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Section 537 (Engine Mechanical - 3.5L GTDI): Installation: Engine

WARNING: This page is about a different car, the 2014 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL DESCRIPTION

G06260116
 Bar, Engine Spreader
303-1454 
G06126494
 Lifting Bracket, Engine
303-F047  (014-00073) or equivalent
G09391547
 2, 200# Floor Crane, Floor Crane
300-OTC1819E  or equivalent
G06136947
 Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool
MATERIAL SPECIFICATION

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		 ESB-M1C93-B
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.
  1. NOTE: Prior to installation of the engine, the torque converter pilot hub must be lubricated with multipurpose grease or damage to the torque converter or the engine crankshaft can occur

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

    Fig 1: Locating Torque Converter Pilot Hub
    G06127674Courtesy of FORD MOTOR CO.
  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 Paint Marks
    G07959423Courtesy of FORD MOTOR CO.
  3. Using the Floor Crane and Engine Spreader Bar, position the engine in the engine compartment.
    G09539615
  4. NOTE: The transmission wiring harness is part of the engine wiring harness.

    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.
      G07958827
  5. Using the Floor Crane and Engine Spreader Bar, position the engine to the transmission.
    G09539615
  6. Align the engine to the transmission and install the 2 LH bellhousing-to-oil pan bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G07959427
  7. Using the Floor Crane and Engine Spreader Bar, raise the engine for clearance for the LH engine support insulator.
    G09539615
  8. 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.
    NOTE: Clean the LH and RH engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to installation.

    Install the LH engine support insulator and the new through bolt.

    • Do not torque at this time.
      Fig 3: Locating LH Engine Support Insulator Through Bolt
      G06126794Courtesy of FORD MOTOR CO.
  9. Lower the engine.
  10. 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.

    Install the 3 new LH engine support insulator bolts.

    • Tighten to 175 Nm (129 lb-ft).
      G07958941
  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).
      G08336462
  12. NOTE: Use only hand tools when installing the engine support insulator stud bolts or damage to the engine support insulator can occur.

    Install the 2 new RH engine support insulator studs.

    • Tighten to 30 Nm (22 lb-ft).
      Fig 4: 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 damage to the engine support insulator can occur.

    Install the 2 new RH engine support insulator nuts.

    • Tighten to 175 Nm (129 lb-ft).
      G07959433
  14. 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.

    Tighten the LH engine mount through bolt.

    • Tighten to 350 Nm (258 lb-ft).
      Fig 5: Locating LH Engine Mount Through Bolt
      G06126794Courtesy of FORD MOTOR CO.
  15. NOTE: Do not lubricate the engine oil filter gasket.

    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.
      G07959435
  17. Install the engine-to-bellhousing bolt.
    • Tighten the bolt, it will be torqued at a later step.
      G07958998
  18. Install the oil pan-to-bellhousing bolt.
    • Tighten to 48 Nm (35 lb-ft).
      G07958999
  19. Tighten the engine-to-bellhousing bolt.
    • Tighten to 48 Nm (35 lb-ft).
      G07958998
  20. Install the LH bellhousing-to-engine bolt.
    • Tighten to 48 Nm (35 lb-ft).
      G07959439
  21. Tighten the LH bellhousing-to-engine bolt.
    • Tighten to 48 Nm (35 lb-ft).
      G07959440
  22. Install the 4 upper bellhousing-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 6: Locating Upper Bellhousing-To-Engine Bolts
      G07958789Courtesy of FORD MOTOR CO.
  23. NOTE: LH shown in illustration, RH similar.

    Install the new 2 LH and RH catalytic converter-to-exhaust manifold nuts.

    • Tighten to 45 Nm (35 lb-ft).
      G07958937
  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).
      G07958960
  25. Install the 4 torque converter nuts.
    • Tighten to 44 Nm (32 lb-ft).
      G08336958
  26. Install the access cover and the 2 pin-type retainers.
    G07476065
  27. Attach the starter motor wiring harness retainer to the oil pan.
    G07407002
  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 7: 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.
      G07958787
  33. NOTE: Only one wire harness retainer and one electrical connector shown in illustration, others similar.

    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.
      G07958786
  34. Install the splash shield and the 4 retainers.
    G08335135
  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.
      G07958986
  36. Install the cowl panel and attach the 2 clips and install the 6 screws.
    G07958930
  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 8: Locating Ground Strap And Bolt
      G06126817Courtesy of FORD MOTOR CO.
  39. Connect the vacuum pump tube.
    G08336948
  40. Attach the wiring harness retainers to the rear of the RH valve cover stud bolt and the rear of the vacuum pump.
    G08336947
  41. Connect the 2 coolant hoses to the degas bottle.
    G07958982
  42. Connect the 2 heater hose couplings at the RH rear of the engine.
    G07958981
  43. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  44. Install the fuel injection pump. For additional information, refer to 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.
      G09540054
  46. Install the A/C compressor belt. For additional information, refer to ACCESSORY DRIVE .
  47. Install the generator. For additional information, refer to CHARGING SYSTEM .
  48. Connect the A/C compressor electrical connector.
    • Attach the A/C compressor wiring harness to the A/C compressor.
      G07958979
  49. Attach the generator wiring harness to the engine front cover.
    G08336942
  50. Install the transmission cooler line bracket and nut to the engine front cover stud bolt.
    • Tighten to 12 Nm (106 lb-in).
      G08336941
  51. Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
    • Tighten to 15 Nm (133 lb-in).
      G07958976
  52. Connect the Battery Junction Box (BJB) wiring harness and the A/C pressure transducer electrical connectors.
    G07958975
  53. Fill the engine with clean engine oil.
  54. 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 AND FILTERING .
  55. 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 AND FILTERING .
  56. Install the cooling module. For additional information, refer ENGINE COOLING .
  57. 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.
      G07958974
  58. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  59. NOTE: Align the index marks made during hood removal.
    NOTE: RH shown in illustration, LH similar.

    Position the hood and install the 4 bolts.

    • Tighten to 12 Nm (106 lb-in).
      Fig 9: Locating Hood Bolts
      G09539580Courtesy of FORD MOTOR CO.
  60. 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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