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Home >> Ford >> 2015 >> Explorer Limited, 3.5L Eng VIN 8, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine - 3.5L GTDI) >> Installation >> Engine

Section 3 (Engine - 3.5L GTDI): Installation: Engine

WARNING: This page is about a different variant/trim than selected.
Special Tool(s)

GFD34410Courtesy of FORD MOTOR COMPANY
 2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
GFD34105Courtesy of FORD MOTOR COMPANY
 Adjustable Grip Arm, 1735A 014-00001 or equivalent
GFD34421Courtesy of FORD MOTOR COMPANY
 Powertrain Lift 300-OTC1585AE or equivalent
General Equipment

Hose Clamp Remover/Installer
Spreader Bar
Material

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
    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.

  1. 1.
    Using the Special Tool(s): 2, 200# Floor Crane, Fold Away 300-OTC1819E. Align the engine to the transaxle.
GFD35081Courtesy of FORD MOTOR COMPANY

  1. 2.

    Install the 5 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
GFD34649Courtesy of FORD MOTOR COMPANY

  1. 3.

    Install the 2 transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
GFD34648Courtesy of FORD MOTOR COMPANY

  1. 4.

    Install the RH halfshaft support bracket and the 2 bolts.
    • Tighten to 40 Nm (30 lb-ft).
GFD35084Courtesy of FORD MOTOR COMPANY

  1. 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).
GFD35083Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 6.
    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.
GFD34645Courtesy of FORD MOTOR COMPANY

  1. 7.

    Using the Floor Crane, install the powertrain and subframe as an assembly on the powertrain lift table.
GFD35081Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 8.
    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.
GFD34645Courtesy of FORD MOTOR COMPANY

  1. 9.

    Install the Adjustable Grip Arm.
GFD34644Courtesy of FORD MOTOR COMPANY

  1. 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.

  1. 11.

    Position the PTU support bracket in place and install the 5 bolts.
    • Tighten to 70 Nm (52 lb-ft).
GFD34643Courtesy of FORD MOTOR COMPANY

  1. 12.

    Attach the transaxle control wire harness retainer to the transaxle stud bolt.
GFD34640Courtesy of FORD MOTOR COMPANY

  1. 13.

    Connect the transaxle control electrical connector.
GFD34639Courtesy of FORD MOTOR COMPANY

  1. 14.

    Connect the A/C compressor and the pressure relief valve electrical connectors.
    • Attach the 3 wiring harness retainers.
GFD35082Courtesy of FORD MOTOR COMPANY

  1. 15.

    Connect the generator B+ cable and install the nut.
    • Tighten to 17 Nm (150 lb-in).
GFD34593Courtesy of FORD MOTOR COMPANY

  1. 16.

    Position back the generator B+ cable cover and connect the generator electrical connector.
GFD34592Courtesy of FORD MOTOR COMPANY

  1. 17.

    Install the ground wire to the RH cylinder head and install the bolt.
    • Tighten to 10 Nm (89 lb-In).
GFD34614Courtesy of FORD MOTOR COMPANY

  1. 18.

    Install the starter, the stud bolt and bolt.
    • Tighten to 27 Nm (20 lb-ft).
GFD34637Courtesy of FORD MOTOR COMPANY

  1. 19.

    Connect the wiring harness retainer to the starter motor stud bolt.
GFD34636Courtesy of FORD MOTOR COMPANY

  1. 20.

    Attach the starter wire terminals and install the 2 nuts.

    1. 1.

      Tighten the B+ terminal nut to 12 Nm (106 lb-in).

    1. 2.

      Tighten the S-terminal nut to 5 Nm (44 lb-in).
GFD35189Courtesy of FORD MOTOR COMPANY

  1. 21.

    Install the starter motor solenoid cover.
GFD34634Courtesy of FORD MOTOR COMPANY

  1. 22.

    Remove the Floor Crane.
GFD35081Courtesy of FORD MOTOR COMPANY

  1. 23.

    Remove the Special Tool(s): Eye, Engine Lift 303-1245.
GFD35080Courtesy of FORD MOTOR COMPANY

  1. 24.

    Install the LH exhaust manifold heat shield and the 3 bolts.
    • Tighten to 14 Nm (124 lb-in).
GFD35079Courtesy of FORD MOTOR COMPANY

  1. 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).
GFD34982Courtesy of FORD MOTOR COMPANY

  1. 26.

