Section 3298 (Engine - 2.7L ECOBOOST (238KW/324PS)): Installation: Engine

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	303-1246 Engine Spreader Bar TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1634 Lift Eyes (2) TKIT-2014D-FL_ROW TKIT-2014D-ROW3
Floor Crane
Trolley Jack
Wooden Block

Materials 

1. 1. Inspect the engine mount-to-frame nut plate for thread damage.
   2. If the nut plate is damaged, remove and discard the engine mount-to-frame nut plate.
   • Clean the engine mount-to-frame mating surfaces of any dirt or foreign material prior to installation.

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2. Lubricate the torque converter pilot hub with multi-purpose grease.

   Material

   : Motorcraft ® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)

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3. 1. Inspect the torque converter stud and flexplate for paint marks.
   2. Align the torque converter stud and flexplate hole near the paint marks to the 12 o'clock position.

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4. Using the floor crane, position the engine in the engine compartment. Use the General Equipment: Floor Crane

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5. • Align the engine to the transmission and install the bolts.
   • Draw the engine and transmission together evenly using the bolts.

     Torque: 35 lb.ft (48 Nm)

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6. Remove the floor jack and the block of wood. Use the General Equipment: Trolley Jack. Use the General Equipment: Wooden Block

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7. Install the LH engine mount and the new engine mount-to-frame bolts.

   Torque: 129 lb.ft (175 Nm)

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8. Using the floor crane, lower the engine assembly into the installed position.
   1. Remove the floor crane and chain. Use the General Equipment: Floor Crane
   2. Remove Special Service Tool: 303-1246 Engine Spreader Bar., 303-1634 Lift Eyes (2).

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9. NOTE: Only use hand tools when installing the engine mount studs or damage to the engine mount can occur.
   NOTE: Apply threadlock to the stud threads prior to installation.

   Install the engine mount studs.

   Material

   : Motorcraft ® Threadlock 262 / TA-26 (WSK-M2G351-A6)

   Torque: 22 lb.ft (30 Nm)

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10. NOTE: Only use hand tools when installing the engine mount nuts or damage to the engine mount can occur.

    Install the new RH engine mount nuts.

    Torque: 111 lb.ft (150 Nm)

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11. NOTE: Only use hand tools when tightening the engine mount through bolts or damage to the engine mount-to-cylinder block bracket can occur.

    Install the new LH engine mount through bolt.

    Torque: 258 lb.ft (350 Nm)

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12. NOTE: Only use hand tools when installing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur.

    Tighten the transmission mount-to-crossmember nuts.

    Torque: 85 lb.ft (115 Nm)

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13. Install the selector lever cable bracket and the LH bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

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14. Install the bracket and the bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

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15. If equipped, attach the 4x4 vent hose retainer.

    Torque: 35 lb.ft (48 Nm)

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16. Install the RH side bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

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17. Install the lower bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

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18. NOTE: Using the crankshaft pulley bolt, turn the engine clockwise.

    Install the new torque converter nuts.

    Torque: 30 lb.ft (40 Nm)

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19. Install the access cover and the retainers.

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20. NOTE: Inspect the case and make sure the old transmission fluid cooler tube O-rings are not stuck in the case.
    NOTE: Install new transmission fluid cooler tube O-rings on the ends of the transmission fluid cooler tubes prior to installing.

    Install new transmission fluid cooler tube O-rings on the transmission fluid cooler tubes.

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21. 1. Position back the transmission cooler fluid cooler tubes and attach the retainer.
    2. Install the new transmission fluid cooler tube bracket bolt.

       Torque: 22 lb.ft (30 Nm)

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22. If equipped, install the selector lever cable splash shield and nut.

    Torque: 106 lb.in (12 Nm)

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23. Install the transmission fluid cooler tube bracket and nut.

    Torque: 106 lb.in (12 Nm)

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24. 1. Push the transmission electrical connector in to connect.
    2. Rotate the transmission electrical connector clockwise.
    3. Attach the wiring harness retainers.
    4. Connect the transmission fluid auxiliary pump electrical connector.

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25. If equipped, attach the 4x4 wiring harness retainers.

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26. Connect the RH catalyst monitor sensor and HO2S electrical connectors.

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27. Connect the LH catalyst monitor sensor and HO2S electrical connectors.

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28. Install new exhaust gaskets.
    • Position the catalytic converters forward into the installed position.

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29. Position the flange onto the studs and loosely install new RH catalytic converter nuts.

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30. Position the flange onto the studs and loosely install new LH catalytic converter nuts.

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31. Evenly tighten the nuts.

    Torque: 30 lb.ft (40 Nm)

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32. Evenly tighten the nuts.

    Torque: 30 lb.ft (40 Nm)

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33. Position the exhaust Y-pipe dual catalytic converter onto the exhaust intermediate pipe and install bolts.
    • Evenly tighten the bolts.

      Torque: 46 lb.ft (63 Nm)

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34. Install the following items:
    1. If equipped. Refer to: Front Driveshaft .
    2. Refer to: Starter Motor .

35. 1. Install the pin-type retainer.
    2. Install the ground wire and bolt.

       Torque: 18 lb.ft (25 Nm)

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36. 1. Install the wiring harness retainer nut.

       Torque: 106 lb.in (12 Nm)

    2. Install the pin-type retainer.

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37. Attach the wiring harness retainer located below the generator to the cylinder block.

