Engine - 2.0L DURATEC-He (110KW/150PS) - Mi4: Installation: Engine

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

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	307-566 Retainer, 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 

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 bell housing bolt.

   Torque: 35 lb.ft (48 Nm)

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6. Install the transmission-to-engine stud bolts.

   Torque: 35 lb.ft (48 Nm)

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7. Attach the wiring harness retainers and install the nut.

   Torque: 89 lb.in (10 Nm)

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8. Connect the transmission wiring harness electrical connectors and the retainers.

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9. Position the auxiliary coolant pump hose and install clamp.

   Use the General Equipment: Hose Clamp Remover/Installer

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10. • Position the wiring harness and attach the generator and A/C wiring harness retainer.
    • Connect the generator electrical connector.
    • Install the B+ cable and the nut.

      Torque: 133 lb.in (15 Nm)

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11. • Connect the A/C compressor and the auxiliary coolant pump electrical connectors and attach the wiring harness retainers.
    • Install the generator B+ cable nut cover.

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12. Install adjustable mounting arm.

    Use the General Equipment: Adjustable Mounting Arm

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13. Remove the floor crane and engine lift equipment.

    Use the General Equipment: Floor Crane

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14. NOTE: Only rotate the crankshaft clockwise.

    Install new torque converter nuts.

    Use the General Equipment: Magnetic Socket

    Torque: 35 lb.ft (48 Nm)

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15. Install the starter motor isolator.

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16. Install the starter motor and the stud bolts.

    Torque: 26 lb.ft (35 Nm)

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17. 1. Position the starter motor wiring housing and install the motor control wire nut.

       Torque: 53 lb.in (6 Nm)

    2. Install the battery positive cable nut.

       Torque: 106 lb.in (12 Nm)

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18. Install the battery terminal cap.

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19. • Install the starter motor bracket and then install the starter motor bracket nuts.

      Torque: 89 lb.in (10 Nm)

    • Attach the wiring harness retainers and position the wiring harness.

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20. • Install a new catalytic converter manifold gasket.

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21. NOTE: Make sure that no components catch.

    Raise the powertrain into the vehicle.

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22. Install the transmission support insulator.

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23. Raise the transmission until the transmission support insulator bracket reaches the transmission support insulator.

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24. Install the transmission support insulator bolt.

    Torque: 109 lb.ft (148 Nm)

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25. Tighten the engine mount studs.

    Torque: 97 lb.in (11 Nm)

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

       Torque: 85 lb.ft (115 Nm)

    2. NOTE: Make sure that the component is installed to the position noted before removal.
       NOTE: Only tighten the bolts finger tight at this stage.

       Install the engine mount bolts finger tight.

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27. Tighten the engine mount bolts.

    Torque: 66 lb.ft (90 Nm)

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28. • 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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29. • Install a new the oil pressure switch.

      Torque: 97 lb.in (11 Nm)

    • Connect the oil pressure switch electrical connector.

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30. NOTE: Make sure that new nuts are installed.

    Attach the catalytic converter.

    Torque: Stage 1: 41 lb.ft (55 Nm)

    Stage 2: 41 lb.ft (55 Nm)

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31. Remove the bolts and the catalytic converter heat shield.

    Torque: 89 lb.in (10 Nm)

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32. Connect the catalyst monitor sensor electrical connector.

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33. Connect the HO2S (heated oxygen sensor) electrical connector.

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34. Connect the EVAP line. Refer to: Quick Release Coupling .

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35. Connect the high pressure fuel line. Refer to: Quick Release Coupling .

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36. • Attach the degas line to the intake manifold and install the retainers
    • Connect the vacuum line to the intake manifold. Refer to: Quick Release Coupling .

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37. Position the transmission shift cable, install the bolts and connect the transmission shift cable.

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38. 1. Attach the coolant hoses to the coolant outlet connector.

       Use the General Equipment: Hose Clamp Remover/Installer

    2. Attach the coolant hoses to the coolant outlet connector. Refer to: Quick Release Coupling .
    • Attach the retainer to the coolant hose.

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39. Attach the upper radiator hose retainer to the transmission bracket.

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40. Attach the retainers to the bracket and connect the electrical connector.

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41. Position the ground wire and attach the wire retainer and install the bolt.

    Torque: 106 lb.in (12 Nm)

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42. Position the battery feed cable to the positive battery cable and install the nut.

    Torque: 44 lb.in (5 Nm)

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43. • Install the battery tray bracket and the nuts.

      Torque: 35 lb.ft (48 Nm)

    • Position the wiring harness, connect the electrical connector and the wiring retainers.

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44. Install the bell housing bolts.

    Torque: 35 lb.ft (48 Nm)

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45. Install the bell housing bolts.

    Torque: 35 lb.ft (48 Nm)

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

    Install a new engine oil filter.

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

    Stage 2: 180°

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47. Attach the radiator lower hose.

    Use the General Equipment: Hose Clamp Remover/Installer

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48. • Position the A/C compressor inlet line and install the nut.

      Torque: 18 lb.ft (25 Nm)

    • Position the A/C compressor outlet line and install the nut.

      Torque: 18 lb.ft (25 Nm)

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49. 1. NOTE: Make sure that a new component is installed.

       Apply a thin coating. Install the gasket and position the muffler and tailpipe.

       Material: Multi-Purpose Grease (SA-M1C9107-A)

    2. NOTE: Make sure that new nuts are installed.

       Install the nuts.

       Torque: 35 lb.ft (48 Nm)

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50. Install catalytic converter bracket and the nuts.

    Torque: 1: 18 lb.ft (25 Nm)

    2: 35 lb.ft (48 Nm)

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51. 1. Install the engine roll restrictor and bracket and the bolts.

       Torque: 129 lb.ft (175 Nm)

    2. Install the engine roll restrictor bolt.

       Torque: 76 lb.ft (103 Nm)

    3. Install the engine roll restrictor bolt.

       Torque: 76 lb.ft (103 Nm)

    4. Install the rear roll restrictor bracket bolt.

       Torque: 129 lb.ft (175 Nm)

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52. Install the RH front halfshaft. Refer to: Front Halfshaft RH .
53. Install the LH front halfshaft. Refer to: Front Halfshaft LH .
54. Attach the hoses.

    Use the General Equipment: Hose Clamp Remover/Installer

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55. Connect the PCM electrical connector.

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56. Install the PCM cover.

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57. Connect the electrical connector.

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58. Install the following items:
    1. Install the cooling fan motor and shroud. Refer to: Cooling Fan Motor and Shroud .
    2. Install the A/C compressor belt. Refer to: Air Conditioning (A/C) Compressor Belt .
    3. Install the LH fender splash shield. Refer to: Fender Splash Shield .
    4. Install the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
    5. Install the battery tray. Refer to: Battery Tray - 2.0L Duratec-HE (110kW/150PS) - MI4 .
    6. Install the degas bottle. Refer to: Degas Bottle .
    7. Install the cowl panel. Refer to: Cowl Panel .

59. Fill and bleed the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
60. Charge the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging .
61. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
62. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
63. Road test the vehicle.