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Removal And Installation: Engine: Material

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MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent WSS-M2C930-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.

All vehicles 

    NOTE: Due to packaging requirements the correct bolt must be used at the damper locations.
    NOTE: The damper contains a clutch which is designed to slip briefly during vehicle operation. It is essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use grease on transmission input shaft. Should the damper become contaminated, it must be replaced.
  1. Install the transaxle damper.
    • Tighten to 29 Nm (21 lb-ft).
      Fig 1: Locating Transaxle Damper Bolts
      G06097936Courtesy of FORD MOTOR CO.
    2. NOTE: When positioning the engine to the transaxle, care must be taken to maintain alignment of the damper spline with the transaxle input shaft.
    NOTE: Transaxle removed from view for clarity.
  2. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 2: Locating Transaxle-To-Engine Bolts
      G06097942Courtesy of FORD MOTOR CO.
  3. Connect the high voltage wiring harness electrical connector.
    • Engage the electrical connector locking tab.
      Fig 3: Locating High Voltage Wiring Harness Electrical Connector
      G06097935Courtesy of FORD MOTOR CO.
  4. Using the Heavy Duty Floor Crane and Engine Lifting Bracket, position the engine and transaxle onto the Powertrain Lift.
    5. NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the Powertrain Lift.
    Fig 4: Securing Engine To Powertrain Lift
    G06095071Courtesy of FORD MOTOR CO.
  5. Using the Universal Adapter Brackets, secure the engine to the Powertrain Lift.
  6. Raise the engine and transaxle into the vehicle.
  7. Install the upper transaxle insulator.
    1. Tighten the nuts to 90 Nm (66 lb-ft).
    2. Tighten the through bolt to 103 Nm (76 lb-ft).
      Fig 5: Locating Upper Transaxle Insulator
      G06097861Courtesy of FORD MOTOR CO.
  8. Install the upper transaxle insulator bracket.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 6: Locating Upper Transaxle Insulator Bracket And Bolts
      G06097860Courtesy of FORD MOTOR CO.
  9. Install the 3 engine mount bracket nuts.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 7: Locating Engine Mount Bracket Nuts
      G06095073Courtesy of FORD MOTOR CO.
  10. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 8: Locating Engine Mount Bracket Bolt
      G06095072Courtesy of FORD MOTOR CO.
  11. Using the Powertrain Lift, raise the subframe into position.
    Fig 9: Raising Subframe Into Position
    G06097949Courtesy of FORD MOTOR CO.
    12. NOTE: RH shown, LH similar.
  12. Install the 2 subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 10: Locating Subframe Nuts
      G06097927Courtesy of FORD MOTOR CO.
    13. NOTE: When installing the subframe bolts, make sure both of the subframe bolts are fully engaged in their cage nuts before tightening to specification.
    NOTE: RH shown, LH similar.
  13. Tighten the 2 subframe bolts.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 11: Locating Subframe Bolts
      G06097926Courtesy of FORD MOTOR CO.
  14. Install the rear roll restrictor, bracket and bolts.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 12: Locating Bolts, Roll Restrictor And Bracket
      G06096259Courtesy of FORD MOTOR CO.
  15. Connect the steering column coupling to the steering gear and install the new steering column coupling pinch bolt.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 13: Locating Steering Column Coupling-To-Steering Gear Pinch Bolt
      G06097924Courtesy of FORD MOTOR CO.
  16. Install the rear transaxle insulator through bolt.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 14: Locating Rear Transaxle Insulator Through Bolt
      G06097870Courtesy of FORD MOTOR CO.
  17. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 15: Locating Transaxle-To-Engine Bolts
      G06097921Courtesy of FORD MOTOR CO.
  18. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 16: Locating Transaxle-To-Engine Bolts
      G06097920Courtesy of FORD MOTOR CO.
  19. Install the engine support crossmember.
    • Tighten the bolts to 90 Nm (66 lb-ft).
    • Tighten the new nut to 175 Nm (129 lb-ft).
      Fig 17: Locating Nut, Bolts And Engine Support Crossmember
      G06097867Courtesy of FORD MOTOR CO.
  20. Install the rear roll restrictor-to-crossmember through bolt.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 18: Locating Rear Roll Restrictor-To-Crossmember Through Bolt
      G06097866Courtesy of FORD MOTOR CO.
  21. Install the lower transaxle insulator through bolt.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 19: Locating Lower Transaxle Insulator Through Bolt
      G06097865Courtesy of FORD MOTOR CO.
  22. Connect the lower radiator hose to the radiator.
    Fig 20: Locating Lower Radiator Hose Clamp
    G06095061Courtesy of FORD MOTOR CO.
  23. Install the A/C compressor and connect the A/C compressor electrical connector.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 21: Locating A/C Compressor Electrical Connector And Bolts
      G06097914Courtesy of FORD MOTOR CO.
  24. Install the auxiliary coolant pump and the electrical connector.
    • Tighten to 10 Nm (89 lb-in).