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38. WARNING: Do not reuse steering column shaft bolts. This may result in fastener failure and steering column shaft detachment or loss of steering control. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
    1. Connect the steering column shaft u-joint to the steering gear.
    2. Install the new steering column shaft bolt.

       Torque: 22 lb.ft (30 Nm)

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39. • Install the wiring terminal and nut.

      Torque: 150 lb.in (17 Nm)

    • Position the protective cover.
    • Connect the generator electrical connector.

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40. • Connect the A/C compressor electrical connector.
    • Attach the wiring harness retainers.

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41. • Install new O-ring seals and gaskets.
    • Connect the A/C tubes and install the nuts.

      Torque: 133 lb.in (15 Nm)

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42. Connect the EVAP tube quick release coupling. Refer to: Quick Release Coupling .

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43. Connect the high-pressure fuel pump fuel feed tube quick release coupling. Refer to: Quick Release Coupling .

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44. 1. Install the MAP sensor and the bolt.

       Torque: 62 lb.in (7 Nm)

    2. Position the vacuum harness pressure sensor and install the bolt.

       Torque: 62 lb.in (7 Nm)

    3. Connect the wiring harness electrical connectors.

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45. Connect the heater core inlet and outlet hoses.

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46. If equipped, attach 4x4 wiring harness retainer to the rear RH valve cover stud bolt.

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47. Connect the engine wiring harness electrical connectors.

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48. Attach the wiring harness retainer, the ground wire terminals and install the nuts.

    Torque: 106 lb.in (12 Nm)

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49. 1. Install the vacuum tube assembly and connect the vacuum tubes.
    2. Connect the quick release couplings. Refer to: Quick Release Coupling .

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50. 1. Connect the crankcase pressure sensor electrical connector.
    2. Connect the PCV tube quick release coupling. Refer to: Quick Release Coupling .

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51. Install the EVAP tube assembly and connect the quick release coupling. Refer to: Quick Release Coupling .

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52. Install the PCV tube and connect the quick release couplings. Refer to: Quick Release Coupling .

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53. Install the coolant hoses and clamps.

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54. Install the following items:
    1. Refer to: Charge Air Cooler (CAC) Outlet Pipe .
    2. Remove the RH and the LH CAC intake pipes. Refer to: Charge Air Cooler (CAC) Intake Pipe .
    3. Refer to: Air Cleaner Outlet Pipe RH .
    4. Refer to: Air Cleaner Outlet Pipe LH .

55. 1. Slide the engine appearance cover into the retaining bracket.
    2. Install the nuts.

       Torque: 44 lb.in (5 Nm)

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56. Install the TC bypass tube and rotate the retaining ring clockwise 180 degrees.

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57. • Install a new O-ring seal and gasket seal.
    • Connect the A/C tube and install the nut.

      Torque: 133 lb.in (15 Nm)

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58. Connect the A/C pressure transducer electrical connector.

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59. Install the following items:
    1. Refer to: Cooling Module .
    2. Refer to: Degas Bottle .
    3. Refer to: Cowl Panel .

60. NOTE: Align the index marks made during hood removal.

    Position the hood and install the nuts.

    Torque: 18 lb.ft (25 Nm)

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61. Install the RH and LH fender splash shields. Refer to: Fender Splash Shield .
62. If equipped, install the skid plate and bolts.

    Torque: 30 lb.ft (40 Nm)

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63. If equipped, install the underbody shield and fasteners.

    Torque: 71 lb.in (8 Nm)

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64. If equipped, install the underbody shield and fasteners.

    Torque: 30 lb.ft (40 Nm)

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65. If equipped, install the skid plate and bolts.

    Torque: 30 lb.ft (40 Nm)

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66. Install the front wheels and tires. Refer to: Wheel and Tire .
67. NOTE: If the filter housing stem is damaged or missing the oil will flow through the reservoir drain port and a loss  of engine oil pressure will occur.

    Inspect the oil filter housing and stem for damage including cracks or separation of the stem from the housing. If damaged, a new oil filter housing assembly must be installed.

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68. • NOTE: Failure to install new oil filter housing-to-engine front cover seals may result in oil leakage.

      Install new oil filter housing-to-engine front cover seals and lubricate with clean engine oil.

      Material

      : Engine Oil - 5W30 - Synthetic Blend

    • NOTE: Failure to install a new oil filter housing stem-to-oil reservoir drain port seal will result with the oil flowing through the reservoir drain port and a loss  of engine oil pressure.

      Install a new oil filter housing stem-to-oil reservoir drain port seal and lubricate with clean engine oil.

      Material

      : Engine Oil - 5W30 - Synthetic Blend

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69. 1. Install a new oil filter element.
    2. Install the oil filter housing.

       Torque: 18 lb.ft (24 Nm)

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70. Fill the engine with clean engine oil. Refer to: Specifications .

    Material

    : Engine Oil - 5W30 - Synthetic Blend

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71. After filling the engine with oil, the oil must flow from the main chamber of the oil pan, through a check valve into the smaller side chamber to correctly register the oil level on the oil level indicator. This may take up to 15 minutes.

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72. Check the oil level and adjust as necessary.

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73. Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
74. Fill and bleed the engine cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding .
75. Check the transmission fluid level. Refer to: Transmission Fluid Level Check .
76. Start and check the exhaust system for leaks.
77. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure using a diagnostic scan tool.