Engine Mechanical - 2.0L: Installation: Engine

SPECIAL TOOLS

	2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
	Lifting Bracket, Engine 303-050 (T70P-6000)
	Powertrain Lift 300-OTC1585AE or equivalent
	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
	Adjustable Grip Arm, 1735A 014-00001 or equivalent

MATERIAL SPECIFICATIONS

Item	Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada) XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)	WSS-M2C945-A
Multi-Purpose Grease XG-4 and/or XL-5	ESB-M1C93-B

NOTE: Lubricate the torque converter pilot hub with multi-purpose grease.
1. Check the installation depth of the torque converter.
   1. Lay a straightedge on the automatic transaxle flange.
   2. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
      Fig 1: Identifying Depth Between Transaxle Flange And Torque Converter Centering Spigot

      Courtesy of FORD MOTOR CO.
2. Using the Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 bellhousing-to-engine fasteners.
   • Tighten to 48 Nm (35 lb-ft).
3. Using the Floor Crane, Engine Lifting Bracket and Spreader Bar, raise the engine and transaxle assembly onto the lift table.
   Fig 2: Raising Engine

   Courtesy of FORD MOTOR CO.
4. Using the Powertrain Lift and Adjustable Grip Arm, secure the engine and transaxle assembly to the lift table.
   Fig 3: Securing Engine To Lift Table Using Powertrain Lift And Adjustable Grip Arm

   Courtesy of FORD MOTOR CO.
NOTE: If new parts are not being used, be sure to align the marks on the flexplate and the stud made during engine removal.
5. Install the 4 torque converter nuts.
   • Tighten to 35 Nm (26 lb-ft).
     Fig 4: Locating Torque Converter Nut

     Courtesy of FORD MOTOR CO.
6. Install the starter motor isolator.
   Fig 5: Locating Starter Motor Isolator

   Courtesy of FORD MOTOR CO.
7. Install the starter motor, stud bolt and the bolt.
   • Install the upper bolt and lower stud bolt finger-tight.
   • Tighten the upper bolt to 35 Nm (26 lb-ft).
   • Tighten the lower stud bolt to 35 Nm (26 lb-ft).
     Fig 6: Locating Starter Stud Bolt And Bolt

     Courtesy of FORD MOTOR CO.
8. Connect the starter motor electrical terminals and install the 2 nuts.
   • Tighten the small nut to 5 Nm (44 lb-in).
   • Tighten the large nut to 12 Nm (106 lb-in).
     Fig 7: Locating Starter Motor Electrical Terminals Nuts

     Courtesy of FORD MOTOR CO.
9. Position the 2 power steering tubes and the wiring harness as an assembly on the engine.
   Fig 8: Locating Power Steering Tubes And Wiring Harness

   Courtesy of FORD MOTOR CO.
10. Install the power steering tube bracket on the A/C compressor stud bolt and install the nut.
    • Tighten to 20 Nm (177 lb-in).
      Fig 9: Locating A/C Compressor Stud Bolt And Nut

      Courtesy of FORD MOTOR CO.
11. Install the engine ground wire and the bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 10: Locating Engine Ground Wire Bolt

      Courtesy of FORD MOTOR CO.
12. Install the power steering tube bracket on the starter motor stud bolt and install the nut.
    • Tighten to 20 Nm (177 lb-in).
      Fig 11: Locating Starter Motor Stud Bolt And Power Steering Tube Bracket

      Courtesy of FORD MOTOR CO.
13. Attach the starter wire harness retainer to the starter motor stud bolt.
    Fig 12: Locating Starter Wire Harness Retainer Of Starter Motor Stud Bolt

    Courtesy of FORD MOTOR CO.
14. Connect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 13: Locating CKP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
15. Attach the 2 CKP sensor wire harness retainers.
    Fig 14: Locating Crankshaft Position (CKP) Sensor Wire Harness Retainers

    Courtesy of FORD MOTOR CO.
16. Attach the wire harness pin-type retainer to the intake manifold.
    Fig 15: Locating Wiring Harness Pin-Type Retainer To Intake Manifold

    Courtesy of FORD MOTOR CO.
17. Connect the Power Steering Pressure (PSP) switch electrical connector.
    Fig 16: Locating Power Steering Pressure Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
18. Connect the A/C compressor electrical connector.
    Fig 17: Locating A/C Compressor Electrical Connector

