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Engine Mechanical - 3.5L Gtdi: Specifications Ford Flex I

Mechanical ~150 words

MATERIAL SPECIFICATIONS

Item	Specification	Fill Capacity
Motorcraft® High Performance Engine RTV Silicone TA-357	WSE-M4G323-A6
Motorcraft® Metal Surface Prep ZC-31-A
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent	WSS-M2C930-A	5.7L (6.0 qt) includes filter change
Motorcraft® Specialty Green Engine Coolant VC-10-A2 (US); CVC-10-A (Canada)	WSS-M97B55-A
Silicone Gasket Remover ZC-30
Thread Sealant with PTFE TA-24	WSK-M2G350-A2
Threadlock and Sealer TA-25	WSK-M2G351-A5

MATERIAL SPECIFICATIONS

GENERAL SPECIFICATIONS

Item	Specification
Engine
Displacement	3.5L Gasoline Turbocharged Direct Injection (GTDI) (214 CID)
No. cylinders	6
Bore/stroke	92.5/86.7 mm (3.641/3.413 in)
Fire order	1-4-2-5-3-6
Oil pressure	Minimum 30 psi @ 1,500 rpm with engine at normal operating temperature
Compression ratio	10.0:1
Spark plug	CYFS-12F Gap = 0.889 mm (0.035 in)
Engine weight (without accessory drive components)	189.01 kg (416.7 lb)
Engine and transaxle assembly weight (without accessory drive components)	288.80 kg (636.7 lb)
Cylinder Head and Valve Train
Cylinder head gasket surface flatness	Flat within 0.08 (0.003 in) length end to end, area 150 mm (5.9 in) x 150 mm (5.9 in) (or full width) should be less than 0.05 mm (0.002 in)
Combustion chamber volume	55.84 cc (3.41 CI)
Valve tappet clearance - intake	0.15-0.25 mm (0.006-0.01 in)
Valve tappet clearance - exhaust	0.360-0.460 mm (0.0142-0.0181 in) Engine must be at room temperature before measuring
Valve guide bore inner diameter	5.519-5.549 mm (0.217-0.218 in)
Valve stem diameter - intake	5.479-5.497 mm (0.2157-0.2164 in)
Valve stem diameter - exhaust	5.466-5.484 mm (0.2151-0.2159 in)
Valve stem-to-guide clearance - intake	0.022-0.070 mm (0.0008-0.0027 in)
Valve stem-to-guide clearance - exhaust	0.035-0.083 mm (0.0013-0.032 in)
Valve head diameter - intake	36.82-37.18 mm (1.44-1.46 in)
Valve head diameter - exhaust	30.82-31.18 mm (1.21-1.22 in)
Valve face runout	0.05 mm (0.0001 in)
Valve face angle	44.5-45.5 degrees
Valve seat width - intake	1.3-1.6 mm (0.051-0.063 in)
Valve seat width - exhaust	1.4-1.7 mm (0.055-0.067 in)
Valve seat runout	0.04 mm (0.0001 in) MAX
Valve seat angle	44.5-45.5 degrees
Valve spring free length (approx.)	55.16 mm (2.17 in)
Valve spring compression pressure (N @ spec. length)	465 N @ 28.0 mm (105 lb @ 1.10 in)
Valve spring installed height	37.0 mm (1.45 in)
Valve spring installed height pressure (N @ spec. length)	265 N @ 37.0 mm (60 lb @ 1.45 in)
Valve spring installed pressure - service limit	10% force loss @ specified height
Camshaft
Theoretical valve lift @ 0 lash	9.0 mm (0.35 in)
Lobe lift - intake	9.0 mm (0.35 in)
Lobe lift - exhaust	9.1 mm (0.36 in)
Allowable lobe lift loss	0.062 mm (0.0024 in)
Camshaft journal bore inside diameter - 1st journal	31.0375-31.0625 mm (1.221-1.222 in)
Camshaft journal bore inside diameter - intermediate journals	25.9875-26.0125 mm (1.023-1.024 in)
Camshaft bearing outside diameter - 1st journal	30.993-31.013 mm (1.2202-1.2209 in)
