Section 54 (Engine - 2.0L DURATEC-He (129KW/175PS)): Installation: Engine

For information on Ford Color Coded Illustrations, refer to OEM COLOR CODING

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	307-566Retainer, Torque Converter TKIT-2006C-FFMFLM TKIT-2006C-LM TKIT-2006C-ROW
Magnetic Socket
Floor Crane
Adjustable Mounting Arm
Hose Clamp Remover/Installer
Powertrain Jack
Wooden Block

Materials 

All vehicles 

1. Lubricate the torque converter pilot hub with multi-purpose grease.

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

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

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3. Using the floor crane and engine lift equipment, install the engine to the transmission on the powertrain table. Use the General Equipment: Floor Crane

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4. Make sure the torque converter stud marked during removal aligns with the flexplate.

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5. Install the transmission-to-engine bolt.

   Torque 35 lb.ft (48 Nm)

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6. Install the transmission-to-engine bolts.

   Torque 35 lb.ft (48 Nm)

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7. Install the engine-to-transmission bolts.

   Torque 35 lb.ft (48 Nm)

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8. Install adjustable mounting arm. Use the General Equipment: Adjustable Mounting Arm

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9. Remove the floor crane and engine lift equipment. Use the General Equipment: Floor Crane

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10. Tighten the engine mount studs.

    Torque 93 lb.in (10.5 Nm)

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11. NOTE: Rotate the engine in a clockwise direction only or engine damage may occur.

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

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12. Install the starter motor isolator.

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13. Install the starter motors and the stud bolts.

    Torque 26 lb.ft (35 Nm)

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14. 1. Position the starter motor wiring housing and install the battery positive cable nut.

       Torque 106 lb.in (12 Nm)

    2. Install the motor control wire nut.

       Torque 53 lb.in (6 Nm)

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15. Install the starter motor bracket and the nuts.

    Torque 89 lb.in (10 Nm)

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16. • Attach the wiring harness retainers.
    • Attach the coolant hose retainer.

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17. Connect the transmission wiring harness electrical connector and retainer.

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18. • Install the catalytic converter manifold stud bolts.

      Torque 150 lb.in (17 Nm)

    • Install the catalytic converter manifold gasket.

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19. Raise the powertrain into the vehicle.

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20. Install the transmission mount bolt.

    Torque 46 lb.ft (63 Nm)

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21. • Install the engine mount and the nuts.

      Torque 59 lb.ft (80 Nm)

    • Install the engine mount bolts.

      Torque 66 lb.ft (90 Nm)

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22. • Remove adjustable mounting arm. Use the General Equipment: Adjustable Mounting Arm
    • Remove the powertrain jack and boards from under the engine and transmission. Use the General Equipment: Powertrain Jack. Use the General Equipment: Wooden Block

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23. Connect the oil pressure switch wiring harness electrical connector.

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24. NOTE: Clean the bolts using a wire brush and apply Motorcraft® Threadlock and Sealer to the threads.

    Install the roll restrictor, bolts and tighten the bolts.

    1. Material

       Motorcraft® Threadlock and Sealer / TA-25-B

       Torque 59 lb.ft (80 Nm)

    2. Material

       Motorcraft® Threadlock and Sealer / TA-25-B

       Torque 63 lb.ft (86 Nm)

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25. Install the transmission-to-oil pan bolts.

    Torque 35 lb.ft (48 Nm)

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26. Install the oil pan-to-transmission stud bolt and bolt.

    Torque 35 lb.ft (48 Nm)

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27. Position the ground wire and install the nut.

    Torque 177 lb.in (20 Nm)

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28. Install the transmission fluid cooler tubes and position the clamps.

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29. Install the cooler bypass valve nut.

    Torque 80 lb.in (9 Nm)

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30. Install the transmission fluid cooler tubes bracket bolt.

    Torque 89 lb.in (10 Nm)

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31. 1. NOTE: Lubricate the seal and backing ring with clean transmission fluid.

       Inspect the transmission fluid tube seal for damage and install new seal if necessary.

    2. Inspect the transmission fluid tube backing ring for damage and install new backing ring if necessary.

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32. Install the cooler bypass valve-to-transmission fluid tube and the bolt.

    Torque 89 lb.in (10 Nm)

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33. 1. NOTE: Lubricate the seal and backing ring with clean transmission fluid.

       Inspect the transmission fluid tube seal for damage and install new seal if necessary.

    2. Inspect the transmission fluid tube backing ring for damage and install new backing ring if necessary.

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34. Install the transmission-to-cooler bypass valve tube and the bolt.

    Torque 89 lb.in (10 Nm)

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35. Tighten the transmission fluid cooler tubes fittings to the cooler bypass valve.

    Torque 22 lb.ft (30 Nm)

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36. Install the LH and RH halfshafts. Refer to: Front Halfshaft LH - 6-Speed Automatic Transmission - 6F15 . Refer to: Front Halfshaft RH - 2.0L Duratec-HE (125kW/170PS) - MI4, FWD .

    All Wheel Drive (AWD) vehicles 

37. Install the LH halfshaft. Refer to: Front Halfshaft LH - 6-Speed Automatic Transmission - 6F15 .
38. Install the transfer case. Refer to: Transfer Case .

    Engine mounted evaporative emission canister purge valve 

39. • Install the EVAP canister purge valve and the nuts.

      Torque 97 lb.in (11 Nm)

    • Attach the retainers.
    • Connect the EVAP canister purge valve quick connect couplings. Refer to: Quick Release Coupling .
    • Connect the EVAP canister purge valve wiring harness electrical connector.