    Courtesy of FORD MOTOR CO.
19. Connect the 2 transaxle electrical connectors.
    Fig 18: Locating Transaxle Electrical Connectors

    Courtesy of FORD MOTOR CO.
20. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.
    Fig 19: Locating Turbine Shaft Speed Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
21. Connect the Output Shaft Speed (OSS) sensor electrical connector.
    Fig 20: Locating Output Shaft Speed Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
22. Position the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) wire connector bracket and install the nut.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 21: Locating HO2S And CMS Wire Connector Bracket And Nut

      Courtesy of FORD MOTOR CO.
23. Install the nut for the HO2S and CMS wire connector bracket.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 22: Locating HO2S And CMS Wire Connector Bracket Nut

      Courtesy of FORD MOTOR CO.
24. Using the lift table, position the engine and transaxle assembly in the vehicle.
25. Install the transaxle mount plate and the 5 nuts.
    • Tighten the center nut to 150 Nm (111 lb-ft).
    • Tighten the 4 outer nuts to 48 Nm (35 lb-ft).
      Fig 23: Locating Transaxle Mount Nuts

      Courtesy of FORD MOTOR CO.
26. Install the engine mount and the 3 bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 24: Locating Engine Mount And Bolts

      Courtesy of FORD MOTOR CO.
27. Install the 2 motor mount nuts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 25: Locating Engine Mount Nuts

      Courtesy of FORD MOTOR CO.
28. Install the 2 oil pan-to-bellhousing bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 26: Locating Oil Pan-To-Bell Housing Bolts

      Courtesy of FORD MOTOR CO.
29. Install the 2 lower bellhousing-to-oil pan bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 27: Locating Lower Bellhousing-To-Oil Pan Bolts

      Courtesy of FORD MOTOR CO.
NOTE: The bolts are different lengths, make sure the bolts are in the correct location.
30. Install the transaxle roll restrictor and the 2 bolts.
    1. Install the transaxle roll restrictor.
    2. Install the short bolt.
    3. Install the long bolt.
       • Tighten to 70 Nm (52 lb-ft).
         Fig 28: Identifying Transaxle Roll Restrictor With Short And Long Bolt

         Courtesy of FORD MOTOR CO.
31. Install the transaxle fluid indicator.
    Fig 29: Locating Transaxle Fluid Level Indicator

    Courtesy of FORD MOTOR CO.
32. Connect the heater hose to the coolant tube.
    Fig 30: Locating Heater Hose Of Coolant Tube

    Courtesy of FORD MOTOR CO.
33. Connect the upper radiator hose and the heater hose to the coolant bypass.
    Fig 31: Locating Upper Radiator Hose And Heater Hose From Coolant Bypass

    Courtesy of FORD MOTOR CO.
34. Connect the coolant degas bottle vent hose to the coolant bypass.
    Fig 32: Locating Coolant Degas Bottle Vent Hose To Coolant Bypass

    Courtesy of FORD MOTOR CO.
35. Connect the coolant degas bottle hose and install the retaining clip.
    Fig 33: Locating Coolant Degas Bottle Hose And Retaining Clip

    Courtesy of FORD MOTOR CO.
36. Install the power steering pump. For additional information, refer to POWER STEERING .
37. Clean and inspect the exhaust manifold flange. For additional information, refer to Exhaust Manifold Cleaning and Inspection in ENGINE SYSTEM - GENERAL INFORMATION .
38. Install the exhaust manifold. For additional information, refer to EXHAUST MANIFOLD  .
39. Connect the power steering cooler tube.
    Fig 34: Locating Power Steering Cooler Tube

    Courtesy of FORD MOTOR CO.
40. Using 2 new O-ring seals, install the power steering tubes to the steering gear and install the bolt.
    • Tighten to 18 Nm (159 lb-in).
      Fig 35: Locating Power Steering Tubes And Bolt

      Courtesy of FORD MOTOR CO.
41. Install the power steering tube clip and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 36: Locating Power Steering Tube Clip Bolt

      Courtesy of FORD MOTOR CO.
42. Install the LH and RH halfshafts. For additional information, refer to FRONT DRIVE HALFSHAFTS .
NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
43. Install a new engine oil filter.
    • Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
      Fig 37: Locating Engine Oil Filter

      Courtesy of FORD MOTOR CO.
44. Connect the lower radiator hose to the radiator.
    Fig 38: Locating Lower Radiator Hose To Radiator

