Section 1230 (Engine - 2.0L ECOBOOST (177KW/240PS) - Mi4): 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-OTC1819E 2, 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
Adjustable Mounting Arm
Hose Clamp Remover/Installer

Materials 

LHD AWD/LHD FWD 

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 and position the engine onto the transmission.

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

      Torque: 35 lb.ft (48 nm)

   2. Install the transmission-to-engine bolts.

      Torque: 35 lb.ft (48 nm)

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4. Install. Use the general equipment: adjustable mounting arm

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5. Remove the engine lift equipment. Use special service tool: 300-OTC1819E 2, 200# floor crane, fold away.

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

      Torque: 44 lb.in (5 nm)

   2. Install the turbocharger inlet pipe bolt.

      Torque: 97 lb.in (11 nm)

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7. Install the crankcase vent tube and connect the crankcase pressure sensor electrical connector.

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   LHD FWD 

8. Install the engine-to-transmission bolts.

   Torque: 35 lb.ft (48 nm)

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   LHD AWD 

9. Install the engine-to-transmission bolts.

   Torque: 35 lb.ft (48 nm)

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10. Tighten the transfer case bolts.

    Torque: 46 lb.ft (63 nm)

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11. Install the transfer case support bracket and the bolts.

    Torque:

    1: 18 lb.ft (25 nm)

    2: 46 lb.ft (63 nm)

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12. Install the transfer case heat shield and the bolts.

    Torque: 97 lb.in (11 nm)

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13. Attach the transfer case vent hose retainer to the engine block.

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    LHD AWD/LHD FWD 

14. Install the rh halfshaft bearing bracket bolts.

    Torque: 35 lb.ft (48 nm)

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15. Connect the coolant hose to the transmission fluid warmer.

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16. • Connect the coolant hose and slide the clip down.
    • Connect the coolant solenoid electrical connector and attach the wiring harness retainer.

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

    Install new torque converter nuts. Use the general equipment: magnetic socket

    Torque: 30 lb.ft (40 nm)

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18. Install the starter motor insulator.

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19. Install the starter motor and the stud bolts.

    Torque: 26 lb.ft (35 nm)

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20. Position the starter motor wiring harness and install the nuts.

    Torque:

    1: 106 lb.in (12 nm)

    2: 53 lb.in (6 nm)

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21. NOTE: Vehicle equipped with cabin heater coolant pump, others similar.
    1. Install the starter motor bracket and the nut.

       Torque: 89 lb.in (10 nm)

    2. Attach the wiring harness retainers.

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22. 1. If equipped, install the start stop cabin heater coolant pump and the nuts.

       Torque: 89 lb.in (10 nm)

    2. Attach the wiring harness retainer.

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23. Install a new catalytic converter gasket.

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24. NOTE: Do not tighten the new catalytic converter-to-turbocharger nuts at this time.

    Install the catalytic converter and the new nuts finger-tight.

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25. NOTE: Do not tighten the catalytic converter support bracket-to-transmission bolts at this time.

    Install the catalytic converter support bracket-to-transmission bolts.

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26. Tighten.

    Torque: 30 lb.ft (40 nm)

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27. Tighten.

    Torque: 18 lb.ft (25 nm)

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28. Install the catalytic converter support bracket bolts.

    Torque: 18 lb.ft (25 nm)

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

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30. Install special service tool: 502-002 (T94P-2100-AH) alignment pins, subframe.

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31. 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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32. 1. Install the engine mount and new nuts.

       Torque: 59 lb.ft (80 nm)

    2. Install new stud bolts.

       Torque: 66 lb.ft (90 nm)

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33. Install the transmission support insulator, apply the thread lock sealant and install the bolt.

    Material motorcraft ® threadlock and sealer / TA-25-B

    Torque: 109 lb.ft (148 nm)

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34. 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 forward subframe bolts.

    Torque: 85 lb.ft (115 nm)

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35. 1. Install the subframe support bracket and the bolts in 2 stages.

       Torque:

       Stage 1: 103 lb.ft (140 nm)

       Stage 2: 180 °

    2. Install the subframe support bracket bolts.

       Torque: 177 lb.in (20 nm)

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36. Remove special service tool: 502-002 (T94P-2100-AH) alignment pins, subframe.

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37. Remove use the general equipment: adjustable mounting arm

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38. Connect the wiring harness electrical connector.

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

      Torque: 89 lb.in (10 nm)

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40. Install the PCM and connect the electrical connectors.

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41. Attach the wiring harness grommet.

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42. Install the PCM cover and the retainers.

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43. NOTE: LH shown, rh similar.

    Both sides. install the subframe support bracket, bolts, studs and the nuts.

    Torque: 18 lb.ft (25 nm)

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44. Position the splash shield and install the retainers.

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45. Install the a/c compressor belt. refer to: Air conditioning (a/c) compressor belt .
46. NOTE: Front bumper cover removed for clarity.

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

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47. Position the splash shield and install the retainers.

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48. Install the engine-to-transmission bolt.

    Torque: 35 lb.ft (48 nm)

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49. Install the transmission-to-engine bolts.

    Torque: 35 lb.ft (48 nm)

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50. • Position a/c tube and install the bolt.

      Torque: 35 lb.ft (48 nm)

    • Position the ground cable and install the bolt.

