Engine - 3.5L GTDI: Installation: Engine

Special Tool(s)

Courtesy of FORD MOTOR COMPANY	Bar, Engine Spreader 303-1454
Courtesy of FORD MOTOR COMPANY	Lift Eye, Right Front 303-1529
Courtesy of FORD MOTOR COMPANY	2, 200# Floor Crane, Floor Crane 300-OTC1819E or equivalent
Courtesy of FORD MOTOR COMPANY	Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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
Motorcraft ® Multi-Purpose Grease XL-5-A	ESB-M1C93-B
Motorcraft ® Threadlock 262 TA-26	WSK-M2G351-A6

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

NOTE: Prior to installation of the engine, the torque converter pilot hub must be lubricated with multi-purpose grease or damage to the torque converter or the engine crankshaft can occur

1.
Lubricate the torque converter pilot hub with multi-purpose grease.

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2.

Align the torque converter stud and flexplate hole near the paint marks at the 12 o'clock position.

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3.

Using the Floor Crane and Engine Spreader Bar, position the engine in the engine compartment.

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NOTE: The transmission wiring harness is part of the engine wiring harness.

4.
Attach the generator wiring harness retainer to the lower LH side of the engine block.
- Position the transmission wiring harness along the side of the transmission for installation.

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5.

Using the Floor Crane and Engine Spreader Bar, position the engine to the transmission.

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6.

Align the engine to the transmission and draw together using the bolts.
- Tighten to 48 Nm (35 lb-ft).

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7.

Using the Floor Crane and Engine Spreader Bar, raise the engine and install the LH engine support insulator.

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NOTE: Clean the LH and RH engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to installation.

NOTE: Only use hand tools when loosening or tightening the LH engine support insulator through bolt or damage to the engine support insulator-to-cylinder block bracket can occur.

8.
Install the LH engine support insulator and the new through bolt.
- Do not torque at this time.

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9.

Lower the engine.

NOTE: Use only hand tools when removing or installing the engine support insulator-to-frame bolts or the damage to the engine support insulator-to-frame nut plate can occur.

10.
Install the new LH engine support insulator bolts.
- Tighten to 175 Nm (129 lb-ft).

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NOTE: Apply threadlock to the stud threads prior to installation.

NOTE: Use only hand tools when installing the engine support insulator stud bolts or damage to the engine support insulator can occur.

11.
Install the RH engine support insulator studs.
- Tighten to 30 Nm (22 lb-ft).

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NOTE: Use only hand tools when installing the RH engine support insulator nuts or damage to the engine support insulator can occur.

12.
Install the new RH engine support insulator nuts.
- Tighten to 175 Nm (129 lb-ft).

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NOTE: Only use hand tools when loosening or tightening the LH engine support insulator through bolt or damage to the engine support insulator-to-cylinder block bracket can occur.

13.
Tighten the LH engine mount through bolt.
- Tighten to 350 Nm (258 lb-ft).

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NOTE: Do not lubricate the engine oil filter gasket.

14.
Install a new engine oil filter.
- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.

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15.

Install the RH side bell housing bolt.
- Tighten to 48 Nm (35 lb-ft).

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16.

Install the LH side bell housing bolts.
- Tighten to 48 Nm (35 lb-ft).

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17.

Install the upper bell housing bolts.
- Tighten to 48 Nm (35 lb-ft).

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18.

Remove the stand.

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19.

Install the lower bell housing bolt.
- Tighten to 48 Nm (35 lb-ft).

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NOTE: Make sure that the mating faces are clean and free of foreign material.

20.
Install the new LH catalytic converter-to-exhaust manifold nuts.
- Tighten to 45 Nm (35 lb-ft).

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21.

Install the new LH catalytic converter-to-exhaust manifold nuts.
- Tighten to 45 Nm (35 lb-ft).

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22.

Position the exhaust Y-pipe dual catalytic converter-to-intermediate pipe and install the bolts.
- Tighten the inner exhaust Y-pipe catalytic converter-to-exhaust intermediate pipe bolt to 63 Nm (46 lb-ft).
- Tighten the outer exhaust Y-pipe catalytic converter-to-exhaust intermediate pipe bolt to 63 Nm (46 lb-ft).

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23.

Install the torque converter nuts.
- Tighten to 44 Nm (32 lb-ft).

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24.

Install the access cover and the pin-type retainers.

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25.

Install the selector lever cable bracket and selector lever cable bracket bolts.
- Tighten to 48 Nm (35 lb-ft).

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26.

Connect the 2 CMS electrical connectors and retainers.
- Connect the transfer case electrical connector harness retainer.
- Connect the transmission harness electrical connector and harness retainers.

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27.

Connect the transfer case electrical connector.

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28.

Connect the RH HO2S electrical connector and position harness in retainer.

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29.

Install the fuel lines in the retainer on the rear of the transmission.

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30.

Install the fuel lines in the bracket on the upper bell housing.

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31.

Attach the starter motor wiring harness retainer to the oil pan.

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32.

Install the starter motor. Refer to Starting System .

