106 lb.in (12 Nm)

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76. Install the EVAP canister purge valve. Refer to: Evaporative Emission Canister Purge Valve .
77. Attach the retainer and connect the vacuum tube coupling.

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78. Attach the retainers, connect the fuel tube couplings.

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79. Install the following items:
    1. Install the battery tray. Refer to: Battery Tray .
    2. Install the upper air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
    3. Install the air cleaner. Refer to: Air Cleaner .

80. Attach the steering column shaft to steering input shaft and install the bolt.

    Torque: 18 lb.ft (25 Nm)

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81. Remove the special tool.

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82. Fill the engine with clean engine oil.

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

83. Fill the cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding .
84. Adjust the selector cable. Refer to: Selector Lever Cable Adjustment - 6-Speed Automatic Transmission - 6F35 .
85. Recharge the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging - Vehicles With: R1234YF Refrigerant .
86. Install the engine appearance cover.

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87. Start and check the exhaust system for leaks.
88. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.