Section 9 (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-OTC1819E2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	303-476 (T94P-9472-A) Socket, Exhaust Gas Oxygen Sensor TKIT-1994-LM/M TKIT-1994-F TKIT-1994-FLM/FM
Lifting Bracket
Cable Ties
Hose Clamp Remover/Installer
Mounting Table Set
Retaining Strap
Wooden Block

Materials 

1. Remove the special service tool.

   Material

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

   Courtesy of FORD MOTOR COMPANY

2. Install the engine floor crane.

   Install Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.

   Install the General Equipment: Lifting Bracket

   Courtesy of FORD MOTOR COMPANY

3. Install the engine and tighten the transmission-to-engine 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. WARNING: Make sure that the engine and transmission assembly is on wooden blocks and secured with suitable retaining straps.

   Install the engine on the table.

   Install the General Equipment: Mounting Table Set

   Courtesy of FORD MOTOR COMPANY

6. Remove the engine floor crane.

   Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.

   Remove the General Equipment: Lifting Bracket

   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 4 torque converter nuts.

   Torque

   : 30 lb.ft (40 Nm)

   Courtesy of FORD MOTOR COMPANY

8. NOTE: Make sure that the component terminals are not bent or damaged.

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

   Courtesy of FORD MOTOR COMPANY

9. Install the starter motor insulator.

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10. 1. Install the starter motor and the stud bolts.

       Torque

       : 35 lb.ft (48 Nm)

    2. Position back the wiring and install the starter motor control wire nut.

       Torque

       : 53 lb.in (6 Nm)

    3. Install the starter motor cable nut.

       Torque

       : 106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

11. 1. Install the starter motor bracket and the nuts.

       Torque

       : 159 lb.in (18 Nm)

    2. Attach the engine wire harness.

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12. Connect the wire harness retainers and the coolant hose retainer.

    Courtesy of FORD MOTOR COMPANY

13. Install the ground cable and the bolt.

    Torque

    : 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

14. Position the coolant hose and connect the hose retainer. Connect the EGR valve coolant hose.

    Use the General Equipment: Hose Clamp Remover/Installer

    Courtesy of FORD MOTOR COMPANY

15. NOTE: Only tighten the nut and bolt finger tight at this stage.

    Install the generator, finger tight the bracket bolt and the nut.

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16. NOTE: Only tighten the bolt finger tight at this stage.

    Install and finger tight the bolt.

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17. Tighten the bolts.

    Torque

    : 18 lb.ft (25 Nm)

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18. • Connect the generator electrical connectors and tighten the nut.

      Torque

      : 106 lb.in (12 Nm)

    • Connect the wire retainer.

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19. Position the accessory drive belt tensioner and install the accessory drive belt.

    Courtesy of FORD MOTOR COMPANY

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

    Torque

    : 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

21. Install the exhaust manifold bracket and the bolts.

    Torque

    : 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

22. Install the exhaust manifold studs.

    Torque

    : 150 lb.in (17 Nm)

    Courtesy of FORD MOTOR COMPANY

23. NOTE: Make sure that no components catch.

    Lower the vehicle.

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24. Clean the transmission support insulator. Install the transmission support insulator and the bolt.

    Material

    : Motorcraft® Threadlock and Sealer / TA-25-B

    Torque

    : 109 lb.ft (148 Nm)

    Courtesy of FORD MOTOR COMPANY

25. Torque the studs.

    Torque

    : 106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

26. NOTE: Make sure that the component is installed to the position noted before removal.
    1. Install the engine mount and the nuts.

       Torque

       : 59 lb.ft (80 Nm)

    2. Install the bolts.

       Torque

       : 66 lb.ft (90 Nm)

    Courtesy of FORD MOTOR COMPANY

27. Remove the following items:
    1. Remove the following items.

       Use the General Equipment: Mounting Table Set

       Use the General Equipment: Wooden Block

       Use the General Equipment: Retaining Strap

28. Install the bolt.

    Torque

    : 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

29. Install the bolts.

    Torque

    : 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

30. Install a new oil filter assembly gasket.

    Courtesy of FORD MOTOR COMPANY

31. Install the oil filter assembly and the bolts.

    Torque

    : 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

32. Connect the oil pressure switch.

    Courtesy of FORD MOTOR COMPANY

33. Connect the oil cooler hoses. Remove the hose clamps.

    Use the General Equipment: Hose Clamp Remover/Installer

    Courtesy of FORD MOTOR COMPANY

34. NOTE: If the transmission has been replaced or overhauled, the halfshaft seals do not need to be replaced.

    Replace the RH halfshaft seal. Refer to: Halfshaft Seal RH .

