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Engine - 3.5L GTDI: Installation: Engine

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING .

Special Tool(s)

GFD338811Courtesy of FORD MOTOR COMPANY
 2, 200# Floor Crane, Fold Away
300-OTC1819E or equivalent
GFD338812Courtesy of FORD MOTOR COMPANY
 Adjustable Grip Arm, 1735A
014-00001 or equivalent
GFD339158Courtesy of FORD MOTOR COMPANY
 Powertrain Lift
300-OTC1585AE or equivalent
GFD338816Courtesy of FORD MOTOR COMPANY
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
Material

Item Specification
Motorcraft® SAE 5W-30 Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil (Canada)
XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada)		 WSS-M2C946-A
NOTE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.
  1. Using the Floor Crane and Spreader Bar, align the transaxle to the engine.
    GFD338870Courtesy of FORD MOTOR COMPANY
  2. Install the 3 engine-to-transaxle bolts.

    • Tighten to 48 Nm (35 lb-ft).

    GFD338888Courtesy of FORD MOTOR COMPANY
  3. Install the LH engine-to-transaxle bolt.

    • Tighten to 48 Nm (35 lb-ft).

    GFD338887Courtesy of FORD MOTOR COMPANY
  4. Install the 2 LH bottom transaxle-to-engine bolts.

    • Tighten to 48 Nm (35 lb-ft).

    GFD338886Courtesy of FORD MOTOR COMPANY
  5. Install the RH halfshaft support bracket and the 2 bolts.

    • Tighten to 40 Nm (30 lb-ft).

    GFD338885Courtesy of FORD MOTOR COMPANY
  6. Install the intermediate shaft bracket 2 studs and the 2 nuts.

    • Tighten the studs to 10 Nm (89 lb-in).

    • Tighten the nuts to 25 Nm (30 lb-ft).

    GFD338884Courtesy of FORD MOTOR COMPANY
  7. NOTE: LH shown, RH similar.

    Install the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

    GFD338883Courtesy of FORD MOTOR COMPANY
  8. Using the Floor Crane and Spreader Bar, install the powertrain and subframe as an assembly on the powertrain lift table.
    GFD338870Courtesy of FORD MOTOR COMPANY
  9. NOTE: LH shown, RH similar.

    Remove the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

    GFD338883Courtesy of FORD MOTOR COMPANY
  10. Install the Adjustable Grip Arm.
    GFD338882Courtesy of FORD MOTOR COMPANY
  11. Install a ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe, to secure the subframe to the powertrain lift table.
  12. Attach the transaxle control wire harness retainer to the transaxle stud bolt.
    GFD338881Courtesy of FORD MOTOR COMPANY
  13. Connect the transaxle control electrical connector.
    GFD338880Courtesy of FORD MOTOR COMPANY
  14. Connect the generator electrical connector.
    GFD338879Courtesy of FORD MOTOR COMPANY
  15. Connect the generator B+ cable and install the nut.

    • Tighten to 17 Nm (150 lb-in).

    GFD338878Courtesy of FORD MOTOR COMPANY
  16. Connect the A/C compressor and pressure relief valve electrical connectors.

    • Attach the wiring harness retainers.

    GFD338877Courtesy of FORD MOTOR COMPANY
  17. Attach the CMS electrical connector.
    GFD338876Courtesy of FORD MOTOR COMPANY
  18. Install the ground wire and the bolt to the RH cylinder head.

    • Tighten to 10 Nm (89 lb-in).

    GFD338793Courtesy of FORD MOTOR COMPANY
  19. Position the PTU support bracket in place and install the 5 bolts.

    • Tighten to 48 Nm (35 lb-ft).

    GFD338875Courtesy of FORD MOTOR COMPANY
  20. Install the starter, the stud bolt and bolt.

    • Tighten to 27 Nm (20 lb-ft).

    GFD338874Courtesy of FORD MOTOR COMPANY
  21. Connect the wiring harness retainer to the starter motor stud bolt.
    GFD338873Courtesy of FORD MOTOR COMPANY
  22. Attach the starter wire terminals and install the 2 nuts.

