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Section 676 (Engine - 3.5L DURATEC (209KW/284PS)): Installation: Engine

WARNING: This page is about a different car, the 2015 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

Special Tool(s) / General Equipment 

GFD39660Courtesy of FORD MOTOR COMPANY
 303-1245 Engine Lift Eye
TKIT-2006UF-FLM
TKIT-2006UF-ROW
Floor Crane
Trolley Jack
Hose Clamp Remover/Installer
Wooden Block

Materials 

Name Specification
Motorcraft ® Multi-Purpose Grease Spray XL-5-A ESB-M1C93-B
Motorcraft ® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP WSS-M2C945-A
Threadlock 262 TA-26 WSK-M2G351-A6

4x2/4x4 

  1. 1.

    1. 1.

      Inspect the engine mount-to-frame nut plate for thread damage.

    1. 2.

      If the nut plate is damaged, remove and discard the engine mount-to-frame nut plate.
    • Clean the engine mount-to-frame mating surfaces of any dirt or foreign material prior to installation.
GFD39164Courtesy of FORD MOTOR COMPANY

  1. 2.

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

    Material

    : Motorcraft ® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)

GFD39526Courtesy of FORD MOTOR COMPANY

  1. 3.

    • Inspect the torque converter stud and flexplate for paint marks.
    • Align the torque converter stud and flexplate hole near the paint marks to the 12 o'clock position.
GFD40052Courtesy of FORD MOTOR COMPANY

  1. 4.

    NOTE: It may be necessary to install a ratchet strap from the front of engine to the chain to keep the engine level.

    Using the floor crane and chain, position the engine in the engine compartment.

GFD39867Courtesy of FORD MOTOR COMPANY

  1. 5.

    Attach the generator wiring harness retainer to the lower LH side of the engine block.
GFD39675Courtesy of FORD MOTOR COMPANY

  1. 6.

    Using the floor crane and chain, position the engine to the transmission. Use the General Equipment: Floor Crane
GFD40053Courtesy of FORD MOTOR COMPANY

  1. 7.

    • Align the engine to the transmission and install LH transmission-to-engine bolt.
    • Do not torque at this time.
GFD39864Courtesy of FORD MOTOR COMPANY

  1. 8.

    Install the engine-to-transmission bolts.

    Torque

    : 35 lb.ft (48 Nm)

GFD39740Courtesy of FORD MOTOR COMPANY

  1. 9.

    Tighten the LH transmission-to-engine bolt.

    Torque

    : 35 lb.ft (48 Nm)

GFD39864Courtesy of FORD MOTOR COMPANY

  1. 10.

    Using the floor crane and chain, raise the engine for clearance to install the LH engine mount. Use the General Equipment: Floor Crane
GFD39866Courtesy of FORD MOTOR COMPANY

  1. 11.

    Install the LH engine mount.
GFD39671Courtesy of FORD MOTOR COMPANY

  1. 12.

    NOTE: Use only hand tools when installing the LH engine mount through bolt or the engine mount may be damaged.
    NOTE: Clean the LH and RH engine mount-to-frame mating surfaces of any dirt or foreign material prior to installation.
    • Install the new LH engine mount through bolt.
    • Do not torque at this time.
GFD39161Courtesy of FORD MOTOR COMPANY

  1. 13.

    NOTE: If installed, remove the ratchet strap.

    Lower the engine and remove the floor crane.

GFD40054Courtesy of FORD MOTOR COMPANY

  1. 14.

    Remove the chain.
GFD39865Courtesy of FORD MOTOR COMPANY

  1. 15.

    Remove the floor jack and a block of wood. Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
GFD39328Courtesy of FORD MOTOR COMPANY

  1. 16.

    Install the LH engine mount bolts.

    Torque

    : 129 lb.ft (175 Nm)

GFD39677Courtesy of FORD MOTOR COMPANY

  1. 17.

    Install the transmission-to-engine bolt.

    Torque

    : 35 lb.ft (48 Nm)

GFD39862Courtesy of FORD MOTOR COMPANY

  1. 18.

    Install the transmission-to-engine bolts.

    Torque

    : 35 lb.ft (48 Nm)

GFD39863Courtesy of FORD MOTOR COMPANY

  1. 19.

    Install the transmission-to-engine bolts.

