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Section 178 (Engine Mechanical - 3.5L-GTDI - F150): Installation: Engine

WARNING: This page is about a different car, the 2012 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G06260116
 Bar, Engine Spreader
303-1454
G06126494
 Lifting Bracket, Engine
303-F047 (014-00073) or equivalent
G07958925
 Lift Eye, Right Front
303-1566
G07959420
 2, 200# Floor Crane, Floor Crane
300-OTC1819E or equivalent
G06139341
 Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool
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); or equivalent		 WSS-M2C946-A, 5W30;
Multi-Purpose Grease
Motorcraft® XL-5 (aerosol) and/or CRC® SL3151		 ESB-M1C93-B
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
    Fig 1: Locating Torque Converter Pilot Hub
    G06127674Courtesy of FORD MOTOR CO.
  1. Lubricate the torque converter pilot hub with multi-purpose grease.
  2. Align the torque converter stud and flexplate hole near the paint marks at the 12 o'clock position.
    Fig 2: Locating Torque Converter Stud And Flexplate Hole Near Paint Marks At 12 O'Clock Position
    G07959423Courtesy of FORD MOTOR CO.
  3. Using the Floor Crane and Engine Spreader Bar, position the engine in the engine compartment.
    Fig 3: Lifting Engine Using Floor Crane And Engine Spreader Bar Assembly
    G07959008Courtesy of FORD MOTOR CO.
    4. 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.
      Fig 4: Locating Generator Wiring Harness Retainer To Engine Block
      G07958827Courtesy of FORD MOTOR CO.
  5. Using the Floor Crane and Engine Spreader Bar, position the engine to the transmission.
    Fig 5: Lifting Engine Using Floor Crane And Engine Spreader Bar Assembly
    G07959008Courtesy of FORD MOTOR CO.
  6. Align the engine to the transmission and install the 2 LH bellhousing-to-oil pan bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 6: Locating LH Bellhousing-To-Oil Pan Bolts
      G07959427Courtesy of FORD MOTOR CO.
  7. Using the Floor Crane and Engine Spreader Bar, raise the engine for clearance for the LH engine support insulator.
    Fig 7: Lifting Engine Using Floor Crane And Engine Spreader Bar Assembly
    G07959008Courtesy of FORD MOTOR CO.
    8. NOTE: Use only hand tools when installing the LH engine support insulator through bolt or the engine support insulator may be damaged.
    NOTE: Clean the LH and RH engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to installation.
    NOTE: Apply threadlock to the bolt threads prior to installation.
  8. Install the LH engine support insulator and the through bolt.
    • Do not torque at this time.
      Fig 8: Locating Engine Support Insulator Bolt
      G06126794Courtesy of FORD MOTOR CO.
  9. Lower the engine.
    10. NOTE: Apply threadlock to the bolt threads prior to installation.
  10. Install the 3 LH engine support insulator bolts.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 9: Locating LH Engine Support Insulator-To-Frame Bolts
      G07958941Courtesy of FORD MOTOR CO.
  11. Position back the coolant hose to the valve cover stud. Install the Charge Air Cooler (CAC) bracket and 2 nuts.
    • Tighten to 6 Nm (53 lb-in).
      Fig 10: Locating CAC Tube Bracket And Nuts
      G07406968Courtesy of FORD MOTOR CO.
    12. NOTE: Apply threadlock to the stud threads prior to installation.
  12. Install the 2 RH engine support insulator studs.
    • Tighten to 15 Nm (133 lb-in).
      Fig 11: Locating RH Engine Support Insulator Studs
      G07959432Courtesy of FORD MOTOR CO.
    13. NOTE: Use only hand tools when installing the RH engine support insulator nuts or the engine support insulator may be damaged.
    NOTE: Apply threadlock to the nut threads prior to installation.
  13. Install the 2 RH engine support insulator nuts.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 12: Locating RH Engine Support Insulator Nuts
      G07959433Courtesy of FORD MOTOR CO.
    14. NOTE: Use only hand tools when tightening the LH engine support insulator through bolt or the engine support insulator may be damaged.
  14. Tighten the LH engine mount through bolt.
    • Tighten to 350 Nm (258 lb-ft).
      Fig 13: Locating Engine Support Insulator Bolt
      G06126794Courtesy of FORD MOTOR CO.
