Section 16 (Engine - 2.5L DURATEC (125KW/170PS)): Installation: Engine

For information on Ford Color Coded Illustrations refer to OEM Color Coding .

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	300-OTC1585AE Powertrain Lift
Courtesy of FORD MOTOR COMPANY	300-OTC1819E2, 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.

   Courtesy of FORD MOTOR COMPANY

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

   Courtesy of FORD MOTOR COMPANY

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

   Torque:

   35 lb.ft (48 Nm)

   Courtesy of FORD MOTOR COMPANY

4. Install the transmission-to-engine bolts.

   Torque:

   35 lb.ft (48 Nm)

   Courtesy of FORD MOTOR COMPANY

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

   Courtesy of FORD MOTOR COMPANY

6. • Remove special service tool.
   • General Equipment: Spreader Bar Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.

   Courtesy of FORD MOTOR COMPANY

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)

   Courtesy of FORD MOTOR COMPANY

8. Install the starter motor insulator.

   Courtesy of FORD MOTOR COMPANY

9. Install the starter motor and the stud bolts.

   Torque:

   26 lb.ft (35 Nm)

   Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

11. Attach the wire harness retainer.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

14. Attach the wire harness retainers.

    Courtesy of FORD MOTOR COMPANY

15. Install the ground cable and the nut.

    Torque:

    159 lb.in (18 Nm)

    Courtesy of FORD MOTOR COMPANY

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)

    Courtesy of FORD MOTOR COMPANY

17. Install the coolant hose and attach the hose retainer. Connect the EGR valve coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

    Courtesy of FORD MOTOR COMPANY

18. Install the generator and the bolts.

    Torque:

    18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Torque:

    106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

20. Position back the generator cable protective cover.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Torque:

    35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

23. Install the exhaust manifold bracket and the bolts.

    Torque:

    35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

24. Install the new exhaust manifold studs.

    Torque:

    150 lb.in (17 Nm)

    Courtesy of FORD MOTOR COMPANY

25. Install a new exhaust manifold gasket.

    Courtesy of FORD MOTOR COMPANY

26. Install the exhaust manifold and the new nuts.

    Torque:

    41 lb.ft (55 Nm)

    Courtesy of FORD MOTOR COMPANY

27. Install the bolts for the exhaust manifold.

    Torque:

    18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Torque:

    89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

29. Connect the CMS (catalyst monitor sensor) electrical connector.

    Courtesy of FORD MOTOR COMPANY

30. Connect the HO2S electrical connector.

    Courtesy of FORD MOTOR COMPANY

31. Attach the HO2S wire harness retainer.

    Courtesy of FORD MOTOR COMPANY

32. 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

    Courtesy of FORD MOTOR COMPANY

33. Install the transmission support insulator nut.

    Torque:

    98 lb.ft (133 Nm)

    Courtesy of FORD MOTOR COMPANY

34. 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)

    Courtesy of FORD MOTOR COMPANY

35. 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

    Courtesy of FORD MOTOR COMPANY

36. Install the new halfshaft seals. Refer to: Halfshaft Seal LH . Refer to: Halfshaft Seal RH - FWD .
37. 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.

    Courtesy of FORD MOTOR COMPANY

38. Install the new inner halfshaft retaining circlip.

    Courtesy of FORD MOTOR COMPANY

39. Install the seal protector.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

41. 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.

    Courtesy of FORD MOTOR COMPANY

42. 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.

    Courtesy of FORD MOTOR COMPANY

43. Install the seal protector.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

45. Install the RH halfshaft assembly.

    Courtesy of FORD MOTOR COMPANY

46. 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)

    Courtesy of FORD MOTOR COMPANY

47. Install the engine bolt.

    Torque:

    35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

48. Install the transmission bolts.

    Torque:

    35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Torque:

    18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Torque:

    1: 80 lb.in (9 Nm) 2: 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

51. Position the bracket and install the nut.

    Torque:

    133 lb.in (15 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

54. Connect the engine harness electrical connector

    Courtesy of FORD MOTOR COMPANY

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

    Torque:

    44 lb.in (5 Nm)

    Courtesy of FORD MOTOR COMPANY

56. Attach the wire harness retainer.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

60. Connect the engine vent hose and attach the hose retainer. Use the General Equipment: Hose Clamp Remover/Installer

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

63. Position the coolant hose clip.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

      Torque:

      106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

69. Install the transmission fluid cooler tube secondary latches.

    Courtesy of FORD MOTOR COMPANY

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

      Torque:

      106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

71. Position the cables and install the nuts.

    Torque:

    1: 71 lb.in (8 Nm) 2: 106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

72. Close the cover.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Torque:

    106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

76. Install the front subframe. Refer to: Front Subframe - 2.7L EcoBoost (238kW/324PS) .
77. Install a new gasket.

    Courtesy of FORD MOTOR COMPANY

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

       Torque:

       35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

79. 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.

    Courtesy of FORD MOTOR COMPANY

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

    MaterialEngine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

82. Install the battery tray. Refer to: Battery Tray .
83. Check the selector lever cable adjustment. Refer to: Selector Lever Cable Adjustment - 2.0L EcoBoost (184kW/250PS) - MI4 .
84. Install the air cleaner. Refer to: Air Cleaner .
85. Fill the engine with clean engine oil.

    MaterialEngine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

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