    Torque

    : 35 lb.ft (48 Nm)

GFD39861Courtesy of FORD MOTOR COMPANY

  1. 20.

    NOTE: Apply threadlock to the engine mount stud bolts.

    Install the RH engine mount stud bolts.

    Material

    : Threadlock 262 / TA-26 (WSK-M2G351-A6)

    Torque

    : 22 lb.ft (30 Nm)

GFD39171Courtesy of FORD MOTOR COMPANY

  1. 21.

    NOTE: Use only hand tools when installing the RH engine mount nuts or the engine mount may be damaged.

    Install the new RH engine mount nuts.

    Torque

    : 129 lb.ft (175 Nm)

GFD39172Courtesy of FORD MOTOR COMPANY

  1. 22.

    NOTE: Use only hand tools when tightening the LH engine mount through bolt or the engine mount may be damaged.

    Tighten the LH engine mount through bolt.

    Torque

    : 258 lb.ft (350 Nm)

GFD39170Courtesy of FORD MOTOR COMPANY

  1. 23.

    Position the RH catalytic converter and install new flange nuts.

    Torque

    : 30 lb.ft (40 Nm)

GFD39634Courtesy of FORD MOTOR COMPANY

  1. 24.

    Position the LH catalytic converter and install new flange nuts.

    Torque

    : 30 lb.ft (40 Nm)

GFD39614Courtesy of FORD MOTOR COMPANY

  1. 25.

    • Position the exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe and install the new bolts.
    • Tighten the inner exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt.

      Torque

      : 46 lb.ft (63 Nm)

    • Tighten the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt.

      Torque

      : 46 lb.ft (63 Nm)

GFD39176Courtesy of FORD MOTOR COMPANY

  1. 26.

    1. 1.

      Push the transmission electrical connector in, to connect.

    1. 2.

      Rotate the transmission electrical connector.

    1. 3.

      Attach the wiring harness retainers.
GFD40055Courtesy of FORD MOTOR COMPANY

4x4 

  1. 27.

    Attach the transfer case vent tube retainer.
GFD39716Courtesy of FORD MOTOR COMPANY

  1. 28.

    Attach the transfer case wiring harness to the transmission wiring harness.
GFD39859Courtesy of FORD MOTOR COMPANY

4x2/4x4 

  1. 29.

    Connect the RHHO2S and catalyst monitor sensors electrical connectors and attach wiring harness retainer.
GFD39619Courtesy of FORD MOTOR COMPANY

  1. 30.

    Attach the catalyst monitor sensor wiring harness retainer to the LH side of the transmission.
GFD39858Courtesy of FORD MOTOR COMPANY

  1. 31.

    Connect the LH HO2S and catalyst monitor sensors electrical connectors and attach wiring harness retainer.
GFD39598Courtesy of FORD MOTOR COMPANY

  1. 32.

    NOTE: Using the crankshaft pulley bolt, turn the engine clockwise.

    Install the torque converter nuts.

    Torque

    : 32 lb.ft (44 Nm)

GFD40056Courtesy of FORD MOTOR COMPANY

  1. 33.

    Install the access cover and pin-type retainers.
GFD39856Courtesy of FORD MOTOR COMPANY

  1. 34.

    Attach the starter motor wiring harness retainer to the oil pan.
GFD39641Courtesy of FORD MOTOR COMPANY

  1. 35.

    Install the starter motor. Refer to: STARTER MOTOR .

  1. 36.

    NOTE: Do not lubricate the engine oil filter seal.

    Install the new engine oil filter.

    Torque

    : Stage 1: 44 lb.in (5 Nm) Stage 2: 180 °

GFD39617Courtesy of FORD MOTOR COMPANY

4x4 

  1. 37.

    Install the front driveshaft. Refer to: Front Driveshaft .

4x2/4x4 

  1. 38.

    If equipped, install the skid plate and the bolts.

    Torque

    : 30 lb.ft (40 Nm)

GFD39149Courtesy of FORD MOTOR COMPANY

  1. 39.

    • If equipped, install the underbody shield and bolts.

      Torque

      : 30 lb.ft (40 Nm)

    • Install the pin-type retainers.
GFD39150Courtesy of FORD MOTOR COMPANY

  1. 40.

    • If equipped, install the transmission housing cover and attach the retainer.
    • Install the bolts.