      Fig 22: Locating Bolts And Auxiliary Coolant Pump Electrical Connector
      G06096250Courtesy of FORD MOTOR CO.
  25. Install the Motor Electronics Cooling System (MECS) pump and the ground strap. Install the 2 bolts.
    • Tighten to 20 Nm (177 lb-in).
      Fig 23: Locating Bolts, MECS Pump And Ground Strap
      G06097913Courtesy of FORD MOTOR CO.
  26. Connect the MECS pump electrical connector and attach the harness retainer.
    Fig 24: Locating MECS Pump Electrical Connector And Harness Retainer
    G06097912Courtesy of FORD MOTOR CO.
  27. Install the wiring harness fasteners, the ground cable and nut.
    • Tighten to 20 Nm (177 lb-in).
      Fig 25: Locating Harness Fasteners, Nut And Ground Cable
      G06097911Courtesy of FORD MOTOR CO.
  28. Connect the transaxle control cable.
    • Install the transaxle control cable bracket and the 2 nuts finger-tight.
    • Attach the transaxle control cable to the control lever.
      Fig 26: Locating Transaxle Control Cable And Transaxle Control Cable Bracket Nuts
      G06097910Courtesy of FORD MOTOR CO.
  29. Position the control lever between the 2 casting ribs on the transaxle case.
    Fig 27: Locating Control Lever And Casting Ribs
    G06097970Courtesy of FORD MOTOR CO.
  30. Place the gear selector lever in the D position.
  31. Tighten the transaxle control cable bracket nuts.
    • Tighten to 22 Nm (16 lb-ft).
  32. To verify the correct cable adjustment, observe the control lever on the transaxle while an assistant shifts the gear selector lever to each range position ending in the D position.
  33. Install the transaxle control snow shield.
    • Tighten to 22 Nm (16 lb-ft).
      Fig 28: Locating Bolts And Transaxle Control Snow Shield
      G06097909Courtesy of FORD MOTOR CO.
  34. Connect the transaxle coolant hoses.
    Fig 29: Locating Transaxle Coolant Hoses
    G06097908Courtesy of FORD MOTOR CO.
  35. Connect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
    Fig 30: Locating Transaxle Coolant Temperature Sensor Electrical Connector And Pin-Type Retainer
    G06097907Courtesy of FORD MOTOR CO.
  36. Position the DC-to-DC converter in place and install the 3 nuts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 31: Locating Nuts And DC-To-DC Converter
      G06097974Courtesy of FORD MOTOR CO.
  37. Connect the DC-to-DC converter electrical connector and 2 wire harness retainer (1 shown).
    • Engage the electrical connector locking tab.
      Fig 32: Locating DC-TO-DC Converter Electrical Connector And Wire Harness Retainers
      G06097905Courtesy of FORD MOTOR CO.
  38. Connect the coolant vent hose,
    Fig 33: Locating Coolant Vent Hose Clamp
    G06097904Courtesy of FORD MOTOR CO.
  39. Connect the 2 low voltage electrical connectors and the engine harness-to-body harness retainer.
    Fig 34: Locating Low Voltage Electrical Connectors And Engine Harness-To-Body Harness Retainer
    G06097903Courtesy of FORD MOTOR CO.
  40. Connect the transaxle harness electrical connector and install the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 35: Locating Stud Bolt And Transaxle Harness Electrical Connector
      G06097852Courtesy of FORD MOTOR CO.
  41. Connect the transaxle selector lever cable fastener to the intake manifold.
    Fig 36: Locating Transaxle Selector Lever Cable Fastener
    G06097901Courtesy of FORD MOTOR CO.
  42. Install the transaxle selector lever cable fasteners on the transaxle stud bolts.
    Fig 37: Locating Transaxle Selector Lever Cable Fasteners
    G06097900Courtesy of FORD MOTOR CO.
  43. Connect the upper evaporative emissions Evaporative Emission (EVAP) tube quick connect coupling to the purge valve. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
    Fig 38: Locating Upper Evaporative Emission Tube Quick Connect Coupling
    G06097899Courtesy of FORD MOTOR CO.
  44. Connect the engine control harness electrical connector.
    Fig 39: Locating Engine Control Harness Electrical Connector
    G06095058Courtesy of FORD MOTOR CO.
  45. If equipped, connect the block heater electrical connector.
    • Attach the harness retainer clips.
      Fig 40: Locating Block Heater Electrical Connector
      G06095050Courtesy of FORD MOTOR CO.
  46. Connect the PCM electrical connector.
    • Position the harness and install the wiring harness retainer.
      Fig 41: Locating PCM Center Electrical Connector And Wiring Harness Retainer
      G06095057Courtesy of FORD MOTOR CO.
  47. Connect the brake booster vacuum hose to the brake booster.
    Fig 42: Locating Brake Booster Vacuum Tube
    G06097895Courtesy of FORD MOTOR CO.
  48. Connect the upper radiator hose to the radiator.
    Fig 43: Locating Upper Radiator Hose Clamp
    G06097986Courtesy of FORD MOTOR CO.
  49. Connect the heater hoses to the heater core.
    Fig 44: Locating Heater Hose Clamps
    G06097893Courtesy of FORD MOTOR CO.
    50. NOTE: Lubricate the oil filter O-ring with clean engine oil before installation.
  50. If equipped, install the oil filter element. For additional information, refer to OIL FILTER ELEMENT .
  51. If equipped, install a new spin-on engine oil filter.
    • Lubricate the spin-on oil filter gasket with clean engine oil. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
      Fig 45: Locating Engine Oil Filter
      G06095070Courtesy of FORD MOTOR CO.

