Section 1500 (Engine - 2.0L DURATEC-He (125KW/170PS) - Mi4): Installation: Engine

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Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	300-OTC1585AE Powertrain Lift
Courtesy of FORD MOTOR COMPANY	300-OTC1819E2, 200# Floor Crane, Fold Away
Courtesy of FORD MOTOR COMPANY	303-D089 (D93P-6001-A3) Spreader Bar
Magnetic Socket
Adjustable Mounting Arm
Hose Clamp Remover/Installer
Wooden Block

Materials 

1. NOTE: If using the existing clutch assembly, align the index marks on the flexplate and the clutch stud made during removal.

   If using a new clutch assembly, make sure the flexplate-to-clutch alignment marks are aligned.

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2. NOTE: Use caution not to damage the transmission wiring harness or sensors.
   NOTE: If using the existing automatic transmission clutch assembly, align the index marks on the flexplate and the clutch stud made during removal.
   NOTE: Automatic transmission shown, manual transmission similar.

   Align the transmission to the engine.

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3. • If equipped with automatic transmission. Install the 4 bellhousing-to-engine fasteners.

     Torque

     : 33 lb.ft (45 Nm)

   • If equipped with manual transmission, Install the 5 bellhousing-to-engine fasteners.

     Torque

     : 33 lb.ft (45 Nm)

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4. Install the ground wire and the nut.

   Torque

   : 177 lb.in (20 Nm)

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5. NOTE: Automatic transmission shown, manual transmission similar.

   Install the engine-to-transmission bolt.

   Torque

   : 33 lb.ft (45 Nm)

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6. Raise the engine and transmission assembly onto the lift table. Use Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away., 303-D089 (D93P-6001-A3) Spreader Bar.

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7. NOTE: Position a block of wood under the transmission.

   Attach the powertrain to the powertrain lift. Use Special Service Tool: 300-OTC1585AE Powertrain Lift. Use the General Equipment: Adjustable Mounting Arm. Use the General Equipment: Wooden Block

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8. Tighten the engine mount studs.

   Torque

   : 93 lb.in (10.5 Nm)

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9. NOTE: Make sure that new flexplate-to-clutch nuts are installed.
   NOTE: Rotate the engine in a clockwise direction only or engine damage may occur.
   NOTE: Using a magnetic socket will help ease the installation of new flexplate-to-clutch nuts. If the flexplate-to-clutch nuts fall into the clutch housing, the transmission will have to be removed to retrieve them.

   Install the new flexplate-to-clutch nuts in the location shown. Use the General Equipment: Magnetic Socket

   Torque: 106 lb.in (12 Nm)

   multimedia:A supplement to the article is available.

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10. NOTE: Make sure that new flexplate-to-clutch nuts are installed.
    NOTE: Rotate the engine in a clockwise direction only or engine damage may occur.
    NOTE: Using a magnetic socket will help ease the installation of new flexplate-to-clutch nuts. If the flexplate-to-clutch nuts fall into the clutch housing, the transmission will have to be removed to retrieve them.

    Install the new flexplate-to-clutch nuts. Tighten the flexplate-to-clutch nuts in sequence shown. Use the General Equipment: Magnetic Socket

    Torque

    : 18 lb.ft (25 Nm)

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11. NOTE: Failure to torque the flexplate-to-clutch nuts in the sequence described may result in a first order engine vibration. Misalignment can be resolved by removing and discarding all 6 flexplate-to-clutch nuts and repeating the previous 2 steps.
    multimedia:A supplement to the article is available.
12. Install the stater motor isolator.

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13. Install the starter motor. Refer to: Starter Motor .
14. Attach the wire harness retainer.

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15. If equipped with automatic transmission. Connect the wiring harness electrical connector.

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16. Position the powertrain into the vehicle.
17. Install the transmission mount bolt.

    Torque

    : 111 lb.ft (150 Nm)

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18. • Install the engine mount and the bolts.

      Torque

      : 66 lb.ft (90 Nm)

    • Install the nuts.

      Torque

      : 59 lb.ft (80 Nm)

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19. Install the engine mounting roll restrictor and the bolts.

    Torque

    : 63 lb.ft (86 Nm)

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20. NOTE: Automatic transmission shown, manual transmission similar.

    Install the oil pan bolts.

    Torque

    : 35 lb.ft (48 Nm)

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21. NOTE: Automatic transmission shown, manual transmission similar.

    Install the oil pan-to-transmission bolt.

    Torque

    : 35 lb.ft (48 Nm)

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22. Install the cooling fan motor and shroud. Refer to: Cooling Fan Motor and Shroud .
23. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.

    Install a new engine oil filter.

