Engine Mechanical - 3.5L Gtdi: Component Locations Ford Flex I

Special Tool(s)

SPECIAL TOOLS DESCRIPTION CHART Handle 205-153 (T80T-4000-W) Installer, VCT Spark Plug Tube Seal 303-1247/2 Remover, VCT Spark Plug Tube Seal 303-1247/1

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SPECIAL TOOLS DESCRIPTION CHART Handle 205-153 (T80T-4000-W) Installer, VCT Spark Plug Tube Seal 303-1247/2 Remover, VCT Spark Plug Tube Seal 303-1247/1

SPECIAL TOOLS DESCRIPTION CHART 3 Jaw Puller 303-D121 or equivalent Installer, Front Cover Oil Seal 303-335 Replacer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Strap Wrench 303-D055 (D85L-6000-A) or equivalent

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SPECIAL TOOLS DESCRIPTION CHART Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Crankshaft Seal 303-1251 Remover, Oil Seal 303-409 (T92C-6700CH)

SPECIAL TOOLS DESCRIPTION CHART Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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SPECIAL TOOLS DESCRIPTION CHART Handle 205-153 (T80T-4000-W) Installer, Rear Main Seal 303-1250 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Slide Hammer 307-005 (T59L-100-B) Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

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SPECIAL TOOLS DESCRIPTION CHART 3 Jaw Puller 303-D121 Alignment Pins 307-399 Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Installer, Front Crankshaft Seal 303-1251 Remover, Oil Seal 303-409 (T92C-6700CH) Replacer, Crankshaft Vibration Damper 303-102 (T74P-6312-B) Strap Wrench 303-D055 (D85L-6000-A)

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SPECIAL TOOLS DESCRIPTION CHART Tool, Camshaft Holding 303-1248

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SPECIAL TOOLS DESCRIPTION CHART Oil Pan Holding Fixture 303-1295

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ITEM DESCRIPTION CHART

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1. Drain the cooling system. For additional information, Refer to «ENGINE COOLING»(ref-372804) .
2. Remove the LH catalytic converter. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .
3. NOTE: The Oil Pan Holding Fixture must be carefully aligned to the mounting bosses on the oil pan. Failure to follow these instructions may result in damage to the oil pan. Position a floor jack and the Oil Pan Holding Fixture under the oil pan.
4. Remove the engine coolant degas bottle. For additional information, Refer to «ENGINE COOLING»(ref-372804) .
5. Disconnect the upper radiator hose from the intake manifold.
6. Remove the A/C tube bracket bolt from the upper RH shock tower. To install, tighten to 15 Nm (133 lb-in).
7. Remove the A/C tube retaining clamp bolt from the lower RH shock tower. To install, tighten to 9 Nm (80 lb-in).
8. Remove the 4 engine mount nuts. To install, tighten to 63 Nm (46 lb-ft).
9. Remove the 3 bolts and the engine mount. To install, tighten to 90 Nm (66 lb-ft).
10. To install, reverse the removal procedure.
11. Fill and bleed the cooling system. For additional information, Refer to «ENGINE COOLING»(ref-372804) .

SPECIAL TOOLS DESCRIPTION CHART Tool, Camshaft Holding 303-1248

SPECIAL TOOLS DESCRIPTION CHART Disconnect Tool, Transmission Cooler Line 307-569 Eye, Engine Lift 303-1245 Halfshaft Remover 205-832 Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 or equivalent Remover, Front Wheel Hub 205-D070 (D93P-1175-B) or equivalent Slide Hammer 100-001 (T50T-100-A) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-00001 or equivalent

