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Engine - Body On

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Special Tool(s) / General Equipment 

GFD459019Courtesy of FORD MOTOR COMPANY
 303-1246 Engine Spreader Bar TKIT-2006UF-FLM TKIT-2006UF-ROW
GFD459020Courtesy of FORD MOTOR COMPANY
 303-1634 Lift Eyes (2) TKIT-2014D-ROW3 TKIT-2014D-FL_ROW
Floor Crane
Trolley Jack
Hose Clamp Remover/Installer
Wooden Block

Materials 

Name Specification
Motorcraft® Multi-Purpose Grease Spray XL-5-A ESB-M1C93-B
Motorcraft® Threadlock 262 TA-26 WSK-M2G351-A6
NOTE: The turbocharger compressor vanes can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, ensure that no debris enters the system. Failure to do so may result in damage to the turbocharger.
    1. Inspect the engine mount-to-frame nut plate for thread damage.
    2. If the nut plate is damaged, remove and discard the engine mount-to-frame nut plate.

    • Clean the engine mount-to-frame mating surfaces of any dirt or foreign material prior to installation.

    GFD458885Courtesy of FORD MOTOR COMPANY
  2. Lubricate the torque converter pilot hub with multi-purpose grease.

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

    GFD459296Courtesy of FORD MOTOR COMPANY
    1. Inspect the torque converter stud and flexplate for paint marks.
    2. Align the torque converter stud and flexplate hole near the paint marks to the 12 o'clock position.
    GFD459297Courtesy of FORD MOTOR COMPANY
  4. With the aid of an assistant, use the floor crane to position the engine in the engine compartment. Use the General Equipment: Floor Crane
    GFD459122Courtesy of FORD MOTOR COMPANY
    • Align the engine to the transmission and install the bolts.

    • Draw the engine and transmission together evenly using the bolts.

      Torque: 35 lb.ft (48 Nm)

    GFD459320Courtesy of FORD MOTOR COMPANY
  6. Remove the floor jack and the block of wood. Use the General Equipment: Trolley Jack. Use the General Equipment: Wooden Block
    GFD459321Courtesy of FORD MOTOR COMPANY
  7. Install the LH engine mount and the new engine mount-to-frame bolts.

    Torque: 129 lb.ft (175 Nm)

    GFD459300Courtesy of FORD MOTOR COMPANY
  8. Using the floor crane, lower the engine assembly into the installed position.

    • Remove the floor crane and chain. Use the General Equipment: Floor Crane

    GFD459322Courtesy of FORD MOTOR COMPANY
  9. Remove Special Service Tool: 303-1634 Lift Eyes (2), 303-1246 Engine Spreader Bar.
    GFD459091Courtesy of FORD MOTOR COMPANY
  10. NOTE: Only use hand tools when installing the engine mount studs or damage to the engine mount can occur.
    NOTE: Apply threadlock to the stud threads prior to installation.

    Install the engine mount studs.

    Material: Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)

    Torque: 22 lb.ft (30 Nm)

    GFD458892Courtesy of FORD MOTOR COMPANY
  11. NOTE: Only use hand tools when installing the engine mount nuts or damage to the engine mount can occur.

    Install the new RH engine mount nuts.

    Torque: 111 lb.ft (150 Nm)

    GFD458893Courtesy of FORD MOTOR COMPANY
  12. NOTE: Only use hand tools when tightening the engine mount through bolts or damage to the engine mount-to-cylinder block bracket can occur.

    Install the new LH engine mount through bolt.

    Torque: 258 lb.ft (350 Nm)

    GFD458891Courtesy of FORD MOTOR COMPANY
  13. NOTE: Only use hand tools when installing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur.

    Tighten the transmission mount-to-crossmember nuts.

    Torque: 85 lb.ft (115 Nm)

    GFD458872Courtesy of FORD MOTOR COMPANY
  14. Install the selector lever cable bracket and the LH bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

    GFD459118Courtesy of FORD MOTOR COMPANY
  15. Install the bracket and the bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

    GFD459117Courtesy of FORD MOTOR COMPANY
  16. NOTE: If equipped.

    Attach the 4x4 vent hose retainer.