    15. NOTE: Do not lubricate the engine oil filter gasket.
  15. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
  16. Install the LH bellhousing-to-engine bolt.
    • Tighten the bolt, it will be torqued at a later step.
      Fig 14: Locating LH Bellhousing-To-Engine Bolt
      G07959435Courtesy of FORD MOTOR CO.
  17. Install the engine-to-bellhousing bolt.
    • Tighten the bolt, it will be torqued at a later step.
      Fig 15: Locating Engine-To-Bellhousing Bolt
      G07958998Courtesy of FORD MOTOR CO.
  18. Install the oil pan-to-bellhousing bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 16: Locating Oil Pan-To-Bellhousing Bolt
      G07958999Courtesy of FORD MOTOR CO.
  19. Tighten the engine-to-bellhousing bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 17: Locating Engine-To-Bellhousing Bolt
      G07958998Courtesy of FORD MOTOR CO.
  20. Install the LH bellhousing-to-engine bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 18: Locating LH Bellhousing-To-Engine Bolt
      G07959439Courtesy of FORD MOTOR CO.
  21. Tighten the LH bellhousing-to-engine bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 19: Locating LH Bellhousing-To-Engine Bolt
      G07959440Courtesy of FORD MOTOR CO.
  22. Install the 4 upper bellhousing-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 20: Locating Upper Bellhousing-To-Engine Bolts
      G07958789Courtesy of FORD MOTOR CO.
    23. NOTE: LH shown in illustration, RH similar.
  23. Install the new 2 LH and RH catalytic converter-to-exhaust manifold nuts.
    • Tighten to 45 Nm (35 lb-ft).
      Fig 21: Locating LH And RH Catalytic Converter-To-Turbocharger Nuts
      G07958937Courtesy of FORD MOTOR CO.
  24. Position the exhaust Y-pipe dual catalytic converter-to-intermediate pipe and install the 2 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).
      Fig 22: Locating Exhaust Y-Pipe Dual Catalytic Converter-To-Exhaust Intermediate Pipe Bolts
      G07958960Courtesy of FORD MOTOR CO.
  25. Install the 4 torque converter nuts.
    • Tighten to 44 Nm (32 lb-ft).
      Fig 23: Locating Torque Converter Nuts
      G07476066Courtesy of FORD MOTOR CO.
  26. Install the access cover and the 2 pin-type retainers.
    Fig 24: Locating Access Cover And Pin-Type Retainers
    G07476065Courtesy of FORD MOTOR CO.
  27. Attach the starter motor wiring harness retainer to the oil pan.
    Fig 25: Locating Starter Motor Wiring Harness Retainer To Oil Pan
    G07407002Courtesy of FORD MOTOR CO.
  28. Install the starter motor. For additional information, REFER to STARTING SYSTEM .
  29. If equipped, install the front driveshaft. For additional information, REFER to DRIVESHAFT .
  30. Install the skid plate and the 4 bolts.
    • Tighten to 48 Nm (35 lb-ft).
  31. Connect the transmission vehicle harness connector by pushing the connector into the transmission and twisting the outer shell.
    Fig 26: Locating Transmission Vehicle Harness Connector
    G06127319Courtesy of FORD MOTOR CO.
  32. Connect the electrical connector retainer to the bracket at the rear of the transmission.
    • Connect the Heated Oxygen Sensor (HO2S) electrical connector.
      Fig 27: Locating HO2S Electrical Connector
      G07958787Courtesy of FORD MOTOR CO.
    33. NOTE: Only one wire harness retainer and one electrical connector shown in illustration, others similar.
  33. If equipped, connect the 5 transmission wire harness retainers to the transfer case wire harness.
    • Connect the 2 HO2S electrical connector retainers.
    • Connect the 2 HO2S electrical connectors.
      Fig 28: Locating Transmission Wire Harness Retainers
      G07958786Courtesy of FORD MOTOR CO.
  34. Install the splash shield and the 4 retainers.
    Fig 29: Locating Splash Shield And Fasteners
    G07410085Courtesy of FORD MOTOR CO.
  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.
      Fig 30: Locating HO2S Electrical Connector To Wiring Harness Retainer
      G07958986Courtesy of FORD MOTOR CO.