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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.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent). Using a steering wheel holding device, hold the steering wheel in the straight-ahead position.
3. Release the fuel system pressure. For additional information, Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-372809) .
4. Recover the A/C system. For additional information, Refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-372762) .
5. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector. Detach the HO2S connector retainer from the bracket.
6. Remove the 4 retainers and the underbody shield.
7. Remove the 3 pin-type retainers, 7 bolts and the front valance.
8. Drain the cooling system. For additional information, Refer to «ENGINE COOLING»(ref-372804) .
9. Remove the front wheels and tires. For additional information, Refer to «WHEELS AND TIRES»(ref-372756) .
10. Remove the 2 lower scrivets from the rubber shield and position the shield aside.
11. NOTE: Apply the brake to keep the halfshafts from rotating. NOTE: RH shown in illustration, LH similar. Remove the RH and LH halfshaft nuts. Do not discard at this time.
12. NOTE: RH shown in illustration, LH similar. Using the Front Wheel Hub Remover, separate the RH and LH halfshaft from the wheel hubs.
13. Remove the bolt from the RH brake hose bracket.
14. Remove the LH and RH catalytic converters. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .
15. Remove the 2 rear engine roll restrictor-to-transaxle bolts.
16. Remove the 2 front engine roll restrictor-to-transaxle bolts.
17. NOTE: RH shown in illustration, LH similar. Remove and discard the upper stabilizer link nuts.
18. NOTE: The hex-holding feature can be used to prevent turning of the stud while removing the nut. NOTE: RH shown in illustration, LH similar. Remove and discard the tie-rod end nuts. Separate the tie-rod ends from the wheel knuckles.
19. NOTE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part number or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. NOTE: Use care when releasing the lower arm and knuckle into the resting position or damage to the ball joint seal or Constant Velocity (CV) boot may occur. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. NOTE: RH shown in illustration, LH similar. Remove and discard the lower ball joint-to-wheel knuckle nuts. Separate the lower ball joints from the wheel knuckles.
20. 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»(ref-372796) . Remove the bolt and disconnect the steering column shaft from the steering gear. Discard the bolt.
21. Remove the bolt and disconnect the 2 Electronic Power Assist Steering (EPAS) electrical connectors (1 shown in illustration) and the wiring retainer (not shown in illustration).
22. Position the Powertrain Lift under the subframe assembly.
23. NOTE: RH shown in illustration, LH similar. Remove the subframe bracket-to-body bolts.
24. NOTE: RH shown in illustration, LH similar. Remove the rear subframe bolts and the subframe brackets.
25. NOTE: RH shown in illustration, LH similar. Remove the front subframe bolts.
26. Lower the subframe assembly from the vehicle.
27. Pull the RH wheel knuckle outboard and rotate it toward the rear of the vehicle. Secure the RH wheel knuckle assembly.
28. Remove the 2 halfshaft bracket bolts.
29. Remove the intermediate and halfshaft assembly. Inspect the intermediate shaft for pitting or damage in the seal contact area. Replace if necessary.
30. NOTE: The sharp edges on the stub shaft splines can slice or puncture the oil seal. Use care when inserting the stub shaft into the transmission or damage to the component may occur. Using the Slide Hammer and Halfshaft Remover, remove the halfshaft from the transmission.
31. Remove and discard the circlip from the stub shaft.
32. Remove the cowl panel grille. For additional information, Refer to «FRONT END BODY PANELS»(ref-372798) .
33. Detach the 2 brake booster vacuum hose retainers (1 shown in illustration) from the strut tower brace.
34. Remove the 4 nuts (2 shown in illustration) and the strut tower brace.
35. Disconnect the PCM and engine harness electrical connectors. Detach the wiring harness retainer.
36. Disconnect the 2 PCM electrical connectors.
37. Remove the engine wiring harness retainer from the bulkhead. Push the tab in. Slide the wiring harness up and out of the bulkhead.
38. Remove the nut and disconnect the A/C tube. Discard the O-ring seal and gasket seal.
39. Remove the nut and the A/C tube. Discard the O-ring seal and gasket seal.
40. Remove the degas bottle. For additional information, Refer to «ENGINE COOLING»(ref-372804) .
41. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-372794) .
42. Disconnect the Turbocharger Boost Pressure (TCBP)/Charge Air Cooler Temperature (CACT) electrical connector.
43. Loosen the 2 clamps and remove the CAC outlet pipe.
44. Remove the battery tray. For additional information, Refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .
45. Disconnect the engine wiring harness electrical connector.
46. Remove the nut and disconnect the ground cable from the negative battery terminal.
47. Remove the nut and disconnect the power feed wires from the positive battery terminal.
48. Disconnect the brake booster vacuum hose quick connect coupling. For additional information, Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-372809) .
49. Disconnect the transaxle control cable from the control lever.
50. Disconnect the transaxle control cable from the shift cable bracket. Detach the wiring harness pin-type retainer.
51. Loosen the 2 clamps and remove the RH CAC tube.
52. Disconnect the 2 heater hoses from the intake manifold.
53. Remove the bolt and ground wire from the engine front cover.
54. Disconnect the upper radiator hose from the intake manifold coolant tube.
55. If equipped, detach the engine block heater harness from the radiator support wiring harness.
56. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling. For additional information, Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-372809) .
57. Disconnect the EVAP valve electrical connector and detach the valve from the intake manifold.
58. Disconnect the quick connect coupling from the intake manifold and remove the EVAP tube assembly. For additional information, Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-372809) .
59. Disconnect the fuel supply tube. For additional information, Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-372809) .
60. NOTE: Index-mark the driveshaft for installation. Remove and discard the 4 bolts and position aside the driveshaft.
61. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
62. Remove and discard the engine oil filter.
63. Remove the A/C tube bracket bolt from the rear of the compressor.
64. Remove the nut and disconnect the upper A/C tube from the compressor. Discard the O-ring seal and gasket seal.
65. Loosen the clamp and disconnect the LH CAC tube from the LH turbocharger.
66. Detach the lower radiator hose retainer from the cooling fan and shroud.
67. Disconnect the lower radiator hose from the radiator.
68. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
69. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
70. Remove the 2 fasteners and the inspection cover.
71. Remove and discard the 4 torque converter bolts.
72. Remove the 4 oil pan-to-transaxle bolts.
73. Remove the 2 LH bottom transaxle-to-engine bolts.
74. Remove the 3 bolts and the RH turbocharger lower bracket.
75. Remove the 2 bolts and the RH halfshaft support bracket.
76. Remove the 3 bolts and the Power Transfer Unit (PTU) support bracket.
77. Remove the 5 bolts and the PTU .
78. NOTE: Position a block of wood under the transaxle. Install the Powertrain Lift and Universal Adapter Brackets.
79. Remove the 3 nuts and the bolt from the transaxle support insulator bracket-to-transaxle.
80. Remove the 4 engine mount nuts.
81. Remove the 3 bolts and the engine mount.
82. Lower the engine and transaxle assembly from the vehicle.
83. Remove the starter motor solenoid cover.
84. Remove the 2 nuts and the starter motor wiring terminals.
85. Disconnect the wiring harness retainer from the starter motor stud bolt.
86. Remove the bolt, stud bolt and the starter.
87. Remove the engine cover mounting stud from the LH valve cover stud bolt.
88. Detach the wiring harness retainer from the valve cover stud bolt.
89. Remove the nut and the oil supply tube bracket from the LH valve cover stud bolt.
90. Remove the 3 bolts and the LH exhaust manifold heat shield.
91. Install the Engine Lift Eye on the LH cylinder head.
92. Disconnect the 2 quick connect couplings and remove the crankcase vent tube. For additional information, Refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-372809) .
93. Disconnect the transaxle control electrical connector.
94. Detach the transaxle control wire harness retainer from the transaxle stud bolt.
95. Detach the 2 wiring harness retainers from the transaxle stud bolts.
96. Remove the bolt and the ground wire from the RH cylinder head.
97. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table.
98. Remove the LH transaxle-to-engine bolt.
99. Remove the 3 transaxle-to-engine bolts. Separate the transaxle from the engine.

