Main Control Cover - 3.5L GTDI: Installation

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

Fig 1: Location of Transaxle Side 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 studbolts in the locations noted during disassembly.

Fig 2: Identifying Main Control Cover Bolts And Stud Bolt

Courtesy of FORD MOTOR CO.

Install the main control cover and loosely install the 14 bolts.
1. Bolt location
2. Studbolt location
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 studbolts and install the 2 nuts.
- Tighten to 9 Nm (80 lb-in).
Fig 4: Location of 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: Location of 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: Location of LH Turbocharger-To-CAC Hose Clamp
Courtesy of FORD MOTOR CO.
Install the underbody shield and the 4 retainers.

Fig 7: Location of 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: Location of LH Turbo Inlet Tube Clamps
Courtesy of FORD MOTOR CO.
Install the crankcase vent tube.

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

Fig 10: Location of LH Turbocharger Air Inlet Hose
Courtesy of FORD MOTOR CO.
Install the vacuum tube on the LH air inlet hose.

Fig 11: Location of LH Air Inlet Hose
Courtesy of FORD MOTOR CO.
Install the brake booster vacuum tube on the LH air inlet hose.

Fig 12: Location of LH Turbocharger Air Inlet Hose
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 & FILTERING .