    52. All-Wheel Drive (AWD) vehicles 

  52. Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal.
    Fig 46: Installing Intermediate Shaft Seal
    G06095387Courtesy of FORD MOTOR CO.
  53. Position the Power Transfer Unit (PTU) in place and install the 4 bolts.
    • Tighten to 45 Nm (33 lb-ft).
      Fig 47: Locating PTU-To-Transaxle Bolts
      G06097892Courtesy of FORD MOTOR CO.
  54. Connect the PTU vent hose.
    Fig 48: Locating PTU Vent Hose
    G06097891Courtesy of FORD MOTOR CO.
  55. Install the PTU heat shield and the bolts.
    • Tighten to 11 Nm (97 lb-in).
      Fig 49: Locating PTU Heat Shield And Bolts
      G06097990Courtesy of FORD MOTOR CO.
    56. NOTE: Catalytic converter manifold is removed for clarity.
  56. Position the PTU-to-engine support bracket and install the bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 50: Locating Power Transfer Unit-To-Engine Bracket Bolts
      G06097889Courtesy of FORD MOTOR CO.
  57. Install the 2 exhaust bracket bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 51: Locating Exhaust Bracket Bolts
      G06097888Courtesy of FORD MOTOR CO.
  58. Install the driveshaft. For additional information, refer to DRIVESHAFT .

    59. All vehicles 

    NOTE: RH side shown, LH similar.
  59. Connect the RH and LH suspension.
    1. Position the tie-rod end and install the retaining nut.
      • Tighten to 55 Nm (41 lb-ft).
    2. Connect the stabilizer bar link and install the nut.
      • Tighten to 63 Nm (46 lb-ft).
        Fig 52: Identifying Tie-Rod End Nut And Stabilizer Bar Link Nut
        G06097993Courtesy of FORD MOTOR CO.
  60. Install the intermediate shaft.
    Fig 53: Locating Intermediate Shaft
    G06095033Courtesy of FORD MOTOR CO.
  61. Install the 2 intermediate shaft bearing retainer nuts.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 54: Locating Intermediate Shaft Bearing Retainer Nuts
      G06095032Courtesy of FORD MOTOR CO.
  62. Install the RH and LH halfshafts. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  63. Install the RH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (133 lb-in).
      Fig 55: Locating Brake Hose Retainer And ABS Sensor Retaining Bolt
      G06097885Courtesy of FORD MOTOR CO.
  64. Install the LH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (133 lb-in).
      Fig 56: Locating LH Brake Hose Retainer And ABS Sensor Bolt
      G06097883Courtesy of FORD MOTOR CO.
  65. Install the exhaust intermediate pipe. For additional information, refer to EXHAUST SYSTEM .
  66. Install the lateral support crossmember and the bolts.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 57: Locating Bolts And Lateral Support Crossmember
      G06095031Courtesy of FORD MOTOR CO.
  67. Install the front wheels and tires. For additional information, refer to WHEELS & TIRES .
  68. Connect the fuel supply tube. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
    Fig 58: Locating Fuel Supply Tube
    G06097879Courtesy of FORD MOTOR CO.
  69. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - HYBRID .
  70. Install the engine coolant degas bottle. For additional information, refer to ENGINE COOLING - HYBRID .
  71. Install the battery and the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  72. Install the engine air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - HYBRID .
  73. Fill the engine with clean engine oil.
  74. Enable the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY .
  75. Reset the Passive Anti-Theft System (PATS). For additional information, refer to ANTI-THEFT - PATS - HYBRID .
  76. Fill and bleed the MECS. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING - HYBRID .
  77. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING - HYBRID .
  78. Fill the transaxle with fluid. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - ELECTRONICALLY CONTROLLED CONTINUOUSLY VARIABLE TRANSMISSION (ECVT) .
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