Section 131 (ENGINE - 2.0L ECOBOOST (184kW/250PS) - MI4): Installation: Engine

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Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	300-OTC1819E2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	303-050 (T70P-6000) Lifting Bracket, Engine
Courtesy of FORD MOTOR COMPANY	307-566 Retainer, Torque Converter TKIT-2006C-FFMFLM TKIT-2006C-LM TKIT-2006C-ROW
Magnetic Socket
Adjustable Mounting Arm
Hose Clamp Remover/Installer

Materials 

2WD/4WD 

1. Lubricate the torque converter hub with multi-purpose grease. Use Special Service Tool: 307-566 Retainer, Torque Converter.

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

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2. Inspect the engine block dowels. If the dowels are damaged or missing, install new engine block dowels.

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3. Align the torque converter stud marked during removal with the flexplate.

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4. Install the bolts.

   Torque: 35 lb.ft (48 Nm)

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

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6. Remove the engine lift equipment. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.

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7. If necessary. Remove Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.

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8. If necessary. Remove Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.

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9. NOTE: When removing any turbocharger air intake system components, make sure to cover any open ports to prevent debris from entering the system. The turbocharger compressor vanes can be damaged by even the smallest particles. All components need to be inspected and cleaned prior to installation or reassembly.
   1. Install the turbocharger inlet pipe, engine appearance cover stud and tighten clamp and stud.

      Torque: 44 lb.in (5 Nm)

   2. Install the turbocharger inlet pipe bolt.

      Torque: 97 lb.in (11 Nm)

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   2WD 

10. Install the engine-to-transmission bolts.

    Torque: 35 lb.ft (48 Nm)

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11. Install the halfshaft support bracket bolts.

    Torque: 35 lb.ft (48 Nm)

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    4WD 

12. Install the engine-to-transmission bolts.

    Torque: 35 lb.ft (48 Nm)

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13. Install the new transfer case to transmission compression seal.

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14. Install the transfer case.

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15. Install new transfer case bolts.

    Torque: 59 lb.ft (80 Nm)

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16. 1. Install the transfer case support bracket and the bolts.

       Torque: 18 lb.ft (25 Nm)

    2. Install the transfer case support bracket-to-engine bolt.

       Torque: 46 lb.ft (63 Nm)

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17. Install the transfer case heat shield and the bolts.

    Torque: 97 lb.in (11 Nm)

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18. Attach transfer case vent hose retainer to the engine block.

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19. Install the halfshaft support bracket and the bolts.

    Torque: 35 lb.ft (48 Nm)

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    2WD/4WD 

20. Position the harness and attach the generator wiring harness retainers.

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21. • Connect the generator electrical connector.
    • Install the B+ cable, nut and position the cover.

      Torque: 150 lb.in (17 Nm)

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22. Attach the wiring harness retainer to the transmission stud bolt.

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23. Connect the electrical connectors and wiring harness retainers.

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

    Install the torque converter nuts. Use the General Equipment: Magnetic Socket

    Torque: 30 lb.ft (40 Nm)

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25. Install the stater motor isolator.

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26. 1. Install the battery cable and install the nut.

       Torque: 106 lb.in (12 Nm)

    2. Install the nut.

       Torque: 53 lb.in (6 Nm)

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27. Install the starter and the stud bolts.

    Torque: 35 lb.ft (48 Nm)

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28. • Install ground wire and nut.

      Torque: 159 lb.in (18 Nm)

    • Attach the coolant hose retainer.

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29. Install a new catalytic converter gasket.

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30. NOTE: Do not tighten the new catalytic converter-to-turbocharger nuts at this time.

    Install the catalytic converter and the new nuts finger-tight.

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31. NOTE: Do not tighten the catalytic converter support bracket-to-transmission bolts at this time.

    Install the catalytic converter support bracket-to-transmission bolts.

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32. Tighten.

    Torque: 30 lb.ft (40 Nm)

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33. Tighten.

    Torque: 18 lb.ft (25 Nm)

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34. Install the catalytic converter support bracket-to-subframe bolts.

    Torque: 18 lb.ft (25 Nm)

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35. Connect the HO2S and catalyst monitor sensor electrical connectors.

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36. Using the powertrain jack, raise the powertrain and subframe as an assembly.

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

       Torque: 85 lb.ft (115 Nm)

    2. Install the bolts.

       Torque: 81 lb.ft (110 Nm)

    3. Install the nut.

       Torque: 66 lb.ft (90 Nm)

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38. Install the transmission mount nut.

    Torque: 98 lb.ft (133 Nm)

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

    Install the new forward subframe bolts.

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40. 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 rearward subframe bolts.
    2. Install the subframe bracket bolts.

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

    Tighten the forward subframe bolts.

    Torque: 173 lb.ft (235 Nm)

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42. 1. Tighten.

       Torque: Stage 1: 76 lb.ft (103 Nm) Stage 2: 270 deg.

    2. Tighten.

       Torque: 35 lb.ft (48 Nm)

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

    Torque: 177 lb.in (20 Nm)

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44. Install the bolts and nuts.

    Torque: 173 lb.ft (235 Nm)

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45. Install the bolts and nuts.

    Torque: 173 lb.ft (235 Nm)

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46. Remove.

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47. Install both front brake disc. Refer to: Brake Disc .
48. 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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49. 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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50. Install the RH anti-lock sensor and the bolt.

    Torque: 80 lb.in (9 Nm)

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

    Torque: 80 lb.in (9 Nm)

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52. Install the transmission-to-engine bolts.

    Torque: 35 lb.ft (48 Nm)

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53. Install the engine-to-transmission bolt.

