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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) 

GFD91562Courtesy of FORD MOTOR COMPANY
 2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
GFD91563Courtesy of FORD MOTOR COMPANY
 Adjustable Grip Arm, 1735A 014-00001 or equivalent
GFD91566Courtesy of FORD MOTOR COMPANY
 Powertrain Lift 300-OTC1585AE or equivalent
GFD91567Courtesy 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.
    GFD91988Courtesy of FORD MOTOR COMPANY
  2. Install the 3 engine-to-transaxle bolts.

    • Tighten to 48 Nm (35 lb-ft).

    GFD92005Courtesy of FORD MOTOR COMPANY
  3. Install the LH engine-to-transaxle bolt.

    • Tighten to 48 Nm (35 lb-ft).

    GFD92004Courtesy of FORD MOTOR COMPANY
  4. Install the 2 LH bottom transaxle-to-engine bolts.

    • Tighten to 48 Nm (35 lb-ft).

    GFD92003Courtesy of FORD MOTOR COMPANY
  5. Install the RH halfshaft support bracket and the 2 bolts.

    • Tighten to 40 Nm (30 lb-ft).

    GFD92002Courtesy 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).

    GFD92001Courtesy 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.

    GFD91624Courtesy 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.
    GFD91988Courtesy 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.

    GFD91624Courtesy of FORD MOTOR COMPANY
  10. Install the Adjustable Grip Arm.
    GFD91623Courtesy 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.
    GFD92000Courtesy of FORD MOTOR COMPANY
  13. Connect the transaxle control electrical connector.
    GFD91999Courtesy of FORD MOTOR COMPANY
  14. Connect the generator electrical connector.
    GFD91998Courtesy of FORD MOTOR COMPANY
  15. Connect the generator B+ cable and install the nut.

    • Tighten to 17 Nm (150 lb-in).

    GFD91997Courtesy of FORD MOTOR COMPANY
  16. Connect the A/C compressor and the pressure relief valve electrical connectors.

    • Attach the wiring harness retainers.

    GFD92079Courtesy of FORD MOTOR COMPANY
  17. Attach the CMS electrical connector.
    GFD92187Courtesy of FORD MOTOR COMPANY
  18. Install the ground wire and the bolt to the RH cylinder head.

    • Tighten to 10 Nm (89 lb-in).

    GFD91995Courtesy of FORD MOTOR COMPANY
  19. Position the PTU support bracket in place and install the 5 bolts.

    • Tighten to 48 Nm (35 lb-ft).

    GFD91451Courtesy of FORD MOTOR COMPANY
  20. Install the starter, the stud bolt and bolt.

    • Tighten to 27 Nm (20 lb-ft).

    GFD91992Courtesy of FORD MOTOR COMPANY
  21. Connect the wiring harness retainer to the starter motor stud bolt.
    GFD91991Courtesy 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).

    GFD92190Courtesy of FORD MOTOR COMPANY
  23. Install the starter motor solenoid cover.
    GFD91989Courtesy of FORD MOTOR COMPANY
  24. Remove the Heavy Duty Floor Crane and Spreader Bar.
    GFD91988Courtesy of FORD MOTOR COMPANY
  25. Remove the Engine Lift Eye from the LH cylinder head.
    GFD91986Courtesy of FORD MOTOR COMPANY
  26. Install the LH exhaust manifold heat shield and the 3 bolts.

    • Tighten to 12 Nm (106 lb-in).

    GFD91985Courtesy 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).

    GFD91984Courtesy of FORD MOTOR COMPANY
  28. Attach the wire 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).

    GFD231479Courtesy 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 .
    GFD231477Courtesy of FORD MOTOR COMPANY
  30. Connect the crankcase vent tube sensor electrical connector and the wire harness retainer.
    GFD231478Courtesy of FORD MOTOR COMPANY
  31. Remove the ratchet strap from the RH knuckle to subframe.
  32. 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).

    GFD91978Courtesy of FORD MOTOR COMPANY
  34. Install the 4 engine mount nuts.

    • Tighten to 63 Nm (46 lb-ft).

    GFD92007Courtesy 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).

    GFD91976Courtesy of FORD MOTOR COMPANY
  36. NOTE: RH shown, LH similar.

    Install the 2 front subframe bolts.

    • Tighten to 200 Nm (148 lb-ft).

    GFD91981Courtesy of FORD MOTOR COMPANY
  37. NOTE: RH shown, LH similar.

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

    GFD92191Courtesy of FORD MOTOR COMPANY
  38. NOTE: RH shown, LH similar.

    Install the 2 rear subframe bolts.

    • Tighten to 150 Nm (111 lb-ft).

    GFD92192Courtesy of FORD MOTOR COMPANY
  39. NOTE: RH shown, LH similar.

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

    GFD91979Courtesy 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.
    GFD91598Courtesy 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).

    GFD91599Courtesy 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).

    GFD91783Courtesy 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.

    GFD91079Courtesy 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).

    GFD91595Courtesy of FORD MOTOR COMPANY
  46. NOTE: RH shown, LH similar.

    Install new upper stabilizer bar link nuts.

    • Tighten to 150 Nm (111 lb-ft).

    GFD91975Courtesy 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).