    Material

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

    Torque

    :Stage 1: 71 lb.in (8 Nm) Stage 2: 180°

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24. Install the lower radiator hose and clamp. Use the General Equipment: Hose Clamp Remover/Installer

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25. NOTE: Install 2 new O-ring seals.
    • Position back the A/C lines and tighten the nuts.

      Torque

      : 177 lb.in (20 Nm)

    • Tighten the bolt.

      Torque

      : 18 lb.ft (25 Nm)

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26. Install the A/C pipe bracket bolt.

    Torque

    : 159 lb.in (18 Nm)

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27. Refer to: Front Halfshaft RH . Refer to: Front Halfshaft LH .
28. If equipped with a manual transmission. Connect the shift cable and tighten the bracket nuts.

    Torque

    : 35 lb.ft (48 Nm)

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29. NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

    If equipped with a manual transmission. Connect the clutch hydraulic tube.

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30. If equipped with an automatic transmission. Position back the shift cable and install the bolts.

    Torque

    : 89 lb.in (10 Nm)

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31. If equipped with an automatic transmission. Attach the selector lever cable retainer.

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32. If equipped with an automatic transmission. Attach the selector lever cable retainer.

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33. If equipped with an automatic transmission. Connect the selector lever cable end to the manual control lever.

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34. Connect the vacuum tube quick release coupling at the rear of the intake manifold.

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35. Connect the electrical connector and the fuel tube quick release coupling. Refer to: Quick Release Coupling .

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36. Connect the fuel tube quick release coupling. Refer to: Quick Release Coupling .

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37. NOTE: Install 5 new catalytic converter-to-cylinder head studs.

    Install the new manifold stud bolts.

    Torque

    : 150 lb.in (17 Nm)

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38. NOTE: Failure to tighten the catalytic converter manifold nuts to specification a second time may cause the converter to develop an exhaust leak.
    NOTE: Always install new fasteners and gaskets as indicated. Clean flange faces prior to new gasket installation to make sure of proper sealing.

    Using a new gasket, position the catalytic converter and install the new catalytic converter manifold-to-cylinder head nuts and tighten in 2 stages in sequence shown.

    Torque

    :Stage 1: Tighten: 41 lb.ft (55 Nm) Stage 2: Retighten: 41 lb.ft (55 Nm)

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39. Install the tailpipe mount bracket bolts.

    Torque

    : 18 lb.ft (25 Nm)

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40. • Install the catalytic converter manifold-to-muffler and tailpipe nuts, tighten the first nut.

      Torque

      : 35 lb.ft (48 Nm)

    • Tighten the second nut.

      Torque

      : 35 lb.ft (48 Nm)

    • Tighten the first nut to specification a second time.

      Torque

      : 35 lb.ft (48 Nm)

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41. Install the bolts to the exhaust manifold.

    Torque

    : 18 lb.ft (25 Nm)

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42. Install the exhaust manifold heat shield, position back the catalyst monitor sensor wiring harness and install the bolts.

    Torque

    : 89 lb.in (10 Nm)

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43. Connect the catalyst monitor sensor electrical connector and wire retainer.

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44. Install the HO2S. Refer to: Heated Oxygen Sensor (HO2S) .
45. If equipped. Connect the engine block heater electrical connector.

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46. Connect the coolant hoses to the heater core and attach the hose retainers.

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47. Connect the coolant hoses and install the hose clips. Use the General Equipment: Hose Clamp Remover/Installer

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48. Position back the wiring harness.

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49. Attach the wiring harness retainers.

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50. Install the bolts on the ground strap and attach the ground cable retainer.

    Torque

    : 177 lb.in (20 Nm)

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51. NOTE: The electrical connector is located behind the PCM case.

    Connect the engine wiring harness electrical connector.

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52. Install the PCM. Refer to: Powertrain Control Module (PCM) .
53. Attach the ground cable retainer.

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54. Install the engine ground strap and nut.

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55. If equipped with automatic transmission. Attach the wiring harness retainers.

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56. Install the following items:
    1. Install the air cleaner and the air cleaner outlet pipe. Refer to: Air Cleaner . Refer to: Air Cleaner Outlet Pipe .
    2. Install the battery tray. Refer to: Battery Tray .
    3. Install the degas bottle. Refer to: Degas Bottle .

57. If equipped with manual transmission, fill and bleed the clutch system. Refer to: Clutch System Bleeding - 6-Speed Manual Transmission - MMT6 .
58. Fill the cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding . Refer to: Cooling System Draining, Filling and Bleeding .
59. Install the underbody shield and the bolts.

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60. Charge the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging - Vehicles With: R134A Refrigerant .
61. Fill the engine with clean engine oil.

    Material

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

62. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.