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Section 1848 (Engine Mechanical - 3.5L GTDI): Installation: Engine

WARNING: This page is about a different car, the 2011 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G07808612
 2, 200# Floor Crane, Fold Away
300-OTC1819E or equivalent
G07808613
 Adjustable Grip Arm, 1735A
014-00001 or equivalent
G07808614
 Powertrain Lift
300-OTC1585AE or equivalent
G07808615
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G07808616
 Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool
MATERIAL

Item Specification
Motorcraft® SAE 5W-30 Premium 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.
    Fig 1: Aligning Transaxle To Engine Using Floor Crane And Spreader Bar
    G07808617Courtesy of FORD
  2. Install the 3 engine-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 2: Locating Transaxle-To-Engine Bolts
      G07808618Courtesy of FORD
  3. Install the LH engine-to-transaxle bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 3: Locating LH Transaxle-To-Engine Bolt
      G07808619Courtesy of FORD
  4. Using the Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift table.
    Fig 4: Positioning Engine And Transaxle Onto Powertrain Lift Bench Using Floor Crane And Spreader Bar
    G07808620Courtesy of FORD
    5. NOTE: Position a block of wood under the transaxle.
    Fig 5: Positioning Block Of Wood Under Transaxle
    G07808621Courtesy of FORD
  5. Install the Powertrain Lift and Adjustable Grip Arms.
  6. Install the ground wire and the bolt to the RH cylinder head.
    • Tighten to 10 Nm (89 lb-in).
      Fig 6: Locating Ground Wire Bolt
      G07808622Courtesy of FORD
  7. Attach the 2 wiring harness retainers to the transaxle stud bolts.
    Fig 7: Locating Wiring Harness Retainers Of Transaxle Stud Bolts
    G07808623Courtesy of FORD
  8. Attach the transaxle control wire harness retainer to the transaxle stud bolt.
    Fig 8: Locating Transaxle Control Wire Harness Retainer
    G07808624Courtesy of FORD
  9. Connect the transaxle control electrical connector.
    Fig 9: Locating Transaxle Control Electrical Connector
    G07808625Courtesy of FORD
  10. Install the crankcase vent tube and connect the 2 quick connect couplings. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION Article.
    Fig 10: Locating Quick Connect Couplings And Crankcase Vent Tube
    G07808626Courtesy of FORD
  11. Install the LH exhaust manifold heat shield and the 3 bolts.
    • Tighten to 14 Nm (124 lb-in).
      Fig 11: Locating LH Exhaust Manifold Heat Shield And Bolts
      G07808627Courtesy of FORD
  12. Install the oil supply tube bracket on the LH valve cover stud bolt and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 12: Locating Oil Supply Tube Bracket And Nut
      G07808628Courtesy of FORD
  13. Attach the wiring harness retainer to the valve cover stud bolt.
    Fig 13: Locating Wiring Harness Retainer
    G07808629Courtesy of FORD
  14. Install the engine cover mounting stud to the LH valve cover stud bolt.
    • Tighten to 6 Nm (53 lb-in).
      Fig 14: Locating Engine Cover Mounting Stud
      G07808630Courtesy of FORD
  15. Install the starter, the stud bolt and bolt.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 15: Locating Stud Bolt And Bolt Of Starter
      G07808631Courtesy of FORD
  16. Connect the wiring harness retainer to the starter motor stud bolt.
    Fig 16: Locating Wiring Harness Fastener
    G07808632Courtesy of FORD
  17. 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).
      Fig 17: Identifying Starter Wire Terminals Nuts
      G07808633Courtesy of FORD
  18. Install the starter motor solenoid cover.
    Fig 18: Locating Starter Motor Solenoid Cover
    G07808634Courtesy of FORD
  19. Raise the engine and transaxle assembly into the vehicle.
  20. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 19: Locating Engine Mount Bolts
      G07808635Courtesy of FORD
  21. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
      Fig 20: Locating Engine Mount Nuts
      G07808636Courtesy of FORD
  22. 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).
