Section 1 (Engine - 3.5L GTDI): Installation: Engine
WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL(S)
| 2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent | |
| Adjustable Grip Arm, 1735A 014-00001 or equivalent | |
| Powertrain Lift 300-OTC1585AE or equivalent | |
| Spreader Bar 303-D089 (D93P-6001-A3) or equivalent |
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.
- 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).
- 7.NOTE: LH shown in illustration, 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.
- 8.
Using the Floor Crane and Spreader Bar, install the powertrain and subframe as an assembly on the powertrain lift table.
- 9.NOTE: LH shown in illustration, 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.
- 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.
- 16.
Connect the A/C compressor and pressure relief valve electrical connectors.- Attach the wiring harness retainers.
- 19.
Position the PTU support bracket in place and install the 5 bolts.- Tighten the bolt to 48 Nm (35 lb-ft).
- 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).
- 1.
- 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).
- 28.
Attach the 4 wiring harness retainer to the valve cover stud bolt.- Install the engine cover mounting stud to the LH valve cover stud bolt.
- Tighten to 6 Nm (53 lb-in).
- Install the engine cover mounting stud to the LH valve cover stud bolt.
- 29.
Install the crankcase vent tube and connect the 2 quick connect couplings. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
- 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).
- 36.NOTE: RH shown in illustration, LH similar.
Install the 2 front subframe bolts.
- Tighten to 200 Nm (148 lb-ft).
- 37.NOTE: RH shown in illustration, LH similar.
Position the subframe brackets and install the 4 bolts finger-tight.
- 38.NOTE: RH shown in illustration, LH similar.
Install the 2 rear subframe bolts.
- Tighten to 150 Nm (111 lb-ft).
- 39.NOTE: RH shown in illustration, LH similar.
Tighten the 4 subframe bracket-to-body bolts to 55 Nm (41 lb-ft).
- 42.NOTE: LH shown in illustration, 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).
- 43.NOTE: LH shown in illustration, 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).
- 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 in illustration, 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.
- 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 in illustration, 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).
- 46.NOTE: RH shown in illustration, LH similar.
Install new upper stabilizer bar link nuts.
- Tighten to 150 Nm (111 lb-ft).
- 47.NOTE: LH shown in illustration, RH similar.
Install the wheel speed sensor and the bolt.
- Tighten to 15 Nm (133 lb-in).
- 55.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).
- 56.
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).
- 57.
Install the A/C tube bracket and bolt to the rear of the A/C compressor.- Tighten to 25 Nm (18 lb-ft).
- 58.
Install a new engine oil filter.- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
- 59.
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).
- 60.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).
- 61.
Install the RH and LH catalytic converters. For additional information, refer to Exhaust System .
- 63.
Install the 2 front suspension height sensors. For additional information, refer to Vehicle Dynamic Suspension .
- 66.
Install the front wheels and tires. For additional information, refer to Wheels and Tires .
- 67.
Connect the fuel supply tube. For additional information, refer to Fuel System - General Information .
- 68.
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 .
- 70.
Connect the EVAP tube quick connect coupling. For additional information, refer to Fuel System - General Information .
- 75.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).
- 76.
Attach the wiring harness pin-type retainer and connect the transaxle control cable to the shift cable bracket.
- 78.
Connect the quick connect coupling to the intake manifold. For additional information, refer to Fuel System - General Information .
- 79.
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).
- 82.
Install the battery tray. For additional information, refer to Battery, Mounting and Cables .
- 83.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).
- 84.
Connect the Turbocharger Boost Pressure (TCBP) /Charge Air Cooler Temperature (CACT) sensor electrical connector.
- 85.
Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering .
- 86.
Install the degas bottle. For additional information, refer to Engine Cooling .
- 87.
Using a new O-ring seal and gasket seal, install the A/C tube and the nut.- Tighten to 15 Nm (133 lb-in).
- 88.
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).
- 89.
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.
- 1.
- 94.
Install the cowl panel grille. For additional information, refer to Front End Body Panels .
- 95.
Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.- Attach the HO2S connector retainer to the bracket.
- 97.
Fill and bleed the cooling system. For additional information, refer to Engine Cooling .
- 98.
Recharge the A/C system. For additional information, refer to Climate Control System - General Information and Diagnostics .