      Torque

      : 71 lb.in (8 Nm)

GFD38415Courtesy of FORD MOTOR COMPANY

  1. 41.

    Remove Special Service Tool: 303-1245 Engine Lift Eye.
GFD39664Courtesy of FORD MOTOR COMPANY

  1. 42.

    Install the ground strap, retainer and bolt to the cowl.

    Torque

    : 80 lb.in (9 Nm)

GFD39855Courtesy of FORD MOTOR COMPANY

4x4 

  1. 43.

    1. 1.

      Attach the transfer case wiring harness retainer to the valve cover stud bolt.

    1. 2.

      Attach the PCM wiring harness retainer to the valve cover.

    1. 3.

      Attach the transfer case wiring harness retainer to the PCM wiring harness.
GFD40057Courtesy of FORD MOTOR COMPANY

4x2/4x4 

  1. 44.

    • Connect the PCM electrical connector and wiring harness retainer.
    • Connect the engine harness electrical connector.
GFD39853Courtesy of FORD MOTOR COMPANY

  1. 45.

    Connect the heater hose to the lower intake manifold at the rear of the engine.
GFD39707Courtesy of FORD MOTOR COMPANY

  1. 46.

    Connect the fuel supply tube quick connect coupling to the fuel rail. Refer to: QUICK RELEASE COUPLING
GFD39852Courtesy of FORD MOTOR COMPANY

  1. 47.

    Install the upper intake manifold. Refer to: Upper Intake Manifold .

  1. 48.

    Attach the generator wiring harness retainer to the oil filter adapter.
GFD39851Courtesy of FORD MOTOR COMPANY

  1. 49.

    Install the generator. Refer to: Generator - 3.5L Duratec (209kW/284PS) .

  1. 50.

    Install the crankcase vent tube to LH valve cover.
GFD39784Courtesy of FORD MOTOR COMPANY

  1. 51.

    Position the coolant hose retainer on the RH valve cover stud bolt and install the nut.

    Torque

    : 71 lb.in (8 Nm)

GFD39850Courtesy of FORD MOTOR COMPANY

  1. 52.

    Install the PCV tube.
GFD39849Courtesy of FORD MOTOR COMPANY

  1. 53.

    1. 1.

      Install the lower radiator hose. Use the General Equipment: Hose Clamp Remover/Installer

    1. 2.

      If equipped, install the oil cooler coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer
GFD40058Courtesy of FORD MOTOR COMPANY

  1. 54.

    1. 1.

      Install the upper radiator hose. Use the General Equipment: Hose Clamp Remover/Installer

    1. 2.

      Position and install the heater hose. Use the General Equipment: Hose Clamp Remover/Installer
GFD39847Courtesy of FORD MOTOR COMPANY

  1. 55.

    Tighten the upper intake manifold support bracket bolt.

    Torque

    : 71 lb.in (8 Nm)

GFD39659Courtesy of FORD MOTOR COMPANY

  1. 56.

    Connect the generator wiring to the engine front cover.
GFD39643Courtesy of FORD MOTOR COMPANY

  1. 57.

    Position the wiring harness and transmission cooler tube bracket and install the nut.

    Torque

    : 106 lb.in (12 Nm)

GFD39642Courtesy of FORD MOTOR COMPANY

  1. 58.

    • Install a new O-ring seal and gasket seal.
    • Connect the A/C tube and install the nut.

      Torque

      : 133 lb.in (15 Nm)

GFD39297Courtesy of FORD MOTOR COMPANY

  1. 59.

    Connect the A/C compressor electrical connector and the wiring harness retainers.
GFD39846Courtesy of FORD MOTOR COMPANY

  1. 60.

    Connect the A/C pressure switch.
GFD39296Courtesy of FORD MOTOR COMPANY

  1. 61.

    Install the following items:

  1. 62.

    Connect the battery ground cable. Refer to: Battery Disconnect and Connect .

  1. 63.

    NOTE: Align the index marks made during hood removal.

    Position the hood and install the nuts.

    Torque

    : 18 lb.ft (25 Nm)

GFD39295Courtesy of FORD MOTOR COMPANY

  1. 64.

    Fill the engine with clean engine oil. Refer to: Specifications .

    Material

    : Motorcraft ® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

GFD39618Courtesy of FORD MOTOR COMPANY

  1. 65.

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

  1. 66.

    Start and check the exhaust system for leaks.
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