      Fig 21: Locating Transaxle Support Insulator Bracket-To-Transaxle Nuts And Bolt
      G07808637Courtesy of FORD
    23. NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is removed from the vehicle.
    Fig 22: Removing Compression Seal
    G07808638Courtesy of FORD
  23. Using a small screwdriver, remove the compression seal and discard.
  24. Using a soft face hammer, install the new compression seal.
    Fig 23: Locating Compression Seal
    G07808639Courtesy of FORD
  25. Position the PTU in place and install the 5 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 24: Locating PTU Bolts
      G07808640Courtesy of FORD
  26. Position the PTU support bracket in place and install the 3 bolts.
    1. Tighten the 2 bolts to 70 Nm (52 lb-ft).
    2. Tighten the bolt to 48 Nm (35 lb-ft).
      Fig 25: Identifying PTU Support Bracket And Bolts
      G07808641Courtesy of FORD
  27. Install the RH halfshaft support bracket and the 2 bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 26: Locating RH Halfshaft Support Bracket And Bolts
      G07808642Courtesy of FORD
  28. Install the RH turbocharger lower bracket and the 3 bolts.
    1. Tighten the bolt to 19 Nm (168 lb-in).
    2. Tighten the 2 bolts to 48 Nm (35 lb-ft).
      Fig 27: Locating RH Turbocharger Lower Bracket And Bolts
      G07808643Courtesy of FORD
  29. Install the 2 LH bottom transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 28: Locating LH Bottom Transaxle-To-Engine Bolts
      G07808644Courtesy of FORD
  30. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 29: Locating Oil Pan-To-Transaxle Bolts
      G07808645Courtesy of FORD
  31. Install 3 new torque converter bolts.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 30: Locating Torque Converter Bolt
      G07808646Courtesy of FORD
  32. Install the inspection cover and the 2 fasteners.
    Fig 31: Locating Inspection Cover And Fasteners
    G07808647Courtesy of FORD
  33. Connect the transaxle cooler tubes and install the 2 secondary latches.
    Fig 32: Locating Secondary Latches
    G07808648Courtesy of FORD
  34. Connect the lower radiator hose to the radiator.
    Fig 33: Locating Lower Radiator Hose Clamp
    G07808649Courtesy of FORD
  35. Attach the lower radiator hose retainer to the cooling fan and shroud.
    Fig 34: Locating Lower Radiator Hose Retainer
    G07808650Courtesy of FORD
    36. NOTE: Align the index marks for the LH Charge Air Cooler (CAC) tube.
  36. Connect the lower LH CAC tube to the LH turbocharger.
    • Tighten to 5 Nm (44 lb-in).
      Fig 35: Locating LH CAC Tube Clamp
      G07808651Courtesy of FORD
  37. 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).
      Fig 36: Locating Upper A/C Tube Nut
      G07808652Courtesy of FORD
  38. Install the A/C tube bracket and bolt to the rear of the A/C compressor.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 37: Locating A/C Tube Bracket Bolt
      G07808653Courtesy of FORD
  39. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
      Fig 38: Locating Engine Oil Filter
      G07808654Courtesy of FORD
  40. 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).
      Fig 39: Locating Driveshaft Bolts
      G07808655Courtesy of FORD
  41. Connect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION Article.
    Fig 40: Locating Fuel Supply Tube
    G07808656Courtesy of FORD
  42. 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 Article.
    Fig 41: Locating Quick Connect Coupling Of Intake Manifold
    G07808657Courtesy of FORD
  43. Connect the EVAP valve electrical connector and attach to the intake manifold.
    Fig 42: Locating EVAP Valve Electrical Connector And Valve
    G07808658Courtesy of FORD
  44. Connect the EVAP tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION Article.
    Fig 43: Locating Evaporative Emission Tube Quick Connect Coupling
    G07808659Courtesy of FORD
  45. If equipped, attach the engine block heater harness to the radiator support wiring harness.
  46. Connect the upper radiator hose to the intake manifold coolant tube.
    Fig 44: Locating Upper Radiator Hose Clamp
    G07808660Courtesy of FORD
  47. Install the ground wire and bolt to the engine front cover.
    • Tighten to 10 Nm (89 lb-in).
      Fig 45: Locating Engine Front Cover Bolt And Ground Wire
      G07808661Courtesy of FORD
  48. Connect the 2 heater hoses to the intake manifold.
    Fig 46: Locating Heater Hoses Clamps
    G07808662Courtesy of FORD
    49. NOTE: Align the index marks for the RH CAC tube.
  49. Install the RH CAC tube and tighten the clamps.
    • Tighten to 5 Nm (44 lb-in).
      Fig 47: Locating RH CAC Tube And Clamps
      G07808663Courtesy of FORD
  50. Attach the wiring harness pin-type retainer and connect the transaxle control cable to the shift cable bracket.
    Fig 48: Locating Shift Cable Bracket And Wiring Harness Pin-Type Retainer
    G07808664Courtesy of FORD
  51. Connect the transaxle control cable to the control lever.
    Fig 49: Locating Selector Lever Cable End
    G07808665Courtesy of FORD
  52. Connect the quick connect coupling to the brake booster. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION Article.