Camshaft bearing outside diameter - intermediate journals	25.937-25.963 mm (1.021-1.022 in)
Camshaft journal-to-bearing clearance, 1st journal - service limit	0.070 mm (0.0027 in) MAX
Camshaft journal-to-bearing clearance, intermediate journals - service limit	0.0755 mm (0.0029 in) MAX
Runout	0.040 mm (0.0015 in) MAX
End play - standard	0.032-0.170 mm (0.0012-0.0066 in)
End play - service limit	0.190 mm (0.00748 in) MAX
Cylinder Block
Cylinder bore diameter - grade 1	92.500-92.520 mm (3.641-3.642 in)
Main bearing bore inside diameter	72.400-72.424 mm (2.8503-2.8513 in)
Head gasket surface flatness	Flat within 0.051 mm (0.0002 in) per one foot of tool length
Crankshaft
Main bearing journal diameter	67.5 mm (2.657 in)
Main bearing journal maximum taper	0.004 mm (0.00015 in)
Main bearing journal maximum out-of-round	0.006 mm (0.00023 in)
Main bearing journal-to-cylinder block clearance	0.026-0.041 mm (0.0010-0.0016 in)
Connecting rod journal diameter	55.983-56.003 mm (2.204-2.205 in)
Connecting rod journal maximum taper	0.004 mm (0.00015 in)
Connecting rod journal maximum out-of-round	0.006 mm (0.00023 in)
Crankshaft maximum end play	0.101-0.291 mm (0.0039-0.0114 in)
Piston and Connecting Rod
Piston diameter - single grade	92.476-92.490 mm (3.6407-3.6413 in)
Piston-to-cylinder bore clearance	0.010 to 0.044 mm (0.0003-0.0017 in)
Piston ring end gap - compression (top, gauge diameter)	0.17-0.27 mm (0.0067-0.0106 in)
Piston ring end gap - compression (bottom, gauge diameter)	0.30-0.55 mm (0.0118-0.0216 in)
Piston ring end gap - oil ring (steel rail, gauge diameter)	0.15-0.45 mm (0.0059-0.0177 in)
Piston ring groove width - compression (top)	1.230-1.25 mm (0.0484-0.0492 in)
Piston ring groove width - compression (bottom)	1.530-1.55 mm (0.0602-0.0610 in)
Piston ring groove width - oil ring	2.53-2.55 mm (0.0996-0.1003 in)
Piston ring width - upper comp ring	1.17-1.19 mm (0.0460-0.0468 in)
Piston ring width - lower comp ring	1.47-1.49 mm (0.0578-0.0586 in)
Piston ring-to-groove clearance (upper and lower compression rings)	0.040-0.080 mm (0.0015-0.0031 in)
Piston pin bore diameter	23.002-23.006 mm (0.9055-0.9057 in)
Piston pin diameter	22.998-23.000 mm (0.9054-0.9055 in)
Piston pin length	59.5 mm (2.343 in)
Piston pin-to-piston fit	0.002 to 0.008 mm (0.00007-0.0003 in)
Piston-to-connecting rod clearance	2.7 mm (0.1 in)
Connecting rod-to-pin clearance - standard	0.007-0.021 mm (0.0002-0.0008 in)
Connecting rod pin bore diameter	23.007-23.019 mm (0.905-0.906 in)
Connecting rod length (center-to-center)	152.68 mm (6.01 in)
Connecting rod maximum allowed bend	0.038 mm (0.0014 in)
Connecting rod maximum allowed twist	0.050 mm (0.0019 in)
Connecting rod bearing bore diameter - grade 1	59.866-59.872 mm (2.3569-2.3571 in)
Connecting rod bearing bore diameter - grade 2	59.873-59.879 mm (2.3572-2.3574 in)
Connecting rod bearing bore diameter - grade 3	59.880-59.886 mm (2.3574-2.3577 in)
Connecting rod bearing-to-crankshaft clearance	0.020-0.054 mm (0.0007-0.0021 in)
Connecting rod side clearance (assembled to crank) - standard	0.175-0.425 mm (0.0068-0.0167 in)
Connecting rod side clearance (assembled to crank) - service limit	0.175-0.425 mm (0.0068-0.0167 in)

