LEMON Manuals: Even more car manuals for everyone
Home >> Lincoln >> 2012 >> MKZ Hybrid >> Repair and Diagnosis >> External Pages >> Different car >> Section 1612 (Engine Mechanical - 2.5L (Except Hybrid)) >> Installation >> Engine - Manual Transaxle

Engine - Manual Transaxle

WARNING: This page is about a different car, the 2012 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G08019920
 2, 200# Floor Crane, Fold Away
300-OTC1819E or equivalent
G06293383
 Powertrain Lift
300-OTC1585AE or equivalent
G08019922
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G08019923
 Adjustable Grip Arm, 1735A
014-00001 or equivalent
G07482720
 Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)		 WSS-M2C945-A
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
  1. Using the Floor Crane and Spreader Bar, position the engine and transaxle together. Install the bellhousing-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    2. NOTE: Position a suitable block of wood under the transaxle.
  2. Using the Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift table.
  3. Install the Powertrain Lift and Adjustable Grip Arm onto the engine.
    Fig 1: Identifying Powertrain Lift And Adjustable Grip Arm (014-00001)
    G08019524Courtesy of FORD MOTOR CO.
  4. Position the generator wiring harness and attach the 4 wiring harness retainers (3 shown in illustration) to the valve cover stud bolts.
    Fig 2: Locating Wiring Harness Retainers
    G06262033Courtesy of FORD MOTOR CO.
  5. Connect the generator B+ wiring harness and install the nut.
    • Tighten to 12 Nm (106 lb-in).
      Fig 3: Locating Nut And Generator B+ Wiring Harness
      G06095140Courtesy of FORD MOTOR CO.
  6. Connect the generator electrical connection.
    Fig 4: Locating Generator Electrical Connection
    G06262425Courtesy of FORD MOTOR CO.
  7. Install the generator air duct.
    Fig 5: Locating Locking Tab And Generator Air Duct
    G06095034Courtesy of FORD MOTOR CO.
  8. Install the starter motor isolator.
    Fig 6: Identifying Starter Motor Isolator
    G06262029Courtesy of FORD MOTOR CO.
  9. Install the starter, bolt and stud bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 7: Locating Starter With Bolts And Studs
      G06262028Courtesy of FORD MOTOR CO.
  10. Position the wiring harness and install the ground wire to the starter motor stud bolt and install the nut.
    • Tighten to 18 Nm (159 lb-in).
      Fig 8: Locating Ground Wire And Starter Motor Stud Bolt
      G06262027Courtesy of FORD MOTOR CO.
  11. Connect the starter wires and install the 2 nuts.
    • Tighten the large starter motor B+ wire nut to 12 Nm (106 lb-in).
    • Tighten the small starter motor solenoid wire nut to 5 Nm (44 lb-in).
      Fig 9: Locating Starter Motor Harness Wire Nuts
      G06262093Courtesy of FORD MOTOR CO.
  12. Attach the A/C compressor wiring harness pin-type retainer to the intake manifold.
    Fig 10: Locating A/C Compressor Wiring Harness Pin-Type Retainer Of Intake Manifold
    G06262025Courtesy of FORD MOTOR CO.
  13. Connect the A/C compressor electrical connector.
    Fig 11: Locating A/C Compressor Electrical Connector
    G08019527Courtesy of FORD MOTOR CO.
  14. Raise the engine and transaxle into the vehicle.
  15. Install the 2 transaxle mount bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 12: Locating Transaxle Mount Bolts
      G06262089Courtesy of FORD MOTOR CO.
  16. Install the engine mount bracket, 2 nuts and the bolt.
    • Tighten the nuts to 103 Nm (76 lb-ft).
    • Tighten the bolt to 115 Nm (85 lb-ft).
      Fig 13: Locating Engine Mount Bracket, Bolts And Nuts
      G06262023Courtesy of FORD MOTOR CO.
  17. Install the 2 oil pan-to-bellhousing bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 14: Locating Oil Pan-To-Bellhousing Bolts
      G06262020Courtesy of FORD MOTOR CO.
  18. Install the bellhousing-to-oil pan bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 15: Locating Bellhousing-To-Oil Pan Bolt
      G06262436Courtesy of FORD MOTOR CO.
  19. Attach the lower radiator hose pin-type retainer to the cooling fan shroud.
    Fig 16: Locating Lower Radiator Hose Pin-Type Retainer Of Cooling Fan Shroud
    G06262085Courtesy of FORD MOTOR CO.