    Fig 50: Locating Brake Booster Vacuum Hose Quick Connect Coupling
    G07808666Courtesy of FORD
  53. Connect the battery power feed wires to the positive battery terminal and install the nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 51: Locating Positive Battery Terminal Nut
      G07808667Courtesy of FORD
  54. Connect the ground cable to the negative battery terminal and install the nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 52: Locating Nut And Ground Cable Of Negative Battery Terminal
      G07808668Courtesy of FORD
  55. Connect the engine wiring harness electrical connector.
    Fig 53: Locating Engine Wiring Harness Electrical Connector
    G07808669Courtesy of FORD
  56. Install the battery tray. For additional information, refer to BATTERY, BATTERY MOUNTING & BATTERY CABLES Article.
    57. NOTE: Align the index marks for the CAC outlet pipe.
  57. Install the CAC outlet pipe and tighten the clamps.
    • Tighten to 5 Nm (44 lb-in).
      Fig 54: Locating CAC Outlet Pipe And Clamps
      G07808670Courtesy of FORD
  58. Connect the Turbocharger Boost Pressure (TCBP)/Charge Air Cooler Temperature (CACT) sensor electrical connector.
    Fig 55: Locating Turbocharger Boost Pressure/Charge Air Cooler Temperature Sensor Electrical Connector
    G07808671Courtesy of FORD
  59. Install the noise generator. For additional information, refer to Intake Air System Components - Exploded View in INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM Article.
  60. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM Article.
  61. Install the degas bottle. For additional information, refer to ENGINE COOLING SYSTEM Article.
  62. Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
    • Tighten to 15 Nm (133 lb-in).
      Fig 56: Locating A/C Tube Nut
      G07808672Courtesy of FORD
  63. 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).
      Fig 57: Locating A/C Tube Nut
      G07808673Courtesy of FORD
  64. 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.
      Fig 58: Identifying Engine Wiring Harness Retainer Tab
      G07808674Courtesy of FORD
  65. Connect the 2 PCM electrical connectors.
    Fig 59: Locating PCM Electrical Connectors
    G07808675Courtesy of FORD
  66. Connect the PCM and engine harness electrical connectors.
    • Attach the wiring harness retainer.
      Fig 60: Locating PCM And Engine Harness Electrical Connectors Or Wiring Harness Retainer
      G07808676Courtesy of FORD
  67. Install the strut tower brace and the 4 nuts.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 61: Locating Strut Tower Brace Nuts
      G07808677Courtesy of FORD
  68. Attach the 2 brake booster vacuum hose retainers (1 shown in illustration) to the strut tower brace.
    Fig 62: Locating Brake Booster Vacuum Hose Retainer
    G07808678Courtesy of FORD
  69. Install the cowl panel grille. For additional information, refer to BODY PANEL SYSTEM - FRONT END BODY PANELS Article.
    70. NOTE: The circlips are unique in size and shape for each shaft. Make sure to use the specified circlip for the application or vehicle damage may occur.
    Fig 63: Locating Stub Shaft Circlip
    G07808679Courtesy of FORD
  70. Install the correct new circlip on the inboard stub shaft.
    71. NOTE: The sharp edges on the stub shaft splines can slice or puncture the oil seal. Use care when inserting the stub shaft into the transmission or damage to the component may occur.
    NOTE: After insertion, pull the halfshaft inner end to make sure the circlip is locked.
  71. Push the stub shaft into the transmission so the circlip locks into the differential side gear.
  72. Rotate the LH wheel knuckle into position and insert the LH halfshaft into the wheel hub.
    73. NOTE: A new Power Transfer Unit (PTU) shaft seal must be installed whenever the intermediate shaft is removed or damage to the components can occur.
  73. Install a new intermediate shaft seal and deflector. For additional information, refer to TRANSFER CASE - POWER TRANSFER UNIT (PTU) Article.
  74. Install the intermediate and halfshaft assembly and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 64: Locating Halfshaft Bracket Bolts
      G07808680Courtesy of FORD
  75. Rotate the RH wheel knuckle into position and insert the RH halfshaft into the wheel hub.
    76. NOTE: Align the index marks on the subframe to the index marks on the underbody that were made during removal.
    Fig 65: Raising Subframe Using Powertrain Lift
    G07808681Courtesy of FORD
  76. Using the Powertrain Lift, raise the subframe into the installed position.
    77. NOTE: RH shown in illustration, LH similar.
  77. Install the 2 front subframe bolts.
    • Tighten to 200 Nm (148 lb-ft).