33.

If equipped, install the front driveshaft. Refer to Driveshaft .

34.

If equipped, install the skid plate and the bolts.
- Tighten to 40 Nm (30 lb-ft).

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35.

Connect the HO2S electrical connector to the wiring harness retainer.
- Connect the HO2S electrical connector to the engine wiring harness at the rear of the LH cylinder head.

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36.

Install the cowl panel grille. Refer to Front End Body Panels .

37.

Install the ground strap and bolt to the cowl.
- Tighten to 10 Nm (89 lb-in).

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38.

Connect the vacuum pump tube. Refer to Fuel System General Information .

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39.

Attach the wiring harness retainers to the rear of the RH valve cover stud bolt and the rear of the vacuum pump.

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40.

Connect the coolant hoses to the degas bottle.

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41.

Using a hose clamp remover/installer, install the heater hose.

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42.

Connect the heater hose couplings at the RH rear of the engine.

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43.

Install the intake manifold. Refer to Intake Manifold .

44.

Install the fuel injection pump. Refer to Engine Controls - Fuel Charging And Controls - 3.5L GTDI .

45.

Connect the PCM electrical connector and the engine harness electrical connector.
- Attach the wiring harness retainers to the fender splash shield.

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46.

Install the generator. Refer to Generator and Regulator .

47.

Install the bolts and the A/C compressor.
- Tighten to 10 Nm (89 lb-in).
- Attach the A/C compressor wiring harness to the A/C compressor.
- Connect the A/C compressor electrical connector.

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48.

Install the A/C compressor belt. Refer to Accessory Drive .

49.

Position back the coolant hose to the valve cover stud. Install the Charge Air Cooler (CAC) bracket and nuts.
- Tighten to 6 Nm (53 lb-in).

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50.

If equipped, reposition the heater pump and install the nuts, the bolt.
- Tighten to 6 Nm (53 lb-in).

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51.
- If equipped, connect the electrical connector.
- If equipped, using a hose clamp remover/installer, connect the heater hose.

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52.

Attach the generator wiring harness to the engine front cover.

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53.

Install the transmission cooler line bracket and nut to the engine front cover stud bolt.
- Tighten to 12 Nm (106 lb-in).

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54.

Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
- Tighten to 15 Nm (133 lb-in).

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55.

Connect the A/C pressure transducer electrical connectors.

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56.

Connect the Battery Junction Box (BJB) wiring harness.

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57.

Fill the engine with clean engine oil.

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58.

Connect the air bypass tube assembly to the air cooler.

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59.

Install the turbocharger outlet pipe and attach the turbocharger outlet pipe to the bracket. Tighten the turbocharger outlet pipe clamps to 5 Nm (44 lb-in) and connect the turbocharger outlet pipe hose.

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60.

Install the turbocharger inlet pipe.
- 1.
  
  Attach the turbocharger inlet pipe to the bracket.
- 2.
  
  Tighten the turbocharger inlet pipe clamp to 5 Nm (44 lb-in).

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61.

Connect the turbocharger inlet pipe hose.

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62.

Install the turbocharger outlet tube, install the turbocharger outlet tube into the retaining clamp and insert the turbocharger outlet tube into the turbocharger outlet tube bracket grommet. Tighten the turbocharger outlet tube clamps to 5 Nm (44 lb-in).

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63.
- 1.
  
  Install the turbocharger inlet tube and insert the turbocharger inlet tube into the turbocharger inlet tube bracket grommet.
- 2.
  
  Tighten the turbocharger inlet tube clamp to 5 Nm (44 lb-in).

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64.

Connect the quick connect couplings and connect the turbocharger bypass tube. Refer to Fuel System General Information .

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65.
- 1.
  
  Connect the PCV pressure sensor electric connector.
- 2.
  
  Connect the PCV tube quick connect couplings. Refer to Fuel System General Information .

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66.
- Connect the Charge Air Cooler (CAC) -to-Throttle Body (TB) pipe to the CAC.
- Connect the Charge Air Cooler (CAC) -to-Throttle Body (TB) pipe to the TB and tighten the clamp.
- Connect electrical connector and the fuel vapor tube quick connect coupling. Refer to Fuel System General Information .

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67.

Remove the oil filler cap and install the engine appearance cover.
- Install the oil filler cap.

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68.

Install the ACL upper tray and secure the retainers.

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69.

Install the Air Cleaner Outlet Pipe. Refer to Intake Air Distribution and Filtering .

70.

Install the cooling module. Refer to Engine Cooling .

71.

Connect the battery ground cable. Refer to Battery, Mounting and Cables .

NOTE: RH shown, LH similar.

NOTE: Align the index marks made during hood removal.

72.
Position the hood and install the 4 bolts.
- Tighten to 12 Nm (106 lb-in).

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73.

Adjust the selector lever cable and install the selector lever cable end on the manual control lever. Verify the selector lever cable is correctly adjusted. Refer to Automatic Transaxle Transmission External Controls .

74.

Start and check the exhaust for leaks.

75.

Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.