    GFD459116Courtesy of FORD MOTOR COMPANY
  17. Install the RH side bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

    GFD459323Courtesy of FORD MOTOR COMPANY
  18. Install the lower bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

    GFD459065Courtesy of FORD MOTOR COMPANY
  19. NOTE: Using the crankshaft pulley bolt, turn the engine clockwise.

    Install the new torque converter nuts.

    Torque: 35 lb.ft (48 Nm)

    GFD459313Courtesy of FORD MOTOR COMPANY
  20. Install the access cover and the retainers.
    GFD459077Courtesy of FORD MOTOR COMPANY
  21. Install new exhaust gaskets.

    • Position the catalytic converters forward into the installed position.

    GFD459308Courtesy of FORD MOTOR COMPANY
  22. Position the flange onto the studs and loosely install new RH catalytic converter nuts.
    GFD459309Courtesy of FORD MOTOR COMPANY
  23. Position the flange onto the studs and loosely install new LH catalytic converter nuts.
    GFD459310Courtesy of FORD MOTOR COMPANY
  24. Evenly tighten the nuts.

    Torque: 30 lb.ft (40 Nm)

    GFD459324Courtesy of FORD MOTOR COMPANY
  25. Evenly tighten the nuts.

    Torque: 30 lb.ft (40 Nm)

    GFD459312Courtesy of FORD MOTOR COMPANY
  26. Position the exhaust Y-pipe dual catalytic converter onto the exhaust intermediate pipe and install bolts.

    • Evenly tighten the bolts.

      Torque: 46 lb.ft (63 Nm)

    GFD458871Courtesy of FORD MOTOR COMPANY
  27. Install the following items:

    1. NOTE: If equipped.

      Front drive shaft. Refer to: Front Driveshaft .

    2. Transmission fluid cooler. Refer to: Transmission Fluid Cooler - 2.7L EcoBoost (238kW/324PS)/3.5L EcoBoost (272kW/370PS)/5.0L 32V Ti-VCT .
    3. Starter motor. Refer to: Starter Motor .

    1. Install the pin-type retainer.
    2. Install the ground wire and bolt.

      Torque: 18 lb.ft (25 Nm)

    GFD458939Courtesy of FORD MOTOR COMPANY
    1. Install the wiring harness retainer nut.

      Torque: 106 lb.in (12 Nm)

    2. Install the pin-type retainer.
    GFD458940Courtesy of FORD MOTOR COMPANY
  30. Position the coolant tubes and attach the retainer to the oil pan.
    GFD458942Courtesy of FORD MOTOR COMPANY
    1. Install the coolant hose and connect the quick release couplings.
    2. Position the coolant hose and connect the quick release coupling.
    3. Position the coolant tube retainer and install the nut.

      Torque: 106 lb.in (12 Nm)

    GFD459325Courtesy of FORD MOTOR COMPANY
  32. Attach the wiring harness retainer located below the generator to the cylinder block.
    GFD459076Courtesy of FORD MOTOR COMPANY
  33. Connect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
    GFD459113Courtesy of FORD MOTOR COMPANY
  34. WARNING: Do not reuse steering column shaft bolts. This may result in fastener failure and steering column shaft detachment or loss of steering control. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

    1. Connect the steering column shaft u-joint to the steering gear.
    2. Install the new steering column shaft bolt.

      Torque: 22 lb.ft (30 Nm)

    GFD458621Courtesy of FORD MOTOR COMPANY
    • Install the wiring terminal and nut.

      Torque: 150 lb.in (17 Nm)

    • Position the protective cover.

    • Connect the generator electrical connector.

    GFD459314Courtesy of FORD MOTOR COMPANY
    • Connect the A/C compressor electrical connectors.

    • Attach the wiring harness retainer.

    GFD459074Courtesy of FORD MOTOR COMPANY
    • Connect the coolant hose quick release coupling.

    • Install the coolant pipe assembly and the clamp. Use the General Equipment: Hose Clamp Remover/Installer

    GFD459112Courtesy of FORD MOTOR COMPANY
  38. Install a new EGR tube gasket.
    GFD459304Courtesy of FORD MOTOR COMPANY
  39. Install the EGR valve assembly and the bolts.
    GFD459111Courtesy of FORD MOTOR COMPANY
  40. Connect the EGR valve electrical connector.
    GFD459110Courtesy of FORD MOTOR COMPANY
    1. Install the EGR tube nuts.

