Ford Fusion Manuals

Ford Fusion: Engine - 1.5L EcoBoost (118kW/160PS) – I4 / Engine. Installation

Special Tool(s) / General Equipment

Ford Fusion. Engine. Installation 300-OTC1819E
2,200# Floor Crane, Fold Away
Ford Fusion. Engine. Installation 303-1502
Lifting Device Engine
TKIT-2012A-FL
TKIT-2012A-ROW
Adjustable Mounting Arm
Hose Clamp Remover/Installer

Materials

Name Specification
Motorcraft® Multi-Purpose Grease Spray
XL-5-A
ESB-M1C93-B
 
Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil
XO-5W20-Q1SP
WSS-M2C945-B1
 

All vehicles

  1. Lubricate the torque converter pilot hub with Multi-Purpose Grease.
    Material: Motorcraft® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)
Ford Fusion. Engine. Installation
  1. Inspect the engine block dowels. If the dowels are damaged or missing, install new engine block dowels.
Ford Fusion. Engine. Installation
  1. Draw the engine to the transmission together and install the bolt.
    Torque: 35 lb.ft (48 Nm)
Ford Fusion. Engine. Installation
  1. Install the engine to transmission bolts.
    Torque: 35 lb.ft (48 Nm)
Ford Fusion. Engine. Installation
  1. Install the engine to transmission bolts.
    Torque: 35 lb.ft (48 Nm)
Ford Fusion. Engine. Installation
  1. Install the Adjustable Mounting Arm.
    Use the General Equipment: Adjustable Mounting Arm
Ford Fusion. Engine. Installation
  1. Remove Special Service Tool: 300-OTC1819E  2,200# Floor Crane, Fold Away.
Ford Fusion. Engine. Installation
  1. Remove Special Service Tool: 303-1502  Lifting Device Engine.
Ford Fusion. Engine. Installation
  1. Install the bracket and the bolts.
    Torque: 97 lb.in (11 Nm)
Ford Fusion. Engine. Installation
  1. Position the halfshaft support bracket and install the bolts.
    Torque: 35 lb.ft (48 Nm)
Ford Fusion. Engine. Installation
  1. Install the TC inlet pipe, bolt and tighten the clamp.
    Torque:
       1:   71 lb.in (8 Nm)
       2:   44 lb.in (5 Nm)
Ford Fusion. Engine. Installation
    • Install the TC outlet pipe, bolt and tighten the clamps.
      Torque:
         1:   71 lb.in (8 Nm)
         2:   44 lb.in (5 Nm)
    • Connect the TC bypass hose.
    • Attach the wiring harness retainers and connect the electrical connectors.
Ford Fusion. Engine. Installation
    • Install the crankcase vent hose.
      Use the General Equipment: Hose Clamp Remover/Installer
    • Attach the wiring harness retainer.
Ford Fusion. Engine. Installation
  1. NOTE: Only rotate the crankshaft in a clockwise direction.

    Match the index-mark the torque converter nuts and tighten the nut.
    Torque: 35 lb.ft (48 Nm)
Ford Fusion. Engine. Installation
  1. Install the starter motor insulator.
Ford Fusion. Engine. Installation
  1. Install the starter motor, bolts and the stud bolt.
    Torque: 35 lb.ft (48 Nm)
Ford Fusion. Engine. Installation
  1. Position the wiring harness and install the nut.
    Torque: 97 lb.in (11 Nm)
Ford Fusion. Engine. Installation
    • Position the wiring harness and install the nut.
      Torque: 159 lb.in (18 Nm)
    • Slide the generator insulator down.
    • Attach the wiring harness retainers and connect the electrical connector.
Ford Fusion. Engine. Installation
  1. Position the starter motor cable and install the nuts.
    Torque:
       1:   53 lb.in (6 Nm)
       2:   106 lb.in (12 Nm)
Ford Fusion. Engine. Installation

Vehicles with automatic start-stop

  1. Connect the coolant hoses.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Installation

All vehicles

  1. Attach the wiring harness retainers and connect the electrical connectors.
Ford Fusion. Engine. Installation
  1. Install the new catalytic converter gasket and loosely install the bolts.
Ford Fusion. Engine. Installation
  1. Install the catalytic converter, bolt and tighten the bolts in sequence shown.
    Torque: 22 lb.ft (30 Nm)
Ford Fusion. Engine. Installation
  1. Install the muffler inlet pipe isolator bracket bolts.
    Torque: 18 lb.ft (25 Nm)
Ford Fusion. Engine. Installation
  1. Tighten the catalytic converter mounting bolts in sequence shown.
    Torque: 22 lb.ft (30 Nm)
Ford Fusion. Engine. Installation
  1. NOTE: Make sure the sensor wiring is routed away from hot surfaces and sharp edges or damage to the wiring may occur.