    1. Tighten the B+ terminal nut to 12 Nm (106 lb-in).
    2. Tighten the S-terminal nut to 5 Nm (44 lb-in).

    GFD339159Courtesy of FORD MOTOR COMPANY
  23. Install the starter motor solenoid cover.
    GFD338871Courtesy of FORD MOTOR COMPANY
  24. Remove the Heavy Duty Floor Crane and Spreader Bar.
    GFD338870Courtesy of FORD MOTOR COMPANY
  25. Remove the Engine Lift Eye from the LH cylinder head.
    GFD338869Courtesy of FORD MOTOR COMPANY
  26. Install the LH exhaust manifold heat shield and the 3 bolts.

    • Tighten to 12 Nm (106 lb-in).

    GFD338774Courtesy of FORD MOTOR COMPANY
  27. Install the oil supply tube bracket on the LH valve cover stud bolt and install the nut.

    • Tighten to 8 Nm (71 lb-in).

    GFD339160Courtesy of FORD MOTOR COMPANY
  28. Connect the wiring harness retainers to the valve cover stud bolts.

    • Install the engine cover mounting stud to the LH valve cover stud bolt.

      • Tighten to 6 Nm (53 lb-in).

    GFD338867Courtesy of FORD MOTOR COMPANY
  29. Install the crankcase vent tube and connect the 2 quick connect couplings. For additional information, refer to Fuel System - General Information .
    GFD338692Courtesy of FORD MOTOR COMPANY
  30. Connect the crankcase vent tube sensor electrical connector and the wire harness retainer.
    GFD338691Courtesy of FORD MOTOR COMPANY
  31. Remove the ratchet strap from the RH knuckle to subframe.
  32. NOTE: Make sure the struts go into the knuckles when raised.

    Raise the subframe and powertrain assembly into the vehicle.

  33. Install the engine mount and the 3 bolts.

    • Tighten to 90 Nm (66 lb-ft).

    GFD339161Courtesy of FORD MOTOR COMPANY
  34. Install the 4 engine mount nuts.

    • Tighten to 63 Nm (46 lb-ft).

    GFD339162Courtesy of FORD MOTOR COMPANY
  35. Install the bolt and the 3 nuts for the transaxle support insulator bracket-to-transaxle.

    • Tighten the bolt to 80 Nm (59 lb-ft).

    • Tighten the nuts to 63 Nm (46 lb-ft).

    GFD339163Courtesy of FORD MOTOR COMPANY
  36. NOTE: RH shown, LH similar.

    Install the 2 front subframe bolts.

    • Tighten to 200 Nm (148 lb-ft).

    GFD338690Courtesy of FORD MOTOR COMPANY
  37. NOTE: RH shown, LH similar.

    Position the subframe brackets and install the 4 bolts finger-tight.

    GFD339111Courtesy of FORD MOTOR COMPANY
  38. NOTE: RH shown, LH similar.

    Install the 2 rear subframe bolts.

    • Tighten to 150 Nm (111 lb-ft).

    GFD339112Courtesy of FORD MOTOR COMPANY
  39. NOTE: RH shown, LH similar.

    Tighten the 4 subframe bracket-to-body bolts to 55 Nm (41 lb-ft).

    GFD338688Courtesy of FORD MOTOR COMPANY
  40. Remove the ratchet strap from the front of the subframe to the rear of the subframe.
  41. Remove the Adjustable Grip Arm and the powertrain lift table.
    GFD339164Courtesy of FORD MOTOR COMPANY
  42. NOTE: LH shown, RH similar.

    Install the strut to the wheel knuckle and install the strut-to-wheel knuckle nuts and bolts.

    • Tighten to 250 Nm (184 lb-ft).

    GFD339165Courtesy of FORD MOTOR COMPANY
  43. NOTE: LH shown, RH similar.

    Install the brake caliper and the guide pin bolts.

    • 432 mm (17 in) brakes: Tighten to 72 Nm (53 lb-ft).

    • 457 mm (18 in) brakes: Tighten to 75 Nm (55 lb-ft).

    GFD339115Courtesy of FORD MOTOR COMPANY
  44. NOTE: Do not tighten the wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.
    NOTE: LH shown, RH similar.
    NOTE: Apply the brake to keep the halfshaft from rotating.

    Using the previously removed wheel hub nut, seat the LH and RH halfshafts.

    • Tighten to 350 Nm (258 lb-ft).

    • Remove and discard the wheel hub nuts.

    GFD339116Courtesy of FORD MOTOR COMPANY
  45. NOTE: The wheel hub nut contains a one time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur.
    NOTE: LH shown, RH similar.
    NOTE: Apply the brake to keep the halfshaft from rotating.

    Install a new wheel hub nuts.