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

Description	Nm	Lb-ft	Lb-in
A/C compressor bolts and nut	25	18
A/C compressor stud	9		80
A/C tube bracket bolt	15		133
A/C tube nut	15		133
A/C tube retaining clamp bolt	9		80
A/C tube-to-compressor nut	15		133
A/C tube bracket-to-compressor bolt	25	18
Accessory drive belt tensioner bolts	11		97
Ball joint nuts	200	148
Battery cable power feed cable nut	6		53
Block drain plug - RH	40	30
Block drain plug - LH (1)
Block heater	40	30
Charge Air Cooler (CAC) tube clamps	5		44
CAC outlet pipe clamps	5		44
Camshaft bearing cap bolts (2)
Camshaft Position (CMP) sensor bolts	10		89
Coolant pump bolts (2)
Connecting rod cap bolts (2)
Crankcase rear seal retainer plate bolts (2)
Crankshaft Position (CKP) sensor bolt	10		89
Crankshaft pulley bolt (2)
Cylinder head bolts (2)
Cylinder head M6 bolt	10		89
Cylinder Head Temperature (CHT) sensor	10		89
Driveshaft-to-Power Transfer Unit (PTU) bolts	70	52
Electronic Power Assist Steering (EPAS) wiring retainer bolt	9		80
Engine cover mounting stud	6		53
Engine front cover bolts (2)
Engine lifting eye bolts	24	18
Engine mount-to-engine nuts	63	46
Engine mount-to-frame bolts	90	66
Engine oil filter (3)
Engine Oil Pressure (EOP) switch	18		159
Engine-to-transaxle bolts	48	35
Exhaust camshaft bolt (2)
Exhaust manifold heat shield bolts	14		124
Exhaust manifold nuts (2)
Exhaust manifold studs	12		106
Exhaust manifold-to-turbocharger bolts	45	33
Flexplate bolts	80	59
Front halfshaft nut	350	258
Fuel rail bolts (2)
Fuel injection pump bolts (2)
Fuel tube bracket-to-engine front cover bolt	10		89
Generator bolt and nut	47	35
Generator B+ terminal nut	17		150
Generator stud	8		71
Ground cable-to-negative battery cable nut	6		53
Ground cable-to-cylinder head bolt	10		89
Ground wire-to-engine front cover bolt	10		89
2010 Flex Service Information	6	Of	9
Halfshaft support bracket bolts	40	30
Heated Oxygen Sensor (HO2S) bracket-to-engine front cover bolt	10		89
Heat shield nut	10		89
High pressure fuel tube flare nut	30	22
High pressure fuel tube bolt	6		53
High pressure fuel tube nut	6		53
Ignition coil-on-plug bolts	7		62
Intake manifold bolts (2)
Intermediate and halfshaft assembly bolts	25	18
Intermediate steering shaft bolt	20		177
Knock Sensor (KS) bolts	20		177
Main bearing bolts (2)
Main bearing cap support brace bolts (2)
Oil filter adapter bolts	10		89
Oil pan bolts (2)
Oil pan drain plug	27	20
Oil pan-to-transaxle bolts	48	35
Oil pump bolts	10		89
Oil pump screen and pickup tube bolts	10		89
Oil supply tube bracket-to-valve cover stud bolt nut	8		71
Power Transfer Unit (PTU) bolts	70	52
PTU support bracket bolts (2)
Radio capacitor bolt	10		89
RH brake hose bracket bolt	30	22
RH CAC tube nut	6		53
RH turbocharger intake pipe clamp	6		53
RH turbocharger intake tube nut	6		53
Roll restrictor bolts	90	66
Secondary timing exhaust camshaft bolt (2)
Secondary timing Variable Camshaft Timing (VCT) bolt (2)
Secondary timing chain tensioner bolts	10		89
Spark plugs	15		133
Stabilizer bar link nuts	150	111
Starter bolt and stud bolt	27	20
Starter B+ terminal nut	12		106
Starter S-terminal nut	5		44
Strut tower brace nuts	30	22
Subframe bracket bolts	55	41
Subframe - front bolts	200	148
Subframe - rear bolts	150	111
Thermostat housing bolts	10		89
Tie-rod end nuts	150	111
Timing chain guide bolts	10		89
Timing chain tensioner bolts	10		89
Torque converter-to-flexplate bolts	55	41
Transaxle support insulator bracket-to-transaxle bolt	80	59
Transaxle support insulator bracket-to-transaxle nuts	63	46
Transaxle-to-engine bolts	48	35
Turbocharger coolant tube banjo bolts	40	30
Turbocharger coolant tube bracket-to-cylinder head bolt	10		89
Turbocharger intake tube clamp	5		44
Turbocharger intake tube-to-RH valve cover nut	6		53
Turbocharger oil return tube bolts	10		89
Turbocharger oil supply quick connect fitting	16		142
Turbocharger oil supply tube banjo bolt	35	26
Turbocharger-to-cylinder block bolts (2)
Turbocharger-to-exhaust manifold bolts	45	33
Turbocharger-to- turbocharger bracket bolts (2)
Upper stabilizer bar link nuts	150	111
Valve cover stud bolts (2)
Variable Camshaft Timing (VCT) housing bolts (2)
VCT bolt (2)
VCT solenoid bolts	10		89
Wheel hub nuts	350	258
Wiring harness retainer stud bolt	10		89
(1) Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees. (2) Refer to the appropriate procedure(s). (3) Tighten to 5 Nm (44 lb-in) plus an additional 180 degrees.

(1)	Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.

(2)	Refer to the appropriate procedure(s).

(3)	Tighten to 5 Nm (44 lb-in) plus an additional 180 degrees.

TORQUE SPECIFICATIONS

Note. On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

The 3.5L Gasoline Turbocharged Direct Injection (GTDI) (4V) is a V-6 engine with the following features

Dual overhead camshafts
Four valves per cylinder
GTDI
An aluminum intake manifold
Aluminum cylinder heads
An aluminum, 60-degree V-cylinder block
Timing chain driven coolant pump
Variable Camshaft Timing (VCT) system
The electronic ignition system with 6 ignition coils

See also:
• JACKING AND LIFTING
• AUTOMATIC TRANSAXLE/TRANSMISSION - 6F50/6F55
• SUPPLEMENTAL RESTRAINT SYSTEM