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Section 214 (Engine Mechanical - 3.5L GTDI): Installation: Engine

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SPECIAL TOOL(S) DESCRIPTION

G09070579
 2, 200# Floor Crane, Fold Away
300-OTC1819E  or equivalent
G09070580
 Adjustable Grip Arm, 1735A
014-00001  or equivalent
G09070581
 Powertrain Lift
300-OTC1585AE  or equivalent
GENERAL EQUIPMENT

Hose Clamp Remover/Installer
Spreader Bar
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)		 WSS-M2C946-A
  1. 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.

    Using the Special Tool(s): 2, 200# Floor Crane, Fold Away 300-OTC1819E.

    Align the engine to the transaxle.

    G09070582
  2. Install the 5 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G09070583
  3. Install the 2 transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G09070584
  4. Install the RH halfshaft support bracket and the 2 bolts.
    • Tighten to 40 Nm (30 lb-ft).
      G09070585
  5. Install the 2 intermediate shaft bracket studs and nuts.
    • Tighten the studs to 10 Nm (89 lb-in).
    • Tighten the nuts to 25 Nm (18 lb-ft).
      G09070586
  6. NOTE: LH shown in illustration, 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.

    G09070587
  7. Using the Floor Crane, install the powertrain and subframe as an assembly on the powertrain lift table.
    G09070588
  8. NOTE: LH shown in illustration, 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.

    G09070589
  9. Install the Adjustable Grip Arm.
    G09070590
  10. 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.
  11. Position the PTU  support bracket in place and install the 5 bolts.
    • Tighten to 70 Nm (52 lb-ft).
      G09070591
  12. Attach the transaxle control wire harness retainer to the transaxle stud bolt.
    G09070592
  13. Connect the transaxle control electrical connector.
    G09070593
  14. Connect the A/C compressor and the pressure relief valve electrical connectors.
    • Attach the 3 wiring harness retainers.
      G09070594
  15. Connect the generator B+ cable and install the nut.
    • Tighten to 17 Nm (150 lb-in).
      G09070595
  16. Position back the generator B+ cable cover and connect the generator electrical connector.
    G09070596
  17. Install the ground wire to the RH cylinder head and install the bolt.
    • Tighten to 10 nm (89 lb-In).
      G09070597
  18. Install the starter, the stud bolt and bolt.
    • Tighten to 27 Nm (20 lb-ft).
      G09070598
  19. Connect the wiring harness retainer to the starter motor stud bolt.
    G09070599
  20. 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).
      G09070600
  21. Install the starter motor solenoid cover.
    G09070601
  22. Remove the Floor Crane.
    G09070602
  23. Remove the Special Tool(s): Eye, Engine Lift 303-1245.
    G09070603
  24. Install the LH exhaust manifold heat shield and the 3 bolts.
    • Tighten to 14 Nm (124 lb-in).
      G09070604
  25. Install the oil supply tube bracket on the LH valve cover stud bolt and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      G09070605
  26. Install the crankcase vent tube and connect the 2 quick connect couplings. Refer to QUICK CONNECT COUPLING .
    • Attach the 3 wiring harness retainers and install the engine cover mounting stud.
      • Tighten to 6 Nm (53 lb-in).
        G09070606
  27. Raise the subframe and powertrain assembly into the vehicle.
  28. Position the engine mount onto the engine studs and install the 4 nuts and 3 bolts hand tight.
    • Tighten the bolts to 90 Nm (66 lb-ft).
    • Tighten the nuts to 63 Nm (46 lb-ft).
      G09070607
  29. Install the transaxle support insulator assembly the 3 nuts and the bolt.
    • Tighten the nuts to 63 Nm (46 lb-ft).
    • Tighten the bolt to 80 Nm (59 lb-ft).
      G09070608
  30. Install the 4 transmission support insulator-to-frame rail bolts.
    • Tighten the 2 bottom bolts to 55 Nm (41 lb-ft).
    • Tighten the 2 top bolts to 70 Nm (52 lb-ft).
      G09070609
  31. NOTE: RH shown in illustration, LH similar.

    Align the subframe and install the new front subframe bolts.

    • Tighten to 200 Nm (148 lb-ft).
      G09070610
  32. NOTE: RH shown in illustration, LH similar.

    Install the rear subframe brackets and the new subframe bracket-to-body bolts.

    • Finger tight at this stage.
      G09070611
  33. NOTE: RH shown in illustration, LH similar.

    Install the new subframe bracket bolts.

    • Tighten to 150 Nm (111 lb-ft).
      G09070612
  34. NOTE: RH shown in illustration, LH similar.

