Section 249 (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
Courtesy of FORD MOTOR COMPANY	307-346 (T97T-7902-A) Retainer, Torque Converter TKIT-1997-F/FLM/LT TKIT-1998-LM (NavigatoR)
Floor Crane
Adjustable Mounting Arm
Hose Clamp Remover/Installer
Powertrain Jack
Wooden Block

Materials 

2WD/4WD 

1. Lubricate the torque converter hub with multi-purpose grease. Remove Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

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

   Courtesy of FORD MOTOR COMPANY

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

   Courtesy of FORD MOTOR COMPANY

3. Position the engine onto the transmission and subframe assembly. Use the General Equipment: Floor Crane

   Courtesy of FORD MOTOR COMPANY

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

   Courtesy of FORD MOTOR COMPANY

5. Install the transmission bellhousing bolts.

   Courtesy of FORD MOTOR COMPANY

6. Tighten.

   Torque: 35 lb.ft (48 Nm)

   Courtesy of FORD MOTOR COMPANY

7. NOTE: 4WD shown, 2WD similar.

   If equipped, install the transmission bellhousing bolt.

   Torque: 35 lb.ft (48 Nm)

   Courtesy of FORD MOTOR COMPANY

8. NOTE: 4WD shown, 2WD similar.

   Install the transmission bellhousing bolts.

   Torque: 35 lb.ft (48 Nm)

   Courtesy of FORD MOTOR COMPANY

9. Install. Use the General Equipment: Adjustable Mounting Arm

   Courtesy of FORD MOTOR COMPANY

10. 1. Remove the floor crane and length of chain with connecting links. Use the General Equipment: Floor Crane
    2. Remove Special Service Tool: 303-1246 Engine Spreader Bar., 303-1634 Lift Eyes (2).

    Courtesy of FORD MOTOR COMPANY

    4WD 

11. Using the bolts, draw the PTU up to the transmission.

    Torque: 66 lb.ft (90 Nm)

    Courtesy of FORD MOTOR COMPANY

12. Install the heat shield and the bolts.

    Torque: 97 lb.in (11 Nm)

    Courtesy of FORD MOTOR COMPANY

    2WD/4WD 

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

    Install the new torque converter nuts.

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

14. Install the access cover and the retainers.

    Courtesy of FORD MOTOR COMPANY

15. Install the starter and the stud bolts.

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

16. Install the bracket and the nuts.

    Torque: 17 lb.ft (23 Nm)

    Courtesy of FORD MOTOR COMPANY

17. 1. Attach the wiring harness retainers.
    2. Connect the starter electrical connector.
    3. Connect the starter cable and install the nut.

       Torque: 106 lb.in (12 Nm)

    4. Position the starter cable protective cover.

    Courtesy of FORD MOTOR COMPANY

18. • Connect the transmission electrical connector.
    • Attach the wiring harness retainers.

    Courtesy of FORD MOTOR COMPANY

19. • Attach the wiring harness retainer.
    • If equipped, attach the PTU vent hose retainer.

    Courtesy of FORD MOTOR COMPANY

20. Attach the wiring harness retainers.

    Courtesy of FORD MOTOR COMPANY

21. 1. Connect the generator cable and install the nut.

       Torque: 159 lb.in (18 Nm)

    2. Position the generator cable protective cover.
    3. Connect the generator electrical connector.

    Courtesy of FORD MOTOR COMPANY

22. Install a new RH catalytic converter gasket.

    Courtesy of FORD MOTOR COMPANY

23. 1. Install the RH catalytic converter.
    2. Install new RH catalytic converter nuts.

       Torque: 30 lb.ft (40 Nm)

    Courtesy of FORD MOTOR COMPANY

24. 1. Install.

       Torque: 22 lb.ft (30 Nm)

    2. Tighten.

       Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

26. Using the powertrain jack, raise the powertrain and subframe assembly into the engine compartment. Use the General Equipment: Powertrain Jack

    Courtesy of FORD MOTOR COMPANY

27. NOTE: The engine mount and bracket are serviced as an assembly. Do not remove the engine mount bracket-to-engine mount bolt, this fastener is not serviceable.
    1. Install the engine mount and bracket assembly and the nuts.