      Torque: 89 lb.in (10 Nm)

    2. Connect the engine wiring harness electrical connectors.
    3. Attach the engine wiring harness and vacuum harness retainer.
    GFD459109Courtesy of FORD MOTOR COMPANY
  42. Install the bracket, the bolt and the nut.

    Torque: 89 lb.in (10 Nm)

    GFD458990Courtesy of FORD MOTOR COMPANY
    1. Connect the high-pressure fuel pump fuel feed tube quick release coupling. Refer to: QUICK RELEASE COUPLING . .
    2. Connect the EVAP tube quick release coupling. Refer to: QUICK RELEASE COUPLING . .
    GFD459108Courtesy of FORD MOTOR COMPANY
  44. Connect the heater core inlet and outlet hoses.
    GFD459326Courtesy of FORD MOTOR COMPANY
  45. Attach the engine wiring harness retainer.
    GFD459106Courtesy of FORD MOTOR COMPANY
    1. Attach the wiring harness retainer.
    2. Connect the engine wiring harness electrical connector.
    3. Connect the PCM electrical connector.
    GFD459105Courtesy of FORD MOTOR COMPANY
  47. Install the wiring ground terminal, the nut, and the wiring harness retainer.

    Torque: 106 lb.in (12 Nm)

    GFD459104Courtesy of FORD MOTOR COMPANY
    1. Connect the PCV tube quick release coupling. Refer to: QUICK RELEASE COUPLING . .
    2. Connect the crankcase pressure sensor electrical connector.
    GFD459103Courtesy of FORD MOTOR COMPANY
    1. Install the EVAP tube assembly and connect the quick release couplings. Refer to: QUICK RELEASE COUPLING . .
    2. NOTE: If equipped.

      Connect the vacuum hose.

    3. Attach the vacuum harness retainer.
    GFD459102Courtesy of FORD MOTOR COMPANY
  50. Install the coolant hoses and clamps. Use the General Equipment: Hose Clamp Remover/Installer
    GFD459101Courtesy of FORD MOTOR COMPANY
  51. Install the TC bypass tube and rotate the retaining ring clockwise 180 degrees.
    GFD458865Courtesy of FORD MOTOR COMPANY
  52. NOTE: Install new O-ring seals and gaskets.

    Connect the A/C tubes and install the nuts.

    Torque: 133 lb.in (15 Nm)

    GFD459100Courtesy of FORD MOTOR COMPANY
  53. NOTE: Install new O-ring seals and gaskets.

    Connect the A/C tube and install the nut.

    Torque: 133 lb.in (15 Nm)

    GFD459099Courtesy of FORD MOTOR COMPANY
  54. Connect the A/C pressure transducer electrical connector.
    GFD459098Courtesy of FORD MOTOR COMPANY
  55. Install the following items:

    1. Right hand (RH) and left hand (LH) CAC intake pipes. Refer to: Charge Air Cooler (CAC) Intake Pipe .
    2. Intake manifold. Refer to: Intake Manifold .
    3. Cooling module. Refer to: Cooling Module .
    4. Degas bottle. Refer to: Degas Bottle .
    5. Cowl panel. Refer to: Cowl Panel .
    6. Hood. Refer to: Hood .

  56. Install a new engine oil filter and fill the engine with clean engine oil. Refer to: Engine Oil Draining and Filling .
  57. NOTE: If equipped.

    Install the skid plate and bolts.

    Torque: 30 lb.ft (40 Nm)

    GFD458869Courtesy of FORD MOTOR COMPANY
  58. NOTE: If equipped.

    Install the underbody shield and fasteners.

    Torque: 30 lb.ft (40 Nm)

    GFD458870Courtesy of FORD MOTOR COMPANY
  59. NOTE: If equipped.

    Install the underbody shield and the bolts.

    Torque: 71 lb.in (8 Nm)

    GFD458868Courtesy of FORD MOTOR COMPANY
  60. Install the RH and LH fender splash shields. Refer to: Fender Splash Shield .
  61. Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
  62. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
  63. Fill and bleed the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
  64. Check the transmission fluid level. Refer to: Transmission Fluid Level Check .
  65. Start and check the exhaust system for leaks.
  66. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
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