SPECIAL TOOLS DESCRIPTION CHART 3 Jaw Puller 303-D121 or equivalent Disconnect Tool, Transmission Cooler Line 307-569 Halfshaft Remover 205-832 Handle 205-153 (T80T-4000-W) Powertrain Lift 014-00765 or equivalent Remover, Front Wheel Hub 205-D070 (D93P-1175-B) or equivalent Remover, Oil Seal 303-409 (T92C-6700CH) Remover, VCT Spark Plug Tube Seal 303-1247/1 Slide Hammer 100-001 (T50T-100-A) Strap Wrench 303-D055 (D85L-6000-A) or equivalent Tool, Camshaft Holding 303-1248 Universal Adapter Brackets 014-00001 or equivalent

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SPECIAL TOOLS DESCRIPTION CHART Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249

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Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

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1. Remove the valve tappets from the cylinder being serviced. For additional information, refer to «VALVE TAPPETS»(ref-372750-S36366520732010093000000) .
2. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke.
3. NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal or engine damage may occur. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. NOTE: If a valve drops into the cylinder, remove the cylinder head. For additional information, refer to «CYLINDER HEAD - RH»(ref-372750-S04912156032010093000000) or «CYLINDER HEAD - LH»(ref-372750-S41231968352010093000000) . Pressurize the cylinder using compressed air.
4. Using the Valve Spring Compressors, remove the keys, retainer and spring.
5. Remove and discard the valve stem seal.

SPECIAL TOOLS DESCRIPTION CHART Spring Lock Coupling Disconnect Tool 310-S039 (T90T-9550-S) or equivalent

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SPECIAL TOOLS DESCRIPTION CHART Spring Lock Coupling Disconnect Tool 310-S039 (T90T-9550-S) or equivalent

SPECIAL TOOLS DESCRIPTION CHART 3 Jaw Puller 303-D121 or equivalent Handle 205-153 (T80T-4000-W) Remover, Oil Seal 303-409 (T92C-6700CH) Remover, VCT Spark Plug Tube Seal 303-1247/1 Strap Wrench 303-D055 (D85L-6000-A) or equivalent

SPECIAL TOOLS DESCRIPTION CHART Heavy Duty Floor Crane 014-00071 or equivalent Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Slide Hammer 307-005 (T59L-100-B) Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

SPECIAL TOOLS DESCRIPTION CHART 3 Jaw Puller 303-D121 or equivalent Handle 205-153 (T80T-4000-W) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Remover, Fuel Injector 310-206 Remover, Oil Seal 303-409 (T92C-6700CH) Remover, VCT Spark Plug Tube Seal 303-1247/1 Slide Hammer 307-005 (T59L-100-B) Spring Lock Coupling Disconnect Tool 310-S039 (T90T-9550-S) or equivalent Strap Wrench 303-D055 (D85L-6000-A) or equivalent Tool, Camshaft Holding 303-1248

SPECIAL TOOLS DESCRIPTION CHART Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249 Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

SPECIAL TOOLS DESCRIPTION CHART Alignment Pins 307-399 Brush, Fuel Injector 310-205 Compressor, Piston Ring 303-D032 (D81L-6002-C) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Engine Lift Eye 303-1245 Handle 205-153 (T80T-4000-W) Heavy Duty Floor Crane 014-00071 or equivalent Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 Installer, Front Crankshaft Seal 303-1251 Installer, Rear Main Seal 303-1250 Installer, VCT Spark Plug Tube Seal 303-1247/2 Seal Installer, Fuel Injector 310-207 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Strap Wrench 303-D055 (D85L-6000-A) or equivalent Tool, Camshaft Holding 303-1248

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SPECIAL TOOLS DESCRIPTION CHART Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-00001 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

SPECIAL TOOLS DESCRIPTION CHART Alignment Pins 307-399 Handle 205-153 (T80T-4000-W) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 Installer, Front Crankshaft Seal 303-1251 Installer, VCT Spark Plug Tube Seal 303-1247/2 Powertrain Lift 014-00765 or equivalent Strap Wrench 303-D055 (D85L-6000-A) or equivalent Tool, Camshaft Holding 303-1248

SPECIAL TOOLS DESCRIPTION CHART Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Compressor, Valve Spring 303-1249 Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

SPECIAL TOOLS DESCRIPTION CHART Alignment Pins 307-399 Handle 205-153 (T80T-4000-W) Heavy Duty Floor Crane 014-00071 or equivalent Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 Installer, Front Crankshaft Seal 303-1251 Installer, VCT Spark Plug Tube Seal 303-1247/2 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Strap Wrench 303-D055 (D85L-6000-A)

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SPECIAL TOOLS DESCRIPTION CHART Handle 205-153 (T80T-4000-W) Heavy Duty Floor Crane 014-00071 or equivalent Installer, Rear Main Seal 303-1250 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool