Section 1 (Engine Mechanical - 3.5L-GTDI): Installation: Engine

SPECIAL TOOLS

	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
	Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

MATERIAL SPECIFICATIONS

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); or equivalent	WSS-M2C946-A, 5W30;

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

   Courtesy of FORD MOTOR CO.
2. Install the 3 engine-to-transaxle bolts.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 2: Locating Engine-To-Transaxle Bolts

     Courtesy of FORD MOTOR CO.
3. Install the LH engine-to-transaxle bolt.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 3: Locating LH Engine-To-Transaxle Bolt

     Courtesy of FORD MOTOR CO.
4. Using the Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift table.
   Fig 4: Aligning Transaxle To Engine Using Floor Crane And Spreader Bar

   Courtesy of FORD MOTOR CO.
NOTE: Position a block of wood under the transaxle.
Fig 5: Identifying Powertrain Lift And Adjustable Grip Arms
Courtesy of FORD MOTOR CO.
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

     Courtesy of FORD MOTOR CO.
7. Attach the 2 wiring harness retainers to the transaxle stud bolts.
   Fig 7: Locating Transaxle Stud Bolt Wiring Harness Retainers

   Courtesy of FORD MOTOR CO.
8. Attach the transaxle control wire harness retainer to the transaxle stud bolt.
   Fig 8: Locating Transaxle Control Wire Harness Retainer

   Courtesy of FORD MOTOR CO.
9. Connect the transaxle control electrical connector.
   Fig 9: Locating Transaxle Control Electrical Connector

   Courtesy of FORD MOTOR CO.
10. Install the crankcase vent tube and connect the 2 quick connect couplings. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 10: Locating Crankcase Vent Tube And Quick Connect Couplings

    Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
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 LH Valve Cover Stud Bolt

      Courtesy of FORD MOTOR CO.
13. Attach the wiring harness retainer to the valve cover stud bolt.
    Fig 13: Locating Valve Cover Stud Bolt Wiring Harness Retainer

    Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
15. Install the starter, the stud bolt and bolt.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 15: Locating Starter Bolt And Studbolt

      Courtesy of FORD MOTOR CO.
16. Connect the wiring harness retainer to the starter motor stud bolt.
    Fig 16: Locating Starter Motor Stud Bolt

    Courtesy of FORD MOTOR CO.
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 B+ And S- Terminals Nuts

       Courtesy of FORD MOTOR CO.
18. Install the starter motor solenoid cover.
    Fig 18: Locating Starter Motor Solenoid Cover

    Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
21. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
      Fig 20: Locating Engine Mount Nuts

      Courtesy of FORD MOTOR CO.
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 Bolts And Nuts

      Courtesy of FORD MOTOR CO.
NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is removed from the vehicle.
Fig 22: Removing Compression Seal Using Screwdriver
Courtesy of FORD MOTOR CO.
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

    Courtesy of FORD MOTOR CO.
25. Position the PTU in place and install the 5 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 24: Locating Bolts And PTU

      Courtesy of FORD MOTOR CO.
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

       Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
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: Identifying Lower RH Turbocharger Bracket And Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
30. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 29: Locating Oil Pan-To-Transaxle Bolts

      Courtesy of FORD MOTOR CO.
31. Install 3 new torque converter bolts.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 30: Locating Torque Converter Bolt

      Courtesy of FORD MOTOR CO.
32. Install the inspection cover and the 2 fasteners.
    Fig 31: Locating Inspection Cover And Fasteners

    Courtesy of FORD MOTOR CO.
33. Connect the transaxle cooler tubes and install the 2 secondary latches.
    Fig 32: Locating Secondary Latches

    Courtesy of FORD MOTOR CO.
34. Connect the lower radiator hose to the radiator.
    Fig 33: Locating Lower Radiator Hose Clamp

    Courtesy of FORD MOTOR CO.
35. Attach the lower radiator hose retainer to the cooling fan and shroud.
    Fig 34: Locating Lower Radiator Hose Retainer

    Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
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 Compressor Upper A/C Tube And Nut

      Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
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 Rear Driveshaft Bolts

      Courtesy of FORD MOTOR CO.
41. Connect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 40: Locating Fuel Supply Tube

    Courtesy of FORD MOTOR CO.
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 .
    Fig 41: Locating EVAP Tube Assembly And Intake Manifold Quick Connect Coupling

    Courtesy of FORD MOTOR CO.
43. Connect the EVAP valve electrical connector and attach to the intake manifold.
    Fig 42: Locating EVAP Valve Electrical Connector And Intake Manifold Valve

