SECTION 303-01A: Engine — 3.5L Ti-VCT
2014 Flex Workshop Manual
SPECIFICATIONS
Procedure revision date: 08/16/2013

Material
Item Specification Fill Capacity
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada) 		WSS-M2C945-A 5.7L (6.0 qt) includes filter change


  General Specifications

Item Specification
Engine
Displacement 3.5L (4V) (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 10.8:1
Spark plug 12405
Spark plug gap 1.25-1.35 mm (0.049-0.053 in)
Engine weight (without accessory drive components) 161 kg (355 lb)
Engine and transaxle weight (without accessory drive components) 260.8 kg (575 lb)
Cylinder Head and Valve Train
Cylinder head gasket surface flatness Flat within 0.08 mm (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 56.651 cc (3.46 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)
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 37.0 mm (1.46 in)
Valve head diameter — exhaust 31.0 mm (1.22 in)
Valve face runout 0.05 mm (0.0001 in)
Valve face angle 44.5-45.5°
Valve seat width — intake 1.3-1.5 mm (0.051-0.059 in)
Valve seat width — exhaust 1.7-2.0 mm (0.067-0.079 in)
Valve seat runout 0.04 mm (0.0001 in) MAX
Valve seat angle 44.5-45.5°
Valve spring free length (approx.) 48.0 mm (1.889 in)
Valve spring compression pressure (N @ spec. length) 525 N @ 27.0 mm (114.7 lb @ 1.06 in)
Valve spring installed height 37.0 mm (1.45 in)
Valve spring installed height pressure (N @ spec. length) 235 N @ 37.0 mm (53 lbs @ 1.45 in)
Valve spring installed pressure — service limit 10% force loss @ specified height
Camshaft
Theoretical valve lift (intake)@ 0 lash 10.0 mm (0.394 in)
Theoretical valve lift (exhaust)@ 0 lash 9.6798 mm (0.38 in)
Lobe lift — intake 10.0 mm (0.394 in)
Lobe lift — exhaust 9.6798 mm (0.38 in)
Allowable lobe lift loss 0.062 mm (0.0024 in)
Camshaft journal bore inside diameter — 1st journal 39.0375-39.0625 mm (1.537-1.538 in)
Camshaft journal bore inside diameter — intermediate journals 25.9875-26.0125 mm (1.023-1.024 in)
Camshaft bearing outside diameter — 1st journal 38.99-39.01 mm (1.535-1.536 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 0.0725 mm (0.0029 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 92.500-92.520 mm (3.641-3.642 in)
Cylinder bore roundness 0.013 mm (0.0005 in)
Cylinder bore taper 0.010 mm (0.0004 in) per 25.4 mm (1 in)
Block main bore roundness 0.008 mm (0.003 in)
Main bearing bore inside diameter 72.400-72.424 mm (2.8503-2.8513 in)
Head gasket surface flatness Flat within 0.150 mm (0.005 in) overall

0.050 mm (0.001 in) per 150 mm (5.905 in) x 150 mm (5.905 in)

0.025 mm (0.0009 in) per 25 mm (0.98 in) x 25 mm (0.98 in)
Head gasket surface finish —
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-main bearing 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 (0.0066-0.01063 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 23.004-23.008 mm (0.9056-0.9058 in)
Piston pin diameter 22.997-23.000 mm (0.9053-0.9055 in)
Piston pin length 55.975 mm (2.203 in)
Piston pin-to-piston fit 0.004 to 0.011 mm (0.00015-0.00043 in)
Piston-to-connecting rod clearance 2.7 mm (0.1 in)
Connecting rod-to-pin clearance — standard 0.007-0.022 mm (0.0002-0.00086 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)



  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 nuts 15 — 133
Accessory drive belt tensioner bolts 11 — 97
Battery cable power feed cable nut 5 — 44
Bellhousing -to-engine bolts 48 35 —
Block coolant drain plug — RH a — — —
Block coolant drain plug — LH b — — —
Block heater 40 30 —
Block oil galley plug — LH 48 35 —
Block oil galley plug — rear 85 63 —
Block oil galley plug — RH 32 24 —
Camshaft bearing cap bolts c — — —
Camshaft Position (CMP) sensor bolts 10 — 89
Connecting rod cap bolts c — — —
Coolant pump bolts c — — —
Crankshaft rear seal retainer plate bolts c — — —
Crankshaft Position (CKP) sensor bolt 10 — 89
CKP sensor heat shield nuts 10 — 89
Crankshaft pulley bolt c — — —
Cylinder head bolts c — — —
Cylinder Head Temperature (CHT) sensor 10 — 89
Engine front cover bolts c — — —
Engine front cover ground wire bolt 10 — 89
Engine ground wire-to-shock tower bolt 10 — 89
Engine lifting eye bolts 24 18 —
Engine mount brace bolt and nut 20 — 177
Engine mount bracket bolts 30 22 —
Engine mount-to-engine nuts 63 46 —
Engine mount-to-frame bolts 90 66 —
Engine oil filter d — — —
Engine Oil Pressure (EOP) switch c — — —
Engine-to-bellhousing bolts 48 35 —
Exhaust manifold/catalytic converter manifold bracket nuts — LH 30 22 —
Exhaust manifold/catalytic converter manifold heat shield bolts 10 — 89
Exhaust manifold/catalytic converter manifold nuts c — — —
Exhaust manifold/catalytic converter manifold studs 12 — 106
Flexplate bolts c — — —
Fuel supply tube-to-engine front cover bolt 10 — 89
Generator bolt and nut 47 35 —
Generator B+ terminal nut 17 — 150
Generator stud 8 — 71
Ground wire-to-body retainer 10 — 89
Ground wire-to-engine bolt 10 — 89
Ground wire-to-RH cylinder head bolt 10 — 89
Ignition coil-on-plug bolts 7 — 62
Knock Sensor (KS) bolts 20 — 177
Lower intake manifold bolts c — — —
Main bearing bolts c — — —
Main bearing cap support brace bolts c — — —
Oil cooler bolts c — — —
Oil filter adapter c — — —
Oil pan bolts c — — —
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
Piston oil cool valves 4 — 35
Power Transfer Unit (PTU) 90 66 —
PTU support bracket bolts 70 52 —
Rear driveshaft-to- PTU flange bolts 70 52 —
Spark plugs 15 — 133
Starter bolt and stud bolt 27 20 —
Starter B+ terminal nut 12 — 106
Starter S-terminal nut 5 — 44
Thermostat housing bolts 10 — 89
Timing chain guide bolts 10 — 89
Timing chain tensioner bolts 10 — 89
Torque converter-to-flexplate bolts 55 41 —
Transaxle mount bracket bolt 80 59 —
Transaxle mount bracket nuts 63 46 —
Transaxle mount through bolt and nut 175 129 —
Transaxle-to-engine bolts 48 35 —
Upper intake manifold bolts c — — —
Upper intake manifold support bracket-to-engine bolt 10 — 89
Upper intake manifold-to-support bracket bolt 10 — 89
Valve cover bolts and stud bolts c — — —
VCT bolts c — — —
VCT oil control solenoid bolts c — — —
a Tighten to 10 Nm (89 lb-in) plus an additional 720 degrees.
b Tighten to 16 Nm (142 lb-in) plus an additional 180 degrees.
c Refer to the procedure in this section.
d Tighten to 5 Nm (44 lb-in) plus an additional 180 degrees.