    Install the crankcase vent tube and connect the 2 quick connect couplings. REFER to Fuel System General Information .
    • Attach the 3 wiring harness retainers and install the engine cover mounting stud.
      • Tighten to 6 Nm (53 lb-in).
GFD34980Courtesy of FORD MOTOR COMPANY

  1. 27.

    Raise the subframe and powertrain assembly into the vehicle.

  1. 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).
GFD34900Courtesy of FORD MOTOR COMPANY

  1. 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).
GFD34464Courtesy of FORD MOTOR COMPANY

  1. 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).
GFD34463Courtesy of FORD MOTOR COMPANY
    NOTE: RH shown, LH similar.

  1. 31.
    Align the subframe and install the new front subframe bolts.
    • Tighten to 200 Nm (148 lb-ft).
GFD34556Courtesy of FORD MOTOR COMPANY
    NOTE: RH shown, LH similar.

  1. 32.
    Install the rear subframe brackets and the new subframe bracket-to-body bolts.
    • Finger tight at this stage.
GFD34557Courtesy of FORD MOTOR COMPANY
    NOTE: RH shown, LH similar.

  1. 33.
    Install the new subframe bracket bolts.
    • Tighten to 150 Nm (111 lb-ft).
GFD34558Courtesy of FORD MOTOR COMPANY
    NOTE: RH shown, LH similar.

  1. 34.
    Tighten the subframe bracket-to-body bolts to 55 Nm (41 lb-ft).
GFD34559Courtesy of FORD MOTOR COMPANY

  1. 35.

    Remove the ratchet strap from the front of the subframe to the rear of the subframe.

  1. 36.

    Remove the Adjustable Grip Arm and the powertrain lift table.
GFD34461Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 37.
    Install the strut to the wheel knuckle and install the strut-to-wheel knuckle nuts and bolts.
    • Tighten to 250 Nm (184 lb-ft).
GFD34462Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 38.
    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).
GFD34560Courtesy of FORD MOTOR COMPANY
    NOTE: Apply the brake to keep the halfshaft from rotating.
    NOTE: LH shown, RH similar.
    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.

  1. 39.
    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.
GFD33835Courtesy of FORD MOTOR COMPANY
    NOTE: Apply the brake to keep the halfshaft from rotating.
    NOTE: LH shown, RH similar.
    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.

  1. 40.
    Install a new wheel hub nuts.
    • Tighten to 350 Nm (258 lb-ft).
GFD34459Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 41.
    Install the new upper stabilizer link nut.
    • Tighten to 150 Nm (111 lb-ft).
GFD34561Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 42.
    Install the wheel speed sensor and the bolt.
    • Tighten to 15 Nm (133 lb-in).
GFD34455Courtesy of FORD MOTOR COMPANY

  1. 43.

    Connect the transaxle cooler tubes and install the 2 secondary latches.
GFD34453Courtesy of FORD MOTOR COMPANY

  1. 44.

    Connect the 2 PTU cooling lines.
GFD35019Courtesy of FORD MOTOR COMPANY

  1. 45.

    Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
GFD34631Courtesy of FORD MOTOR COMPANY

  1. 46.

    Install 3 new torque converter bolts.
    • Tighten to 55 Nm (41 lb-ft).
GFD35190Courtesy of FORD MOTOR COMPANY

  1. 47.

    Install the inspection cover and the 2 fasteners.
GFD34629Courtesy of FORD MOTOR COMPANY

  1. 48.

    Connect the lower radiator hose to the radiator.
    • Attach the lower radiator hose retainer to the cooling fan and shroud.
GFD35018Courtesy of FORD MOTOR COMPANY
    NOTE: Align the index marks for the LH Charge Air Cooler (CAC) tube.

  1. 49.
    Connect the lower LH CAC tube to the LH turbocharger.
    • Tighten to 5 Nm (44 lb-in).
GFD35017Courtesy of FORD MOTOR COMPANY
    NOTE: Do not lubricate the oil filter seal.

  1. 50.
    Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
GFD34928Courtesy of FORD MOTOR COMPANY

  1. 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).
GFD35016Courtesy of FORD MOTOR COMPANY

  1. 52.