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    All vehicles 

40. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.

    Install a new engine oil filter.

    Torque: Stage1: 71 lb.in (8 Nm) / Stage 2: 180 deg.

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41. Install the coolant fan motor and shroud. Refer to: Cooling Fan Motor and Shroud .
42. Attach the lower radiator coolant hose retainer to the coolant fan motor and shroud.

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43. Install the lower radiator coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

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44. • Remove the support and position the catalytic converter onto the studs.
    • Install the new nuts and tighten in sequence shown.

      Torque: Stage1: Tighten: 41 lb.ft (55 Nm) / Stage 2: Retighten: 41 lb.ft (55 Nm)

    Fig 1: Catalytic Converter Manifold Tightening Sequence

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45. 1. Attach the muffler and tailpipe hanger.
    2. Connect and tighten the catalytic converter-to-muffler and tailpipe nut.

       Torque 177 lb.in (20 Nm)

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46. Install the bolts for the catalytic converter support bracket.

    Torque 18 lb.ft (25 Nm)

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47. NOTE: Typical catalytic converter shown, sensor position may vary by application.
    • Install the catalytic converter heat shield and the bolts.

      Torque 89 lb.in (10 Nm)

    • Attach the catalyst monitor sensor wiring harness.

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48. Connect the catalyst monitor sensor electrical connector and wire retainer.

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49. Install the following items:
    1. Install the HO2S. Refer to: Heated Oxygen Sensor (HO2S) .
    2. Install the A/C compressor belt. Refer to: Air Conditioning (A/C) Compressor Belt .
    3. Install the RH fender splash shield. Refer to: Fender Splash Shield .

50. Uncover the covered ports and install new O-ring seal.
    1. Install the A/C line and the nut.

       Torque 159 lb.in (18 Nm)

    2. Install the A/C line support bracket nut.

       Torque 27 lb.in (3 Nm)

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51. • Uncover the covered ports.
    • Install new O-ring seal.
    • Install the A/C line and the nut.

      Torque 159 lb.in (18 Nm)

    • Connect the A/C pressure switch wiring harness electrical connector.
    • Attach the A/C line retainers.

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52. • Uncover the covered ports.
    • Install new O-ring seal.
    • Position the A/C line and install the nut.

      Torque 159 lb.in (18 Nm)

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53. • Uncover the covered ports.
    • Install new O-ring seals.
    • Position the A/C lines and install the nuts.

      Torque 159 lb.in (18 Nm)

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54. Connect the transmission fluid auxiliary pump electrical connector.

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55. Connect the transmission TSS sensor wiring harness electrical connector and retainer.

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56. Position the ground cable and install the bolt.

    Torque 106 lb.in (12 Nm)

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57. • Install the degas bottle coolant tube and attach the pinch clamp to the radiator.
    • Attach the degas bottle coolant tube retainers.

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58. • Install the EVAP canister purge valve tube and connect quick release coupling. Refer to: Quick Release Coupling .
    • Attach the EVAP canister purge valve tube retainers.

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    All vehicles 

59. • Connect the EVAP canister purge valve tube quick release coupling to the intake manifold. Refer to: Quick Release Coupling .
    • Attach the EVAP canister purge valve tube retainers.

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60. Connect the brake vacuum tube to the intake manifold.

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61. Connect the coolant hoses to the heater core.

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62. • Position the degas bottle hose and install the clamp. Use the General Equipment: Hose Clamp Remover/Installer
    • Install the upper radiator hose, retainers and the clamps. Use the General Equipment: Hose Clamp Remover/Installer

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63. Connect the fuel tube quick release coupling and the retainers. Refer to: Quick Release Coupling .

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64. • Position the shift cable and install the bolt.

      Torque 89 lb.in (10 Nm)

    • Connect the selector lever cable end to the manual control lever.

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65. If equipped, install and attach the block heater wiring harness retainers.

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66. If equipped, connect the block heater wiring harness electrical connector.

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67. If equipped cabin heater coolant pump, connect the coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer

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68. Install the battery tray bracket and the nuts.

    Torque 89 lb.in (10 Nm)

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69. • Connect the engine harness wiring connector.
    • Attach the plastic housing to battery tray bracket.

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70. Attach the wire harness retainers to the plastic housing on battery tray bracket.

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71. Install the battery feed wire and nut to junction box.

    Torque 106 lb.in (12 Nm)

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72. Close the junction box cover and attach tabs.

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73. Install the degas bottle on the tabs.

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74. • Install the coolant hoses to the degas bottle. Use the General Equipment: Hose Clamp Remover/Installer
    • Attach the coolant hose retainer.

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75. Install the following items:
    1. Install the battery tray. Refer to: Battery Tray .
    2. Install the RH headlight assembly. Refer to: Headlamp Assembly .

76. 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.
    1. 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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77. Fill the engine with clean engine oil. Refer to: Specifications .

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78. Recharge the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging - Vehicles With: R134A Refrigerant .
79. Adjust the selector lever cable. Refer to: Selector Lever Cable Adjustment - 6-Speed Automatic Transmission - 6F35 .
80. Install the air cleaner and the air cleaner outlet pipe. Refer to: Air Cleaner . Refer to: Air Cleaner Outlet Pipe .
81. Fill and bleed the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
82. Check the transmission fluid level. Refer to: Transmission Fluid Level Check .
83. Start and check the exhaust system for leaks.
84. If equipped, install the underbody shield and the bolts.

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85. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.