SECTION 303-01B: Engine — 3.5L GTDI
| 2014 Flex Workshop Manual
|
SPECIFICATIONS
| Procedure revision date: 08/16/2013
|
| 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-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 | 5.7L (6 qt) includes filter change |
| Motorcraft® Silicone Gasket Remover
ZC-30 | — | — |
| Motorcraft® Orange Antifreeze/Coolant Concentrated
VC-3-B (US); CVC-3-B2 (Canada) | WSS-M97B44-D | — |
| Motorcraft® Thread Sealant with PTFE
TA-24 | WSK-M2G350-A2 | — |
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 |
| Spark plug | 12405 |
| Spark plug gap | 0.889 mm (0.035 in) |
| Oil pressure | Minimum 30 psi @ 1,500 rpm with engine at normal operating temperature |
| Compression ratio | 10.0:1 |
| 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.) | 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) | 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 | 0.0725 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 — grade 1 | 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) |
| 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 | 23.004-23.008 mm (0.9056-0.9058 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 | 0.004 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 | 0.007-0.021 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) |
Torque Specifications
| Description | Nm | lb-ft | lb-in |
|---|---|---|---|
| A/C compressor stud 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 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 | — |
| Charge Air Cooler (CAC) tube clamps | 5 | — | 44 |
| CAC outlet pipe clamps | 5 | — | 44 |
| Camshaft bearing cap bolts c | — | — | — |
| Camshaft Position (CMP) sensor bolts | 10 | — | 89 |
| Coolant pump bolts c | — | — | — |
| Connecting rod cap bolts c | — | — | — |
| Crankcase rear seal retainer plate bolts c | — | — | — |
| Crankshaft Position (CKP) sensor bolt | 10 | — | 89 |
| Crankshaft pulley bolt c | — | — | — |
| Cylinder head bolts c | — | — | — |
| 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 c | — | — | — |
| Engine lifting eye bolts | 24 | 18 | — |
| 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-transaxle bolts | 48 | 35 | — |
| Exhaust camshaft bolt c | — | — | — |
| Exhaust manifold heat shield bolts | 12 | — | 106 |
| Exhaust manifold nuts c | — | — | — |
| Exhaust manifold studs | 12 | — | 106 |
| Exhaust manifold-to-turbocharger bolts | 45 | 33 | — |
| Flexplate bolts c | — | — | — |
| Front engine roll restrictor-to-transaxle bolts | 90 | 66 | — |
| Front halfshaft nut | 350 | 258 | — |
| Fuel rail bolts c | — | — | — |
| Fuel injection pump bolts c | — | — | — |
| 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 |
| 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 c | — | — | — |
| High pressure fuel tube nut c | — | — | — |
| Ignition coil-on-plug bolts | 7 | — | 62 |
| Intake manifold bolts c | — | — | — |
| Intermediate and halfshaft assembly bolts | 25 | 18 | — |
| Intermediate steering shaft bolt | 20 | — | 177 |
| Knock Sensor (KS) bolts | 20 | — | 177 |
| Main bearing bolts c | — | — | — |
| Main bearing cap support brace bolts c | — | — | — |
| Oil filter adapter bolts 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 |
| Oil supply tube bracket-to-valve cover stud bolt nut | 8 | — | 71 |
| Power Transfer Unit (PTU) bolts | 70 | 52 | — |
| PTU support bracket bolts c | — | — | — |
| 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 | 103 | 76 | — |
| Secondary timing exhaust camshaft bolt c | — | — | — |
| Secondary timing Variable Camshaft Timing (VCT) bolt c | — | — | — |
| 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 pin c | — | — | — |
| Timing chain tensioner arm pin c | — | — | — |
| 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 | 40 | 30 | — |
| Turbocharger-to-cylinder block bolts c | — | — | — |
| Turbocharger-to-exhaust manifold bolts | 45 | 33 | — |
| Turbocharger-to- turbocharger bracket bolts c | — | — | — |
| Upper stabilizer bar link nuts | 150 | 111 | — |
| Valve cover stud bolts c | — | — | — |
| Variable Camshaft Timing (VCT) housing bolts c | — | — | — |
| VCT bolt c | — | — | — |
| VCT solenoid bolts | 10 | — | 89 |
| Wheel hub nuts | 350 | 258 | — |
| Wiring harness retainer stud bolt | 10 | — | 89 |