    Attach the retainer and connect the electrical connector.
Ford Fusion. Engine. Installation
  1. Tighten the engine mount studs.
    Torque: 89 lb.in (10 Nm)
Ford Fusion. Engine. Installation
  1. Using the powertrain lift, raise the powertrain and subframe as an assembly.
Ford Fusion. Engine. Installation
    1. Install the engine mount and the nuts.
      Torque: 85 lb.ft (115 Nm)
    1. Install the engine mount bolts finger-tight.
Ford Fusion. Engine. Installation
  1. Install the transmission support insulator nut.
    Torque: 98 lb.ft (133 Nm)
Ford Fusion. Engine. Installation
  1. NOTE: Align the reference marks made during removal.

    Install the subframe front mounting bolts finger-tight.
Ford Fusion. Engine. Installation
  1. NOTE: Align the reference marks made during removal.

    1. Install the subframe support bracket and the bolts finger-tight.
    1. Install the subframe support bracket bolts finger-tight.
Ford Fusion. Engine. Installation
  1. NOTE: While tightening the subframe bolts, make sure the front subframe does not move.

    Install the subframe rear mounting bolts.
    Torque: 173 lb.ft (235 Nm)
Ford Fusion. Engine. Installation
    1. Tighten the subframe support bracket bolts in 2 stages.
      Torque:
        Stage 1:  76 lb.ft (103 Nm)
        Stage 2:  270°
    1. Tighten the subframe support bracket bolts.
      Torque: 44 lb.ft (60 Nm)
Ford Fusion. Engine. Installation
  1. Remove.
    Use the General Equipment: Adjustable Mounting Arm
Ford Fusion. Engine. Installation
  1. Tighten the engine mount bolts.
    Torque: 66 lb.ft (90 Nm)
Ford Fusion. Engine. Installation
  1. Position the RH wheel knuckle assembly, install the bolts and the nuts.
    Torque: 173 lb.ft (235 Nm)
Ford Fusion. Engine. Installation
  1. Position the LH wheel knuckle assembly, install the bolts and the nuts.
    Torque: 173 lb.ft (235 Nm)
Ford Fusion. Engine. Installation
  1. Install the brake disc.
    Refer to: Brake Disc (206-03 Front Disc Brake, Removal and Installation).
  1. Position the RH stabilizer bar link and install the nut.
    Torque: 85 lb.ft (115 Nm)
Ford Fusion. Engine. Installation
  1. Position the LH stabilizer bar link and install the nut.
    Torque: 85 lb.ft (115 Nm)
Ford Fusion. Engine. Installation
  1. Position the wheel speed sensor and install the bolt.
    Torque: 80 lb.in (9 Nm)
Ford Fusion. Engine. Installation
  1. Position the wheel speed sensor and install the bolt.
    Torque: 80 lb.in (9 Nm)
Ford Fusion. Engine. Installation
  1. Install the catalytic converter grommet and the nuts.
    Torque: 18 lb.ft (25 Nm)
Ford Fusion. Engine. Installation
  1. Install the engine to transmission bolts.
    Torque: 35 lb.ft (48 Nm)
Ford Fusion. Engine. Installation
  1. Position the auxiliary water pump and install the bolts.
    Torque: 17 lb.ft (23 Nm)
Ford Fusion. Engine. Installation
  1. Install the new muffler inlet pipe gasket.
Ford Fusion. Engine. Installation
  1. Position the muffler inlet pipe and install the nuts.
    Torque: 35 lb.ft (48 Nm)
Ford Fusion. Engine. Installation
  1. Install the cross support and the bolts.
    Torque: 33 lb.ft (45 Nm)
Ford Fusion. Engine. Installation
  1. Install the engine oil filter.
    Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)
    Torque: 128 lb.in (14.5 Nm)
Ford Fusion. Engine. Installation
  1. NOTE: Use new O-ring seals and gasket seals.

    Position the A/C lines and install the nuts.
    Torque:
       1:   133 lb.in (15 Nm)
       2:   89 lb.in (10 Nm)
Ford Fusion. Engine. Installation
  1. Connect the electrical connectors and attach the retainers.
Ford Fusion. Engine. Installation
  1. Connect the coolant hose.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Installation
  1. Connect the coolant hoses.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Installation
  1. Install the lower radiator support, retainers and the bolts.
    Torque: 177 lb.in (20 Nm)
Ford Fusion. Engine. Installation
  1. NOTE: LF inner fender well removed for clarity.

