Section 5 (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-OTC1585AE Powertrain Lift
Courtesy of FORD MOTOR COMPANY	300-OTC1819E2, 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)

   Courtesy of FORD MOTOR COMPANY

2. Inspect the engine block dowels. If the dowels are damaged or missing, install new engine block dowels.

   Courtesy of FORD MOTOR COMPANY

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

   Courtesy of FORD MOTOR COMPANY

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

   Torque: 35 lb.ft (48 Nm)

   Courtesy of FORD MOTOR COMPANY

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

   Torque: 35 lb.ft (48 Nm)

   Courtesy of FORD MOTOR COMPANY

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

   Courtesy of FORD MOTOR COMPANY

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

   Courtesy of FORD MOTOR COMPANY

8. 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)

   Courtesy of FORD MOTOR COMPANY

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

   Courtesy of FORD MOTOR COMPANY

10. Install the transmission bolts.

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

11. Install the new transfer case to transmission compression seal.

    Courtesy of FORD MOTOR COMPANY

12. Install the transfer case.

    Courtesy of FORD MOTOR COMPANY

13. Install new transfer case bolts.

    Torque: 59 lb.ft (80 Nm)

    Courtesy of FORD MOTOR COMPANY

14. 1. Install the transfer case support bracket and the bolts.

       Torque: 18 lb.ft (25 Nm)

    2. Torque

       : 46 lb.ft (63 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 97 lb.in (11 Nm)

    Courtesy of FORD MOTOR COMPANY

16. Attach the transfer case vent hose retainer.

    Courtesy of FORD MOTOR COMPANY

17. Install the halfshaft support bracket and the bolts.

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

18. Attach the wiring harness retainers.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

21. 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)

    Courtesy of FORD MOTOR COMPANY

22. Install the starter motor insulator.

    Courtesy of FORD MOTOR COMPANY

23. Install the starter motor and the stud bolts.

    Torque: 26 lb.ft (35 Nm)

    Courtesy of FORD MOTOR COMPANY

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

       Torque: 106 lb.in (12 Nm)

    2. Torque

       : 53 lb.in (6 Nm)

    Courtesy of FORD MOTOR COMPANY

25. Courtesy of FORD MOTOR COMPANY

    1. Install the starter motor bracket and the nuts.

       Torque: 89 lb.in (10 Nm)

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

    Courtesy of FORD MOTOR COMPANY

27. Install a new catalytic converter gasket.

    Courtesy of FORD MOTOR COMPANY

28. Install the catalytic converter and the new nuts.

    Torque: 30 lb.ft (40 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

32. 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.

    Courtesy of FORD MOTOR COMPANY

33. • 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)

    Courtesy of FORD MOTOR COMPANY

34. 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)

    Courtesy of FORD MOTOR COMPANY

35. 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)

    Courtesy of FORD MOTOR COMPANY

36. 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 deg.

    2. Torque

       : 46 lb.ft (62 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

38. Remove the bolts and the adjustable mounting arm and the special tool. Use Special Service Tool: 300-OTC1585AE Powertrain Lift. Use the General Equipment: Adjustable Mounting Arm

    Courtesy of FORD MOTOR COMPANY

39. NOTE: Front bumper cover removed for clarity.

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

    Courtesy of FORD MOTOR COMPANY

40. Connect the engine wiring harness connector.

    Courtesy of FORD MOTOR COMPANY

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

      Torque: 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

42. Install the PCM and connect the electrical connectors.

    Courtesy of FORD MOTOR COMPANY

43. Attach the wiring harness grommet.

    Courtesy of FORD MOTOR COMPANY

44. Install the PCM housing cover and the screws.

    Courtesy of FORD MOTOR COMPANY

45. NOTE: LH shown, RH similar.

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

    Torque: 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

46. 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)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

48. 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 deg.

    Courtesy of FORD MOTOR COMPANY

49. Install the front brake discs. Refer to: Brake Disc .
50. 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)

    Courtesy of FORD MOTOR COMPANY

51. NOTE: LH shown, RH similar.

    Connect the front wheel speed sensor.