      Fig 66: Locating Front Subframe Bolts
      G07808682Courtesy of FORD
    78. NOTE: RH shown in illustration, LH similar.
    Fig 67: Locating Subframe Support Brackets Bolts
    G07808683Courtesy of FORD
  78. Position the subframe brackets and install the 4 bolts finger-tight.
    79. NOTE: RH shown in illustration, LH similar.
  79. Install the 2 rear subframe bolts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 68: Locating Rear Subframe Bolts
      G07808684Courtesy of FORD
    80. NOTE: RH shown in illustration, LH similar.
    Fig 69: Locating Subframe Support Bracket Bolts
    G07808685Courtesy of FORD
  80. Tighten the 4 subframe bracket-to-body bolts to 55 Nm (41 lb-ft).
  81. Connect the 2 Electronic Power Assist Steering (EPAS) electrical connectors (1 shown in illustration) and attach the wiring retainer (not shown in illustration) and install the bolt.
    • Tighten to 9 Nm (80 lb-in).
      Fig 70: Locating Electronic Power Assist Steering Electrical Connector, Wiring Retainer And Bolt
      G07808686Courtesy of FORD
    82. 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 Article.
  82. Install the steering intermediate shaft onto the steering gear and install a new bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 71: Locating Steering Column Shaft Bolt
      G07808687Courtesy of FORD
    83. NOTE: RH shown in illustration, LH similar.
  83. Position the ball joints into the wheel knuckles. Install the new ball joint nuts.
    • Tighten to 200 Nm (148 lb-ft).
      Fig 72: Locating Ball Joint Nut
      G07808688Courtesy of FORD
    84. NOTE: The hex-holding feature can be used to prevent turning of the stud while installing the nuts.
    NOTE: RH shown in illustration, LH similar.
  84. Install new tie-rod end nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 73: Locating Tie-Rod End Nuts
      G07808689Courtesy of FORD
    85. NOTE: RH shown in illustration, LH similar.
  85. Install new upper stabilizer bar link nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 74: Locating Upper Stabilizer Link Nuts
      G07808690Courtesy of FORD
  86. Install the 2 front engine roll restrictor-to-transaxle bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 75: Locating Front Engine Roll Restrictor-To-Transaxle Bolts
      G07808691Courtesy of FORD
    87. NOTE: The bracket has keyed tabs to orient the roll restrictor.
  87. Position the rear roll restrictor bracket with the keyed tabs aligned to the rear roll restrictor and install the bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 76: Locating Rear Roll Restrictor Bracket And Bolts
      G07808692Courtesy of FORD
  88. Install the RH and LH catalytic converters. For additional information, refer to EXHAUST SYSTEM Article.
  89. Position the RH brake hose bracket and install the bolt.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 77: Locating Brake Tube Bracket Bolt
      G07808693Courtesy of FORD
    90. 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: Apply the brake to keep the halfshaft from rotating.
    NOTE: RH shown in illustration, LH similar.
  90. Using the previously removed RH and LH wheel hub nuts, seat the halfshaft.
    • Tighten to 350 Nm (258 lb-ft).
    • Remove and discard the wheel hub nuts.
      Fig 78: Locating RH And LH Wheel Hub Nuts
      G07808694Courtesy of FORD
    91. 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: Apply the brake to keep the halfshaft from rotating.
    NOTE: RH shown in illustration, LH similar.
  91. Install a new RH and LH wheel hub nut.
    • Tighten to 350 Nm (258 lb-ft).
      Fig 79: Locating RH And LH Wheel Hub Nuts
      G07808695Courtesy of FORD
  92. Install the 2 scrivets in the rubber shield.
    Fig 80: Locating Scrivets In Rubber Shield
    G07808696Courtesy of FORD
  93. Install the front wheels and tires. For additional information, refer to WHEELS & TIRES Article.
  94. Fill the engine with clean engine oil.
  95. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING SYSTEM Article.
  96. Install the front splash shield, 3 pin-type retainers and the 7 bolts, when the cooling system or engine service is finished.
    Fig 81: Locating Bolts And Pin-Type Retainers Of Front Splash Shield
    G07808697Courtesy of FORD
  97. Install the underbody shield and the 4 retainers.
    Fig 82: Locating Underbody Shield Retainers
    G07808698Courtesy of FORD
  98. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
    • Attach the HO2S connector retainer to the bracket.
      Fig 83: Locating LH Heated Oxygen Sensor (HO2S) Electrical Connector
      G07808699Courtesy of FORD
  99. Refill the transaxle fluid. For additional, refer to AUTOMATIC TRANSMISSION - AUTOMATIC TRANSAXLE/TRANSMISSION - 6F50/6F55 Article.
  100. Recharge the A/C system. For additional information, refer to HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS Article.
  101. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.
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