Section 1206 (Engine - 2.3L ECOBOOST (201KW/273PS)): 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-OTC 1585AE Powertrain Lift
Courtesy of FORD MOTOR COMPANY	300-OTC 1819E2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	307-566 Retainer, Torque Converter TKIT-2006C-FFMFLM TKIT-2006C-LM TKIT-2006C-ROW
Courtesy of FORD MOTOR COMPANY	502-002 (T94P-2100-AH) Alignment Pins, Subframe
Magnetic Socket
Steering Wheel Holder
Adjustable Mounting Arm
Hose Clamp Remover/Installer

Materials 

1. Remove Special Service Tool: 307-566 Retainer, Torque Converter.

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

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2. Align the torque converter stud marked during removal with the flexplate.

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3. Install the engine and the transmission-to-engine bolt.

   Torque: 35 lb.ft (48 Nm)

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4. Install the upper transmission-to-engine bolts.

   Torque: 35 lb.ft (48 Nm)

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5. Install the adjustable mounting arm and the bolts. Use the General Equipment: Adjustable Mounting Arm

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6. Remove the floor crane and spreader bar. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.

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7. 1. Install the turbocharger inlet pipe, engine appearance cover stud and tighten clamp.

      Torque: 44 lb.in (5 Nm)

   2. Install the turbocharger inlet pipe bolt.

      Torque: 97 lb.in (11 Nm)

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8. Install the crankcase vent tube and connect the electrical connector.

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9. Install the transmission bolts.

   Torque: 35 lb.ft (48 Nm)

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10. Tighten the PTU bolts.

    Torque: 46 lb.ft (63 Nm)

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11. 1. Install the PTU support bracket and the bolts.

       Torque: 18 lb.ft (25 Nm)

    2. Torque: 46 lb.ft (63 Nm)

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12. Install the PTU heat shield and the bolts.

    Torque: 97 lb.in (11 Nm)

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13. Install the RH halfshaft bearing bracket bolts.

    Torque: 35 lb.ft (48 Nm)

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14. Attach the wiring harness retainers.

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

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16. Attach the PTU vent hose retainer.

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17. Connect the upper radiator hose. Use the General Equipment: Hose Clamp Remover/Installer

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18. NOTE: Only rotate the crankshaft in a clockwise direction.

    Install the new torque converter nuts. Use the General Equipment: Magnetic Socket

    Torque: 30 lb.ft (40 Nm)

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19. Install the starter motor insulator.

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20. Install the starter motor and the stud bolts.

    Torque: 26 lb.ft (35 Nm)

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21. 1. Position the starter motor wiring harness and install the nuts.

       Torque: 106 lb.in (12 Nm)

    2. Torque: 53 lb.in (6 Nm)

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

       Torque: 89 lb.in (10 Nm)

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23. • Attach the wiring harness retainers to the starter motor bracket.
    • Attach coolant hose retainer to the starter motor stud bolt.

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24. Install a new catalytic converter gasket.

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25. Install the catalytic converter and the new nuts.

    Torque: 30 lb.ft (40 Nm)

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26. Install the bolts for the catalytic converter support bracket.

    Torque: 18 lb.ft (25 Nm)

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27. Connect the HO2S and catalyst monitor sensor electrical connectors.

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28. Install Special Service Tool: 502-002 (T94P-2100-AH) Alignment Pins, Subframe.

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29. NOTE: Make sure the struts go into the knuckles when the powertrain and subframe assembly is raised.
    NOTE: Make sure the transmission cooler tubes are in place when raised.

    Using the powertrain lift, raise the powertrain and subframe assembly.

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30. • Clean the bolt and apply thread locking sealant.

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

    • Install the transmission support insulator and bolt.

      Torque: 109 lb.ft (148 Nm)

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

       Torque: 59 lb.ft (80 Nm)

    2. Install the stud bolts.

       Torque: 66 lb.ft (90 Nm)

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32. NOTE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.

    Install the front subframe bolts.

    Torque: 85 lb.ft (115 Nm)

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33. 1. Install the rear subframe support brackets and the bolts. Tighten in 2 stages.

       Torque:

       Stage 1: 103 lb.ft (140 Nm)

       Stage 2: 180 °

    2. Torque: 46 lb.ft (62 Nm)

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34. Remove Special Service Tool: 502-002 (T94P-2100-AH) Alignment Pins, Subframe.