  20. If equipped, connect the block heater electrical connector and position back the block heater shield.
    • Attach the 8 block heater wiring harness retainers (1 shown in illustration).
      Fig 17: Locating Block Heater Shield, Electrical Connector And Wiring Harness Retainer
      G06262084Courtesy of FORD MOTOR CO.
  21. Install the lower radiator hose to the thermostat housing.
    Fig 18: Locating Lower Radiator Hose Of Thermostat Housing
    G06262016Courtesy of FORD MOTOR CO.
  22. Attach the Knock Sensor (KS) electrical connector to the intake manifold.
    Fig 19: Locating Knock Sensor (KS) Electrical Connector Of Intake Manifold
    G06262377Courtesy of FORD MOTOR CO.
  23. Install a new O-ring seal and connect the upper A/C tube to the condenser and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 20: Locating Upper A/C Condenser Tube Mounting Nut
      G06262014Courtesy of FORD MOTOR CO.
  24. Attach the coolant vent hose retaining clip to the A/C tube.
    Fig 21: Identifying Coolant Vent Hose Retaining Clip Of A/C Tube
    G06262013Courtesy of FORD MOTOR CO.
  25. Install a new O-ring seal and connect the upper A/C tube and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 22: Locating A/C Tube Nut And O-Ring Seal
      G06262079Courtesy of FORD MOTOR CO.
  26. Install the A/C tube/windshield washer reservoir bracket bolt.
    • Tighten to 7 Nm (62 lb-in).
      Fig 23: Locating A/C Tube/Windshield Washer Reservoir Bracket Bolt
      G06262444Courtesy of FORD MOTOR CO.
  27. Install the ground wire on the engine mount and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 24: Locating Engine Mount Ground Wire And Nut
      G08019513Courtesy of FORD MOTOR CO.
  28. Attach the transaxle control cables to the bracket.
    • Connect the control cables to the control levers.
      Fig 25: Locating Transaxle Control Cable
      G06262074Courtesy of FORD MOTOR CO.
  29. Install the clutch slave cylinder and the 2 bolts.
    • Tighten to 22 Nm (16 lb-ft).
      Fig 26: Locating Clutch Slave Cylinder Bolts
      G06262076Courtesy of FORD MOTOR CO.
  30. Install the 2 clutch tube bracket bolts.
    • Tighten to 22 Nm (16 lb-ft).
      Fig 27: Locating Clutch Tube Bracket Bolts
      G06262075Courtesy of FORD MOTOR CO.
  31. Connect the heater hose in-line connector and connect the upper radiator and heater hoses to the coolant outlet.
    Fig 28: Locating Coolant Outlet Heater Hoses
    G06262006Courtesy of FORD MOTOR CO.
  32. Attach the coolant hoses retainer.
    Fig 29: Identifying Coolant Hose Retainer
    G06262005Courtesy of FORD MOTOR CO.
  33. Connect the fuel supply tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 30: Locating Fuel Supply Tube Quick Connect Coupling
    G06095056Courtesy of FORD MOTOR CO.
  34. Connect the fuel vapor return tube.
    Fig 31: Locating Fuel Vapor Return Tube
    G06095055Courtesy of FORD MOTOR CO.
  35. Insert the brake booster vacuum supply tube into the locking ring on the intake manifold.
    Fig 32: Locating Brake Booster Vacuum Supply Tube Of Intake Manifold
    G06262390Courtesy of FORD MOTOR CO.
  36. Connect the crankcase vent tube to the valve cover.
    Fig 33: Locating Crankcase Vent Tube Of Valve Cover
    G06262001Courtesy of FORD MOTOR CO.
  37. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .
  38. Install the engine oil filter.
    • Lubricate the engine oil filter gasket with clean engine oil and tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
  39. Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position.
    Fig 34: Identifying Powertrain Lift Under Subframe
    G07463314Courtesy of FORD MOTOR CO.
    40. NOTE: LH shown in illustration, RH similar.
  40. Install the front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 35: Locating Front Subframe Nut
      G06261999Courtesy of FORD MOTOR CO.
    41. NOTE: LH shown in illustration, RH similar.
    Fig 36: Locating Subframe Bracket And Bolt
    G06262394Courtesy of FORD MOTOR CO.
  41. Position the subframe brackets and install the bolts finger-tight.
    42. NOTE: LH shown in illustration, RH similar.
  42. Install the subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 37: Locating Subframe Nut
      G06262395Courtesy of FORD MOTOR CO.