       Torque: 59 lb.ft (80 Nm)

    2. Install the bolts and nut.

       Torque:

       Nut: 66 lb.ft (90 Nm)

       Bolt: 81 lb.ft (110 Nm)

    Courtesy of FORD MOTOR COMPANY

28. Install the transmission mount bolts.

    Torque: 59 lb.ft (80 Nm)

    Courtesy of FORD MOTOR COMPANY

29. NOTE: Align the reference marks made during removal.
    NOTE: Only tighten the bolts finger tight at this stage.

    Install the new subframe bolts.

    Courtesy of FORD MOTOR COMPANY

30. NOTE: Align the reference marks made during removal.
    NOTE: Only tighten the bolts finger tight at this stage.
    1. Install the subframe brackets and the new subframe bolts.
    2. Install the subframe bracket bolts.

    Courtesy of FORD MOTOR COMPANY

31. NOTE: While tightening the subframe bolts, make sure the front subframe does not move.

    Tighten the subframe bolts.

    Torque: 173 lb.ft (235 Nm)

    Courtesy of FORD MOTOR COMPANY

32. 1. Tighten.

       Torque:

       Stage 1: 76 lb.ft (103 Nm)

       Stage 2: 270 °

    2. Tighten.

       Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

33. Install the bolts and nuts.

    Torque: 173 lb.ft (235 Nm)

    Courtesy of FORD MOTOR COMPANY

34. Remove. Use the General Equipment: Adjustable Mounting Arm

    Courtesy of FORD MOTOR COMPANY

35. Install the bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

    Courtesy of FORD MOTOR COMPANY

36. Remove. Use the General Equipment: Powertrain Jack Use the General Equipment: Wooden Block

    Courtesy of FORD MOTOR COMPANY

    4WD 

37. Tighten.

    Torque: 66 lb.ft (90 Nm)

    Courtesy of FORD MOTOR COMPANY

38. Install the driveshaft. Refer to: Rear Driveshaft .

    2WD/4WD 

39. Install the following items:
    1. LH catalytic convertor. Refer to: Catalytic Converter LH .
    2. Exhaust flexible pipes. Refer to: Exhaust Flexible Pipe .

40. Install the subframe support bracket and the nuts.

    Torque: 33 lb.ft (45 Nm)

    Courtesy of FORD MOTOR COMPANY

41. Install the following items:
    1. NOTE: Do not allow the brake caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur.

       Remove the LH brake disc. Refer to: Brake Disc .

    2. RH front halfshaft. Refer to: Front Halfshaft RH - 2.7L EcoBoost (238kW/324PS), All-Wheel Drive (AWD) . Refer to: Front Halfshaft RH - FWD .

42. 1. Position the tie rod end into the wheel knuckle.
    2. Install the new tie rod end nut.

       Torque: 111 lb.ft (150 Nm)

    Courtesy of FORD MOTOR COMPANY

43. 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.

    Position the RH sway bar link and install the new nut.

    Torque: 85 lb.ft (115 Nm)

    Courtesy of FORD MOTOR COMPANY

44. 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.

    Position the LH sway bar link and install the new nut.

    Torque: 85 lb.ft (115 Nm)

    Courtesy of FORD MOTOR COMPANY

45. Install the LH anti-lock sensor and the bolt.

    Torque: 80 lb.in (9 Nm)

    Courtesy of FORD MOTOR COMPANY

46. Install the A/C compressor, the bolts and the stud bolt.

    Torque: 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

47. Connect the A/C compressor inlet and outlet line fittings and install the nuts.

    Torque: 159 lb.in (18 Nm)

    Courtesy of FORD MOTOR COMPANY

48. • Connect the A/C compressor electrical connectors.
    • Slide the insulator over the A/C compressor electrical connector.
    • Attach the wiring harness retainers.

    Courtesy of FORD MOTOR COMPANY

49. 1. Position the A/C line bracket onto the generator stud.
    2. Attach the wiring harness retainer.

    Courtesy of FORD MOTOR COMPANY

50. Install the generator nut.

    Torque: 35 lb.ft (47 Nm)

    Courtesy of FORD MOTOR COMPANY

51. Install the RH front suspension height sensor. Refer to: Front Suspension Height Sensor .
52. Connect and attach the engine harness electrical connector.

    Courtesy of FORD MOTOR COMPANY

53. Connect the transmission fluid cooler tubes to the transmission fluid cooler thermal bypass valve.

    Courtesy of FORD MOTOR COMPANY

54. Install the transmission fluid cooler tube secondary latches.

    Courtesy of FORD MOTOR COMPANY

55. 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.