    Courtesy of FORD MOTOR CO.
44. Connect the EVAP tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 43: Locating Evaporative Emission Tube Quick Connect Coupling

    Courtesy of FORD MOTOR CO.
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

    Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
48. Connect the 2 heater hoses to the intake manifold.
    Fig 46: Locating Heater Hoses Clamps

    Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
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

    Courtesy of FORD MOTOR CO.
51. Connect the transaxle control cable to the control lever.
    Fig 49: Locating Control Lever Transaxle Control Cable

    Courtesy of FORD MOTOR CO.
52. Connect the quick connect coupling to the brake booster. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 50: Locating Brake Booster Quick Connect Coupling

    Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
54. Connect the ground cable to the negative battery terminal and install the nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 52: Locating Negative Battery Terminal Ground Cable And Nut

      Courtesy of FORD MOTOR CO.
55. Connect the engine wiring harness electrical connector.
    Fig 53: Locating Engine Wiring Harness Electrical Connector

    Courtesy of FORD MOTOR CO.
56. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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

      Courtesy of FORD MOTOR CO.
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

    Courtesy of FORD MOTOR CO.
59. Install the noise generator. For additional information, refer to REMOVAL AND INSTALLATION Intake Air System Components - Exploded View .
60. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
61. Install the degas bottle. For additional information, refer to ENGINE COOLING .
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 And Nut

      Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
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

       Courtesy of FORD MOTOR CO.
65. Connect the 2 PCM electrical connectors.
    Fig 59: Locating PCM Electrical Connectors

    Courtesy of FORD MOTOR CO.
66. Connect the PCM and engine harness electrical connectors.
    • Attach the wiring harness retainer.
      Fig 60: Locating PCM And Engine Harness Electrical Connectors

      Courtesy of FORD MOTOR CO.
67. Install the strut tower brace and the 4 nuts.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 61: Locating Strut Tower Brace And Nuts

      Courtesy of FORD MOTOR CO.
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 And Strut Tower Brace

    Courtesy of FORD MOTOR CO.
69. Install the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
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 Circlip Over Stub Shaft
Courtesy of FORD MOTOR CO.
70. Install the correct new circlip on the inboard stub shaft.
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.
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) .
74. Install the intermediate and halfshaft assembly and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 64: Locating Halfshaft Assembly Bolts

      Courtesy of FORD MOTOR CO.
75. Rotate the RH wheel knuckle into position and insert the RH halfshaft into the wheel hub.
NOTE: Align the index marks on the subframe to the index marks on the underbody that were made during removal.
Fig 65: Identifying Powertrain Lift Under Subframe
Courtesy of FORD MOTOR CO.
76. Using the Powertrain Lift, raise the subframe into the installed position.
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

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
Fig 67: Locating Subframe Support Brackets Bolts
Courtesy of FORD MOTOR CO.
78. Position the subframe brackets and install the 4 bolts finger-tight.
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

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
Fig 69: Locating Subframe Support Bracket Bolts
Courtesy of FORD MOTOR CO.
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) and install the bolt.
    • Tighten to 9 Nm (80 lb-in).
      Fig 70: Locating Bolt And Electronic Power Assist Steering Electrical Connectors

      Courtesy of FORD MOTOR CO.
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 .
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 Intermediate Shaft Bolt

      Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
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 Bar Link Nut

      Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
88. Install the RH and LH catalytic converters. For additional information, refer to EXHAUST SYSTEM .
89. Position the RH brake hose bracket and install the bolt.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 77: Locating RH Brake Hose Bracket Bolt

      Courtesy of FORD MOTOR CO.
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 Halfshaft Nuts

      Courtesy of FORD MOTOR CO.
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 Halfshaft Nuts

      Courtesy of FORD MOTOR CO.
92. Install the 2 scrivets in the rubber shield.
    Fig 80: Locating Scrivets In Rubber Shield

    Courtesy of FORD MOTOR CO.
93. Install the front wheels and tires. For additional information, refer to WHEELS AND TIRES .
94. Fill the engine with clean engine oil.
95. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
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

    Courtesy of FORD MOTOR CO.
97. Install the underbody shield and the 4 retainers.
    Fig 82: Locating Retainers And Underbody Shield

    Courtesy of FORD MOTOR CO.
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

      Courtesy of FORD MOTOR CO.
99. Refill the transaxle fluid. For additional, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - 6F50/6F55 .
100. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
101. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.