    Courtesy of FORD MOTOR CO.
45. Install the cooling fan motor and shroud. For additional information, refer to ENGINE COOLING .
46. Using 2 new O-ring seals, connect the A/C tubes to the compressor.
    Fig 39: Locating A/C Tube O-Rings

    Courtesy of FORD MOTOR CO.
47. Install the 2 A/C tube-to-compressor nuts.
    • Tighten to 15 Nm (133 lb-in).
      Fig 40: Locating A/C Tube-To-Compressor Nuts

      Courtesy of FORD MOTOR CO.
48. Position and attach the 2 B+ battery cable wire harness retainers.
    Fig 41: Locating B+ Battery Cable Wire Harness Retainers From Valve Cover Stud Bolts

    Courtesy of FORD MOTOR CO.
49. Install the generator. For additional information, refer to CHARGING SYSTEM .
50. Install the accessory drive belt and tensioner. For additional information, refer to ACCESSORY DRIVE .
51. Install the 2 front wheels and tires. For additional information, refer to WHEELS AND TIRES .
52. Install the engine oil level indicator.
    Fig 42: Locating Engine Oil Level Indicator

    Courtesy of FORD MOTOR CO.
53. Install the transmission fluid cooler tubes on the transaxle and slide the latches to the locked position.
    Fig 43: Installing Transmission Fluid Cooler Tubes On Transaxle

    Courtesy of FORD MOTOR CO.
54. Install the secondary latches.
    Fig 44: Locating Transmission Fluid Cooler Tube Secondary Latches

    Courtesy of FORD MOTOR CO.
55. Connect the transaxle shift cable to the lever and bracket.
    Fig 45: Locating Transaxle Shift Cable

    Courtesy of FORD MOTOR CO.
56. Connect the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical connectors and attach the wire harness retainer.
    Fig 46: Locating Heated Oxygen Sensor And Catalyst Monitor Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
57. Connect the starter wire harness electrical connector.
    Fig 47: Locating Starter Wire Harness Electrical Connector

    Courtesy of FORD MOTOR CO.
58. Connect the 3 PCM electrical connectors.
    Fig 48: Locating PCM Electrical Connectors

    Courtesy of FORD MOTOR CO.
59. Install the ground wire and nut on the negative battery terminal.
    • Tighten to 10 Nm (89 lb-in).
      Fig 49: Locating Ground Wire And Nut On Negative Battery Terminal

      Courtesy of FORD MOTOR CO.
60. Attach the engine harness to the coolant outlet bracket harness retainer.
    Fig 50: Locating Engine Harness Of Coolant Outlet Bracket Harness Retainer

    Courtesy of FORD MOTOR CO.
61. Connect and attach the 2 engine harness electrical connectors.
    Fig 51: Locating Engine Harness Electrical Connectors

    Courtesy of FORD MOTOR CO.
62. Install the power brake booster vacuum tube into the quick connect fitting.
    Fig 52: Locating Vacuum Tube Of Quick Release Fitting

    Courtesy of FORD MOTOR CO.
63. Position and connect the Evaporative Emission (EVAP) tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 53: Locating Evaporative Emission (EVAP) Tube And Position Aside

    Courtesy of FORD MOTOR CO.
64. Connect the fuel tube quick connect coupling to the fuel tube near the bulkhead. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 54: Locating Fuel Tube Quick Connect Coupling From Fuel Tube Near Bulkhead

    Courtesy of FORD MOTOR CO.
65. Install the negative battery cable ground and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 55: Locating Negative Battery Cable Ground Bolt

      Courtesy of FORD MOTOR CO.
66. Attach the 3 positive battery cable wire harness retainer.
    Fig 56: Locating Positive Battery Cable Wire Harness Retainers

    Courtesy of FORD MOTOR CO.
67. Connect the positive battery cable nut.
    • Tighten to 10 Nm (89 lb-in).
      Fig 57: Locating Positive Battery Cable Terminal Nut

      Courtesy of FORD MOTOR CO.
68. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
69. Connect the crankcase vent tube to the valve cover.
    Fig 58: Locating Crankcase Vent Tube

    Courtesy of FORD MOTOR CO.
70. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
71. Fill the engine with clean engine oil.
72. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
73. Evacuate and charge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
74. Install the splash shield, pin-type retainer and the 2 bolts.
    Fig 59: Locating Splash Shield, Pin-Type Retainer And Bolts

    Courtesy of FORD MOTOR CO.