    Courtesy of FORD MOTOR COMPANY

52. 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)

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

55. Install the new lower transfer case bolts.

    Torque: 59 lb.ft (80 Nm)

    Courtesy of FORD MOTOR COMPANY

56. If equipped, connect the transfer case temperature sensor.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

58. NOTE: Install new bolts.

    Install new bolts and the brackets.

    Torque: 26 lb.ft (35 Nm)

    Courtesy of FORD MOTOR COMPANY

59. Install the RH front halfshaft. Refer to: Front Halfshaft RH .
60. Install a new exhaust gasket.

    Courtesy of FORD MOTOR COMPANY

61. Position the exhaust and install the nuts.

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

64. Install the body brace, bolts and nuts.

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

66. Lubricate the oil filter sealing surface and install.

    Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

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

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

68. 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)

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 44 lb.in (5 Nm)

    Courtesy of FORD MOTOR COMPANY

70. 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)

    Courtesy of FORD MOTOR COMPANY

71. Install the underbody shields and the retainers.

    Courtesy of FORD MOTOR COMPANY

72. Install the front wheels and tires. Refer to: Wheel and Tire .
73. 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.

    Courtesy of FORD MOTOR COMPANY

74. NOTE: Finger-tight at this stage.

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

    Courtesy of FORD MOTOR COMPANY

75. Install the transmission cooling block bolts.

    Torque: 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

76. 1. Tighten the cooling lines nuts.

       Torque: 22 lb.ft (30 Nm)

    2. Tighten the cooling line nut.

       Torque: 80 lb.in (9 Nm)

    Courtesy of FORD MOTOR COMPANY

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

      Torque: 18 lb.ft (25 Nm)

    • Attach the transmission shift cable.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

80. Install the TRCM bracket and the nut.

    Torque: 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

81. Position the TRCM and install the bolts.

    Torque: 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

82. Install the TRCM bracket nut.

    Torque: 133 lb.in (15 Nm)

    Courtesy of FORD MOTOR COMPANY

83. Install the degas bottle. Refer to: Degas Bottle 2.3L EcoBoost .
84. Connect the upper radiator hose and retainer. Use the General Equipment: Hose Clamp Remover/Installer

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

86. • Connect the fuel pressure sensor electrical connector.
    • Connect the EVAP canister purge valve quick release coupling. Refer to: Quick Release Coupling 2.3L EcoBoost .

    Courtesy of FORD MOTOR COMPANY

    1. Connect the fuel hose spring lock coupling. Refer to: Spring Lock Couplings 2.3L EcoBoost .
87. Connect the brake vacuum pump quick release coupling and retainer.

    Courtesy of FORD MOTOR COMPANY

88. 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)

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 80 lb.in (9 Nm)

    Courtesy of FORD MOTOR COMPANY

93. Install the battery tray. Refer to: Battery Tray .
94. 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)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

96. Install the following items:
    1. Install the upper air cleaner outlet tube. Refer to: Air Cleaner Outlet Pipe 2.3L EcoBoost .
    2. Install the air cleaner. Refer to: Air Cleaner 2.3L EcoBoost .
97. NOTE: If equipped with block heater.

    If equipped with block heater, attach the retainers.

    Courtesy of FORD MOTOR COMPANY

98. 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)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

100. Install the engine compartment fuse box cover.

     Courtesy of FORD MOTOR COMPANY

101. Fill the engine with clean engine oil. Refer to: Specifications 2.3L EcoBoost  .

     Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

     Courtesy of FORD MOTOR COMPANY

102. Connect both battery cables. Refer to: Battery Disconnect and Connect .
103. Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding 2.3L EcoBoost .
104. Recharge the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging .
105. 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.

     Courtesy of FORD MOTOR COMPANY

106. Check the transfer case fluid level. Refer to: Transfer Case Fluid Level Check .
107. Start and check the exhaust system for leaks.
108. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
109. 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.