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35. Remove the bolts and the adjustable mounting arm and the special tool. Use Special Service Tool: 300-OTC 1585AE Powertrain Lift. Use the General Equipment: Adjustable Mounting Arm

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36. NOTE: Front bumper cover removed for clarity.

    Connect the turbocharger boost pressure and charge air temperature sensor electrical connector.

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37. Connect the engine wiring harness connector.

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38. • Attach the wiring harness retainer.
    • Install the PCM housing and the bolts.

      Torque: 89 lb.in (10 Nm)

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39. Install the PCM and connect the electrical connectors.

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40. Attach the wiring harness grommet.

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41. Install the PCM housing cover and the screws.

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42. NOTE: LH shown, RH similar.

    Install the subframe support frame, height sensor, bolts and nuts.

    Torque: 18 lb.ft (25 Nm)

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43. NOTE: LH shown, RH similar.
    • Connect the height sensor electrical connector and the wire retainers.
    • Position height sensor bracket and install the bolt.

      Torque: 97 lb.in (11 Nm)

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44. Position the fender splash shield and install the retainers.

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45. NOTE: Make sure the struts are seated into the knuckles.
    NOTE: LH shown, RH similar.
    NOTE: Install new bolts on both sides.

    Install a new bolt in the wheel knuckle.

    Torque:

    Stage 1: 59 lb.ft (80 Nm)

    Stage 2: 180 °

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46. Install the front brake discs. Refer to: Brake Disc .
47. NOTE: Use the internal or external hex-holding feature to prevent the ball and stud from turning while removing or installing the stabilizer bar link nuts. The link boot seal must not be allowed to twist while tightening the link nuts or damage to the boot seal will occur.
    NOTE: LH shown, RH similar.
    NOTE: Install new nuts on both sides.

    Position the front stabilizer bar link and install the nut.

    Torque: 46 lb.ft (62 Nm)

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48. NOTE: LH shown, RH similar.

    Connect the front wheel speed sensor.

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49. 1. Align and install the catalytic converter support bracket and the studs.

       Torque: 71 lb.in (8 Nm)

    2. Install the nuts.

       Torque: 18 lb.ft (25 Nm)

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50. Install the oil pan-to-transmission bolt.

    Torque: 35 lb.ft (48 Nm)

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51. Install the oil pan-to-transmission bolt.

    Torque: 35 lb.ft (48 Nm)

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52. Tighten the PTU bolts.

    Torque: 46 lb.ft (63 Nm)

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53. 1. Position the driveshaft.
    2. Align the driveshaft with the index-mark made during removal.

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54. NOTE: Install new bolts.

    Install new bolts and the brackets.

    Torque: 26 lb.ft (35 Nm)

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55. Install a new exhaust gasket.

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56. Position the exhaust and install the nuts.

    Torque: 35 lb.ft (48 Nm)

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57. If equipped, connect the exhaust pressure sensor hose. Use the General Equipment: Hose Clamp Remover/Installer

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58. If equipped, connect the exhaust gas temperature sensor electrical connector and the retainers.

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59. Install the body brace, bolts and nuts.

    Torque: 35 lb.ft (48 Nm)

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60. If equipped, install the underbody side panels and the retainers.

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61. Lubricate the oil filter sealing surface and install.

    Material: Motorcraft ® SAE 5W-30 Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

    Torque:

    Stage 1: 71 lb.in (8 Nm)

    Stage 2: 180 °

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62. Position the ground cable and install the bolt and wire retainer.

    Torque: 35 lb.ft (48 Nm)

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63. NOTE: Install new O-ring seals and gaskets.
    1. Position the A/C lines and install the nuts.

       Torque: 133 lb.in (15 Nm)

    2. Install the bolt and the wire harness retainers.

       Torque: 177 lb.in (20 Nm)

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64. Install the CAC outlet tube and tighten the clamps.

    Torque: 44 lb.in (5 Nm)

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65. 1. Install the CAC inlet tube and the nuts.

       Torque: 97 lb.in (11 Nm)

    2. Tighten the clamps.

       Torque: 44 lb.in (5 Nm)

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66. Install the underbody shields and the retainers.