  36. Install the cowl panel and attach the 2 clips and install the 6 screws.
    Fig 31: Locating Cowl Panel Clips And Screws
    G07958930Courtesy of FORD MOTOR CO.
  37. Install the cowl panel grille. For additional information, REFER to FRONT END BODY PANELS .
  38. Install the ground strap and bolt to the cowl.
    • Tighten to 10 Nm (89 lb-in).
      Fig 32: Locating Ground Strap And Bolt
      G06126817Courtesy of FORD MOTOR CO.
  39. Attach the wiring harness retainers to the rear of the RH valve cover stud bolt and the rear of the RH cylinder head.
    Fig 33: Locating Wiring Harness Retainers From Rear Of RH Valve Cover Stud Bolt And Rear Of RH Cylinder Head
    G07958983Courtesy of FORD MOTOR CO.
  40. Connect the 2 coolant hoses to the degas bottle.
    Fig 34: Locating Coolant Hoses To Degas Bottle
    G07958982Courtesy of FORD MOTOR CO.
  41. Connect the 2 heater hose couplings at the RH rear of the engine.
    Fig 35: Locating Heater Hose Couplings
    G07958981Courtesy of FORD MOTOR CO.
  42. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD  .
  43. Install the fuel injection pump. For additional information, REFER to FUEL CHARGING AND CONTROLS - 3.5L GTDI .
  44. Connect the PCM electrical connector and the engine harness electrical connector.
    • Attach the wiring harness retainers to the fender splash shield.
      Fig 36: Locating Wiring Harness Retainers From Fender Splash Shield
      G07958980Courtesy of FORD MOTOR CO.
  45. Install the A/C compressor belt. For additional information, REFER to ACCESSORY DRIVE .
  46. Install the generator. For additional information, REFER to CHARGING SYSTEM .
  47. Connect the A/C compressor electrical connector.
    • Attach the A/C compressor wiring harness to the A/C compressor.
      Fig 37: Locating A/C Compressor Electrical Connector
      G07958979Courtesy of FORD MOTOR CO.
  48. Attach the generator wiring harness to the engine front cover.
    Fig 38: Locating Generator Wiring Harness To Engine Front Cover
    G07407004Courtesy of FORD MOTOR CO.
  49. Install the transmission cooler line bracket and nut to the engine front cover stud bolt.
    • Tighten to 12 Nm (106 lb-in).
      Fig 39: Locating Transmission Cooler Tube Bracket And Nut
      G07410347Courtesy of FORD MOTOR CO.
  50. Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
    • Tighten to 15 Nm (133 lb-in).
      Fig 40: Locating A/C Tube And Nut
      G07958976Courtesy of FORD MOTOR CO.
  51. Connect the Battery Junction Box (BJB) wiring harness and the A/C pressure transducer electrical connectors.
    Fig 41: Locating BJB Wiring Harness And A/C Pressure Transducer Electrical Connectors
    G07958975Courtesy of FORD MOTOR CO.
  52. Fill the engine with clean engine oil.
  53. Install the 2 Charge Air Cooler (CAC) inlet tubes and the CAC outlet tube. For additional information, refer to 3.5L Gasoline Turbocharged Direct Injection (GTDI) Charge Air Cooler (CAC) and Tubes Exploded View in INTAKE AIR DISTRIBUTION & FILTERING .
  54. Install the LH and RH turbocharger intake tubes. For additional information, refer to 3.5L Gasoline Turbocharged Direct Injection (GTDI) Charge Air Cooler (CAC) and Tubes Exploded View in INTAKE AIR DISTRIBUTION & FILTERING .
  55. Install the cooling module. For additional information, refer ENGINE COOLING .
  56. If equipped, connect the block heater electrical connector at the thermostat housing.
    • Attach the block heater wiring harness retainer to the LH valve cover stud bolt.
      Fig 42: Locating Block Heater Electrical Connector At Thermostat Housing
      G07958974Courtesy of FORD MOTOR CO.
  57. Connect the battery ground cable. For additional information, REFER to BATTERY, MOUNTING AND CABLES .
    58. NOTE: Align the index marks made during hood removal.
    NOTE: RH shown in illustration, LH similar.
  58. Position the hood and install the 4 bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 43: Locating Hood Bolts
      G06126496Courtesy of FORD MOTOR CO.
  59. 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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