    Connect the electrical connector.
Ford Fusion. Engine. Installation
  1. Install the deflector shields and the retainers.
Ford Fusion. Engine. Installation
  1. Install the stone guard and the retainers.
Ford Fusion. Engine. Installation
  1. Install the RH and LH front wheels and tires.
    Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
  1. Install the accessory drive belt.
    Refer to: Accessory Drive Belt (303-05A Accessory Drive - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
  1. Remove the cooling module support.
Ford Fusion. Engine. Installation
    • Install the degas bottle and the retainer.
      Torque: 80 lb.in (9 Nm)
    • Connect the coolant hoses.
      Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Installation
  1. Attach the wiring harness retainer and connect the electrical connector.
Ford Fusion. Engine. Installation
  1. Connect the PCM electrical connector.
Ford Fusion. Engine. Installation
  1. Connect the coolant hose.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Installation
  1. Connect the coolant hoses to the transmission fluid heater coolant control valve and install the clamps.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Installation
  1. Connect the coolant hoses to the heater core.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Installation
  1. Connect the gearshift cable end to selector lever assembly and install the bolts.
    Torque: 18 lb.ft (25 Nm)
Ford Fusion. Engine. Installation
  1. NOTE: If equipped with block heater.

    Attach the retainers and connect the coolant tube.
Ford Fusion. Engine. Installation
  1. Attach the retainer and connect the coolant hose.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Installation
  1. Connect the transmission fluid cooler tubes.
Ford Fusion. Engine. Installation
  1. Install the transmission fluid cooler tubes secondary latches.
Ford Fusion. Engine. Installation
  1. Connect the coolant hose.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Installation
  1. Position the wiring harness, install the bolts and attach the retainers.
    Torque: 97 lb.in (11 Nm)
Ford Fusion. Engine. Installation
  1. Position the wiring harness and install the nuts.
    Torque: 89 lb.in (10 Nm)
Ford Fusion. Engine. Installation
  1. Close the battery cable terminal cover.
Ford Fusion. Engine. Installation
  1. Position and install the fuse box.
Ford Fusion. Engine. Installation
  1. Position the wiring harness and install the stud bolt.
    Torque: 106 lb.in (12 Nm)
Ford Fusion. Engine. Installation
  1. Install the EVAP canister purge valve.
    Refer to: Evaporative Emission Canister Purge Valve (303-13A Evaporative Emissions - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
  1. Connect the crankcase pressure sensor wiring harness electrical connector and wire harness retainer.
Ford Fusion. Engine. Installation
  1. Attach the retainer and connect the vacuum tube coupling.
Ford Fusion. Engine. Installation
  1. Attach the retainers, connect the fuel tube couplings.
Ford Fusion. Engine. Installation
  1. Install the following items:
    1. Install the battery tray.
      Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
    2. Install the upper air cleaner outlet pipe.
      Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
    3. Install the air cleaner.
      Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
  1. Attach the steering column shaft to steering input shaft and install the bolt.
    Torque: 18 lb.ft (25 Nm)
Ford Fusion. Engine. Installation
  1. Remove the special tool.
Ford Fusion. Engine. Installation
  1. Fill the engine with clean engine oil.
    Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)
  1. Fill the cooling system.
    Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine Cooling - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
  1. Adjust the selector cable.
    Refer to: Selector Lever Cable Adjustment - 1.5L EcoBoost (118kW/160PS) – I4 (307-05A Automatic Transmission External Controls - 6-Speed Automatic Transmission – 6F35, General Procedures).
  1. Recharge the A/C system.
    Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging - Vehicles With: R1234YF Refrigerant (412-00 Climate Control System - General Information, General Procedures).
  1. Install the engine appearance cover.
Ford Fusion. Engine. Installation
  1. Start and check the exhaust system for leaks.
  1. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
  1. Check and, if necessary, adjust front toe.
    Refer to: Front Toe Adjustment (204-00 Suspension System - General Information, General Procedures).

    Engine. Assembly

    S..

    Engine Cooling - 1.5L EcoBoost (118kW/160PS) – I4

    ..

    Other information:

    Ford Fusion 2013–2020 Service Manual: Climate Control Housing - Vehicles With: Dual Automatic Temperature Control (DATC). Removal and Installation


    Removal NOTE: Removal steps in this procedure may contain installation details. Remove the instrument panel upper section. Refer to: Instrument Panel Upper Section (501-12 Instrument Panel and Console, Removal and Installation). Detach the wiring harness retainer, remove the nuts and the instrument panel upper brace. Torque: 133 lb.in (15 Nm) ..

    Ford Fusion 2013–2020 Service Manual: Evaporator Inlet and Outlet Manifold - 2.7L EcoBoost (238kW/324PS). Removal and Installation


    Special Tool(s) / General Equipment Hose Clamp Remover/Installer Removal NOTICE: During the removal or installation of components, cap, tape or otherwise appropriately protect all openings and tubes/fittings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation. NOTE: Removal steps in this procedure may..

    Categories

    Child Safety Locks

    When these locks are set, the rear doors cannot be opened from the inside.

    Ford Fusion. Child Safety Locks

    read more

    Copyright © 2022 www.fofusion2.com