      Torque: 35 lb.ft (48 nm)

    • Attach the wiring harness retainer.

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

    Both sides. install the new wheel knuckle to strut bolt and tighten in 2 stages.

    Torque:

    Stage 1: 59 lb.ft (80 nm)

    Stage 2: 180 °

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52. Install the front brake disc. refer to: Brake disc .
53. 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.

    Both sides. position the front stabilizer bar link and install the nut.

    Torque: 35 lb.ft (48 nm)

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54. NOTE: LH shown, rh similar.

    Both sides. connect the wheel speed sensor electrical connector.

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55. If equipped, install the rh and LH front suspension height sensors. refer to: Front suspension height sensor .

    LHD AWD 

56. Tighten the transfer case bolts.

    Torque: 46 lb.ft (63 nm)

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57. Align the index-mark on driveshaft to the rear axle pinion flange.

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58. NOTE: Install new bolts.

    Install the new driveshaft-to-pinion flange bolts.

    Torque: 26 lb.ft (35 nm)

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    LHD AWD/LHD FWD 

59. NOTE: Make sure that the mating faces are clean and free of foreign material.

    Install the new muffler inlet pipe gasket.

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60. Position the muffler inlet pipe and install the nuts.

    Torque: 35 lb.ft (48 nm)

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61. If equipped, connect the exhaust pressure sensor hose. Use the general equipment: hose clamp remover/installer

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

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63. Install the cross support and the bolts.

    Torque: 177 lb.in (20 nm)

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64. 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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65. 1. NOTE: Use new o-ring seals and gasket seals.

       Connect the a/c tubes and install the nuts.

       Torque: 133 lb.in (15 nm)

    2. Connect the a/c pressure sensor electrical connector and the wiring harness retainer.

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66. Install the CAC tube and tighten the clamps.

    Torque: 44 lb.in (5 nm)

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67. 1. Install the CAC tube and the nuts.

       Torque: 97 lb.in (11 nm)

    2. Tighten the clamp.

       Torque: 44 lb.in (5 nm)

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68. Connect the bypass hose, the electrical connector and the wire retainer. Use the general equipment: hose clamp remover/installer

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69. Position the CAC tube and tighten the clamp.

    Torque: 44 lb.in (5 nm)

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70. • Position the transmission tube bracket and install the nut.

      Torque: 89 lb.in (10 nm)

    • Connect the wiring harness electrical connectors.
    • Attach the wiring harness connectors.

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71. Install the transmission tubes to bottom side of transmission fluid cooler bypass valve.

    Torque: 22 lb.ft (30 nm)

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72. Install the front wheels and tires. refer to: Wheel and tire .
73. • Position the transmission shift cable and install the bolts.

      Torque: 18 lb.ft (25 nm)

    • Attach the transmission shift cable.

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

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75. Connect the upper radiator hose and retainer. Use the general equipment: hose clamp remover/installer

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76. Connect the lower radiator hose to the thermostat housing. Use the general equipment: hose clamp remover/installer

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77. Install the bracket and the nut.

    Torque: 18 lb.ft (25 nm)

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78. Position the transmission control and install the bolts.

    Torque: 18 lb.ft (25 nm)

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79. Install the transmission control bracket nut.

    Torque: 133 lb.in (15 nm)

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80. Install the degas bottle. refer to: Degas bottle .
81. Connect the coolant hoses. Use the general equipment: hose clamp remover/installer

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82. 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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83. Connect the vacuum tube and attach the retainer.

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84. • Attach the wiring harness retainer.
    • Install the ground wire and bolt.

      Torque: 106 lb.in (12 nm)

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85. Position the ground cables and install the bolt. Attach the wiring harness retainer.

    Torque: 106 lb.in (12 nm)

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

      Torque: 35 lb.ft (48 nm)

    • If equipped, attach the wiring harness retainers.

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87. Install the wiring harness and the nut.

    Torque: 80 lb.in (9 nm)

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88. 1. Connect the wiring harness electrical connector.
    2. Attach the wiring harness retainer.

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89. Install the battery tray. refer to: Battery tray .
90. Position the wiring harness and install the nuts.

    Torque:

    1: 44 lb.in (5 nm)

    2: 106 lb.in (12 nm)

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91. Connect the main wiring harness to the BJB and attach the retainers.

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92. Install the following items:
    1. Upper air cleaner outlet pipe. refer to: Air cleaner outlet pipe .
    2. Refer to: Air cleaner .

93. Install the BJB cover.

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94. If equipped with block heater, attach the retainers.

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95. Install the underbody side panels and the retainers.

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96. • Install the stone guard and the retainers.
    • Install the underbody shield and the retainers.

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97. 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).

    Attach the steering column shaft to steering input shaft and install the new bolt.

    Torque: 21 lb.ft (28 nm)

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98. Remove the holding tool.

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99. Connect the battery ground cable. refer to: Battery disconnect and connect .
100. Fill the engine with clean engine oil. refer to: specifications .

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101. 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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102. Fill and bleed the cooling system. refer to: Cooling system draining, vacuum filling and bleeding .
103. Recharge the a/c system. refer to: Air conditioning (a/c) system recovery, evacuation and charging .
104. Start and check the exhaust system for leaks.
105. Use the powertrain control module (PCM) misfire monitor profile correction routine in the diagnostic scan tool.