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

    G09070613
  35. Remove the ratchet strap from the front of the subframe to the rear of the subframe.
  36. Remove the Adjustable Grip Arm and the powertrain lift table.
    G09070614
  37. NOTE: LH shown in illustration, 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).
      G09070615
  38. NOTE: LH shown in illustration, 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).
      G09070616
  39. 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 in illustration, 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.
      G09070617
  40. 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 in illustration, 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).
      G09070618
  41. NOTE: LH shown in illustration, RH similar.

    Install the new upper stabilizer link nut.

    • Tighten to 150 Nm (111 lb-ft).
      G09070619
  42. NOTE: LH shown in illustration, RH similar.

    Install the wheel speed sensor and the bolt.

    • Tighten to 15 Nm (133 lb-in).
      G09070620
  43. Connect the transaxle cooler tubes and install the 2 secondary latches.
    G09070621
  44. Connect the 2 PTU  cooling lines.
    G09070622
  45. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G09070623
  46. Install 3 new torque converter bolts.
    • Tighten to 55 Nm (41 lb-ft).
      G09070624
  47. Install the inspection cover and the 2 fasteners.
    G09070625
  48. Connect the lower radiator hose to the radiator.
    • Attach the lower radiator hose retainer to the cooling fan and shroud.
      G09070626
  49. 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).
      G09070627
  50. NOTE: Do not lubricate the oil filter seal.

    Install a new engine oil filter.

    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
      G09070628
  51. 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).
      G09070629
  52. Install the A/C tube bracket and bolt to the rear of the A/C compressor.
    • Tighten to 25 Nm (18 lb-ft).
      G09070630
  53. Align 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).
      G09070631
  54. Install the RH and LH catalytic converter. Refer to CATALYTIC CONVERTER -- LH, 3.5L GTDI , and CATALYTIC CONVERTER -- RH, 3.5L GTDI .
  55. 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 CLOCKSPRING , and CLOCKSPRING ADJUSTMENT .

    Align and connect the steering column shaft to the steering gear and install the bolt.

    • Tighten to 20 Nm (177 lb-in).
      G09070632
  56. Connect the 2 heater hoses to the intake manifold.
    G09070633
  57. 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).
      G09070634
  58. If equipped, attach the engine block heater harness to the radiator support wiring harness.
    G09070635
  59. Attach the wiring harness pin-type retainer and connect the transaxle control cable to the shift cable bracket.
    G09070636
  60. Connect the transaxle control cable to the control lever.
    G09070637
  61. 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.
      G09070638
  62. Connect the PCM electrical connector.
    G09070639
  63. Connect the engine harness electrical connector.
    G09070640
  64. Connect the upper radiator hose to the intake manifold coolant tube.

    General Equipment: Hose Clamp Remover/Installer.

    • Install the ground wire and bolt to the engine front cover.
      • Tighten to 10 Nm (89 lb-in).
        G09070641
  65. Install the EVAP  canister purge valve. Refer to EVAPORATIVE EMISSION CANISTER PURGE VALVE -- 3.5L GTDI .
  66. Connect the fuel supply tube. REFER to QUICK CONNECT COUPLING .
    G09070642
  67. Install the strut tower brace and the 4 nuts.
    • Tighten to 30 Nm (22 lb-ft).
      G09070643
  68. Connect the brake booster vacuum hose quick connect coupling to the intake manifold, brake booster and CAC  . REFER to QUICK CONNECT COUPLING .
    • Attach the brake booster vacuum hose to strut tower brace.
      G09070644
  69. NOTE: Align the index marks for the CAC  outlet pipe.

    Install the CAC  outlet pipe and tighten the 2 clamps.

    • Tighten to 5 Nm (44 lb-in).
    • Connect the Turbocharger Boost Pressure (TCBP)/Charge Air Cooler Temperature (CACT) electrical connector.
      G09070645
  70. Install the degas bottle. REFER to DEGAS BOTTLE .
  71. 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).
      G09070646
  72. Install the accessory drive belt. Refer to ACCESSORY DRIVE BELT -- 3.5L GTDI .
  73. Install the underbody air duct and the 3 twist lock retainers.
    G09070647
  74. NOTE: RH shown in illustration, LH similar.

    Install the 2 RH and 2 LH lower pin-type retainers for the engine splash shields.

    G09070648
  75. Install the front wheels and tires. REFER to WHEEL AND TIRE .
  76. Connect the engine wiring harness electrical connector and install the ground wires and the retainer.
    • Tighten to 10 Nm (89 lb-in).
      G09070649
  77. 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).
      G09070650
  78. Install the battery tray. REFER to BATTERY AND BATTERY TRAY - EXPLODED VIEW .
  79. Install the engine ACL  and ACL  outlet pipe. REFER to INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW .
  80. Install the cowl panel. REFER to COWL PANEL .
  81. Fill the engine with clean engine oil.
  82. Fill and bleed the cooling system. REFER to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  83. Recharge the A/C system. REFER to AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING for DATC, or AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING for EMTC.
  84. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.
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