Section 3 (Engine - 3.5L ECOBOOST (235KW/320PS)): Installation: Engine

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING .

Special Tool(s) / General Equipment 

Materials 

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

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

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2. • 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.

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3. • Using the floor crane, lower the engine onto the engine crossmember. Use the General Equipment: Floor Crane
   • Install new engine mount nuts.

     Torque: 85 lb.ft (115 Nm)

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4. Remove the commercially available quick links and floor crane. Use the General Equipment: Floor Crane

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5. Using the powertrain lift table raise the engine into the vehicle.

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6. Align the engine to the transmission and draw together using the bolts.

   Torque: 35 lb.ft (48 Nm)

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7. Install new engine crossmember bolts.

   Torque: 46 lb.ft (63 Nm)

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8. Install the RH engine crossmember bracket and new bolts.

   Torque: 22 lb.ft (30 Nm)

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9. Install new RH engine crossmember bracket bolts.

   Torque: 46 lb.ft (63 Nm)

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10. Install the RH wheel liner and fasteners.

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11. Install the LH engine crossmember bracket and new bolts.

    Torque: 22 lb.ft (30 Nm)

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12. Install new LH engine crossmember bracket bolts.

    Torque: 46 lb.ft (63 Nm)

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13. Install the LH wheel liner and fasteners.

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14. Remove the adjustable mounting arm from the RH side of the engine crossmember. Use the General Equipment: Adjustable Mounting Arm

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15. Remove the adjustable mounting arm from the LH side of the engine crossmember. Use the General Equipment: Adjustable Mounting Arm

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16. Remove the powertrain lift table and wood blocks. Use the General Equipment: Wooden Block

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17. Position back the ground wire and install the retainers.

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18. Install the RH side bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

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19. Install the shift cable bracket and the LH side bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

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20. Install the upper bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

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21. Remove the stand. Use the General Equipment: Vehicle/Axle Stands

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22. Install the lower bellhousing bolt.

    Torque: 35 lb.ft (48 Nm)

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23. NOTE: Do not lubricate the engine oil filter gasket.

    Install a new oil filter.

    Torque:

    Stage 1: 44 lb.in (5 Nm)

    Stage 2: 180°

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24. • Using a new gasket, position the LH catalytic converter flange onto the TC.
    • Install new nuts.

      Torque: 30 lb.ft (40 Nm)

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25. Install the RH catalytic converter flange and new nuts.

    Torque: 30 lb.ft (40 Nm)

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26. Attach the exhaust hanger and install the exhaust flange bolts.

    Torque: 30 lb.ft (40 Nm)

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

    Install new torque converter nuts.

    Torque: 35 lb.ft (48 Nm)

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28. Install the access cover and the retainers.

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29. Install the hoses and the pin-type retainers.

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30. • Install the upper coolant hose.
    • Follow directions to connect the quick release coupling type 2. Connect the coolant hose. Refer to: Quick Release Coupling .

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31. Position the harness and install the bolt.

    Torque: 53 lb.in (6 Nm)

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    Vehicles with front axle 

32. Remove the pin-type retainer and position the vent tube.

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33. Install the support bracket and bolts.

    Torque: 295 lb.ft (400 Nm)

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34. Install the axle assembly. Refer to: Axle Assembly .

    Vehicles equipped with dual generators 

35. Position back and attach the wire harness, install the bolt.

    Torque: 71 lb.in (8 Nm)

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36. Install the accessory drive bracket, stud and bolts hand tight then tighten in the sequence shown in illustration.

    Torque: Bolt 1: 28 lb.in (3.2 Nm)

    Stud 2: 28 lb.in (3.2 Nm)

    Bolt 3: 26 lb.ft (35 Nm)

    Bolt 4: 26 lb.ft (35 Nm)

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37. Tighten the accessory drive bracket fasteners.

    Torque: Bolt 1: 35 lb.ft (47.5 Nm)

    Stud 2: 26 lb.ft (35 Nm)

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38. Install the A/C compressor.

    Vehicles equipped with single generator 

39. Remove the nut, detach wiring harness conduit and position the harness aside.

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    All vehicles 

40. Install the wiring harness conduit bolt and the heater hose pin-type retainer.

    Torque: 97 lb.in (11 Nm)

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41. Remove the bolt and detach the wiring harness retainer.

    Torque: 106 lb.in (12 Nm)

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42. • Connect the electrical connectors.
    • Install the ground wires and bolts.

      Torque: 106 lb.in (12 Nm)

    • Connect the pin-type retainers.

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43. Install and connect the heater hoses.

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44. Install the ground wire, nut and attach the pin-type retainer.

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45. Install the ground wire cover.

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46. • Install the generator B+ terminal nut.

      Torque: 142 lb.in (16 Nm)

    • Position the protective cover.
    • Connect the generator electrical connector and attach wiring harness retainer.

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47. Install the following items:
    1. NOTE: RH and LH.

       Refer to: Catalyst Monitor Sensor .

    2. NOTE: RH and LH.

       Refer to: Heated Oxygen Sensor (HO2S) .

    3. Refer to: Starter Motor .

48. Install the front wheels and tires. Refer to: Wheel and Tire .
49. Follow directions to connect the quick release coupling type 10. Connect the fuel line. Refer to: Quick Release Coupling .

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    Vehicles equipped with single generator 

50. Connect the A/C compressor electrical connector and attach the wiring harness retainers.

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51. Install the A/C tubes and nuts.

    Torque: 159 lb.in (18 Nm)

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    All vehicles 

52. Connect the heater hose quick release coupling.

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53. • Connect the heater and degas bottle hoses. Use the General Equipment: Hose Clamp Remover/Installer
    • If equipped. Connect the block heater electrical connector and attach the wiring harness retainers.

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54. Connect the PCM electrical connector.

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55. Connect the drive line control module.

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56. Remove the bolts and position the degas bottle.

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57. Connect the brake vacuum tube.

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58. Install the noise insulator and screw.

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59. Install the LH TC outlet pipe and clamp.

    Torque: 53 lb.in (6 Nm)

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60. • Install the LH TC inlet pipe and clamp.

      Torque: 53 lb.in (6 Nm)

    • Connect the PCV tube quick release coupling.

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61. Install the RH TC outlet pipe, tighten the clamp and connect the vacuum hose.

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62. Install the RH TC inlet pipe, tighten the clamps and connect the vacuum hose.

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63. Install the air cleaner outlet pipe, tighten the clamps an connect the vacuum hose.

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64. • Install the CAC outlet pipe and tighten the clamp.
    • Follow directions to connect the quick release coupling type 4. Connect the fuel vapor tube quick release coupling.
    • Connect the wiring harness electrical connector and attach the retainer.

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65. Install the following items:
    1. Refer to: Cooling Module .
    2. Refer to: Wheel and Tire .

66. Connect the battery ground cable.
67. Fill the engine with clean engine oil. Refer to: Specifications .

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68. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure using a diagnostic scan tool.