    • Tighten to 350 Nm (258 lb-ft).

    GFD339166Courtesy of FORD MOTOR COMPANY
  46. NOTE: RH shown, LH similar.

    Install new upper stabilizer bar link nuts.

    • Tighten to 150 Nm (111 lb-ft).

    GFD338677Courtesy of FORD MOTOR COMPANY
  47. NOTE: LH shown, RH similar.

    Install the wheel speed sensor and the bolt.

    • Tighten to 15 Nm (133 lb-in).

    GFD339167Courtesy of FORD MOTOR COMPANY
  48. Install the 4 oil pan-to-transaxle bolts.

    • Tighten to 48 Nm (35 lb-ft).

    GFD338858Courtesy of FORD MOTOR COMPANY
  49. Install 3 new torque converter bolts.

    • Tighten to 55 Nm (41 lb-ft).

    GFD338857Courtesy of FORD MOTOR COMPANY
  50. Install the inspection cover and the 2 fasteners.
    GFD338856Courtesy of FORD MOTOR COMPANY
  51. Connect the transaxle cooler tubes and install the 2 secondary latches.
    GFD339119Courtesy of FORD MOTOR COMPANY
  52. If equipped, connect the 2 PTU coolant hoses.
    GFD339168Courtesy of FORD MOTOR COMPANY
  53. If equipped, install the oil cooler hose retainer to the subframe.
    GFD339169Courtesy of FORD MOTOR COMPANY
  54. If equipped, connect the oil cooler hoses.
    GFD339170Courtesy of FORD MOTOR COMPANY
  55. Connect the lower radiator hose to the radiator.
    GFD339171Courtesy of FORD MOTOR COMPANY
  56. Attach the lower radiator hose retainer to the cooling fan and shroud.
    GFD339172Courtesy of FORD MOTOR COMPANY
  57. NOTE: Align the index marks for the LH Charge Air Cooler(CAC) tube.

    Connect the lower LH CAC tube to the LH turbocharger.

    • Tighten to 5 Nm (44 lb-in).

    GFD339173Courtesy of FORD MOTOR COMPANY
  58. Using a new O-ring seal and gasket seal, install the upper A/C tube to the A/C compressor and install the nut.

    • Tighten to 15 Nm (133 lb-in).

    GFD339174Courtesy of FORD MOTOR COMPANY
  59. Position the A/C tube bracket and install the bolt to the rear of the A/C compressor.

    • Tighten to 25 Nm (18 lb-ft).

    GFD339175Courtesy of FORD MOTOR COMPANY
  60. Install a new engine oil filter.

    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.

    GFD339176Courtesy of FORD MOTOR COMPANY
  61. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 new bolts.

    • Tighten to 70 Nm (52 lb-ft).

    GFD339177Courtesy of FORD MOTOR COMPANY
  62. NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Supplemental Restraint System .

    Install the steering intermediate shaft onto the steering gear and install a new bolt.

    • Tighten to 20 Nm (177 lb-in).

    GFD339178Courtesy of FORD MOTOR COMPANY
  63. Install the RH and LH catalytic converters. For additional information, refer to Exhaust System .
  64. Install the 3 scrivets in the rubber shield.
    GFD338661Courtesy of FORD MOTOR COMPANY
  65. Install the front splash shield, 3 pin-type retainers and the 7 bolts, when the cooling system or engine service is finished.
    GFD339179Courtesy of FORD MOTOR COMPANY
  66. If equipped, install the skid plate and the 10 bolts.

    • Tighten to 70 Nm (52 lb-ft).

    GFD339180Courtesy of FORD MOTOR COMPANY
  67. If equipped, install the underbody shield and the 4 retainers.
    GFD339181Courtesy of FORD MOTOR COMPANY
  68. Install the front wheels and tires. For additional information, refer to Wheels and Tires .
  69. Connect the fuel supply tube. For additional information, refer to Fuel System - General Information .
    GFD338841Courtesy of FORD MOTOR COMPANY
  70. Install the Evaporative Emission(EVAP) tube assembly and connect the quick connect coupling to the intake manifold. For additional information, refer to Fuel System - General Information .
    GFD338659Courtesy of FORD MOTOR COMPANY
  71. Connect the EVAP valve electrical connector and attach to the intake manifold.
    GFD339182Courtesy of FORD MOTOR COMPANY
  72. Connect the EVAP tube quick connect coupling. For additional information, refer to Fuel System - General Information .
    GFD339183Courtesy of FORD MOTOR COMPANY
  73. If equipped, attach the engine block heater harness to the radiator support wiring harness.
  74. Connect the upper radiator hose to the intake manifold coolant tube.
    GFD339184Courtesy of FORD MOTOR COMPANY
  75. Install the ground wire and bolt to the engine front cover.

