Section 250 (Engine Mechanical - 2.0L DURATEC): Installation: Engine

WARNING: This page is about a different car, the 2014 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S) DESCRIPTION

	300-OTC1585AE Powertrain Lift
	300-OTC1819E 2, 200# Floor Crane, Fold Away
	303-D089 (D93P-6001-A3) Spreader Bar
Magnetic Socket
Adjustable Mounting Arm
Hose Clamp Remover/Installer
Wooden Block

MATERIALS SPECIFICATION

Name	Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.) XO-5W20-QSP (U.S.)	WSS-M2C945-A

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.
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 in illustration below, manual transmission similar.

Align the transmission to the engine.
- 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)
Torque : 177 lb.in (20 Nm)
NOTE: Automatic transmission shown in illustration below, manual transmission similar.

Torque : 33 lb.ft (45 Nm)
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 .
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

multimedia:A supplement to the article is available.
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 in illustration below.

Use the General Equipment: Magnetic Socket

Torque : 106 lb.in (12 Nm)
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 the sequence shown in illustration below.

Use the General Equipment: Magnetic Socket

Torque : 18 lb.ft (25 Nm)

multimedia:A supplement to the article is available.
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.
Refer to: STARTER MOTOR .
If equipped with automatic transmission.
Position the powertrain into the vehicle.
Torque : 111 lb.ft (150 Nm)
Torque :
Stage 1: Tighten the 2 nuts to:: 59 lb.ft (80 Nm)

Stage 2: Tighten the 2 bolts to:: 66 lb.ft (90 Nm)
Torque : 63 lb.ft (86 Nm)
NOTE: Automatic transmission shown in illustration below, manual transmission similar.

Torque : 35 lb.ft (48 Nm)
NOTE: Automatic transmission shown in illustration below, manual transmission similar.

Torque : 35 lb.ft (48 Nm)
Refer to: COOLING FAN MOTOR AND SHROUD .
NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.

Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)

Torque :

Stage 1: 71 lb.in (8 Nm)

Stage 2: 180
Use the General Equipment: Hose Clamp Remover/Installer
NOTE: Install 2 new O-ring seals.
- Tighten the nuts to:
  Torque : 177 lb.in (20 Nm)
- Tighten the bolt to:
  Torque : 18 lb.ft (25 Nm)
Torque : 159 lb.in (18 Nm)
Refer to: FRONT HALFSHAFT RH .
Refer to: FRONT HALFSHAFT LH .
If equipped with a manual transmission.
Torque : 35 lb.ft (48 Nm)
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.
If equipped with an automatic transmission.
Torque : 89 lb.in (10 Nm)
If equipped with an automatic transmission.
If equipped with an automatic transmission.
If equipped with an automatic transmission.
Refer to: QUICK RELEASE COUPLING .
Refer to: QUICK RELEASE COUPLING .
NOTE: Install 5 new catalytic converter-to-cylinder head studs.

Torque : 150 lb.in (17 Nm)
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 5 new catalytic converter manifold-to-cylinder head nuts and tighten in 2 stages in the sequence shown in illustration below.

Torque :

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

Stage 2: Retighten:: 41 lb.ft (55 Nm)
Torque : 18 lb.ft (25 Nm)
- 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)
Torque : 18 lb.ft (25 Nm)
Torque : 89 lb.in (10 Nm)
Refer to: HEATED OXYGEN SENSOR (HO2S) .
If equipped.
Use the General Equipment: Hose Clamp Remover/Installer
Torque : 177 lb.in (20 Nm)
NOTE: The electrical connector is located behind the PCM case.
Refer to: POWERTRAIN CONTROL MODULE (PCM) .
If equipped with automatic transmission.
Install the following items:
1. Refer to: AIR CLEANER .
  Refer to: AIR CLEANER OUTLET PIPE .
2. Refer to: BATTERY TRAY .
3. Refer to: DEGAS BOTTLE .
If equipped with manual transmission, fill and bleed the clutch system.
Refer to: CLUTCH SYSTEM BLEEDING - 6-SPEED MANUAL TRANSMISSION - MMT6 .
Refer to: COOLING SYSTEM DRAINING AND VACUUM FILLING .
Refer to: COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
Refer to: AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING .
Fill the engine with clean engine oil.
Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (U.S.)/XO-5W20-QSP (U.S.) (WSS-M2C945-A)
After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.