    Install the A/C tube bracket and bolt to the rear of the A/C compressor.
    • Tighten to 25 Nm (18 lb-ft).
GFD35015Courtesy of FORD MOTOR COMPANY

  1. 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).
GFD34563Courtesy of FORD MOTOR COMPANY

  1. 54.

    Install the RH and LH catalytic converter. REFER to Exhaust System .
    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 Supplemental Restraint System .

  1. 55.
    Align and connect the steering column shaft to the steering gear and install the bolt.
    • Tighten to 20 Nm (177 lb-in).
GFD34564Courtesy of FORD MOTOR COMPANY

  1. 56.

    Connect the 2 heater hoses to the intake manifold.
GFD34915Courtesy of FORD MOTOR COMPANY
    NOTE: Align the index marks for the RH CAC tube.

  1. 57.
    Install the RH CAC tube and tighten the clamps.
    • Tighten to 5 Nm (44 lb-in).
GFD35014Courtesy of FORD MOTOR COMPANY

  1. 58.

    If equipped, attach the engine block heater harness to the radiator support wiring harness.
GFD35013Courtesy of FORD MOTOR COMPANY

  1. 59.

    Attach the wiring harness pin-type retainer and connect the transaxle control cable to the shift cable bracket.
GFD35185Courtesy of FORD MOTOR COMPANY

  1. 60.

    Connect the transaxle control cable to the control lever.
GFD34442Courtesy of FORD MOTOR COMPANY

  1. 61.

    Install the engine wiring harness retainer to the bulkhead.

    1. 1.

      Slide the wiring harness in the bulkhead.

    1. 2.

      Make sure the wiring harness retainer tab is below the bulkhead lip.
GFD34565Courtesy of FORD MOTOR COMPANY

  1. 62.

    Connect the PCM electrical connector.
GFD35011Courtesy of FORD MOTOR COMPANY

  1. 63.

    Connect the engine harness electrical connector.
GFD35010Courtesy of FORD MOTOR COMPANY

  1. 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).
GFD34918Courtesy of FORD MOTOR COMPANY

  1. 65.

    Install the EVAP canister purge valve. REFER to Evaporative Emissions .

  1. 66.

    Connect the fuel supply tube. REFER to Fuel System General Information .
GFD35078Courtesy of FORD MOTOR COMPANY

  1. 67.

    Install the strut tower brace and the 4 nuts.
    • Tighten to 30 Nm (22 lb-ft).
GFD35009Courtesy of FORD MOTOR COMPANY

  1. 68.

    Connect the brake booster vacuum hose quick connect coupling to the intake manifold, brake booster and CAC. REFER to Fuel System General Information .
    • Attach the brake booster vacuum hose to strut tower brace.
GFD35008Courtesy of FORD MOTOR COMPANY
    NOTE: Align the index marks for the CAC outlet pipe.

  1. 69.
    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.
GFD34979Courtesy of FORD MOTOR COMPANY

  1. 70.

    Install the degas bottle. REFER to Engine Cooling .

  1. 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).
GFD34431Courtesy of FORD MOTOR COMPANY

  1. 72.

    Install the accessory dive belt. REFER to Accessory Drive .

  1. 73.

    Install the underbody air duct and the 3 twist lock retainers.
GFD34445Courtesy of FORD MOTOR COMPANY
    NOTE: RH shown, LH similar.

  1. 74.
    Install the 2 RH and 2 LH lower pin-type retainers for the engine splash shields.
GFD34430Courtesy of FORD MOTOR COMPANY

  1. 75.

    Install the front wheels and tires. REFER to Wheels and Tires .

  1. 76.

    Connect the engine wiring harness electrical connector and install the ground wires and the retainer.
    • Tighten to 10 Nm (89 lb-in).
GFD35007Courtesy of FORD MOTOR COMPANY

  1. 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).
GFD34426Courtesy of FORD MOTOR COMPANY

  1. 78.

    Install the battery tray. REFER to Battery, Mounting and Cables .

  1. 79.

    Install the engine ACL and ACL outlet pipe. REFER to Intake Air Distribution and Filtering .

  1. 80.

    Install the cowl panel. REFER to Front End Body Panels .

  1. 81.

    Fill the engine with clean engine oil.

  1. 82.

    Fill and bleed the cooling system. REFER to Engine Cooling .

  1. 83.

    Recharge the A/C system. REFER to Climate Control DATC or REFER to Climate Control EMTC .

  1. 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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