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67. Install the front wheels and tires. Refer to: Wheel and Tire .
68. NOTE: Inspect the transmission cooling tube O-ring seals for damage.
    NOTE: Removing the bolts will aid in the installation of the transmission cooling tubes.

    Remove the transmission cooling block bolts.

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69. NOTE: Finger-tight at this stage.

    Install the cooling lines nuts to the cooling block and nut finger-tight.

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70. Install the transmission cooling block bolts.

    Torque: 18 lb.ft (25 Nm)

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71. 1. Tighten the cooling lines nuts.

       Torque: 22 lb.ft (30 Nm)

    2. Tighten the cooling line nut.

       Torque: 80 lb.in (9 Nm)

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72. • Position the transmission shift cable and install the bolts.

      Torque: 18 lb.ft (25 Nm)

    • Attach the transmission shift cable.

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73. 1. Connect the heater hoses.
    2. Rotate the heater hose tabs.

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74. Connect the lower radiator hose to the thermostat housing. Use the General Equipment: Hose Clamp Remover/Installer

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75. Install the TRCM bracket and the nut.

    Torque: 18 lb.ft (25 Nm)

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76. Position the TRCM and install the bolts.

    Torque: 18 lb.ft (25 Nm)

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77. Install the TRCM bracket nut.

    Torque: 133 lb.in (15 Nm)

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78. Install the degas bottle. Refer to: Degas Bottle .
79. Connect the upper radiator hose and retainer. Use the General Equipment: Hose Clamp Remover/Installer

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80. Connect the coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer

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81. 1. Connect the fuel hose spring lock coupling. Refer to: Spring Lock Couplings .
    • Connect the fuel pressure sensor electrical connector.
    • Connect the EVAP canister purge valve quick release coupling. Refer to: Quick Release Coupling .

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82. Connect the brake vacuum pump quick release coupling and retainer.

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83. Position the wiring harness ground and install the bolt and the wiring harness retainer to the LH frame rail.

    Torque: 106 lb.in (12 Nm)

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84. Position the EPAS wiring harness ground and install the bolt and wiring harness retainer.

    Torque: 106 lb.in (12 Nm)

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85. Install the air cleaner support bracket, nuts and attach the wiring harness retainer.

    Torque: 35 lb.ft (48 Nm)

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86. Connect and attach the wiring harness connector to the air cleaner support bracket.

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87. Install the cable and nut to the positive battery cable.

    Torque: 80 lb.in (9 Nm)

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88. Install the battery tray. Refer to: Battery Tray .
89. 1. Install the battery feed cable and the nut.

       Torque: 44 lb.in (5 Nm)

    2. Install the battery feed cable and the nut.

       Torque: 106 lb.in (12 Nm)

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90. Connect the main wiring harness to the fuse box and attach the wiring harness retainers.

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91. Install the following items:
    1. Install the upper air cleaner outlet tube. Refer to: Air Cleaner Outlet Pipe .
    2. Install the air cleaner. Refer to: Air Cleaner .

92. NOTE: If equipped with block heater.

    If equipped with block heater, attach the retainers.

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93. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of vehicle control. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

    Install a new steering column coupling-to-steering gear bolt.

    Torque: 21 lb.ft (28 Nm)

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94. Remove the steering wheel holder. Use the General Equipment: Steering Wheel Holder

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95. Install the engine compartment fuse box cover.

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96. Fill the engine with clean engine oil. Refer to: Specifications .

    Material: Motorcraft ® SAE 5W-30 Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

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97. Connect both battery cables. Refer to: Battery Disconnect and Connect .
98. Fill the cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding .
99. Recharge the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging .
100. 1. NOTE: Lubricating the grommets with silicone grease will aid in the installation of the engine appearance cover, and any future removal and installation of the cover.

        Lubricate each grommet with silicone grease.

        Material: Motorcraft ® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

     2. Position the engine appearance cover onto engine with the grommets aligned with the studs.
     3. Press down on the engine appearance cover at each grommet location to attach the grommets onto the studs.

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101. Start and check the exhaust system for leaks.
102. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
103. If equipped with dynamic suspension, calibrate the suspension height sensor. Connect the scan tool and carry out the Ride Height Calibration routine. Follow the scan tool directions.