    GFD91591Courtesy of FORD MOTOR COMPANY
  48. Install the 4 oil pan-to-transaxle bolts.

    • Tighten to 48 Nm (35 lb-ft).

    GFD91974Courtesy of FORD MOTOR COMPANY
  49. Install 3 new torque converter bolts.

    • Tighten to 55 Nm (41 lb-ft).

    GFD91973Courtesy of FORD MOTOR COMPANY
  50. Install the inspection cover and the 2 fasteners.
    GFD91972Courtesy of FORD MOTOR COMPANY
  51. Connect the transaxle cooler tubes and install the 2 secondary latches.
    GFD92193Courtesy of FORD MOTOR COMPANY
  52. If equipped, connect the 2 PTU coolant hoses.
    GFD91969Courtesy of FORD MOTOR COMPANY
  53. Connect the lower radiator hose to the radiator.
    GFD91968Courtesy of FORD MOTOR COMPANY
  54. Attach the lower radiator hose retainer to the cooling fan and shroud.
    GFD91967Courtesy of FORD MOTOR COMPANY
  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).

    GFD91966Courtesy of FORD MOTOR COMPANY
  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).

    GFD91965Courtesy of FORD MOTOR COMPANY
  57. Install the A/C tube bracket and bolt to the rear of the A/C compressor.

    • Tighten to 25 Nm (18 lb-ft).

    GFD91964Courtesy of FORD MOTOR COMPANY
  58. Install a new engine oil filter.

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

    GFD91963Courtesy of FORD MOTOR COMPANY
  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).

    GFD91962Courtesy of FORD MOTOR COMPANY
  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).

    GFD91961Courtesy of FORD MOTOR COMPANY
  61. Install the RH and LH catalytic converters. For additional information, refer to Exhaust System .
  62. Install the 3 scrivets in the rubber shield.
    GFD91414Courtesy of FORD MOTOR COMPANY
  63. Install the 2 front suspension height sensors. For additional information, refer to Vehicle Dynamic Suspension .
  64. Install the front valance, 7 bolts and 3 pin-type retainers.
    GFD91944Courtesy of FORD MOTOR COMPANY
  65. Install the underbody shield and the 4 retainers.
    GFD91851Courtesy of FORD MOTOR COMPANY
  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 .
    GFD91960Courtesy of FORD MOTOR COMPANY
  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 .
    GFD91804Courtesy of FORD MOTOR COMPANY
  69. Connect the EVAP valve electrical connector and attach to the intake manifold.
    GFD91959Courtesy of FORD MOTOR COMPANY
  70. Connect the EVAP tube quick connect coupling. For additional information, refer to Fuel System General Information .
    GFD91835Courtesy of FORD MOTOR COMPANY
  71. If equipped, attach the engine block heater harness to the radiator support wiring harness.
  72. Connect the upper radiator hose to the intake manifold coolant tube.
    GFD91818Courtesy of FORD MOTOR COMPANY
  73. Install the ground wire and bolt to the engine front cover.

    • Tighten to 10 Nm (89 lb-in).

    GFD91817Courtesy of FORD MOTOR COMPANY
  74. Connect the 2 heater hoses to the intake manifold.
    GFD91814Courtesy of FORD MOTOR COMPANY
  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).

    GFD91958Courtesy of FORD MOTOR COMPANY
  76. Attach the wiring harness pin-type retainer and connect the transaxle control cable to the shift cable bracket.
    GFD91957Courtesy of FORD MOTOR COMPANY
  77. Connect the transaxle control cable to the control lever.
    GFD91956Courtesy of FORD MOTOR COMPANY
  78. Connect the quick connect coupling to the intake manifold. For additional information, refer to Fuel System General Information .
    GFD91955Courtesy of FORD MOTOR COMPANY
  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).

    GFD91568Courtesy of FORD MOTOR COMPANY
  80. Connect the engine wiring harness electrical connector.
    GFD91954Courtesy of FORD MOTOR COMPANY
  81. Position back the ground wire and install the nut.

    • Tighten to 6 Nm (53 lb-in).

    GFD91953Courtesy of FORD MOTOR COMPANY
  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).

    GFD91952Courtesy of FORD MOTOR COMPANY
  84. Connect the Turbocharger Boost Pressure (TCBP) /Charge Air Cooler Temperature (CACT) sensor electrical connector.
    GFD91951Courtesy of FORD MOTOR COMPANY
  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).

    GFD91950Courtesy of FORD MOTOR COMPANY
  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).

    GFD91949Courtesy of FORD MOTOR COMPANY
  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.

    GFD92194Courtesy of FORD MOTOR COMPANY
  90. Connect the PCM electrical connector.
    GFD91947Courtesy of FORD MOTOR COMPANY
  91. Connect the engine harness electrical connector.
    GFD91946Courtesy of FORD MOTOR COMPANY
  92. Install the strut tower brace and the 4 nuts.

    • Tighten to 30 Nm (22 lb-ft).

    GFD91945Courtesy of FORD MOTOR COMPANY
  93. Attach the 2 brake booster vacuum hose retainers to the strut tower brace.
    GFD91833Courtesy of FORD MOTOR COMPANY
  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.

    GFD91850Courtesy of FORD MOTOR COMPANY
  96. Fill the engine with clean engine oil.
  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 .
  99. Perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.
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