Section 2 (Engine - 2.3L ECOBOOST (199KW/270PS)): Installation: Engine

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

Special Tool(s) / General Equipment 

7-Speed Manual Transmission - MT88/10-Speed Automatic Transmission - 10R60 

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

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2. With the aid of an assistant and using the floor crane, install the engine. Use the General Equipment: Floor Crane

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3. 1. Make sure the engine mount tab is aligned with the slot on the LH engine mount bracket/oil filter adapter.
   2. Make sure the engine mount tab is aligned with the slot on the RH engine mount bracket.

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4. NOTE: Automatic transmission shown, manual transmission similar.

   Install the RH bellhousing bolts.

   Torque: 35 lb.ft (48 Nm)

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5. Remove the engine lift equipment. Use the General Equipment: Floor Crane

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6. NOTE: Automatic transmission shown, manual transmission similar.

   Remove floor jack and a block of wood. Use the General Equipment: Trolley Jack. Use the General Equipment: Wooden Block

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   7-Speed Manual Transmission - MT88 

7. Install the lower bellhousing stud bolts.

   Torque: 35 lb.ft (48 Nm)

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8. Install the LH transmission bolts.

   Torque: 35 lb.ft (48 Nm)

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9. Install the upper bellhousing stud bolts.

   Torque: 35 lb.ft (48 Nm)

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10. Position coolant bracket on the transmission stud bolt and install the nut.

    Torque: 159 lb.in (18 Nm)

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11. Install the coolant tube bolt under EGR cooler.

    Torque: 97 lb.in (11 Nm)

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12. Attach the catalyst monitor sensor wiring harness retainer.

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13. • Attach the fuel tube and vapor line retainer to the RH bracket.
    • Detach the transmission and transfer case vent tubes retainer from the LH bracket.

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    10-Speed Automatic Transmission - 10R60 

14. Install the lower bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

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15. Install the LH transmission bolts behind transmission fluid cooler.

    Torque: 35 lb.ft (48 Nm)

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16. Install the upper bellhousing stud bolts.

    Torque: 35 lb.ft (48 Nm)

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17. Position coolant brackets on the transmission stud bolts and install the nuts.

    Torque: 159 lb.in (18 Nm)

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18. Install the coolant tube bolt under EGR cooler.

    Torque: 97 lb.in (11 Nm)

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19. • Attach the fuel tube and vapor line retainer to the RH bracket.
    • Attach the transmission and transfer case vent tubes retainer to the LH bracket.

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20. NOTE: Only rotate the crankshaft in a clockwise direction.
    NOTE: Use a magnetic socket to hand start the torque converter nuts.

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

    Torque: 35 lb.ft (48 Nm)

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21. Connect the coolant hoses to the transmission fluid cooler. Use the General Equipment: Hose Clamp Remover/Installer

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22. Position the wiring harness and connect transmission electrical connector and the wiring harness retainers.

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    7-Speed Manual Transmission - MT88/10-Speed Automatic Transmission - 10R60 

23. NOTE: Automatic transmission shown, manual transmission similar.

    Remove and discard the transmission mount nuts.

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24. NOTE: Automatic transmission shown, manual transmission similar.

    Install the new transmission mount nuts and tighten.

    Torque: 85 lb.ft (115 Nm)

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25. Install a new RH engine mount stud.

    Torque: 22 lb.ft (30 Nm)

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26. Install a new RH mount nut and tighten.

    Torque: Stage 1: 22 lb.ft (30 Nm) Stage 2: 120 deg.

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27. Install the LH engine mount stud.

    Torque: 22 lb.ft (30 Nm)

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28. Install a new LH engine mount nut and tighten.

    Torque: Stage 1: 22 lb.ft (30 Nm) Stage 2: 120 deg.

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    NOTE: Steps 28 thru 31 is for vehicles with sway bar disconnect. Step 32 is for vehicles without sway bar disconnect.
29. Remove and discard the nuts and position the sway bar disconnect forward.

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30. Position the sway bar disconnect and install the new nuts and bolts.

    Torque: 66 lb.ft (90 Nm)

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31. Connect the sway bar disconnect wiring harness electrical connectors and the retainers.

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32. Install the sway bar disconnect skid plate and the bolts.

    Torque: 22 lb.ft (30 Nm)

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33. Position the sway bar and install the new nuts and bolts.

    Torque: 66 lb.ft (90 Nm)

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34. Install the catalytic converter. Refer to: Catalytic Converter - 10-Speed Automatic Transmission - 10R60 . Refer to: Catalytic Converter - 7-Speed Manual Transmission - MT88 .
35. Install the RH splash shield bracket and the nut.

    Torque: 97 lb.in (11 Nm)

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36. 1. Position the generator and install the stud bolts.

       Torque: 18 lb.ft (25 Nm)

    2. Install the generator stud.

       Torque: 89 lb.in (10 Nm)

    3. Install the generator nut.

       Torque: 18 lb.ft (25 Nm)

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37. Connect the lower radiator hose to the thermostat housing and the retainer to the generator stud bolt. Use the General Equipment: Hose Clamp Remover/Installer

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38. Attach wiring harness retainer to LH side of the cylinder block.

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39. NOTE: Automatic transmission shown, manual transmission similar.

    Install the starter motor insulator.