    Courtesy of FORD MOTOR COMPANY

56. • 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: Motorcraft ® SAE 5W-30 Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

    • 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: Motorcraft ® SAE 5W-30 Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

    Courtesy of FORD MOTOR COMPANY

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

       Torque: 18 lb.ft (24 Nm)

    Courtesy of FORD MOTOR COMPANY

58. Position the wiring harness and attach the retainer.

    Courtesy of FORD MOTOR COMPANY

59. 1. Connect the high-pressure fuel pump fuel feed tube quick release coupling. Refer to: Quick Release Coupling .
    2. Connect the EVAP tube quick release coupling. Refer to: Quick Release Coupling .

    Courtesy of FORD MOTOR COMPANY

60. • Connect the engine wiring harness electrical connector and retainer.
    • Connect the PCM electrical connector.

    Courtesy of FORD MOTOR COMPANY

61. 1. Install the ground wire and the bolt.

       Torque: 159 lb.in (18 Nm)

    2. Attach the wiring harness retainers.

    Courtesy of FORD MOTOR COMPANY

62. 1. Connect the lower radiator hose. Use the General Equipment: Hose Clamp Remover/Installer
    2. Connect the heater hose. Use the General Equipment: Hose Clamp Remover/Installer
    3. Attach the heater hose retainer.
    4. Install the bolt.

       Torque: 80 lb.in (9 Nm)

    Courtesy of FORD MOTOR COMPANY

63. 1. Install the radiator hose onto the engine and retaining tab.
    2. Tighten the radiator hose clamp.

       Torque: 48 lb.in (5.4 Nm)

    3. Attach the heater hose retainer.

    Courtesy of FORD MOTOR COMPANY

64. 1. Attach the cable to the transmission control lever.
    2. Position the cable and install the bolt.

       Torque: 62 lb.in (7 Nm)

    Courtesy of FORD MOTOR COMPANY

65. Connect the vacuum tube quick release couplings. Refer to: Quick Release Coupling .

    Courtesy of FORD MOTOR COMPANY

66. Install the bolt and attach the wiring harness retainers.

    Torque: 106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

67. Install the nuts and connect the electrical connector.

    Torque: 106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

68. Close the cover.

    Courtesy of FORD MOTOR COMPANY

69. • Position the top part of junction box.
    • Latch the tabs.

    Courtesy of FORD MOTOR COMPANY

70. Install the ground cable and stud bolt.

    Torque: 106 lb.in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

71. Install the following items:
    1. Refer to: Battery Tray .
    2. Refer to: Accessory Drive Belt .
    3. Refer to: Charge Air Cooler (CAC) Outlet Pipe .
    4. Refer to: Charge Air Cooler (CAC) Intake Pipe .
    5. Refer to: Air Cleaner Outlet Pipe RH .
    6. Refer to: Air Cleaner Outlet Pipe LH .
    7. Refer to: Degas Bottle .

72. 1. Install the engine appearance cover and the nut.

       Torque: 42 lb.in (4.8 Nm)

    2. Install the bolt.

       Torque: 93 lb.in (10.5 Nm)

    Courtesy of FORD MOTOR COMPANY

73. Install the underbody shields and the retainers.

    Courtesy of FORD MOTOR COMPANY

74. If equipped, install the underbody shields and the retainers.

    Courtesy of FORD MOTOR COMPANY

75. Install the front underbody shield and the retainers.

    Courtesy of FORD MOTOR COMPANY

76. Install the underbody shields and the retainers.

    Courtesy of FORD MOTOR COMPANY

77. Install the front wheels and tires. Refer to: Wheel and Tire .
78. Position steering column shaft and install a new bolt.

    Torque: 18 lb.ft (25 Nm)

    Courtesy of FORD MOTOR COMPANY

79. Remove the holding device.

    Courtesy of FORD MOTOR COMPANY

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

    Material: Motorcraft ® SAE 5W-30 Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)

    Courtesy of FORD MOTOR COMPANY

81. 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.

    Courtesy of FORD MOTOR COMPANY

82. Fill and bleed the engine cooling system. Refer to: Cooling System Draining, Vacuum Filling And Bleeding .
83. Charge the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation And Charging .
84. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.