    • Tighten to 10 Nm (89 lb-in).

    GFD338655Courtesy of FORD MOTOR COMPANY
  76. Connect the 2 heater hoses to the intake manifold.
    GFD338654Courtesy of FORD MOTOR COMPANY
  77. NOTE: Align the index marks for the RH CAC tube.

    Install the RH CAC tube and tighten the clamps.

    • Tighten to 5 Nm (44 lb-in).

    GFD339185Courtesy of FORD MOTOR COMPANY
  78. Attach the wiring harness pin-type retainer and connect the transaxle control cable to the shift cable bracket.
    GFD338836Courtesy of FORD MOTOR COMPANY
  79. Connect the transaxle control cable to the control lever.
    GFD339186Courtesy of FORD MOTOR COMPANY
  80. Connect the quick connect coupling to the intake manifold. For additional information, refer to Fuel System - General Information .
    GFD338834Courtesy of FORD MOTOR COMPANY
  81. Connect the battery power feed wire to the positive battery terminal and install the nut.

    • Connect the electrical connector.

    • Tighten to 6 Nm (53 lb-in).

    GFD339187Courtesy of FORD MOTOR COMPANY
  82. Connect the engine wiring harness electrical connector.
    GFD339188Courtesy of FORD MOTOR COMPANY
  83. Position back the ground wire and install the bolt.

    • Tighten to 6 Nm (53 lb-in).

    GFD339189Courtesy of FORD MOTOR COMPANY
  84. Install the battery tray. For additional information, refer to Charging System (Battery, Battery Mounting and Battery Cables) .
  85. NOTE: Align the index marks for the CAC outlet pipe.

    Install the CAC outlet pipe and tighten the clamps.

    • Tighten to 5 Nm (44 lb-in).

    GFD339190Courtesy of FORD MOTOR COMPANY
  86. Connect the Turbocharger Boost Pressure(TCBP) /Charge Air Cooler Temperature(CACT) sensor electrical connector.
    GFD339191Courtesy of FORD MOTOR COMPANY
  87. If equipped, install the noise generator. For additional information, refer to Intake Air System Components -- Exploded View in Intake Air Distribution and Filtering .
  88. Install the engine Air Cleaner(ACL) and ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering .
  89. Install the degas bottle. For additional information, refer to Engine Cooling .
  90. Using a new O-ring seal and gasket seal, install the A/C tube and the nut.

    • Tighten to 15 Nm (133 lb-in).

    GFD339192Courtesy of FORD MOTOR COMPANY
  91. Using a new O-ring seal and gasket seal, connect the A/C tube and install the nut.

    • Tighten to 15 Nm (133 lb-in).

    GFD339193Courtesy of FORD MOTOR COMPANY
  92. Install the engine wiring harness retainer to the bulkhead.

    1. Slide the wiring harness in the bulkhead.
    2. Make sure the wiring harness retainer tab is below the bulkhead lip.

    GFD339148Courtesy of FORD MOTOR COMPANY
  93. Connect the PCM electrical connector.
    GFD339194Courtesy of FORD MOTOR COMPANY
  94. Connect the engine harness electrical connector.
    GFD339195Courtesy of FORD MOTOR COMPANY
  95. Install the strut tower brace and the 4 nuts.

    • Tighten to 30 Nm (22 lb-ft).

    GFD339196Courtesy of FORD MOTOR COMPANY
  96. Attach the 2 brake booster vacuum hose retainers to the strut tower brace.
    GFD339197Courtesy of FORD MOTOR COMPANY
  97. Install the cowl panel grille. For additional information, refer to Front End Body Panels .
  98. Connect the LH Heated Oxygen Sensor(HO2S) electrical connector.

    • Attach the HO2S connector retainer to the bracket.

    GFD339198Courtesy of FORD MOTOR COMPANY
  99. Fill the engine with clean engine oil.
  100. Fill and bleed the cooling system. For additional information, refer to Engine Cooling .
  101. Recharge the A/C system. For additional information, refer to Climate Control System - General Information and Diagnostics .
  102. Perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.
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