35. Clean and inspect the RH inner halfshaft splines and mating surfaces.

    Courtesy of FORD MOTOR COMPANY

36. Rotate the steering wheel fully to the LH side.

    Courtesy of FORD MOTOR COMPANY

37. NOTE: Make sure that the strut is not moved more than necessary to prevent damage to top mount.
    NOTE: The inner constant velocity (CV) joint must not be bent more than 18°.
    NOTE: The outer constant velocity (CV) joint must not be bent more than 45°.

    Install the seal protector in the RH seal. Install the RH halfshaft in the transmission and remove the seal protector before the halfshaft is fully installed.

    Courtesy of FORD MOTOR COMPANY

38. Push the RH halfshaft into the differential until the bearing lines up with the bearing bracket.

    Courtesy of FORD MOTOR COMPANY

39. Install the new halfshaft bearing retaining strap and new nuts.

    Torque

    :Stage 1: 44 lb.in (5 Nm)

    Stage 2: 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

40. NOTE: Suspension fasteners are critical parts that affect the performance of vital components and systems. Failure of these fasteners may result in major service expense. Use the same or equivalent parts if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Tighten fasteners as specified.
    NOTE: Make sure a new nut and bolt is installed.

    Insert the RH lower ball joint into the wheel knuckle and install a new bolt and nut.

    Courtesy of FORD MOTOR COMPANY

41. Position back the RH flexible brake hose back and install a new bolt.

    Torque

    : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

42. NOTE: Make sure a new nut is installed.

    Attach the RH tie rod and install the new nut.

    Torque

    : 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

43. NOTE: If the transmission has been replaced or overhauled, the halfshaft seals do not need to be replaced.

    Replace the LH halfshaft seal. Refer to: Halfshaft Seal LH .

44. Clean and inspect the inner LH halfshaft splines and mating surfaces.

    Courtesy of FORD MOTOR COMPANY

45. NOTE: Make sure that a new component is installed.

    Install a new LH halfshaft retaining circlip.

    Courtesy of FORD MOTOR COMPANY

46. Install the seal protector in the LH halfshaft seal.

    Courtesy of FORD MOTOR COMPANY

47. Rotate the steering wheel fully to the RH side.

    Courtesy of FORD MOTOR COMPANY

48. NOTE: Make sure that the strut is not moved more than necessary to prevent damage to top mount.
    NOTE: The inner constant velocity (CV) joint must not be bent more than 18°.
    NOTE: The outer constant velocity (CV) joint must not be bent more than 45°.
    NOTE: Do not fully install shaft at this time.

    Remove the seal protector before the halfshaft is fully installed.

    Courtesy of FORD MOTOR COMPANY

49. NOTE: When seated correctly, the halfshaft circlip can be felt as it snaps into the differential side gear groove.

    Push the LH halfshaft into the differential.

    Courtesy of FORD MOTOR COMPANY

50. NOTE: Suspension fasteners are critical parts that affect the performance of vital components and systems. Failure of these fasteners may result in major service expense. Use the same or equivalent parts if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Tighten fasteners as specified.
    NOTE: Make sure a new nut and bolt is installed.

    Insert the LH lower ball joint into the wheel knuckle and install a new nut and bolt.

    Torque

    : 61 lb.ft (83 Nm)

    Courtesy of FORD MOTOR COMPANY

51. Position back the LH flexible brake hose and install a new bolt.

    Torque

    : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

52. Install the roll restrictor bracket and the bolts.

    Torque

    : 59 lb.ft (80 Nm)

    Courtesy of FORD MOTOR COMPANY

53. NOTE: Make sure that new bolts are installed.

    Position the roll restrictor and install the bolts.

    Torque

    : 92 lb.ft (125 Nm)

    Courtesy of FORD MOTOR COMPANY

54. Connect the PCM electrical connectors and retainers.

    Courtesy of FORD MOTOR COMPANY

    Vehicles without powertrain control module (PCM) security shield 

55. Install the PCM housing cover and the retainers.

    Courtesy of FORD MOTOR COMPANY

    Vehicles with powertrain control module (PCM) security shield 

56. Install the PCM housing cover and tighten the shear bolt until the head is sheared off.

    Courtesy of FORD MOTOR COMPANY

    All vehicles 

57. Install the fender splash shield. Refer to: Fender Splash Shield .
58. NOTE: LH side shown in illustration, RH similar.

    Install the side frame supports and bolts.

    Torque

    : 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

59. NOTE: LH side shown in illustration, RH similar.

    Install the front frame support bolts.

