Main Control Cover - 3.5L GTDI: Installation

Inspect the transaxle side cover seal for damage and install new if necessary.

Fig 1: Locating Main Control Cover Seal
Courtesy of FORD MOTOR CO.

NOTE: Inspect the 20-pin solenoid body connector seal to make sure that the seal is on the inside of the main control cover or a transmission fluid leak will occur.

NOTE: Install the stud bolts in the locations noted during disassembly.

Install the main control cover and loosely install the 14 bolts.
1. Bolt location
2. stud bolt location
  
  Fig 2: Identifying Main Control Cover Bolts
  Courtesy of FORD MOTOR CO.
Tighten the main control cover bolts in the sequence shown in illustration.
- Tighten to 12 Nm (106 lb-in).
  
  Fig 3: Identifying Main Control Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Position the transmission fluid cooler thermal bypass valve and transmission fluid cooler tube assembly on the main control cover stud bolts and install the 2 nuts.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 4: Locating Transmission Fluid Cooler Thermal Bypass Valve And Nuts
  Courtesy of FORD MOTOR CO.
Connect the transaxle electrical connector and install the wiring harness fastener on the main control cover stud.

Fig 5: Locating Transaxle Electrical Connector And Wiring Harness Fastener
Courtesy of FORD MOTOR CO.
Position the LH turbocharger-to-CAC hose on the turbocharger and tighten the clamp.
- Tighten to 5 Nm (44 lb-in).
  
  Fig 6: Locating LH Turbocharger-To-Charge Air Cooler Hose Clamp
  Courtesy of FORD MOTOR CO.
Install the underbody shield and the 4 retainers.

Fig 7: Locating Retainers And Underbody Shield
Courtesy of FORD MOTOR CO.
Position the LH turbocharger inlet tube in place and tighten the 2 clamps.
- Tighten to 5 Nm (44 lb-in).
  
  Fig 8: Locating LH Turbo Inlet Tube Clamps
  Courtesy of FORD MOTOR CO.
Install the crankcase vent tube.

Fig 9: Locating Quick Connect Couplings And Crankcase Vent Tube
Courtesy of FORD MOTOR CO.
Install the bypass hose on the LH turbocharger air inlet hose.

Fig 10: Locating Constant Tension Clamp
Courtesy of FORD MOTOR CO.
Install the vacuum tube on the LH air inlet hose.

Fig 11: Locating Vacuum Tube
Courtesy of FORD MOTOR CO.
Install the brake booster vacuum tube on the LH air inlet hose.

Fig 12: Locating Brake Booster Vacuum Tube
Courtesy of FORD MOTOR CO.
Fill the transaxle with clean transmission fluid, refer to TRANSMISSION FLUID DRAIN AND REFILL .
Install the ACL and outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM article.