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40. Install the starter motor. Refer to: Starter Motor .
41. If equipped, connect the block heater wiring harness retainer to the RH side of engine block.

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42. NOTE: Automatic transmission shown, manual transmission similar.
    • If equipped, connect the block heater wiring harness retainers to transmission.
    • If equipped, connect the block heater wiring harness retainer to the RH side transmission stud bolt.

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43. If equipped, connect the block heater wiring harness electrical connector and retainers.

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44. Position and install the steering shaft and the new bolt.

    Torque: 22 lb.ft (30 Nm)

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45. Install the LH splash shield bracket and the nut.

    Torque: 97 lb.in (11 Nm)

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46. Position the wiring harness on the generator stud bolt and install the nut.

    Torque: 97 lb.in (11 Nm)

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47. Attach the wiring harness retainers to the front of the oil pan.

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48. Install the ground wire and the stud bolt.

    Torque: 177 lb.in (20 Nm)

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49. 1. Lubricate the new engine oil filter sealing surface with clean engine oil.
    2. Install the new engine oil filter.

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

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50. Position the A/C compressor and install the bolt and stud bolts.

    Torque: 18 lb.ft (25 Nm)

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51. Position the A/C compressor bracket and install the nut.

    Torque: 89 lb.in (10 Nm)

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52. • Attach the wiring harness retainers to engine ground bolt and to the A/C compressor bracket and A/C line.
    • Connect the A/C pressure sensor electrical connector.
    • Connect the A/C wiring harness electrical connectors.

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53. Connect the coolant hoses to engine coolant tubes. Use the General Equipment: Hose Clamp Remover/Installer

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54. • Connect the coolant hose to the rear coolant tube. Use the General Equipment: Hose Clamp Remover/Installer
    • Connect the degas bottle to from coolant tube. Use the General Equipment: Hose Clamp Remover/Installer
    • Connect the heater hose to the coolant tube. Use the General Equipment: Hose Clamp Remover/Installer

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55. Connect the upper radiator to coolant tube. Use the General Equipment: Hose Clamp Remover/Installer

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56. Install the CAC pipe and diverter valve assembly.

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57. 1. Install the CAC pipe support bracket and the bolt.

       Torque: 18 lb.ft (25 Nm)

    2. Install the CAC pipe support bracket bolt.

       Torque: 27 lb.in (3 Nm)

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58. Tighten the turbocharger tube clamps.

    Torque: 44 lb.in (5 Nm)

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59. Connect the diverter valve electrical connector and the wiring harness retainers.

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60. Position the RH CAC pipe and install the clip.

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61. Install the LH CAC pipe assembly and install the clip.

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62. NOTE: When installing the high-pressure fuel pump noise insulator, spreading the openings will reduce the risk of damage.

    Install the high-pressure fuel pump noise insulator.

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63. • Install the high-pressure fuel pump crash bracket and the bolts finger tight.
    • Tighten the bolts in the sequence shown.

      Torque: 97 lb.in (11 Nm)

    Fig 1: High-Pressure Fuel Pump Crash Bracket Bolts Tightening Sequence

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64. Install the lower foam high-pressure fuel pump cover and the retainer.

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65. • Install the lower plastic high-pressure fuel pump cover and the retainer.
    • Position the fuel tube and connect the spring lock coupling. Refer to: Spring Lock Couplings .

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66. Install the upper plastic and foam high-pressure fuel pump cover and attach the tabs.

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67. • Position the wiring harness and attach the retainers.
    • Attach the wiring harness retainer to the rear engine lift eye.

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68. Connect the PCM electrical connector and attach the wiring harness retainers.

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69. Connect the engine wiring harness electrical connector and the retainer.

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70. Install brake vacuum tube, retainer and connect the wiring harness electrical connector.

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71. • Position the brake vacuum tube assembly and connect the quick release coupling and the retainer to the intake manifold. Refer to: Quick Release Coupling .
    • Connect the quick release coupling to the brake booster hose. Refer to: Quick Release Coupling .

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72. Position the ground cable and install the bolt and retainer.

    Torque: 106 lb.in (12 Nm)

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73. • Install the new crankcase vent tube.
    • If the replacement crankcase vent tube part comes with no crankcase pressure sensor, reprogram the PCM. Refer to: Module Programming .
    • If the replacement crankcase vent tube came without a crankcase pressure sensor, tape the wiring harness electrical connector back to the wiring harness.
    • If the replacement crankcase vent tube comes with a crankcase pressure sensor, connect the wiring harness electrical connector.

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74. Remove the following items:
    1. Install the engine rear undershield. Refer to: Engine Rear Undershield .
    2. Install the engine front undershield. Refer to: Engine Front Undershield .
    3. Install the LH and RH fender splash shields. Refer to: Fender Splash Shield .
    4. Install the EVAP canister purge valve. Refer to: Evaporative Emission Canister Purge Valve .
    5. Install the accessory drive belt. Refer to: Accessory Drive Belt .
    6. Install the air cleaner. Refer to: Air Cleaner .
    7. Install the hood. Refer to: Hood .
    8. Install the battery tray. Refer to: Battery Tray .

75. Remove the holding device.

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

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77. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
78. Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
79. Start and check the exhaust system for leaks.
80. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
81. Road test the vehicle.