    43. NOTE: LH shown in illustration, RH similar.
    Fig 38: Locating Front Subframe Nut
    G06262396Courtesy of FORD MOTOR CO.
  43. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
    44. NOTE: LH shown in illustration, RH similar.
  44. Install the sway bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 39: Locating Sway Bar Link Nut
      G06261995Courtesy of FORD MOTOR CO.
    45. NOTE: LH shown in illustration, RH similar.
  45. Install tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install the cotter pin.
      Fig 40: Locating Tie-Rod Ends Nuts And Cotter Pin
      G06261993Courtesy of FORD MOTOR CO.
  46. Install the Electronic Power Assist Steering (EPAS) system wiring harness ground and the bolt.
    • Tighten to 12 Nm (106 lb-in).
      Fig 41: Locating Electronic Power Assist Steering (EPAS) System Wiring Harness Ground And Bolt
      G06261992Courtesy of FORD MOTOR CO.
  47. Attach the EPAS system wiring harness pin-type retainer to the subframe under the LH fender splash shield.
    Fig 42: Locating EPAS System Wiring Harness Pin-Type Retainer
    G06261991Courtesy of FORD MOTOR CO.
  48. Attach the 2 EPAS system wiring harness pin-type retainers to the subframe.
    Fig 43: Locating EPAS System Wiring Harness Pin-Type Retainer
    G06261990Courtesy of FORD MOTOR CO.
  49. Connect the 2 EPAS system electrical connectors.
    Fig 44: Locating EPAS System Electrical Connectors
    G06262402Courtesy of FORD MOTOR CO.
  50. Install the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  51. Install the LH splash shield and the 6 pin-type retainers (4 shown in illustration).
    Fig 45: Locating LH Splash Shield And Pin-Type Retainers
    G06261988Courtesy of FORD MOTOR CO.
  52. Position the LH fender splash shield and install the 4 screws.
    Fig 46: Locating LH Fender Splash Shield Mounting Screws
    G06261987Courtesy of FORD MOTOR CO.
  53. Install the RH splash shield and the 6 pin-type retainers (4 shown in illustration).
    Fig 47: Locating Pin-Type Retainers And RH Splash Shield
    G06269420Courtesy of FORD MOTOR CO.
  54. Position the RH fender splash shield and install the 4 screws.
    Fig 48: Locating RH Fender Splash Shield Mounting Screws
    G06257214Courtesy of FORD MOTOR CO.
  55. Install the engine roll restrictor bolt.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 49: Locating Engine Roll Restrictor Bolt
      G06261984Courtesy of FORD MOTOR CO.
  56. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips (2 shown in illustration) into the body.
    • From under the vehicle, verify that the seal is correctly installed on the steering gear and the retaining clips are fully engaged into the dash.
      Fig 50: Locating Steering Gear-To-Dash Seal And Clips
      G06261983Courtesy of FORD MOTOR CO.
  57. If equipped, install the 7 screws and the underbody cover.
    Fig 51: Locating Underbody Cover Screws
    G06257240Courtesy of FORD MOTOR CO.
  58. Install the steering column shaft onto the steering gear and install the bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 52: Locating Steering Column Shaft Mounting Bolts
      G06261981Courtesy of FORD MOTOR CO.
  59. Install the steering joint cover and the 2 nuts.
    Fig 53: Locating Steering Joint Cover And Nuts
    G06261980Courtesy of FORD MOTOR CO.
  60. Connect the 2 engine harness electrical connectors.
    Fig 54: Locating Engine Harness Electrical Connector
    G06261978Courtesy of FORD MOTOR CO.
  61. Attach the 2 negative battery cable pin-type retainers to the transaxle mount and battery tray bracket.
    Fig 55: Locating Negative Battery Cable Pin-Type Retainers
    G06261977Courtesy of FORD MOTOR CO.
  62. Install the ground wire-to-body and the bolt.
    • Tighten to 12 Nm (106 lb-in).
      Fig 56: Locating Ground Wire And Bolt
      G06262414Courtesy of FORD MOTOR CO.
  63. Connect the engine wiring harness electrical connector.
    Fig 57: Locating Engine Wiring Harness Electrical Connector
    G06261975Courtesy of FORD MOTOR CO.
  64. Install the 2 battery cables to the positive battery cable and the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 58: Locating Positive Battery Cable With Nuts
      G06262041Courtesy of FORD MOTOR CO.
  65. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  66. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L .
  67. Fill the engine with clean engine oil.
  68. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  69. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
  70. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.
scientia non olet · About LEMON Manuals