    Torque

    : 124 lb.in (14 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Torque

    : 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Torque

    : 1: 80 lb.in (9 Nm)

    2: 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

62. Connect the A/C compressor electrical connector.

    Courtesy of FORD MOTOR COMPANY

63. Install the A/C compressor belt. Refer to: Air Conditioning (A/C) Compressor Belt .
64. • Install the degas bottle.
    • Connect the lower and upper coolant hoses. Connect the hose retainer.

      Use the General Equipment: Hose Clamp Remover/Installer

    Courtesy of FORD MOTOR COMPANY

65. • Connect and clamp the lower radiator hose.

      Use the General Equipment: Hose Clamp Remover/Installer

    • Connect and clamp the coolant hose.

      Use the General Equipment: Hose Clamp Remover/Installer

    Courtesy of FORD MOTOR COMPANY

66. If equipped. Connect the block heater electrical connector.

    Courtesy of FORD MOTOR COMPANY

67. Position the radiator coolant hose and connect the retainer.

    Courtesy of FORD MOTOR COMPANY

68. Connect the engine vent hose and the coolant hoses.

    Use the General Equipment: Hose Clamp Remover/Installer

    Courtesy of FORD MOTOR COMPANY

69. Connect the fuel vapor tube.

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

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71. Connect the brake booster tube to the intake manifold.

    Courtesy of FORD MOTOR COMPANY

72. Position back the transmission fluid cooler. Install the stud, bolt and nuts. Connect the coolant hose.

    Torque

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

    2.: 18 lb.ft (25 Nm)

    3.: 80 lb.in (9 Nm)

    Courtesy of FORD MOTOR COMPANY

73. Install the seal and the backing ring. Position back the transmission cooling tube and install the bolt.

    Material

    : Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

    Torque

    : 80 lb.in (9 Nm)

    Courtesy of FORD MOTOR COMPANY

74. Install the seal and the backing ring. Position back the transmission cooling tube and install the bolt.

    Material

    : Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)

    Torque

    : 80 lb.in (9 Nm)

    Courtesy of FORD MOTOR COMPANY

75. Position back the transmission shift cable. Install the bolts and connect the transmission shift cable.

    Torque

    : 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

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

      Torque

      : 35 lb.ft (48 Nm)

    • Connect the electrical connector and connect the wiring retainers.

    Courtesy of FORD MOTOR COMPANY

77. Connect the wiring harness retainers to the frame rail and install the bolts.

    Torque

    : 1: 159 lb.in (18 Nm)

    2: 106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

78. Install a new exhaust manifold gasket.

    Courtesy of FORD MOTOR COMPANY

79. Position the exhaust manifold and install the nuts. Tighten the nuts in sequence shown in illustration.

    Torque

    :Stage 1: 177 lb.in (20 Nm)

    Stage 2: 41 lb.ft (55 Nm)

    Courtesy of FORD MOTOR COMPANY

80. Install the bolts for the exhaust manifold bracket.

    Torque

    : 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

81. Position the exhaust support bracket and install the bolts.

    Torque

    : 18 lb.ft (24 Nm)

    Courtesy of FORD MOTOR COMPANY

82. Position the exhaust manifold heat shield and install the bolts.

    Torque

    : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

83. Using the special tool, install the HO2S.

    Use Special Service Tool: 303-476 (T94P-9472-A) Socket, Exhaust Gas Oxygen Sensor.

    Torque

    : 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

84. 1. Using a new gasket, position back the exhaust system.
    2. Install the nuts.

       Torque

       : 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

85. NOTE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.

    Remove the exhaust flexible pipe support.

    Remove the General Equipment: Cable Ties

    Courtesy of FORD MOTOR COMPANY

86. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.

    Material

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

    Courtesy of FORD MOTOR COMPANY

87. Connect the HO2S electrical connector and catalyst monitor sensor electrical connector. Connect the wire retainers.

    Courtesy of FORD MOTOR COMPANY

88. Connect the main wiring harness to the fuse box and the battery feed cable.

    Torque

    : 106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

89. Install the engine compartment fuse box cover.

    Courtesy of FORD MOTOR COMPANY

90. Install the battery tray. Refer to: Battery Tray - 2.5L Duratec (125kW/170PS) .
91. Install the cowl panel. Refer to: Cowl Panel .
92. Fill the engine with clean engine oil.

    Material

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

93. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
94. Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
95. Check the transmission fluid level. Refer to: Transmission Fluid Level Check .
96. If the engine was disassembled, preform the Misfire Monitor Neutral Profile Correction procedure.