Engine - Body Off

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

Special Tool(s) / General Equipment 

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

Materials 

1. 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.

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2. 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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3. With the aid of an assistant, use the floor crane to position the engine assembly in the chassis. Use the General Equipment: Floor Crane

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4. • 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)

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5. Install the bellhousing bolts.

   Torque: 35 lb.ft (48 Nm)

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

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7. Install the LH engine mount and the new engine mount-to-frame bolts.

   Torque: 129 lb.ft (175 Nm)

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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

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9. Remove Special Service Tool: 303-1634 Lift Eyes (2)., 303-1246 Engine Spreader Bar.

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10. 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)

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11. Follow directions to release the quick release coupling type 10. Connect the high-pressure fuel pump fuel feed tube quick release coupling. Refer to: Quick Release Coupling .

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12. Attach the engine wiring harness retainers.

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13. Install the bracket, the bolt and the nut.

    Torque: 89 lb.in (10 Nm)

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    NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris if found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
14. Install the gaskets.

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15. Tighten the bolts in 2 stages.

    Torque:Stage 1: Bolts 1 through 8 in sequence:: 44 lb.in (5 Nm); Stage 2: Bolts 8 through 1 in reverse sequence:: 89 lb.in (10 Nm)

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16. Attach the wiring harness retainers to the rear of the intake manifold.

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17. Position the crankcase vent tube and connect the crankcase pressure sensor electrical connector.

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18. 1. Install the EVAP canister purge valve up onto the tab.
    2. Follow directions to connect the quick release coupling type 19. Connect the EVAP canister purge valve vapor tube. Refer to: Quick Release Coupling .
    3. Connect the EVAP canister purge valve electrical connector.

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19. Install a new EGR tube gasket.

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20. Install a new gasket.

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21. Install the EGR valve assembly and the bolts.

    Torque: 89 lb.in (10 Nm)

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22. 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 retainer.

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23. Install the EGR tube bolts.

    Torque: 89 lb.in (10 Nm)

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24. 1. Install the ignition coil-on-plug and the stud bolt.

       Torque: 53 lb.in (6 Nm)

    2. Attach the wiring harness retainer.
    3. Connect the ignition coil-on-plug electrical connector.

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25. 1. Install the differential pressure feedback EGR sensor and the clamps.
    2. Install the nut.

       Torque: 53 lb.in (6 Nm)

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26. Attach the wiring harness connector retainers.

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27. 1. Follow directions to connect the quick release coupling type 19. Connect the fuel vapor tube. Refer to: Quick Release Coupling .
    2. Follow directions to connect the quick release coupling type 1. Connect the tube. Refer to: Quick Release Coupling .
    3. Follow directions to connect the quick release coupling type 3. Connect the crankcase vent tube. Refer to: Quick Release Coupling .
    • Attach the tube retainer.

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28. 1. Connect the throttle body electrical connector.
    2. Connect the differential pressure feedback EGR sensor electrical connector.
    3. Connect the MAP sensor electrical connector.
    4. Attach the wiring harness retainers.

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29. Follow directions to connect the quick release coupling type 3. Install the crankcase vent tube. Refer to: Quick Release Coupling .

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30. Install new exhaust gaskets.
    • Position the catalytic converters forward into the installed position.

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31. Position the flange onto the studs and loosely install new RH catalytic converter nuts.

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32. Position the flange onto the studs and loosely install new LH catalytic converter nuts.

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33. Evenly tighten the nuts.

    Torque: 30 lb.ft (40 Nm)

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34. Evenly tighten the nuts.

    Torque: 30 lb.ft (40 Nm)

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35. NOTE: Using the crankshaft pulley bolt, turn the engine clockwise.

    Install the new torque converter nuts.

    Torque: 30 lb.ft (40 Nm)

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36. Install the access cover and the retainers.

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37. Attach the wiring harness retainer located below the generator to the cylinder block.

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38. • Install the wiring terminal and nut.

      Torque: 150 lb.in (17 Nm)

    • Position the protective cover.
    • Connect the generator electrical connector.

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39. Connect the A/C compressor electrical connectors.

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40. 1. Install the wiring harness retainer nut.

       Torque: 106 lb.in (12 Nm)

    2. Install the pin-type retainer.

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41. 1. Install the coolant tube assembly and the nut.

       Torque: 106 lb.in (12 Nm)

    2. Follow directions to connect the quick release coupling type 5. Connect the EGR coolant hose. Refer to: Quick Release Coupling .
    3. Remove the nut and position the coolant tube assembly aside.

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42. 1. Install the coolant hose assembly and clamps. Use the General Equipment: Hose Clamp Remover/Installer
    2. Attach the coolant hose retaining clip,

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43. 1. Install the radiator coolant hose and clamp. Use the General Equipment: Hose Clamp Remover/Installer
    2. Install the radiator coolant hose assembly and clamp. Use the General Equipment: Hose Clamp Remover/Installer
    3. Connect the coolant hose quick connector.
    4. Connect the heater hose quick connector.
    5. Install the coolant hose and clamp. Use the General Equipment: Hose Clamp Remover/Installer

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44. 1. Position the CAC inlet pipe and attach the pipe to the grommet.
    2. Tighten the CAC inlet pipe clamps.

       Torque: 48 lb.in (5.4 Nm)

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45. 1. Position the CAC inlet pipe and attach the pipe to the grommet.
    2. Tighten the CAC inlet pipe clamps.

       Torque: 48 lb.in (5.4 Nm)

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46. Install the CAC outlet pipe and clamps.

    Torque: 48 lb.in (5.4 Nm)

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47. Install the TC bypass tube and rotate the retaining ring clockwise 180 degrees.

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48. 1. Position the LH air cleaner outlet pipe onto the TC and into the grommet
    2. Tighten the clamp.

       Torque: 48 lb.in (5.4 Nm)

    3. Follow directions to connect the quick release coupling type 3. Connect the crankcase vent tube. Refer to: Quick Release Coupling .
    4. Follow directions to connect the quick release coupling type 26. Connect the vapor tube. Refer to: Quick Release Coupling .
    5. Follow directions to connect the quick release coupling type 8. Connect the vapor tube. Refer to: Quick Release Coupling .
    6. Connect the TC bypass tube.

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49. 1. Position the RH air cleaner outlet pipe and attach the pipe to the grommet.
    2. Tighten the clamp.

       Torque: 48 lb.in (5.4 Nm)

    3. Position the coolant hose into the clip.

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50. Install the body. Refer to: Body .
51. Install the lower bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

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52. Install the lower bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

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53. 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)

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54. 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)

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55. 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)

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56. • Position the exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe and install the bolts.
    • Tighten the inner exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt.

      Torque: 30 lb.ft (40 Nm)

    • Tighten the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt.

      Torque: 30 lb.ft (40 Nm)

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57. If equipped, install the front driveshaft. Refer to: Front Driveshaft .
58. Position the coolant tubes and install the nut.

    Torque: 119 lb.in (13.5 Nm)

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59. Install the following items:
    1. If equipped, secondary generator. Refer to: Generator - 2.7L EcoBoost (238kW/324PS) .
    2. Starter motor. Refer to: Starter Motor .

60. Install a new engine oil filter and fill the engine with clean engine oil. Refer to: Engine Oil Draining and Filling .
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. Start and check the exhaust system for leaks.
65. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.