    Torque: 35 lb.ft (48 Nm)

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54. Lubricate the oil filter sealing surface and install.

    Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

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

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55. Install the A/C compressor belt. Refer to: Air Conditioning (A/C) Compressor Belt .
56. 1. NOTE: Use new O-ring seals and gasket seals.

       Connect the A/C lines and install the nuts.

       Torque: 133 lb.in (15 Nm)

    2. Install the support bracket nut.

       Torque: 18 lb.ft (25 Nm)

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57. Connect the A/C compressor electrical connectors and wiring harness retainers.

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58. Connect and attach the engine harness electrical connector.

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59. NOTE: RH side shown, LH side similar.

    Position the splash shield and install the fasteners on both sides.

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    4WD 

60. Install the new lower transfer case bolts.

    Torque: 59 lb.ft (80 Nm)

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61. Install the rear driveshaft. Refer to: Rear Driveshaft .
62. Install the RH front halfshaft. Refer to: Front Halfshaft RH - 2.0L EcoBoost (184kW/250PS) - MI4, All-Wheel Drive (AWD) .

    2WD/4WD 

63. Install a new exhaust gasket.

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64. Position the exhaust and install the new nuts.

    Torque: 35 lb.ft (48 Nm)

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65. Install the subframe support bracket and the nuts.

    Torque: 33 lb.ft (45 Nm)

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66. NOTE: When removing any turbocharger air intake system components, make sure to cover any open ports to prevent debris from entering the system. The turbocharger compressor vanes can be damaged by even the smallest particles. All components need to be inspected and cleaned prior to installation or reassembly.

    Install the CAC tube and tighten the clamps.

    Torque: 44 lb.in (5 Nm)

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67. NOTE: When removing any turbocharger air intake system components, make sure to cover any open ports to prevent debris from entering the system. The turbocharger compressor vanes can be damaged by even the smallest particles. All components need to be inspected and cleaned prior to installation or reassembly.
    1. Install the CAC tube and the nuts.

       Torque: 97 lb.in (11 Nm)

    2. Tighten the clamp.

       Torque: 44 lb.in (5 Nm)

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68. Connect the CAC hose, electrical connector and the wire retainer. Use the General Equipment: Hose Clamp Remover/Installer

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69. NOTE: When removing any turbocharger air intake system components, make sure to cover any open ports to prevent debris from entering the system. The turbocharger compressor vanes can be damaged by even the smallest particles. All components need to be inspected and cleaned prior to installation or reassembly.

    Position the CAC tube and tighten the clamp.

    Torque: 44 lb.in (5 Nm)

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70. Install the underbody shields and the retainers.

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71. Install the front underbody shield and the retainers.

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72. Install the underbody shields and the retainers.

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73. Install the underbody shields and the retainers.

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74. Install the front wheels and tires. Refer to: Wheel and Tire .
75. 1. Remove.
    2. Install.

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76. Install the upper air deflector and the retainers.

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77. Connect the fuel tube and EVAP canister purge valve quick release couplings. Refer to: Quick Release Coupling .

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78. Connect the transmission fluid cooler tubes to the transmission fluid cooler thermal bypass valve.

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79. Install the transmission fluid cooler tube secondary latches.

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80. Connect the shift cable, install the bolts.

    Torque: 18 lb.ft (25 Nm)

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81. NOTE: Vehicles with auxiliary heater.
    • Vehicles with auxiliary heater, connect the coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer
    • Attach the upper radiator hose retainer.

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82. NOTE: Vehicles without auxiliary heater.
    • Vehicles without auxiliary heater, connect the coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer
    • Connect the coolant hose quick connect coupling.

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83. Connect the vacuum tube at the brake vacuum pump and retainer.

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84. Push the intake manifold retainer in and install the brake vacuum tube.

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85. Install the crankcase vent tube, connect the electrical connector and wiring harness retainer.

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86. • Connect the lower radiator hose to the thermostat housing. Use the General Equipment: Hose Clamp Remover/Installer
    • Attach the coolant tube return hose retainer.

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87. • Connect the PCM electrical connector.
    • Connect the engine harness electrical connector and retainer.

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88. Attach wire harness retainers to the engine mount and valve cover stud bolt.

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89. Install the bolts and attach the wiring harness retainers.

    Torque: 106 lb.in (12 Nm)

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90. Position the electrical wiring harness cables and install the nuts.
    1. Torque: 71 lb.in (8 Nm)
    2. Torque: 106 lb.in (12 Nm)

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91. Close the cover.

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92. • Position the top part of junction box.
    • Latch the tabs.

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93. Connect the junction box electrical connector.

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94. Install the ground cable and stud bolt.

    Torque: 106 lb.in (12 Nm)

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95. Install the following items:
    1. Refer to: Battery Tray .
    2. Refer to: Air Cleaner .
    3. Refer to: Air Cleaner Outlet Pipe .
    4. Refer to: Degas Bottle .

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

    Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

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97. Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
98. 1. NOTE: Lubricating the grommets with silicone grease will aid in the installation of the engine appearance cover, and any future removal and installation of the cover.

       Lubricate each grommet with silicone grease.

       Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

    2. Position the engine appearance cover onto engine with the grommets aligned with the studs.
    3. Press down on the engine appearance cover at each grommet location to attach the grommets onto the studs.

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

    Torque: 18 lb.ft (25 Nm)

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100. Remove the holding device.

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101. Charge the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging .
102. Check the transmission fluid level. Refer to: Transmission Fluid Level Check .
103. Check the transfer case fluid level. Refer to: Transfer Case Fluid Level Check .
104. Start and check the exhaust system for leaks.
105. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure using a diagnostic scan tool.